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ValveModeling
From ControlsWiki
Note:

Video lecture available for this section!

Authors: Erin Knight, Matthew Russell, Dipti Sawalka, Spencer Yendell

Date Presented: 9/19/06, Revised: 9/26/06
First round reviews for this page
(http://controls.engin.umich.edu/wiki/index.php/Image:ValveModelingReviews.doc)
Rebuttal for this page
(http://controls.engin.umich.edu/wiki/index.php/Image:ValveModelingRebuttal.doc)

Contents
1 Introduction
2 Flow through a Valve
2.1 Flow Characteristics
2.2 Valve Coefficient, Cv
3 Pressure Drop
4 Control Valve Gain
4.1 Constant Pressure Drop
4.2 Variable Pressure Drop
5 Rangeability
6 Modeling Installed Valve Characteristics
7 Special Considerations for the Equation describing Flow Through a Valve
8 Example 1: Verbal Model of a Control Valve
8.1 Problem Statement:
8.2 Solution
9 Example 2: Modeling Installed Valve Characteristics
9.1 Problem Statement
9.2 Solution
10 References

Introduction
A valve acts as a control device in a larger system; it can be modeled to regulate the flow of material
and energy within a process. There are several different kinds of valves (butterfly, ball, globe etc.),
selection of which depends on the application and chemical process in consideration. The sizing of
valves depends on the fluids processing unit (heat exchanger, pump etc.) which is in series with the
valve. Sizing and selection of valves is discussed in the other wiki article on Valve Selection. Valves
need to be modeled to perform effectively with respect to the process requirements. Important
components for the modeling of control valves are:
1. Flow

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2. Inherent Flow Characteristics

3. Valve Coefficient, Cv
4. Pressure Drop
5. Control Valve Gain
6. Rangeability
7. Installed Characteristics
Efficient modeling of the valves can optimize the performance and stability of a process as well as
reduce development time and cost for valve manufacturers.
In the following sections we briefly define the various variables and equations involved in modeling
valves.The purpose of the following sections is to give you an overview of the equations required to
model the valves for a particular system. Example problems at the end of the article have been
provided to aid in the qualitative and quantitative understanding of how valves are modeled for
chemical engineering processes.

Flow through a Valve

The following equation is a general equation used to describe flow through a valve. This is the
equation to start with when you want to model a valve and it can be modified for different situations.
The unfamiliar components such as valve coefficient and flow characteristics will be explained
further.

F = volumetric flow rate

Cv = valve coefficient, the flow in gpm (gallons per minute) that flows through a valve that has a
pressure drop of 1psi across the valve.
Pv = pressure drop across the valve
sg = specific gravity of fluid
x = fraction of valve opening or valve "lift" (x=1 for max flow)
f(x) = flow characteristic

Flow Characteristics
The inherent flow characteristic, f(x), is key to modeling the flow through a valve, and depends on
the kind of valve you are using. A flow characteristic is defined as the relationship between valve
capacity and fluid travel through the valve.
There are three flow characteristics to choose from:

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1. f(x) = x for linear valve control

2. f(x) =
for quick opening valve control
3. f(x) = Rx 1 for equal percentage valve control
R= valve design parameter (between 20 and 50)
note these are for a fixed pressure drop across the valve
Whereas a valve TYPE (gate, globe or ball) describes the geometry and mechanical characteristics of
the valve, the valve CONTROL refers to how the flow relates to the "openness" of the valve or "x."
1. Linear: flow is directly proportional to the valve lift (used in steady state systems with constant
pressure drops over the valve and in liquid level or flow loops)
2. Equal Percentage - equal increments of valve lift (x) produce an equal percentage in flow change
(used in processes where large drops in pressure are expected and in temperature and pressure
control loops)
3. Quick opening: large increase in flow with a small change in valve lift (used for valves that need
to be turned either on or off frequently or where instant maximum flow is required, for example,
safety systems)
For the types of valves discussed in the valve selection article, the following valve characteristics are
best suited:
1. Gate Valves - quick opening 2. Globe Valves - linear and equal percentage 3. Ball Valves - quick
opening and linear 4. Butterfly Valves - linear and equal percentage

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Cvmax depends on pipe characteristics and was chosen to be 110 gpm in this example. Constant
pressure throughout the pipe line is assumed and the curves are accurate when the valve position is
between 5% and 95% open.
Comparing the slopes of the graphs for the quick opening and equal percentage valves, we can see
that a quick opening valve would experience greater change in flow with slight change in valve
position in the lower flow range. The opposite is true for the higher range of flow. The equal
percentage valve experiences slighter change in flow with respect to valve position in the lower
range of flow.
When selecting the appropriate control valve, it is often the goal of the engineer to choose a valve
that will exhibit a linear relationship between F and x over the normal operating position(s) of the
valve. This linear relationship provides the most control for the operator. The flow characteristic
observed through an installed valve, and all process factors considered (i.e. total pressure drop, etc.),
is termed the installed flow characteristic. Therefore, it is not always the case that an inherently
linear valve is desirable or even useful. An inherently linear valve is appropriate when there is a
linear relationship between the valve position and the actual flow rate; however, consider the case
where
and of significant value. In this case a valve with inherent equal percentage flow
characteristic would be appropriate. The inherently non-linear valve would compensate for PL and
result in an installed linear flow characteristic.

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Valve Coefficient, Cv
The valve coefficient, Cv, is defined as the flow in gpm that flows through a valve with a pressure
drop of 1psi across the valve (Pv = 1psi). Cv is an important parameter that comes up in other
modeling equations. It is specific to the valve you are using.

d = internal diameter of the pipe in inches

K = resistance coefficient
K is specific to the pipe shape, diameter and material. Table of typical K values
(http://www.westerndynamics.com/Download/friclossfittings.pdf)

Pressure Drop
The pressure drop in the pipe line (pressure drop due to the pipe line and any other equipment in
series with the valve), PL, is defined as:

f = flow through the pipe in gallons per minute [gpm]

kL = [

] = constant friction coefficient for the pipe and any equipment in series with the valve

sg = specific gravity of the liquid

The pressure drop across the valve is defined as:

So, the total pressure drop is described by the equation:

If the line pressure drop is negligble (constant pressure in the pipe line) then PL = 0 and Po =
Pv. When PL = 0 a valve with a linear flow characteristic will be desirable. When
and of significant value, a valve with flow characteristics closer to an equal percentage or quick
opening valve will be more desirable.

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Control Valve Gain

The gain of a control valve (KL) is defined as the steady-state change in output (flow through a
valve, f ) divided by the change in input (controller signal, m). The flow through a valve, f, can have
units of gallons per minute (gpm), pounds per hour (lb/hr) or standard cubic feet per hour (scfh). The
controller signal, m, usually has units of percent of controller output (%CO). The basic relationship
for control valve gain is shown below.

One objective when choosing a valve is to achieve "constant valve gain". The gain is a product of the
dependence of valve position on controller output, the dependence of the flow on Cv, and the
dependence of Cv on the valve position. The change in valve coefficient, Cv, with respect to valve
position depends on the valve characteristics f(x).
For linear characteristics

For equal percentage

Constant Pressure Drop
The dependence of flow on the Cv depends on the pressure drop, so the equation for gain is different
when there is a constant pressure drop or a variable pressure drop. If the inlet and outlet pressures do
not vary with flow, the gain for either liquid or gas flow in mass units is:

%CO = percent controller output

W = mass flow rate
R = valve design parameter (usually between 20 and 50)
Note: the sign is positive if the valve fails closed (air-to-open) and negative if the valve fails open
(air-to-close)
Variable Pressure Drop
The valve gain for variable pressure drop is more complicated. As an example, the gain for an equal
percentage is

kL = constant friction coefficient for line, fittings, equipment, etc.

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The flow term cancels some of the effect of the Cv term until the valve is fully opened, so this gain is
less variable with valve opening. Therefore the installed characteristics are much more linear when
compared to the inherent characteristics of an equal percentage valve.

Rangeability
Valve rangeability is defined as the ratio of the maximum to minimum controlable flow through the
valve. Mathematically the maximum and minimum flows are taken to be the values when 95% (max)
and 5% (min) of the valve is open.

Rangeability =

Flow at 95% valve position

-------------------------Flow at 5% valve position

A smaller rangeablilty correlates to a valve that has a small range of controllable flowrates. Valves
that exhibit quick opening characteristics have low rangeablilty values. Larger rangeability values
correlate to valves that have a wider range of controllable flows. Linear and equal percentage valves
fall into this category.
Another case to consider is when the pressure drop across the valve is independent of the flow
through the valve. If this is true then the flow is proportional to CV and the rangeability can be
calculated from the valve's flow characteristics equation.

Modeling Installed Valve Characteristics

When a valve is installed in series with other pieces of equipment that produce a large pressure drop
in the line compared to the pressure drop across the valve, the actual valve characteristics deviate
from the inherent characteristics. At large in-line pressure drops the pressure drop, and consequently
the valve coefficient, varies with flow through the valve. These changes can cause changes in the
rangeabilty and distorts inherent valve characteristics.
In the following Microsoft Excel model, the variation from inherent valve characteristics is
illustrated. A number of parameters can be changed to match the flow conditions through a valve.
This model simulates both linear and equal percentage valve characteristics. To more clearly
demonstrate the deviation from inherent characteristics; simply change the CVmax value of the valve.
Notice how the installed valve characteristics and valve rangeability change drastically.
Installed Valve Characteristcs Model
(http://controls.engin.umich.edu/wiki/index.php/Image:Installed_Valve_Model.xls)

Special Considerations for the Equation describing Flow

Through a Valve
Compressible Fluids
Manufacturers such as Honeywell, DeZurik, Masoneilan and Fischer Controls have modified
the flow equation to model compressible flows. The equations are derived from the equation
for flow through a valve but include unit conversion factors and corrections for temperature
and pressure, which affect the density of the gas. It is important to remember to account for
these factors if you are working with a compressible fluid such as steam.

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Accuracy
This equation, and its modified forms, is most accurate for water, air or steam using
conventional valves installed in straight pipes. If you are dealing with non-Newtonian, viscous
or two phase systems the calculations will be less accurate.

Example 1: Verbal Model of a Control Valve

Problem Statement:
Verbally model a fail open control valve positioned as a safety measure on a reactor processing an
exothermic reaction.
Solution
1.)Describe the Process: In the fail-open control valve a quick opening valve opens with a failure
signal. Open is its default position once the signal goes off.
2.) Identify Process Objectives and Constraints: A fail-open control valve is a safety measure. For
example, if your cooling heat exchanger fails and the reactor starts to heat up and produce excess
gases, the fail-open control valve would release excess gasses before pressure builds up to produce
an explosion. The size of the valve is a constraint because it limits how much fluid can escape. The
valve size determines the maximum flow rate. The shape and angles of the valve are modeling
constraints. Sudden and gradual contraction or enlargement of the pipe diameter inside the valve and
the connecting piping, will change the resistance coefficient and therefore the maximum velocity.
3.) Identify Significant Disturbances: Significant internal disturbances include the escalating
pressure and temperature as the exothermic reaction gets out of control.
4.) Determine the Type and Location of Sensors: A pressure sensor would be located in the tank
with the control valve that would provide the signal to the fail-open control valve. To achieve
redundancy, a temperature sensor would be located on the heat exchanger to signal failure of the
cooling apparatus.
5.) Determine the Location of Control Valves: A fail-open control valve (or multiple valves)
would be placed on the top of the tank to allow exit of the gasses in the processing unit.
6.) Apply a Degree-of-Freedom Analysis: The only manipulated variable is the valve coefficient.
This depends on the valves diameter and resistance coefficient K. The control objective is the
maximum flow rate. The pressure drop will vary according to the failure. Therefore there is one
degree of freedom.
7.) Implement Energy Management: This doesnt apply to our confined example, but in a larger
system we could install a backup cooler if this reaction were truly dangerous.
8.) Control Process Production Rate and Other Operating Parameters: The exit flow rate can
not exceed the maximum flow rate through the control valve.
9.) Handle Disturbances and Process Constraints: If our first control valve fails to sufficiently
lower the tank pressure, a signal would be sent to a second valve and depending on the reaction, a
backup cooling system. A secondary cooling system would be too expensive for many cases, but if

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you were dealing with a nuclear reactor or something highly explosive it may be worth the
investment.
10.) Check Component Balances: Does not apply. Preventing accumulation is the point of this
control valve.
11.) Apply Process Optimization: Our manipulatable variable is choosing a valve with a specific
Cv. The valve should be able to withstand extreme temperatures and high pressures. It would be a
gate valve, which opens completely upon failure. For other sizing concerns refer to Valve Sizing.

Example 2: Modeling Installed Valve Characteristics

Problem Statement
A new valve is being installed downstream from a water pump. The friction coefficient of the pump
and associated piping that will be in series with the new valve is

The flow through the line from the pump is 300 gpm. The desired pressure drop across the valve is 4
psi. A high level of control is desired for the flow through the new valve. Two valves are being
considered, one has an inherent linear characteristic, the other is equal percentage (=50). From the
manufacturers literature, both have a CVmax value of 200. Use the Installed Valve Characteristcs
Model (http://controls.engin.umich.edu/wiki/index.php/Image:Installed_Valve_Model.xls) to
determine which valve has a higher range of controllable flows values.
Solution
To view the valve model spreadsheet with the correct inputs, click here
(http://controls.engin.umich.edu/wiki/index.php/Image:VMsln.xls) .
Note that the pressure drop across the pipe is 13.5psi, which is significantly larger than the pressure
drop across the valve (4 psi). These conditions indicate that the characteristic flow through the valves
may not match the inherent characteristics. This is verified by the plots and also by the calculated
rangeability values shown in the valve model spreadsheet. The equal percentage valve has a higher
rangeabilty value, corresponding to a higher range of controllable flows.

References
Bequette, B. Wayne. Process Control Modeling, Design, and Simulation, Upper Saddle River,
New Jersey: Prentice Hall.
Crane Co. Flow of Fluids Through Valves, Fittings, and Pipe, Joliet, IL: CRANE.
"Friction Losses in Pipe
Fittings" (http://www.westerndynamics.com/Download/friclossfittings.pdf) (PDF), Western
Dynamics, LLC., retrieved September 11, 2006.
Perry, R. H., and D. Green (ed). Perry's Chemical Engineering Handbook, 7th ed. New York:
McGraw-Hill.
Seborg, Dale E., Thomas F. Edgar, Duncan A Mellichamp. Process Dynamics and Control,
New York: John Wiley & Sons.
Smith, Carlos A., Armando B. Corripio. Principles and Practice of Automatic Process
Control, 3rd ed. New York: John Wiley & Sons.

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"Valve Sizing and Selection." (http://www.cheresources.com/valvezz.shtml) The Chemical

Engineers' Resource Page. 1442 Goswick Ridge Road, Midlothian, VA 23114. retrieved Sept
24, 2006.
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This page was last modified on 2 April 2014, at 18:19.
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