SELECTION AND SIZING OF CONTROL VALVES FOR
NATURAL GAS
Carol L. Nolte
The C.J. Nolte Co.
The purpose of this paper is to help the user understand
the information needed to properly select and size a con-
trol valve for natural gas service. With so many different
manufactures of control valves we wont focus on one;
however the information listed is required by all manu-
factures in order to provide you with the best valve for
the application. Most manufactures will assist you in
sizing your application.
The first step in sizing a control valve is to determine the
required Cv or capacity required through the control
valve at different operating conditions. It is not enough to
size for one condition, rather all the conditions must be
considered.
Once you have completed sizing a valve for the given
conditions you need to determine if that valve will oper-
ate and control well over all of those conditions. Most
valves have an optimum control range. For instance a
manufacture may only guarantee good control if the
valves is operated between 10-85% of its capacity. Its
important to know those limits. Keep in mind that that
information may not be part of sizing tables or programs.
Besides the basic information for sizing there are sever-
al factors to weigh when sizing and selecting a control
valve. A control valve is part of a large system and can
affect numerous aspects of that system. Lets look at the
questions and information needed to properly size and
select a control valve and why.
The questions to consider and why:
1. WILL THE VALVE BE USED FOR PRESSURE OR
FLOW CONTROL?
Some instrumentation is better suited for flow control
verses pressure control. If youre doing flow control will
you have pressure overrides? Again this choice will effect
the instrumentation you will use. Normally flow control is
done with a combination of a positioner and controller
whereas pressure control can often be accomplished
with a simpler pilot scheme.
2. WHAT ARE THE MINIMUM AND MAXIMUM INLET
AND OUTLET PRESSURES AS WELL AS THE MINI-
MUM AND MAXIMUM FLOW RATES?
Not knowing the minimum inlet pressure or maximum
flow rate can cause us to undersize a regulator. This can
cause you to have a valve that doesnt get enough gas
through the line. This can also cause high vibration which
167
can loosen fittings and damage other pieces of equip-
ment.
Not knowing the minimum flow rate or maximum inlet
pressure can cause us to oversize a regulator. If you
oversize a flexible element regulator it may cause the
regulator to open unevenly and destroy the flexible ele-
ment. Over sizing globe, ball or plug valves causes
cycling which can cause the internals to wear out. High
cycling can also cause high vibration which again can
loosen fittings and damage other pieces of equipment.
Proper sizing doesnt sacrifice good control for future
flow. Instead look at using valves with better rangeability
as well as considering using additional runs.
3. WILL THE INLET PRESSURES AND/OR FLOWS
FLUCTUATE?
Flexible element regulators are subject to droop. Droop
is caused by the pilot. If pressure and flow rates are
constant than droop isnt an issue. Some pilots are less
susceptible to droop than other pilots.
4. DOES THE DESIGN CALL FOR A MONITOR
REGULATOR, AND IF SO WILL IT BE PASSIVE OR
WORKING?
If the monitor regulator is passive or wide open then the
control valve should be sized as having a passive moni-
tor regulator. Having a monitor regulator can reduce the
capacity of the regulator run depending on what type of
valve will be used as a monitor.
If a working monitor (two pressure cut with a monitor
override)will be used both valves need to be sized sepa-
rately as independent valves taking separate cuts. What
you choose as an intermediate pressure is very impor-
tant here.
Lets look at an example of sizing passive verses work-
ing monitor regulators. In this example well size for a
flexible element regulator for pressure control with an
inlet pressure of 500 psi and an outlet of 60 psi. If we
look at a 2 regulator the capacity is 1537 MSCFH. If we
add a passive monitor the capacity is 1224 MSCFH. If
we have a working monitor with 500 psi in 200 psi out on
the first cut and 200 in and 60 out on the second cut my
capacity is 628 MSCFH, because the capacity of the first
cut is 1537 MSCFH, but the second cut is only 628
MSCFH. If we change our intermediate pressure from
200 psi to 300 psi our capacity increases to 927 MSCFH.
500 psi in to 300 psi out is 1489 MSCFH and 300 psi in
to 60 psi out is 927 psi. Different regulator brands and
types will have different capacities, but the rule is the
same; the greater the pressure drop the greater the
capacity.
A working monitor installation may not respond fast
enough for a fast acting system, such as a power plant
trip.
5. IS PRESSURE DROP A FACTOR?
In some areas of the system you may have a situation
where the inlet to the control valve may fluctuate. If there
are going to be times when the inlet pressure is close to
the desired outlet pressure, than you have to size for
these cases. You may want to go with a single cut regu-
lator and a wide open monitor valve that has a minimal
pressure drop such as a ball valve regulator. You can also
choose to size the application such that the monitor is
working when the inlet pressure is sufficient, and passive
when the differential is too small.
6. IF THERE IS A MONITOR, HOW CLOSE IS IT TO
THE PRIMARY REGULATOR?
Certain types of control valves are not quick responding
and if placed to close to the down stream regulator, may
cycle.
7. WILL THERE BE A RELIEF VALVE, AND IF SO, HOW
CLOSE WILL IT BE SET TO THE CONTROL VALVES
SET POINT?
Its often desirable in some systems to operate as close
to the lines maximum operating pressure as possible but
if the regulator doesnt have tight control or doesnt lock
off well the relief will weep.
8. ARE THERE NOISE CONCERNS?
Most sizing programs can give you predicted noise
levels. Please keep in mind these predictions dont take
into consideration surrounding structures; youll have to
figure that in yourself. If noise is an issue you have many
options to choose from such as low noise trim, burying
the valves and even adding diffusers and silencers. All of
these options have pluses and minuses.
Low noise trim may reduce capacity but increase range-
ability.
Burying control valves will allow you to lessen the foot-
print of the station, increase the velocity through the
valve (many companies allow 100 fps velocity - approxi-
mately 68 MPH through above grade valves and 200 fps
through buried valves), but if you need to work on the
valve you have to get to it.
Diffusers and silencers can be sized for a particular noise
reduction and pressure drop, but they have to be used
with clean gas or in conjunction with a filter because they
can catch debris.
168
Another way to reduce the noise at one location is to use
a working monitor installation and have the control
valves separated so you can not hear the noise generat-
ed from one regulator while located at the other one. The
noise generated by each regulator will be less that if the
total pressure reduction was done on one regulator.
Also, keep in mind that using low noise trims can trans-
fer the noise from the audible range to the ultrasonic
range. If the station has an ultrasonic meter that ultra-
sonic noise could severely effect the operation of the
meter.
9. HOW TIGHT DOES THE CONTROL NEED TO BE?
If you are feeding a large system you may not care if your
control fluctuates a bit. If youre feeding a short system
control may be critical to the equipment downstream.
Youll have to choose a valve that can meet your criteria.
10. WHAT IS THE SIZE AND CONFIGURATION OF
THE INLET AND OUTLET PIPING?
Velocities of over 100 fps in above grade pipe can cause
ultrasonic and audible noise as well a pipe vibration.
Velocities of over 200 fps in below grade pipe can create
noise that can be heard in above grade pipe, and inter-
nal erosion.
Reducers and increases, elbows, tees, and flow restrict-
ing lock valves will create turbulence, affecting capacity
and velocity.
Youll need to be able to sense the pressure that is being
controlled. Your control is only as good as the signal you
give the controller. Sense lines connections should be
placed in straight laminar pipe and be located 10 pipe
diameters downstream, and 5 pipe diameters upstream,
of any turbulence creating piping configuration.
11. WILL THE STATION BE IN A VAULT?
If the station is located in a vault youll need to consider
such issues as water infiltration, can the valve and instru-
mentation needed to control it be submerged or will you
have to make other provisions? Youll also need to make
sure that the valve and instrumentation can be serviced
in that size space.
12. WILL THERE BE REMOTE CONTROL?
One thing youll need to consider is the range of the con-
trol device. For instance if you want to add a motor drive
to a pilot on a control valve, if the spring in the pilot has
a control range of 200-600 psi and it takes 15 turns of
the adjustment screw to achieve that range you would
need to make sure the motor can give you 15 turns.
You also need to consider what type of signal the remote
control devise will output. If the signal requires power do
you have power available and how reliable is it?
Furthermore, how will the remote control devise affect
the devise its controlling? If its constantly tweaking a set
point can that valve and instrumentation take it?
13. IS BLEED GAS AN ISSUE?
If you are concerned about bleed gas for reasons such
as call outs or reducing fugitive emission reduction youll
need to select a valve that can be combined with instru-
mentation to eliminate or reduce bleed. Flexible element
style regulators can be operated with pilots that bleed
into the downstream system. Control valves such as
globe, plug and ball valves can be operated with instru-
mentation with no or low bleed and some equipment can
be bleed into the downstream piping.

14. WHAT IS YOUR DESIRED MODE OF FAILURE?

All valves can fail. If they do, do you want them to fail in
the full open, full closed or last position? For instance a
flexible element style regulator in most cases will fail
open. If youve chosen that style valve youll need to
insure that you have overpressure protection if neces-
sary.

15. WILL THERE BE TEMPERATURE

CONDITIONING?
Approximately, a 15 PSI (1 atmosphere) pressure drop
= 1 degree Fahrenheit temperature drop. Low tempera-
tures can cause ice build up around outlet piping, this
can cause cracks in foundations or heaves in the high-
way. It can also reduce the maximum operating pressure
of steel pipe. For instance, class 600 pipe below 20F is
no longer rated to 1480 psi. Also, the reduced gas tem-
perature may create water and hydrocarbon condensate.

Low and high temperatures can affect soft goods in

valves and instrumentation as well as high temperatures.
Make sure you know what the acceptable temperature
ranges for the media and atmospheric temperatures are
for the valve.

CONCLUSION
Selecting and sizing control valves is not as simple as
calculating capacity. Many factors have to be taken into
consideration. Over looking even one aspect of an instal-
lation can lead to costly mistakes. Since many situations
and experiences in our industry arent documented its
important to draw from the experience of people with
first hand field experience. Give as much information as
possible to vendors in order to help you make the right
choice in proper valve selection. Also, make sure to con-
sider your operating personnel and the type of equip-
ment they prefer.

169