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Test Bench for Process Control Valves.

Conference Paper · October 2007

DOI: 10.1109/CERMA.2007.4367675 · Source: IEEE Xplore

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 Fourth Congress of Electronics, Robotics and Automotive Mechanics
Test Bench for Process Control Valves.
G. Aragón-Camarasa, G. Aragón-González, A. Canales-Palma, A. León-Galicia
Programa de Desarrollo Profesional en Automatización. UAM Azcapotzalco. Av. San Pablo #
180, Col. Reynosa. Azcapotzalco, 02200. México, D.F. Tel. y Fax: 5318-905
e-mail: gag@correo.azc.uam.mx
Abstract
A test bench was conceived in order to determine
experimentally the flow coefficient [CV] for process
control valves, operating with compressible fluids,
under established regulations by the standards
ANSI/ISA-75.02-1996 and ANSI/ISA-75.01.01-2002.
This test bench is used to verify the calibration of
valves with continually variable opening, after they
have been repaired. The measurements in the test
bench allow establishing the CV of these valves for
various opening percentages. It was necessary to
review the CV equation for compressible fluids, to
proceed with the flow sensor selection. This equation
was obtained under similarity conditions, by the
equality of Euler numbers between prototype and
model (test specimen). It is also described the
electronic instrumentation for measuring flow,
temperature and pressure difference, the design and
the development of electronic circuits which control
the instrumentation, and the algorithms for the
operation and acquisition of measurements.
1. Introduction
The process control valves are widely used in
manufacture operations and industrial processes. These
valves open and close to connect or suspend fluid
supply, or to control the feeding of liquids and gases
flowing to certain process. A typical application is the
steam feeding for heating a vulcanizing press or for
plastic injection. These valves are designed and built
with different shapes and various materials, in function
of the liquid, steam or gas in use in several factories.
A process control valve generally represents the last
element of a control loop installed in a process line.
These valves are actuated by a remote signal, often
pneumatic, to command their opening and closing.
Other types of control valves are more refined and do
not only take two positions (on/off); they could even
change the plug area for altering continually the flow
rate that goes through the valve.
0-7695-2974-7/07
Unrecognized Copyright
$25.00Information
© 2007 IEEE 139
DOI 10.1109/CERMA.2007.31
For operating continually variable valves is
necessary to know the relationship between the
aperture percentages and the flow amount, for a certain
pressure drop applied between the input and output of
the valve. Frequently it is used a standardized
procedure for defining the flow capacity of process
control valves. It is a well-known numeric size
denominated flow capacity coefficient and denoted by
CV. This coefficient was introduced in 1944 by a
manufacture company of valves named Masoneilan,
originally for liquid flows [1]. In a short time it was
adopted universally like a practical manner for
showing the valve capacity. It is an indication of how
many flow could pass through in a control valve, when
it is applied a well de-fined pressure difference. Higher
CV, the flow capacity is greater, for a certain pressure
drop. Different valves or unlike port diameters, but
with the same CV, have exactly identical flow capacity.
Traditionally, for valves that carries a compressible
fluid, the flow capacity coefficient was defined as the
air flow —expressed on standard conditions in
ft3/min— that will cross through the valve when it is
applied a pressure difference of 1 psi [6.89 kPa] (For
liquid flow, CV is defined as the water flow at 60 °F
(288.7 K), expressed in gallons per minute, that cross
the valve and create a pressure drop of 1 PSI [6.89
kPa]; (see for example, [2]). Despite the flow capacity
coefficient CV was originally defined in English Units,
this coefficient could be built in metric units [3].
Usually some authors distinguish the coefficient in
metric units as “flow factor” and they symbolize it with
KV.
On the other hand, when process valves fail, generally
by seat wear problems, it must be recalibrated after
repair it. In other words, it must be verified
experimentally the flow capacity coefficient of the
valve for different opening. There are international
standards that describe tests for these valves, where
there is established the necessary instrumentation and
the right experimental procedures. In the literature are
several works recommending procedures for the
experimental determination of the flow capacity
coefficient [4], for liquid flow ([5] and [6]), as well as
 Figure 1. Test circuit suggested by the standard.
flow of gas and steam, ([7] and [8]). In these papers are contains a detailed flow diagram to execute the
suggested experimental equations, very similar to those calculations for compressible fluids and define the CV.
found in the standards [9] and [10]. However, from one S TART

manufacturing company to another, the obtained

results with the experimental determination of CV do
not necessary match or represent the same, because
Throttle
On/Off Valve
type
they are based in different test procedures [11].
In this work is described the operation of a new test
Op en the
bench, to determine the CV of process control valves V alve
Open t he valve at
a desirable %

with compressible fluid under the regulations

established by the standards [9] and [10]. This test
bench is used to verify the calibration of valves with Pressurize th e
system and adjust
at ∆p = 1 psi
continually variable opening, after they have been
repaired. The measurements in the test bench allow
Record p1, p2,
establishing the CV of these valves for various opening QyT

percentages.
In order to proceed with the flow sensor selection, it Evaluate Cv

was necessary to review the CV equation for

compressible fluids. This equation was obtained under NO ¿Other YES
similarity conditions, by the equality of Euler numbers open ning?

between prototype and model (test specimen). It is also

described the electronic instrumentation for measuring END

flow, temperature and pressure difference, the design

and the development of electronic circuits which
control the instrumentation, and the algorithms for the
operation and acquisition of measurements.
2. Test procedures for control valves
The standard [9] suggests the test procedures for
determining the capacity of control valves. The eighth
and ninth sections of this standard define, respectively,
the test procedure and the data evaluation procedure
for compressible flows.
Figure 1 shows the basic construction of the test
system. The standard [10], defines equations for sizing
control valves and indicates the result as a flow
capacity coefficient, CV. The seventh section of this
standard includes the equations for compressible flows.
Figure 2 shows, summarized, the test procedure fol-
lowed with our test bench. The annex B.2 of [9]
Figure 2. Flow coefficient test procedure.
The test bench instrumentation was chosen under
specifications of standards [9] and [10]. Three physical
variables must be recorded: pressure, temperature and
flow rate, with the following characteristics:
ƒ Pressure. All pressure measurements should be
taken with an error not exceeding ±2% of the
actual value.
ƒ Temperature. The flow temperature should be
measured within an error not exceeding ±1ºC
(±2ºF) of actual value.
ƒ Flow. The flow rate instrumentation may be any
device that meets specified accuracy. This
instrument will be used to determine the true time
average flow rate within an error not exceeding ±
2 percent of the actual value. The resolution and
repeatability of the instrument must be within ±
0.5 percent.

140
 The selection for pressure and temperature sensors  xp ρ 
1
2

was immediate, because we only considered the vp = vm  1 m  , (3)

operation limits for these variables. The readings, for  ∆p m ρ p 
 
valve characterization, are taken at environmental
temperature (300 K) and is expected a pressure drop hence,
not bigger than 50 psi [344 kPa] between the valve’s 1

 xp ρ s ρ pe 
2

ports, with a static pressure not greater than 1 MPa. vp = vm  1 m m  , (4)

However, for selecting a flow sensor it was  ∆p m ρ me s p ρ p 
 
necessary to specify the flow range, because there is a
wide range of valves that could be characterized with since,
this test bench. A greater valve capacity (greater CV)
means that a bigger flow rate may pass through the ρ m ρ m ρ me ρ ae ρ pe ρ m 1 ρ pe
= = sm , (5)
valve, for a certain pressure difference. ρ p ρ me ρ ae ρ pe ρ p ρ me s p ρ p
So it was necessary to develop the CV concept
for compressible flow and convert this numeric size to The relative density’s is an adimensional ratio that
flow rate, at free air conditions, for limiting the compares the gas density with the air density, both to
maximum flow that it may be recorded during a test standard conditions (subscript e; Te = 15.6 °C = 60 °F
valve. and Pe = 101 325 Pa = 14.73 psia).
.
As Q = vA and the orifice transversal area of the
3. Flow coefficient for valves with valve is the same, used like model or prototype, hence:
compressible fluids 1 1

 ρp   
2 2

 = Q m  xp1 ρ m s m  ,
. .
The CV coefficient of a valve prototype is Qp  (6)
 ρ pe   ∆p m ρ me s p 
established experimentally, taking measures of its    
capacity in conditions of dynamic similarity through The ratios ρ/ρe express the density change of each
Euler number [12]. The Euler number relates the gas (P, T), in model and prototype, with respect to the
inertia forces with the pressure forces, in an corresponding density in standard conditions (Pe, Te).
adimensional ratio: The equation of ideal gases, including the
v compressibility factor z, is:
Eu = , (1)
(2∆p/ρ ) 1
2
ρ 1 P Te
= , (7)
ρ e z Pe T
where v is the average velocity of the flow through
the valve, ∆p is the applied pressure difference and ρ Thus the flow rates of each side of the equations
is the liquid’s flow density. The measurements are could be expressed as flow rates in standard conditions,
performed passing a flow of certain test gas through . . ρ
Qe = Q , then:
the valve (the valve operating as a model), to produce a ρe
pressure drop of 1 psi (6.89 kPa). We will consider that
in model and prototype flow any pair of gases, not
1 1

ρp  ρ pe   
2 2

 = Q m ρ m  xp1 ρ m e s m  ,
. .
necessarily in standard conditions. So, the dynamic Qp  (8)
ρ pe  ρp  ρ me  ∆p m ρ m s p 

similarity is established by the equality of Euler  
numbers between model and prototype:
and for the model:
vm vp 1
= , (2) . .  ρ pe ∆p m ρ m s p 
2

(2∆p/ρ )m 1
2
(2∆p/ρ )p 1
2
Q me = Q pe 
 ρ p xp1 ρ me s m 
 , (9)
 
The pressure drop, applied between the inlet port, 1,
and outlet port, 2, of the valve, is the difference ∆p = Now, if the model is tested with air in standard
p1 - p2. This pressure drop in the prototype can be conditions, with a flow rate that produces the pressure
expressed as a ratio x of the absolute pressure at the
valve inlet, ∆pp = x · p1. Thus, the Eq. (2) is:

141
 BUFFER

V1
Pressu re Signal Decoder 12 V
Sensor 1 Amplification ADC0820
Micro con-
4-20 mA
troller 1 LCD
PIC16F877
Pressu re Signal Decoder V2
Sensor 2 Amplification ADC0820 R1 12 V R2
4-20 mA
240 W 1.0k W
BUFFER 4

U2 4

PC Salida 2
R3
U1
BUFFER Sensor 6 2

3 1.0kW 6 ADC0800

3 ADC_salida
Temperature Signal Decoder 7 1 5 LM741AH/883
Sensor Amplification ADC0820 7 1 5 LM741AH/883
Micro con-
4-20 mA troller 2 LCD
PIC16F877
Decoder
Flo w Sensor
ADC0820
0-5 V

BUFFER

Figure 3. Block diagram for the Figure. 4. Arrangement of operational

electronic circuit. amplifiers.
drop ∆pm = 1 psi, then ρm = ρme , sm = 1 and result for the CV, for a given flow regime (laminar or
. turbulent), and certain flow condition (choked or non-
Q me = C v . Thus: choked flow).
Then, with this equation for the CV factor it is
. 1

Q pe  ρ pe s p p1 
2
possible to design the valve testing conditions. The test
Cv =   , (10) can be executed with any gas and any pressure
p1  ρ p x  difference, measuring the flow rate advancing through
the valve. Usually air is the most suitable gas to run the
So that the expression for CV is:
test and, given an expected flow coefficient factor, we
. 1 can choose an appropriate ∆p to get a flow rate that fits
Q pe  s p T1z p e  2
in the test bench instrumentation capacity. Using this
Cv =   , (11)
p1  x Te  equation a single test measure is needed to obtain the
valve CV for a given flow regime and condition.
ρ pe p e zT1
since:= .
ρ e p1 Te 4. Electronic circuit for the bench
The Eq. (6) was multiplied by the transversal area instrumentation
of the valve, supposing that is identical in model and
prototype. But, it is very often that a fluid stream is The electronic circuit for the test bench was
reduced when it goes through an orifice, forming the designed with the following characteristics.
called vena contracta. In the vena contracta it is ƒ Independent circuits for each measurement
showed a slimming of the transverse section, which it instruments.
implies a velocity rise and, thus, a pressure decrease ƒ 8 bit of resolution for each instrument.
that changes the density of the gas. ƒ A LCD display for measuring each instrument.
Taking account the last phenomenon, we include ƒ Communications between the computer and the
the expansion factor Y in the right denominator and if electronic circuit through PC’s DB25 port.
we denote N7 = (Te / Pe) ½, thus the equation is: ƒ The electronic components are independent from
the computer.
.
Q pe  s p T1z 
1
2 The first stage of the electronic circuit has
Cv =   , (12) analogical inputs, in correspondence with the
N 7 p1Y  x  measurement sensors that produce current or voltage
signals, proportional to the variable measured by each
To evaluate the expansion factor Y is used the
sensor. In the Fig. 3 we show the analogical signal
equation (32) of [10].
intervals delivered by the sensors. As these signals are
The last expression was obtained supposing a
not uniform, it was necessary to homogenize them
pressure drop of 1 psi applied in the model during the
through a circuit that converts a current signal to a
test, but this not mandatory. This equality defines a
voltage signal (of 0-5V).
unique flow coefficient for each valve with certain
Figure 4 shows the arrangement of operational
opening percentage. The many possible combinations
amplifiers that converts from current to voltage. If the
of applied pressure difference and corresponding flow
rate through the valve will give the same numeric

142
 START
VCC
5V

Configuration of t he
Microcon troller an d the LC D
R1
J1 10k?
R2 Active
Decoder
Key = A PIC16F877
100?
_MCLR_ RB7 A8
RA0 RB6 A7
RA1 RB5 A6
RA2 RB4 A5
RA3 RB3 A4 LCD Take reading
RA4
RA5
RB2
RB1
A3
A2
from port
RE0 RB0 A1
RE1 VDD_
RE2 VSS_
4MHz _VDD RD7
_VSS RD6 Co nvert measure
0 OSC1 RD5
1 OSC2 RD4 (binary -> BCD)
RC0 RC7
Cristal RC1 RC6
RC2 RC5
RC3 RC4
RD0 RD3
RD1 RD2
P = ((2 4·x)/255)·25 [psi] T = ((180·x)/255) + 401.67 [ºR] Q = (100·x)/255 [AC FM]

Co nvert measure
(BCD -> ASCII)

EOC EOC
SOC SOC
¿Measure YES
NO Send data toLCD (ASCII
of 2 Clean reg isters
sensors?
and control bits )
ADC0820 ADC0820
1 sensor 1 sensor

Figure 5. Microcontroller for measurement Figure. 6. Algorithm for the microcontrollers.

processing.
input to the circuit is a current it delivers a positive
voltage drop, in accordance with the calculated
resistors.
After homogenize the analogical signals, they are
converted into a binary combination, for reading a
measure or for sending it to a computer. It is used an
analogical-digital converter to make the conversion
from a proportional analogical voltage to binary data.
For each measurement instrument is used an 8 bits
converter, for counting the minimum measurements
required to perform a test. Hence the minimum
resolution by the converters is:
VT
resolution =
2n − 1
The converter resolution is 20 mV, enough to
obtain a truthful measure of the physical variables.
After the coding is finished the binary combination is
captured by one of the microcontrollers (Fig. 5). The
microcontroller process the reading executed by the
measurement instrument; subsequently, in the LCD
display is showed the measure in the respective units.
the algorithm is repeated; if the answer is true the
microcontroller sends the processed data to the LCD
display, the employed registers are cleaned and the
microcontroller repeats the same algorithm and it
stays in cycle, until the circuit is turned off.
On the other hand, at the converter’s output is
used an arrangement of bidirectional buffers. In this
way the electronic circuit is communicated with the
computer and the data transmission is carried out at a
greater speed through the computers parallel port.
The algorithm for the data acquisition is showed in
the Fig. 7. The reading processing is similar to that
used in the microcontroller, but the data taken of each
one of the converters is handled with a graphic
, (13)
environment, programmed specifically for the
computer that processes the data and determines the
CV coefficient.
START
Configuration of Parallel
Port of PC
Switch on B uffer

In Fig. 6 are showed the algorithm designed for this

Take reading and save it
process. Also, it is used a microcontroller for each in a register
x 4

two measurement instruments.

Switch o ff
At the beginning this algorithm configures the Buffer

ports and initiates the LCD display. Later it is

triggered one of the analogical-digital converters, to Add to register's table
read the measure from the port where the convert is and arrange data

connected. This measure is converted from a binary

word to a BCD word, for processing the equations NO Last data
to acquire?

showed in Fig. 6. YES

Immediately the processed data is converted to
END
ASCII code, for displaying characters in the LCD.
Finally the algorithm asks if the acquisitions of the Figure 7. Algorithm for data acquisition
two converters are completed. If the answer is false through the parallel port.

143
 Characteristic curves of two types of valves (Linear and Equal plug).
60
50
40
Cv 30
20
10
0
0 20
Figure 8. Characteristics curves for two types of valves.
5. Conclusions
The flow capacity coefficient CV was determined
experimentally, taking flow rate, pressure difference
and temperature measurements. The valves that can be
characterized with this test bench include as the on-off
as the continually variable. For the last ones, a finite
number of tests must be done with different openings,
in order to graph the characteristic curve of the control
process valve (see Fig. 8, with the characteristics
curves for two types of valves).
The test bench is fixed over a light structure of
aluminum profiles, and could be transported to execute
tests in the field. For its operation is necessary the
supply of compressed air at 600 kPa, and 100 W of
electrical power at 110 VCA. The electronic circuit
with the graphic environment running under MS
Windows may be installed in any PC (see Fig. 9).
Figure 9. Test bench for control valves.
6. References
[1] Masoneilan, Bulletin OZ1000 7/00, “Masoneilan Control
Valve Sizing Handbook”. Masoneilan Control Valves.
Dresser Industries, Inc., (2000).
View publication stats
Linear plug
Equal plug
40 60 80 100 120
%opening
[2] SEMASPEC-90120394B-STD “Test Method for
Determination of Valve Flow Coefficient for Gas
Distribution System Components”, SEMATECH Technology
Transfer. Approved 22 February of 1993.
http://www.sematech.org/
[3] FCI 84-1-1985, “Metric Definition of the Valve Flow
Coefficient Cv”. Fluid Controls Institute (1985).
[4] Wing Paul, Jr., “Practical Determination of Control Valve
Cv”. ISA Journal Vol. 7 No. 9 pag: 90-93, (1960).
[5] Rahmeyer, William J. “Control valve testing procedures
and equations for liquid flows”. Utah Water Research
Laboratory, (N/A).
http://www.engineering.usu.edu/cee/faculty/rahm/Appendix
A.pdf
[6] SEMI F32-0706, “Test Method for Determination of
Flow Coefficient for High Purity Shutoff Valves”.
Semiconductor Equipment and Materials Institute. Approved
in May of 2006. http://www.semi.org/
[7] Driskell, L., “Control-valve selection and sizing” Unit 7,
pag: 115-128, Research Triangle Park, NC: Instrument
Society of America (1983).
[8] Fu W.-S.; Ger J.-S., “A concise method for determining a
valve flow coefficient of a valve under compressible gas
flow”, Exp. therm. fluid sci., vol. 18, no4, pp. 307-313
(1998).
[9] ANSI/ISA-75.02-1996, “Control Valve Capacity Test
Procedures”. Approved 1 October of 1996, ISA.
[10] ANSI/ISA-75.01.01-2002, “Flow Equations for Sizing
Control Valves”. Approved 8 April de 2002, ISA.
[11] Fleischer H., Forster K. y Franson D., “Clearing the air
on pneumatic valve ratings”, Machine Design., pp. 97-100
(2000).
[12] Rahmeyer, William J. and Driskell, Less., “Control
valve flow coefficients”. J. of Transportation Engineering,
Vol. III, No. 4, pp. 358-364, (1985).
144