manual de usuario nelprof 6

7/30/2019 Manual de Usuario Nelprof 6

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NELPROF 6.0 USERS GUIDE

Java Version 1.6

Published by

METSO

P.O.Box 310FIN-00811 HELSINKI

Finland

Editor:

Ismo NiemelEsa Lumme

Petri KanervaVesa LempinenJari Kirmanen

Jussi Koukkuluoma

Copyright 2010 by Metso and the authors. All rights reserved. No part of this publication

may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans electronic, mechanical, photocopying, recording or otherwise, without the prior

permission of the publisher.

While this information is presented in good faith and believed to be accurate, Metso does

not guarantee satisfactory results from reliance upon such information. Nothing containedherein is to be construed as a warranty or guarantee, express or implied, regarding the

performance, merchantability, fitness or any other matter with respect to the products, nor

as a recommendation to use any product or process in conflict with any patent. Metsoreserves the right, without notice, to alter or improve the designs or specifications of the

products and methods described herein.

Produced and printed in Finland by Metso

Helsinki 2010


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Contents

Contents...........................................................................................................................1

1 NELPROF 6.0 USERS GUIDE..................................................................................1

2 Introduction to Nelprof Control and On-off calculation..............................................2

3 The Project Tree...........................................................................................................4

4 Control valve sizing and analysis.................................................................................4

5 On-off valve sizing and analysis................................................................................15

6 User settings...............................................................................................................18

7 User preferences.........................................................................................................19

8 File Functions.............................................................................................................19

9 Mass Operations.........................................................................................................19

10 SIL calculation tool..................................................................................................21

11 Help..........................................................................................................................2712 Appendix 1. Valves included in Nelprof..................................................................27

13 Appendix 2. Nelprof load factor for rotary control valves.......................................27

14 Appendix 3. General control valve selection guidelines..........................................28

15 Cavitation noise level is high...................................................................................29

16 Control torque of the actuator is too small...............................................................29

17 Flow marginal is large..............................................................................................29

18 Flow marginal is small.............................................................................................30

19 Flow velocity in valve inlet port is high...................................................................3020 Flow velocity in valve outlet port is high.................................................................30

21 Installed flow characteristics have not been analysed..............................................31

22 Maximum gain within the control range is high......................................................31

23 Minimum gain within the control range is small.....................................................32

24 Noise level is high....................................................................................................32

25 Opening or closing torque of the actuator is too small............................................32

26 Opening or closing torque with maxi dp is too high. ...............................................33

27 Output thrust of the actuator is too small.................................................................33

28 Pressure is too high for the valve size......................................................................33

29 Ratio of maximum and minimum gain within the control range is high.................33

30 Supply pressure of the instrumentation air to the actuator is insufficient................34

31 Torque in control position with control dp is too high.............................................34

32 Valve is in flashing flow conditions.........................................................................34


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33 Valve nominal size is larger than pipeline nominal size..........................................34

34 Valve nominal size is small compared to pipeline nominal size..............................34

35 Valve opening with maximum required capacity is high.........................................35

36 Valve opening with maximum required capacity is low..........................................35

37 Valve opening with minimum required capacity is low..........................................35

38 Valve shaft diameter is smaller than actuator hole..................................................36

39 Valve shaft diameter is too big to fit into the actuator hole.....................................36

40 Valve does not have enough capacity......................................................................36

41 Pressure is too high for the valve type.....................................................................36

42 Cavitation intensity is high.......................................................................................37


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1 NELPROF 6.0 USERS GUIDE

1.1 General

1.1.1 Introduction

Welcome to the Metso Valve Sizing and Selection program Nelprof Version 6.0. Nelprof

Version 6.0 is a valve selection expert system for Control, On-off and ESD valves. Inaddition to the calculation equations, it also includes expertise in the interpretation of

results. It analyses selections and gives selection advice for control valves.

Version 6.0 includes the technical selection from flow and control point of view a new

module for actuator selection for On-off valves and SIL (safety integrity level) calculations.Control performance criteria, such as installed flow characteristics, cavitation and noise,

form the basis for selection. Additional features are helping in the selections in the new

version. However, one may find information about wide range of issues in literature

presented along with the sizing program.

The new features of Version 6.0 are:

On-off calculation module

SIL and PFD (probability to fail on demand) calculation tool for 1oo1 and 1oo1D

valve assemblies

Flexible export with adapters to Metso datasheet generator (For Metso users)

Control Valve Sizing Coefficients book updated

This Users Guide is specifically edited to Nelprof version 6.0. Wherever the reference is

made to Nelprof in this Users Guide, Nelprof 6.0 is referred to.

1.1.2 Selection limitations

Selection is limited to flow, control and torque requirements regarding control and on-off

valves valves. The user shall check the following aspects of selection separately:

Pressure, temperature limitations

Pressure drop limitations (mechanical strength)

Materials suitability

Constructions suitability

Available valve-actuator connections

Commercial aspects

Checking of the valve construction (i.e. bearings, seats, gland backings) suitability, and inthe case of uncommon materials also the valve body, is left to the user.


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SIL calculation tool is intended to be used in the quotation phase only and does not

correspond to and cannot be used instead of calculations made engineering departmentnominated expert.

1.1.3 System requirements

The Nelprof 6.0 is intended for use on Microsoft Windows XP, Vista, and 7 operating

systems running on the Intel Architecture platform, with the disc space requirement ofabout 300 Mb.

1.1.4 Useful Windows commands

Following mouse and keyboard functions used in Windows helps to work with Nelprof 6.0

as well:

Using the mouse - Use the mouse to point and the left mouse button to select. A singlemouse click usually selects an item from the list box and only in some cases can you double

click to select an item from the list and close the current window. Pressing the right mousebutton causes a popup menu (if one exists) to appear. Start the program by double clicking

the program icon.

Using the keyboard - For some functions you can also use the fast key commands, e.g.

Ctrl + item letter.

Enter Move to next field/row/column (in input grid)

Tab Move to the next field/columnShift + Tab Move to previous field/column

Esc In an input window means cancel

Some Nelprof 6.0 keyboard commands:

Arrows/Tab Move in the input grid

Ctrl + S Saves the selected item an it's sub items

Ctrl + R Adds a new area tag in the treeCtrl + T Adds a new control tag in the tree

Ctrl + I Adds a new control sizing in the tree

Delete Deletes the selected item(s)

Ctrl + F Opens the find tag dialogCtrl + P Prints the sizing(s)

Ctrl + X CutCtrl + C Copy

Ctrl + V Paste

Ctrl + D Duplicate


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For more information about Windows refer to the Windows Users Guide or start the

Windows Tutorial from the start Help menu.

2 Introduction to Nelprof Control and On-off calculation

2.1 Starting Nelprof

Start Nelprof by double clicking on the Nelprof icon or by clicking the Nelprof 6.0 icon in

the start menu or on the desktop. A disclaimer notice appears on the screen. Click OK toaccept the disclaimer notice. The main Nelprof window appears on the screen.

2.2 Step 1 - Identification creation

When the program is first time used, it asks for your first name and last name. This

information is used to create unique identification of your projects. This information can belater changed when needed in Preferences - User Preferences menu.

2.3 Step 2 - Creating Project and entering Project properties

To start the sizing you have to first create a Project. You can do this by selecting File|NewProject from the menu. New project appears in the project tree. Click the text Project in

the tree and you see the Project Info screen. Enter the data to the fields. Part of thisinformation will show up in the printouts. Under project, there is always at least one area.

One project can cover several areas, depending on actual plant/project. All new created

project trees have by default a structure which includes one area under the project, one tag

under the area and one sizing under the tag. The tree can be expanded with the followingsteps

2.4 Step 3 - Creating Area and entering Area properties

Under each project you can have several Areas. Each area can represent a part or a section

of a project. More areas can be created by selecting Create|Add Area from the menu or byclicking the Add Area button from the tool bar. When you add a new area, it will be empty

and a tag or tags need to be created separately to proceed to a calculation. Area name can

be changed from the Area field name menu which appears when you click the text Areaat the project tree.

2.4 Step 4 - Creating Tag and entering Tag properties

After you have created a project with an area, you can create a Tag. This can be done by

selecting Create|Add Tag from the menu or by clicking the Add Tag button from the toolbar. When you add tag, one sizing will appear automatically under the tag. Select Create|

Add On-off Tag with a red valve icon to create On-off tag and select Create|Add ControlTag to create Control tag with a light blue valve icon.


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New Tag appears accordingly in the project tree and by clicking the Tag text you see the

Tag Properties screen. Enter the tag details to the corresponding fields when available. Partof this information will appear in the printouts.

2.5 Step 5 - Entering Input data

Select the sizing that you created in the Step 4 (See Step 10 for adding more sizing

calculations under each tag). To enter input data you must first select the process fluid

phase: liquid, water, gas, steam, pulp or 2-phase. The corresponding input screen appearsand you can fill in the information concerning piping, fluid, flow, pressures, valve and

actuator. If you do not want to size an actuator uncheck the Actuator sizing checkbox.

You can proceed from a field to another by pressing Tab, Enter, Arrow or by using the

mouse. With right mouse button you can copy column, clear column orcopy field whencursor is on data entry area. The program will warn you if information is missing or if

values are out of limits.

2.6 Step 6 - Selection

After all required input data have been entered, selection is performed by clicking thebutton CALCULATE.

When using automatic valve size selection, the size is selected according to the flow and

control requirements. Openings, noise, flow velocity, flow characteristics, cavitation etc.

are evaluated as the size selection criteria. Specify the valve size when entering input datato perform manual valve sizing.

Actuator size is selected according to opening, closing and control torque. For control theactuator is sized to obtain a certain amount of extra power for good control performance.

Specify the actuator size and for spring return actuators also the spring rating to performmanual selection.

For On-off sizing the automatic actuator size is selected according to BTO (break to open)

and ETC (end to close) requirements including the recommended actuator sizing safety

factor.

2.7 Step 7 Analysis

After calculation the valves short code and size appears in the Result box. The actual

analysis can be performed through the tabs located under the tool bar. The following

analysis functions are available for control valve sizing:

Sizing

Valve and actuator sizing with results, e.g. openings, noise, required operational

torques etc.


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Notes and warnings

VDMA Noise level as a function of valve travel for the installed valve for control

valves

Notes and warnings regarding the selected valve and actuator for given process data

for control valves

Own remarks field

Characteristic curves

Inherent charaterisctis: Intrinsic Cv curve of the selected valve

Installed flow characteristic: Characteristic flow as a function of valve travel

installed in a process

Installed gain: Gain as a function of characteristic mass flow installed in a process

Installed pressure level: Upstream and downstream pressures as functions of valve

travel.

2.8 Step 8 - Saving and loading data

Data is saved as projects. One project is one XML file which should be named when saving

the file. You can save all projects by selecting File|Save All from the menu or by clickingthe Save all -button in the toolbar. You can save data of certain project by selecting the

project from the tree and clicking the save button on the toolbar or by selecting File|Save.This will save data of that project and all its sub-items. The default path for project files ispresented in Preferences-User preferences and it can be changed to whatever user wants.

To import sizing data from other data formats like csv, select File|Import/Export from

the menu. Adapter Window is opened and usage is explained in different chapter.

2.9 Step 9 - Printing

Printout can have one project, with multiple areas, tags and sizings. With different languageproperties files, different language versions of the printout can be made.

User must select printable objects from the project tree. Several sizing sheets can be printed

at once. Mark the sizings you wish to print and select File|Print from the menu or by

clicking the Print button from the tool bar.


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Figure 1. Sizing selections for printing

Language selection and selection of printed objects is performed after print command has

been pressed. English is the default language. Optional languages are available for thecontrol valve sizing only.


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Figure 2.Printing selection options

If you have problems in printing, make sure all connections are correctly in place and use

the printer setup to define the printer and printer defaults.

2.10 Step 10 - New calculation and exiting the program

New calculation can be created by pressing the Add sizing button from the tool bar or from

menu. Select Create|Add Control sizing to create a Controlsizing and Create|Add On-off sizing to create an On-offsizing. If you do not want to save the old sizing you can typeover the old input data and re-calculate.

To exit Nelprof 6.0, select File|Exit from the menu. If any data have been changed, Nelprof

will ask if you want to save this data before exiting.

3 The Project Tree

In the project tree you can add, rename, delete, copy, cut, find and print tree items. You

can also sort tags in a project by their creation date or name. The Project tree is located onthe left-hand side of the user interface. Right mouse button brings a popup menu onto

screen.

Figure 3. The Project Tree

Each file represents a project. Under that there are areas, tags and sizings. One project caninclude several areas, one area can include several Tags. Every tag can include several

sizings.


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To view Project info, click the project name. To view Area info, click the area name. To

view Tag info, click the Tag name. To view Sizing, click the sizing name. After this youcan see the sizing input/output data on your Nelprof main window.

To Create a new project, area, tag or sizing, select the place from the project tree where

you want to place the new object and choose File|Add Project, Create|Add Area,Create|Add Tag orCreate|Add Sizing from the menu.

To Rename a project, area or tag, use the properties window of each object.

To Delete a project, area, tag or sizing, select the object(s) that you want to delete with

right mouse button and press delete button. The object(s) will be deleted permanently.

To Print a sizing, just select it by checking the box on the left side of the sizing name from

the Project tree and click the print button in the toolbar. If you want to select more than oneArea, Tag or Sizing, check them all. Note that by checking the area, all objects of an area

will be selected.

4 Control valve sizing and analysis

Automatic valve size selection is based only on flow and control. Selection considers topics

such as valve opening, noise level, flow velocities, cavitation for liquids and installed flowcharacteristics. The program does not consider special requirements of fluids or processes.

It is very important to study the suitability of the valve materials and construction

separately for each application.

To size a valve, follow the steps shown in chapter 2. A more detailed description of sizing

in different fluid phases is given in this chapter.

4.1 Liquid and water sizing

4.1.1 Input data for liquid and water sizing

You can select liquid or water sizing by pressing the appropriate button on the input data

window. When sizing for liquid and water flow you enter data as shown in the next figure.Certain information will appear automatically.


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Figure 4.Input data for liquid and water sizing

Changing the units, see chapter 5 on User settings.

(1)

Process fluid selection. A selection of fluids is available in upper field. Free

description of the fluid can be entered in the lower field.

(2)

Spec grav. Specific gravity (not included in water sizing). Enter Spec gravity. Orleave this field empty and enter Density. If neither is entered, the specific gravity for

water is used.

(3)Density (not included in water sizing). Enter Density. Or leave this field empty and

enter Spec gravity. If neither is entered, the specific gravity for water is used in the

calculation.(4)

Crit press. Critical pressure. If not entered, the critical pressure for water is used in

the calculation.(5)

Viscosity. If entered, Nelprof will check for non-turbulent flow conditions and

correct the calculations if necessary. See more details in the Flow Control Manual.

(6)

Special service req. By default service is Normal. If known that process in questionhas special requirement is known to cause friction increase due to the application or

fluid other selection can be used accordingly. Other selection can affect to therecommended actuator sizing safety factor.

(7)

DPm. The process pressure ratio factor. This is needed for installed flowcharacteristics and gain calculation in one flow case scenario. DPm defines the

portion of the total system pressure losses as taken by the control valve at maximum


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flow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss

is taken by the valve, 70% by the piping and pipe components). For Finetrol

valve default value is 0.5. DPm is not needed if two or more flow cases are given.Look for more details in the Flow Control Manual.

(8)

Design P. Max design pressure condition for the Tag. Input value fordocumentation. Value does not automatically affect to the valve selection within theprogram. Manual considerations in the valve selection must be made according to

the requirements.

(9)

Design Tmax. Max design temperature for the Tag. Input value for documentation.

Value does not automatically affect to the valve selection within the program.

Manual considerations in the valve selection must be made according to therequirements

(10)

Design Tmin. Min design temperature for the Tag. Input value for documentation.

Value does not automatically affect to the valve selection within the program.Manual considerations in the valve selection must be made according to the

requirements

(11)

Inlet dia.Nominal diameter of the upstream pipeline.

(12)

Outlet dia. If not entered, the nominal diameter of the downstream pipeline is

assumed to be the same as the inlet diameter.

(13)

Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule.

(14)Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is

entered, then Sch 40 will appear as the default value. Needed only for noisecalculation.

(15)

Flow Rate. Flow rates for four different flow conditions can be entered.(16)

Inlet Temp. Temperature at upstream conditions.

(17)

Inlet Press. Pressure at upstream conditions.

(18)

Press Diff. Differential pressure across the valve with corresponding flow rate. Thevalue must be lower than the given upstream pressure. Enter either pressure

differential or outlet pressure.

(19)

Outlet press. Outlet pressure of the valve. Enter either pressure differential or outletpressure.

(20)


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Vap Press. Vapour pressure. Provided automatically for liquids included in

Nelprof. The value that Nelprof provides can be replaced by the users own valueby typing over the default value. Value entered is vapour pressure of the liquid at

upstream temperatures. A careful search for accurate vapour pressure is

recommended, as this information is needed in cavitation and flashing flow

calculations.(21)

Valve. By pressing this button you can open a valve type list and selection dialog.

Valve type can be selected from here or by using fields 18, 19 and 20.(22)

Type. Select valve type from the list.

(23)

Press rating. Pressure rating required. Select rating from the list. If you select All,valves available in all ratings are listed in Code column.

(24)

Code. Select valve code from the list.(25)

Size. Valve nominal size/reduction. Will be automatically selected when autom

appears instead of size.

4.1.2 Results for liquid and water sizing

Figure 5.Results for liquid and water sizing

Max

capacity

Maximum flow capacity of the chosen control valve, taking into account piping

reducers.

Reqcapacity

Calculated capacity needed for flow conditions specified in the same column.

Travel Opening as a percentage of full travel, excluding initial opening. The initialopening is the travel before the flow starts.

Opening Opening in degrees for rotary valves, including initial opening.

Noise Predicted sound pressure level based on the VDMA 24422 (May 1979) or

enhanced IEC 60534-8-4 standard. A high noise level for liquid flow is a goodindication of a high cavitation level. Q-Trim or similar low-recovery valves are


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recommended in case of high noise levels. The maximum recommended

hydrodynamic noise levels in valves calculated with non-insulated schedule 40piping are:

- 80 dB(A) for valve sizes up to 80 mm (3") size,

- 85 dB(A) for valve sizes 100-150 mm (4"-6") size,

- 90 dB(A) for valve sizes 200-350 mm (8"-14") size,- 95 dB(A) for valve sizes 400 mm (16") and larger size.

The figures are given considering the valve operation. Workplace safety regulations, and

end-user specifications etc. may dictate other maximum values.

Flow

velocity

Flow velocity at the valve inlet. The maximum recommended valve inlet

velocities are as follows:a) Continuous duty

- Butterfly valves 7 m/s, 23 ft/s.

- Cage-guided globe valves 15 m/s, 50 ft/s.- All other valves 10 m/s, 32 ft/s.

b) Infrequent Duty

- Butterfly valves 8.5 m/s, 27 ft/s.- Cage-guided globe valves 18 m/s, 60 ft/s.

- All other valves 12 m/s, 39 ft/s.

Terminal

dpOften referred to as Critical pressure drop. Whenever the differential pressure ishigher than the terminal pressure drop the valve will experience high intensities

of cavitation. The use of Q-Trim or similar is recommended to avoid cavitation

problems. In cases where conditions result in flashing, the terminal pressure drop

is not significant. Then, word "flashing" will appear in this field. Flow ControlManual offers more information of the meaning of terminal pressure drop.

Fl coeff The pressure recovery factor of the valve with this particular opening.

4.2 Gas and steam sizing

4.2.1 Input data for gas and steam sizing

When sizing for gas and steam flow the data should be entered as shown in the next figure.

Some of the information will appear automatically.


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Figure 6.Input data for gas and steam flow

Changing the units, see chapter 5 User settings.

(1)


description of the fluid can be entered in the lower field.(2)

Spec grav. Specific gravity. Enter Specific gravity. Enter either Spec gravity or Mol

Weight.(3)

Mol weight. Molecular weight (not included in steam sizing). Enter either Spec

gravity or Mol Weight. If neither is entered, the upstream density must be enteredinstead of compressibility in process data area.

(4)Spec heats. Ratio of Specific Heats. If not entered, the value 1.4 for air is used. For

steam sizing 1.3 will appear automatically.(5)

Special service req. By default service is Normal. If known that process in question

has special requirement is known to cause friction increase due to the application orfluid other selection can be used accordingly. Other selection can affect to the

recommended actuator sizing safety factor.

(6)

DPm. The process pressure ratio factor. This is needed for installed flow

characteristics and gain calculation in one flow case scenario. DPm defines the

portion of the total system pressure losses as taken by the control valve at maximumflow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss


valve default value is 0.5. DPm is not needed if two or more flow cases are given.

Look for more details in the Flow Control Manual.

(7)

Design P. Max design pressure condition for the Tag. Input value for

documentation. Value does not automatically affect to the valve selection within the


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program. Manual considerations in the valve selection must be made according to

the requirements.(8)




(9)

Design Tmin. Min design temperature for the Tag. Input value for documentation.Value does not automatically affect to the valve selection within the program.

Manual considerations in the valve selection must be made according to the

requirements(10)


(11)

Outlet dia. If not entered, the nominal diameter of the downstream pipeline isassumed to be the same as the inlet diameter.

(12)

Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule.(13)

Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is


(14)



(16)

nlet Press. Pressure at upstream conditions.(17)

Press Diff. Differential pressure across the valve with corresponding flow rate. The

value must be lower than the given upstream pressure. Enter either pressuredifference or outlet pressure.

(18)

Outlet press. Outlet pressure of the valve. Enter either press difference or outletpress.

(19)

Compress orUpstream Density. Compressibility is provided automatically for the

gases included in Nelprof. The value that Nelprof provides can be replaced by theusers own value by typing over the default value. Upstream density is provided

automatically in steam sizing.

(20)

Valve. By pressing this button you can open a valve type selection dialog. Valve

type can be selected from here or by using the fields 18, 19 and 20.

(21)


(22)


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Press rating. Pressure rating required. Select rating from the list.

(23)

Code. Select valve code from the list.

(24)

Size. Valve nominal size/reduction. Will be automatically selected when autom

appears instead of size.

4.2.2 Results for gas and steam flow

Figure 7.Results for gas and steam sizing

Max

capacity


reducers.

Req

capacity


Travel Opening as a percentage of full travel, excluding the initial opening. The initial

opening is the travel before the flow starts.

Opening Opening in degrees for rotary valves, including the initial opening.

Noise Predicted sound pressure level based on the VDMA 24422 (May 1979) or IEC

60534-8-3 standard. In most countries 85 dB(A) is the maximum permitted noiselevel. A noise level higher than 110 dB(A) will subject piping and equipment to

possible vibration damage. Q-Trim or similar low-noise valves are recommended

to reduce noise. Also, downstream resistors such as diffusers and A-plates can beused to reduce noise.

Flow

velocity

Flow velocity at the valve outlet. The maximum recommended valve outlet

velocities are as follows:

- 0.5 Mach for continuous control,- 0.7 Mach for infrequent duty, e.g. flaring and venting.

Xt coeff Valve pressure drop ratio factor with this particular opening. Defined according

to standards IEC60534 and ISA S75.

4.3 Pulp stock sizing

In pulp flow sizing the input information is almost the same as in liquid flow sizing. The

difference is in fluid description, in which you specify the stock type and also consistency.

4.3.1 Input data for Pulp Stock Sizing


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When sizing for pulp flow the data is entered as shown in the next figure. Compared with

water sizing, the differences are in fluid description and consistency.

Figure 8.Input data for Pulp Stock Sizing


(1)

Process fluid selection. Free description of the fluid can be entered in the lower

line.(2)

Consist %. The consistency of the pulp stock. More details of calculation are given

in the Flow Control Manual.

(3)

Crit press. Critical pressure. If not entered, the critical pressure for water is used inthe calculation.

(4)


has special requirement is known to cause friction increase due to the application or

fluid other selection can be used accordingly. Other selection can affect to therecommended actuator sizing safety factor.

(5)


characteristics and gain calculation in one flow case scenario. DPm defines theportion of the total system pressure losses as taken by the control valve at maximum

flow rate. The default value for liquid flow is 0.3 (30% of total system pressure lossis taken by the valve, 70% by the piping and pipe components). For Finetrol

valve default value is 0.5. DPm is not needed if two or more flow cases are given.Look for more details in the Flow Control Manual.

(6)

Design P. Max design pressure condition for the Tag. Input value fordocumentation. Value does not automatically affect to the valve selection within the


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program. Manual considerations in the valve selection must be made according to

the requirements.(7)




(8)

Design Tmin. Min design temperature for the Tag. Input value for documentation.Value does not automatically affect to the valve selection within the program.


requirements(9)


(10)

Outlet dia. If not entered, the nominal diameter of the downstream pipeline isassumed to be the same as the inlet diameter.

(11)

Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule.(12)

Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is


(13)



(15)

Inlet Press. Pressure at upstream conditions.(16)


value must be lower than the given upstream pressure. Enter either press differentialor outlet press.

(17)

Outlet press. Outlet pressure of the valve. Enter either pressure differential or outletpressure.

(18)


type can be selected from here or by using the fields 18, 19 and 20.(19)


(20)

Press rating. Pressure rating required. Select rating from the list.

(21)

Code. Select valve code from the list.(22)


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Size. Valve nominal size/reduction. Will be automatically selected when automappears instead of size.

4.3.2 Results for Pulp sizing

Figure 9. Results for Pulp sizing

Max

capacity


reducers.

Req

capacity



opening is the area where the seat and closing member overlap.


Noise Predicted sound pressure level based on the VDMA 24422 (May 1979) or

enhanced IEC 60534-8-4 standard. A high noise level for liquid flow is a goodindication of a high cavitation level. Q-Trim, Flash-Flo or similar low-recovery

valves are recommended in case of high noise levels. The maximum

recommended hydrodynamic noise levels in valves calculated with non-insulatedschedule 40 piping are as follows:

- 80 dB(A) for valve sizes up to 80 mm (3") size,

- 85 dB(A) for valve sizes 100-150 mm (4"-6") size,- 90 dB(A) for valve sizes 200-350 mm (8"-14") size,

- 95 dB(A) for valve sizes 400 mm (16") and larger size.

Note: Q-trim can be used up to 4% pulp consistency.

The figures are given considering the valve operation. Workplace safety regulations, end-user specifications etc. may dictate other maximum values.

Flow

velocity

Flow velocity at valve inlet. The maximum recommended valve inlet velocities

are as follows:


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a) Continuous duty

- Butterfly valves 7 m/s, 23 ft/s.- Cage-guided globe valves 15 m/s, 50 ft/s.


b) Infrequent Duty

- Butterfly valves 8.5 m/s, 27 ft/s.- Cage-guided globe valves 18 m/s, 60 ft/s.


Terminal

dpWhenever the differential pressure is higher than the terminal pressure drop thevalve will experience high intensities of cavitation. The use of Q-Trim or Flash-

Flo type trims is recommended to avoid cavitation problems. In cases where

conditions result in flashing, the terminal pressure drop is not significant. Then,word "flashing" will appear in this field. Flow Control Manual offers more

information of the meaning of terminal pressure drop.

Fl coeff The pressure recovery factor of the valve with this particular opening.

4.4 2-phase flow sizing

This calculation allows you to size valves for liquid + gas and liquid + vapour mixtures.

Consider the results of liquid + vapour calculation very carefully. The calculation methods

are the best available, but the behaviour of a saturated liquid + vapour mixture is verydifficult to predict. The method used provides very accurate results when the percentage of

vapour in the fluid is high. The error increases as the percentage of vapour in the fluid

decreases. You can find more detailed information on calculation in the Flow ControlManual.

4.4.1 Input data for 2-phase flow sizing

When sizing for 2-phase flow you can enter data as shown in the next figure.

Figure 10. Input data for 2-phase flow sizing


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(1)

Process fluid selection, liquid.(2)

Process fluid selection, gas or vapour.(3)

L spec grav. Specific gravity of the liquid component. Enter Spec gravity or leave

this out and enter Density.

(4)

Density. Enter Density. Or leave this out and enter Spec gravity. If neither isentered, the specific gravity for water is used in the calculation.

(5)

Crit press. Critical pressure of the liquid. If not entered, the critical pressure forwater is used in the calculation.

(6)

G spec grav. Specific gravity of the gaseous component. Enter either Specificgravity or Density.

(7)

Mol weight. Enter either Specific gravity or Density. If neither is entered, theupstream density must be entered instead of compressibility in process data area.

(8)

Spec heats. Ratio of Specific Heats. If not entered, the value of air is used. For

steam sizing 1.3 will appear automatically.(9)




(10)


characteristics and gain calculation in one flow case scenario. DPm defines the

portion of the total system pressure losses as taken by the control valve at maximum

flow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss


valve default value is 0.5. DPm is not needed if two or more flow cases are given.

Look for more details in the Flow Control Manual.

(11)

Design P. Max design pressure condition for the Tag. Input value fordocumentation. Value does not automatically affect to the valve selection within the

program. Manual considerations in the valve selection must be made according tothe requirements.

(12)

Design Tmax. Max design temperature for the Tag. Input value for documentation.Value does not automatically affect to the valve selection within the program.


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requirements(13)




(14)

Inlet dia.Nominal diameter of the upstream pipeline.(15)


assumed to be the same as the inlet diameter.(16)


(17)

Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither isentered, then Sch 40 will appear as the default value. Needed only for noise

calculation.

(18)

Gas Flow. The flow rate of the gaseous component for four different flow

conditions can be entered.

(19)

Liq flow. The flow rates of the liquid component for four different flow conditions

can be entered.

(20)


(21)

Inlet Press. Pressure at upstream conditions.

(22)


value must be lower than the given upstream pressure. Enter either pressure

differential or outlet pressure.(23)

Outlet press. Outlet pressure of the valve. Enter either pressure differential or outlet

pressure.(24)

Liq vap press. Liquid vapour pressure. Provided automatically for liquids included

in Nelprof. The value that Nelprof provides can be replaced by the users own value

by typing over the default value. Vapour pressure of the liquid at upstreamtemperatures. A careful search for accurate vapour pressure is recommended, as this

information is needed in cavitation and flashing flow calculations.

(25)

Gas comp orGas Upstream. Compressibility or density of the gas component at

upstream conditions. Compressibility is specified when either the specific gravity or

molecular weight is specified. A typical compressibility value is 1.0. Upstreamdensity must be given if specific gravity or molecular weight is not known.

(26)


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type can be selected from here or by using fields 18, 19 and 20.(27)


(28)

Press rating. Pressure rating required. Select rating from the list.(29)


(30)

Size. Valve nominal size/reduction. Will be automatically selected when automappears instead of size.

4.4.2 Results for 2-phase sizing

Figure 11. Results for 2-phase sizing

Max

capacity


reducers.

Req

capacityCalculated capacity needed for flow conditions specified in the same column.


opening is the area where the seat and closing member overlap.


Eff

density

The average density of the liquid + gas mixture.

Terminal

dpOften referred to as Critical pressure drop. Applicable for the liquid component.Whenever the differential pressure is higher than the terminal pressure drop the

valve will experience high intensities of cavitation. The use of Q-Trim or similar

trims is recommended to avoid cavitation problems. In cases where conditionsresult in flashing, the terminal pressure drop is not significant.

4.5 Actuator sizing

If you want to size a valve without an actuator, uncheck the Actuator sizing selection in theinput data screen.

Actuator sizing is based on operation in control as well as the opening/closing of the valve.

In control, the valve torque/thrust is calculated according to the given information on flow


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and pressure. In closing/opening, valve torque/thrust is calculated according to dp Shutoff.Valve-required torque is calculated according to actual dimensions and friction coefficients,dynamic flow-induced forces are also considered. The valve type and size as well as the

flow conditions are required for actuator sizing.

4.5.1 Actuator sizing input data for rotary valves

Figure 12. Actuator sizing input data for rotary valves

Seat Select valve seat type from the list.

Gland

pack

Select gland packing type from the list.

Bearings Select valve bearing type from the list. This information is not required for globe

valves.

Safety

factor

Customer safety factor. The actuator size selection is depending on the selected

safety. The default value on the screen for customer value is 1.0. Minimum

recommended safety factor by Metso is 1.1 for Open and Close and about 1.6 forcontrol open/close positions.

DP

shutoff

Maximum shutoff pressure against which the valve must open and close.

Actuator By pressing this button you can open an actuator type selection dialog.Actuator

type can be selected from here or by using field Code.

Code Select actuator code from the list.Size Actuator size code. Will be automatically selected when Autom appears instead

of size.

Supply

press

Supply pressure of the instrumentation air to the actuator. This affects selection

of the spring for single-acting actuators.

Spring

rate

Spring rate or stiffness of the spring. Expressed as nominal pressure of the

spring. Select a spring rate equal or lower than the available supply pressure.

Spring rate cannot be selected for linear actuators.

Select the actuator spring when selecting the actuator size manually. The actuator spring

rate is expressed as the nominal spring rate pressure: e.g. B1J, size 20, has three differentspring rate options: 3 barG corresponding to BJK20, 4 barG corresponding to BJ20 and 5.5barG corresponding to BJV20. In automatic sizing the program selects the spring rate

according to the available supply pressure.

4.5.2 Actuator sizing results for rotary valves


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Figure 13. Actuator sizing results for rotary valves

To open Torque required to begin opening the valve. Breakaway torque for eccentric

valves and friction torque for concentric valves. Calculated with dp Shutoff.Equals to BTO (break to open) torque with On-off calculation.

Opening

LF

Opening load factor. Load factor is the required torque divided by the available

torque. A value of 62 means that 62% of the torque given by the actuator outputtorque is needed to open the valve. The opening load factor should be below 90

to allow some safety margin in the selection.Control

open

Torque required in modulating the control when increasing opening. Equals the

friction torque + dynamic torque. Dynamic torque tends to close or open thevalve, depending on the type of valve. Calculated with control flow conditions.

Ctrl open

LF

Control to open load factor. Load factor is the required torque divided by the

available torque. A value of 28 means that 28% of the actuator output torque isneeded to slightly increase the opening of the valve. The control to open load

factor should be below 60 for high-friction valves; for low-friction valves it can

be slightly higher. Extra torque in modulating the control is needed to allowsmooth, stiction-free control.

Control

Close

Torque required in modulating the control when decreasing opening. Equals the

friction torque - dynamic torque. Dynamic torque tends to close or open thevalve, depending on the type of the valve. Calculated with control flow

conditions.

Ctrl close

LF

Control to open load factor. Load factor is the required torque divided by the

available torque. A value of 25 means that 25% of the actuator output torque isneeded to slightly decrease the opening of the valve. The control to close load

factor should be below 60 for high-friction valves; for low-friction valves it can

be slightly higher. Extra torque in modulating the control is needed to allowsmooth stiction-free control.

To Close The torque required to fully close the valve. For eccentric valves this is the

torque needed to attain tightness; for concentric valves it is the friction torque.

Calculated with dp Shutoff. Equals to ETC (end to close) torque with On-offcalculation.

Closing

LF

Closing load factor. Load factor is the required torque divided by the available

torque. A value of 62 means that 62% of the torque given by the actuator outputtorque is needed to close the valve. The closing load factor should be below 90 to

allow some safety margin in the selection.


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4.6 Sizing Resistors i.e. plates and diffusers

To do resistor sizing, you have to calculate the valve first selecting size manually in the

Size field. Automatic valve size selection is not available for diffuser and plate sizing.Please note also that resistor sizing is not available for 2-phase flow. Then, to define a

resistor, click the Resistorsbutton.

4.6.1 Defining resistors for liquid flow

After you have clicked the Resistors button the following window appears:

Figure 14.Liquid resistor defining window

When selecting one of the plate options available you also specify the required size as wellas the New Valve dp. The new valve pressure differential defines that portion of the

original pressure differential that is allocated to the control valve. The remainder is for the

plate. The plate-effective flow area is defined according to this information. The permittedsizes for plates are the sizes between the nominal valve diameter and the downstream pipe


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diameter.

For liquid flow, select the following options:

The Liquid Baffle Plate is a flat baffle plate with straight holes. The hole number anddiameter are altered case by case to fit the specified conditions exactly. The baffle plate is

usually installed downstream of the valve.

Orifice Plate, Downstream. The orifice plate is a simple single-hole plate used in flow rate

measurement. When installed downstream it increases the downstream pressure of thevalve itself.

Orifice Plate, Upstream. When installed upstream it decreases the upstream pressure of

the control valve.

After you have specified the resistor, press the OK button. After this the valve can be sizedby pressing the Calculatebutton on the sizing screen. If you want to size the valve without

the resistor, just uncheck the Resistors check box.

4.6.2 Results for a valve with a resistor for a liquid flow

When you size a valve with a resistor there will be some additional information on theresults.

Figure 15.Results for a valve with a resistor for a liquid flow

The max capacity, req capacity, travel, opening, noise, flow velocity terminal dp and Fl

coeffare the same as for normal liquid sizing (see results for liquid and water sizing).

Plate

areaPlate area is the plates effective flow area, i.e., portion of the hole/holes from thewhole plate.

New

dp

New dp is the valve new dp. When the resistor is selected, part of the pressure drop

designated to the valve will go to the resistor. New dp will show how much is left


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for the valve.

4.6.3 Defining resistors for gaseous flow

After you have clicked the Resistors button the following window appears:

Figure 16. Gas resistor defining window

When selecting one of the plate options available you also specify the required size or the

New Valve dp. The new valve pressure differential defines that portion of the original

pressure differential that is allocated to the control valve. The remainder is for the plate.The plate-effective flow area is defined according to this information. The permitted sizes

for plates are the sizes between the nominal valve diameter and the downstream pipe

diameter.

For gaseous flow, select the following options:

1-Stage

Diffuser.

The 1-stage diffuser is always installed downstream of the valve. You must

also specify the New Valve dp. The new valve pressure differential defines

that portion of the original pressure differential allocated to the control valve,

the remainder is for the diffuser. A default value is always shown. Diffusersare fabricated case-by-case so that the New valve dp affects the design of the

diffuser tube.

2-Stage The 2-stage diffuser gives lower noise levels than a single-stage diffuser.


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Diffuser.

Attenuator

Plate.The attenuator plate has specific hole geometry to achieve better noise-reduction capability than that achieved with just simple straight holes. To

make an attenuator plate sizing calculation, select the size of the plate. The

permitted sizes are those between the nominal valve diameter and downstream

pipe diameter.

After you have specified the resistor, press the OK button. After this the valve can be sized

by pressing the Calculatebutton on the sizing screen. If you want to size the valve without

the resistor, just uncheck the Resistors check box.

4.6.4 Results for a valve with a resistor for a gaseous flow

When you size a valve with a resistor there will be some additional information in the

results.

Figure 17.Results for a valve with a diffuser for gas flow

Min

outlet

pipe

The minimum outlet pipe diameter for diffusers.

New dp New dp is the valve new dp. When the resistor is selected, part of the pressuredrop designated to the valve will go to the resistor. New dp will show how much

is left for the valve.

4.7 Comparing the results of two sizings

The Comparison tab can be used to compare the sizing results of two sizing views. First

select the sizing from the project tree that you want to compare. Then select the comparison

tab. Now by clicking from the project tree you can select different sizings for comparison.

See picture.


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Figure 18. Comparing the two sizings

After comparing the sizing views, you may compare the characteristic curves by selecting

Characteristic Curves tab.

4.8 Characteristic curves

The flow characteristics of an installed control valve are discussed in detail in the Flow

Control Manual. The main principle is to approximate the static performance throughoutthe entire opening range for defined upstream and downstream pressure changes as

functions of the flow rate. The pressure changes are calculated as second-degree


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polynomials, if two or three flow cases are given. If only one flow case is given, the

pressures are approximated with the DPm factor. There are certain situations in whichNelprof cannot reliably calculate the installed flow characteristic curves:

There are no suitable valves for the application.

Two flow cases with the same flow rate Upstream pressure increases with increasing flow or downstream pressure decreases

with increasing flow 2-phase flow

4.8.1 Characteristic curves

The Characteristic curves can be observed by selecting the Characteristic curves tab. See

the picture below.

Figure 19. The characteristic curves


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Inherent Flow Characteristics. The inherent flow characteristics is the relative Cv curve

of the valve. The inherent flow characteristic is always available and can be printed evenwhen the installed flow characteristic cannot.

Installed Flow Characteristics. The installed flow characteristics is the relative flow rate

through an installed valve. The installed flow characteristic describes the static performanceof the valve under actual conditions and thus gives valuable prediction of valveperformance.

Installed Gain. Installed gain is the slope of the installed flow characteristic curve. With

gain curve, valve controllability and accuracy under actual conditions can be established.

Details on analysis can be found in the Flow Control Manual.

Installed Pressure Level. The installed pressure level graph presents the upstream anddownstream pressures as functions of the relative valve opening. These curves are defined

by selection of the DPm factor, or in multiple-flow cases the pressures are fitted to flow

data as second-degree polynomials.

4.8.2 Notes and warnings

The Noise curve and notes can be observed by selecting the Notes and warnings tab. See

the picture below.


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Figure 20.Installed Noise Curve, Notes and Warnings + Remarks

Installed Noise. The installed noise curve gives the estimated VDMA noise levels

throughout opening of the valve.

Notes and Warnings:

Notes and warnings are shown for the selected valves.

Both warnings and notes should be taken into account when the valve is selected.

Warning is an indication of a potentially more severe problem than a note.

Selecting a note or a warning with the mouse will open the explanation system. A

short description of the note or warning background is included in the explanationsystem. The explanation comprises theory, problem and solutions sections.

For some of the notes there are references to the Flow Control Manual. Clicking a

reference once will open the Flow Control Manual at the corresponding page.

5 On-off valve sizing and analysis


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On-off valve sizing tool is in practice intended for the calculation of correct size actuator.

Automatic actuator size selection is based on valve required torque and selected actuatoravailable output. The tool calculates the required torque at selected shutoff pressure

difference. Calculation considers topics such as valve construction e.g. seat, bearing and

packing type and material and also the differences of the actuator output at different

travel. The program does not consider special requirements of fluids or processes. Howevera safety factor can be applied for the automatic actuator calculation to take into account

these requirements. It is very important to study the suitability of the valve materials and

construction separately for each application.

To start a sizing, follow the steps shown in chapter 2. A more detailed description of sizinga On-off valve is given in this chapter.

5.1 Input data

After you have created and opened the On-off calculation you should first select the phase

by pressing the appropriate button on the input data window. Depending on the selectedphase the fluid description box content varies the same way as above with the control

calculation (see chapter 4).Certain information will appear automatically.

Changing the units, see chapter 5 on User settings.

(1)


description of the fluid can be entered in the lower field.

(2)

L or G Spec grav. Specific gravity of the fluid (not included in water sizing). EnterSpec gravity. Or leave this field empty and enter Density for liquids and Molecular

weight for gases. This field is optional for On-off calculations and used only for

documentation purposes.(3)

Density (only with liquid sizing). Enter Density. Or leave this field empty and enter

Spec gravity. This field is optional for On-off calculations and used only fordocumentation purposes.

(4)

Crit press. Critical pressure. (only with liquid sizing). If not entered, the critical

pressure for water is used in the calculation. This field is optional for On-offcalculations and used only for documentation purposes.

(5)

Viscosity. (only with liquid sizing). This field is optional for On-off calculationsand used only for documentation purposes.

(6)

Mol weight. Molecular weight (only with gas sizing). This field is optional for On-off calculations and used only for documentation purposes.

(7)

Spec heats. Ratio of Specific Heats. (only with gas and steam sizing). This field isoptional for On-off calculations and used only for documentation purposes.


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(8)

Consist %. The consistency of the pulp stock. (only with gas sizing). This field isoptional for On-off calculations and used only for documentation purposes.

(9)




(10)

Design P. Max design pressure condition for the Tag. Input value for

documentation. Value does not automatically affect to the valve selection within the

program. Manual considerations in the valve selection must be made according tothe requirements.

(11)


Value does not automatically affect to the valve selection within the program.Manual considerations in the valve selection must be made according to the

requirements

(12)




(13)

Inlet dia.Nominal diameter of the upstream pipeline.(14)


assumed to be the same as the inlet diameter.

(15)


(16)

Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither isentered, then Sch 40 will appear as the default value. Needed only for noise

calculation.

(17)


(18)

DP-shutoff. Pressure differential across the valve at closed position.

(19)

Valve. By pressing this button you can open a valve type list and selection dialog.

Valve type can be selected from here or by using fields 20, 21 and 22.

(20)


(21)

Press rating. Pressure rating required. Select rating from the list. If you select All,valves available in all ratings are listed in Code column.

(22)


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(23)

Size. Valve nominal size/reduction. Valve size to be selected manually. Sizes larger

than pipeline cannot be used

(24)

Seat. Select valve seat type from the list.(25)

Gland pack. Select gland packing type from the list.

(26)

Bearings. Select bearing type from the list.

(27)

Safety factor. Customer safety factor. The automatic actuator size selection isdepending on the selected safety. The default value on the screen for customer value

is 1.0. Minimum recommended safety factor by Metso is 1.2 for BTO and ETC

positions which is taken into account automatically.

(28)

Actuator. By pressing this button you can open an actuator type selection dialog.Actuatortype can be selected from here or by using field Code.

(29)

Code. Select actuator code from the list.

(30)

Size. Actuator size code. Will be automatically selected when Autom instead ofmanually selected size.

(31)

Supply press. Supply pressure of the instrumentation air to the actuator.(32)

Spring rate. Spring rate or stiffness of the spring. Expressed as nominal pressure of

the spring. Select a spring rate equal or lower than the available supply pressure.

Figure 21 .Input data for liquid and water sizing


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Select the actuator spring when selecting the actuator size manually. The actuator spring

rate is expressed as the nominal spring rate pressure: e.g. B1J, size 20, has three differentspring rate options: 3 barG corresponding to BJK20, 4 barG corresponding to BJ20 and 5.5

barG corresponding to BJV20. In automatic sizing the program uses only the standard

spring.

5.2 On-off calculation results

Figure 22.Max valve capacity for selected On-off valve.

Maxcapacity

Maximum flow capacity of the chosen control valve at fully open. FpCv istaking into account piping reducers and Cv is the inherent max Cv value.

Figure 23.Results for On-off calculation

Valve torques

BTO

(Break To

Open)

The torque required to start opening the valve from closed position.

Calculated with dp Shutoff. Equals to the To open torque with control valve

calculation.

ETC (End

To Close)The torque required to fully close the valve. Calculated with dp Shutoff.Equals to the To close torque with control valve calculation.


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Actuator torques

BTO

(Break To

Open)

Torque available of the selected actuator at the opening of the valve to the

opening direction from fully closed position. Calculated with given Supply

press.

ETC (End

To Close)

Torque available of the selected actuator at the closing of the valve to the

closing direction. Calculated with given Supply press.

Safety factors

BTO

(Break To

Open)

The calculated safety factor ie. the ratio of Actuator available BTO torque to

the Valve required BTO torque for the selected valve and actuator.

ETC (End

To Close)

The calculated safety factor ie. the ratio of Actuator available ETC torque to

the Valve required ETC torque for the selected valve and actuator.

5.2.1 Torque and safety factor details

More torque and safety factor details are available by enabling the Show details selectionabove the Calculate button.

Figure 24. Show details selection

This selection will enable the so called running torque values.


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Figure 25.Detailed torque and safety factor results with running torques

Running torques definitions

RTO is Run To Open, at the point of 50% travel towards the opening direction.

RTC is Run To Close, at the point of 50% travel towards the closing direction.

ETO is End To Open, at the point of 100% travel ie. to fully open position towards the

opening direction.

BTC is Break To Close, at the point of 100% travel when starting to close the valve

towards the closing direction.

At all above point the valve torques represents the valve required torque to operate the

valve to the particular direction, actuator torque the available torque to operate the valveand safety factors the ratio of the available to the required torque.

5.2.2 Recommended safety factor

By default the minimum recommended safety factor for actuator selection for on-off valves

is 1.2. In case the application or process is such that a bigger safety factor is to be used the

program can take these needs into account in few ways and limitations.

1. Customer or process licensor requires a certain safety. User should input this value

into Safety factor fields shown below. This will be handled in the program as theminimum value for automatic actuator selection.


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Figure 26.Safety factor input

2. Application or valve service is known to have special requirements which are

related to the particular fluid and might cause increasing valve friction. Depending

of the valve type an increased safety might be recommended.

Figure 27.Special service requirement selection

3. High temperature with gases and low temperature with both liquids and gases mightincrease safety factor recommendation depending on the valve type.

If there are several reasons - of those mentioned above - to increase safety factor thegoverning ie. the highest safety factor is applied.

For selection of non-Metso actuators the recommended safety factor should always be

applied and sent to actuator vendor. The recommended safety factor can be enabled to theuser interface as in the selection on below.

Figure 28.Recommended safety factor selection

The value will be seen as a result as below.

Figure 29.Recommended safety factor result

5.3 Printing On-off sizings

Selections on the user interface and printing screen defines the amount of data to be printed

on On-off valve sizing sheet. The standard print with BTO and ETC torques and safety

factor appears with default selection.


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Figure 30.Printing selections

To print also the running torque details as mentioned in the previous chapter the Show

details selection must be enabled at the On-off sizing interface.

As can be seen in the above Figure Valve torques, Actuator torques and Safety factors can

be selected separately ie. user can select the extent of the data in the printouts. As an

example if a non-Metso actuator is to be used user can print only the Valve torque and for

example theRecommended Safety Factor.

6 User settings

6.1 Units

For most input data there are several possible unit selection options.


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6.1.1 Changing a single unit

You can change any unit in the input or output grid. Simply click the unit field to access alist of possible units. Select the unit that you want. See the picture below. However, do take

note that Inlet Press unit selection will dictate units for Press diff, Outlet press and Vap

press (when applicable). For these three fields user cannot change unit for an individual

field. The unist appearing are according to Inlet press unit selected, so that Vap press isgiven as absolute pressure (for example barA) and Press diff is given as plain unit (for

example bar).

Note also that for flow rate conversions, Nelprof does not provide mass flow/volumetricflow conversions or vice versa. This type conversions must be done manually. Flow

Control Manual, has instructions how to to do the conversions.

Figure 31. Changing a unit for flow rate

Nelprof will ask if you want to convert the old value to new unit. Select yes, cancel or no. If

YES is selected the unit is changed and the value recalculated, if NO is selected the unit ischanged but value is not recalculated and if CANCEL is selected the unit is not changed

and the value is not changed.

7 User preferences

7.0.2 Setting project units

You can set units for one project by selecting that project from the Project Tree. Now you

will see the Project Properties screen. In the lower left corner you will find the Set ProjectUnits button and Set Project Parametersbutton. See the following picture.


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Figure 32. Selection of units for sizing project

Set the units as you want and press OK. Pressing the SI or US buttons will reset the SI or

US units. The units will be valid in new sizings only. The units of existing sizings will not

change.

7.1 Language selection for printing

Note: The screen language is always English even though printing language is beenchanged. On-off and SIL Calculation print outs are only available in English.

8 File Functions

8.1 Saving data

You can save all input data to the database by selecting File|Save All from the menu or byclicking the save all -button on the toolbar. You can save data of sizing/tag/project by

selecting the sizing/tag/project from the tree and clicking the save button on the toolbar or

by selecting File|Save. This will save data of that specified tree item and its sub-items.


46/81

9 Mass Operations

9.1 Selecting

User can select sizings from tag tree by clicking tic boxes. If Tag is clicked, all sizings in

that tag are selected. If all sizings of a tag are selected, tag is also selected. Same logicapplies to project.

Figure 33. Selection logic

9.1.1 Mass Calculations

Mass calculation is started by selecting sizings that are wanted to be calculated. It does notmatter, if check marks exist in other project levels than sizings as well. Mass Calculation

starts from Calculation|Mass Calculation. Calculation takes 1-3 seconds each. Sizing

names are highlighted after mass calculation depending if calculation was succesfull.

Calculated sizings are marked with grey background.

Figure 34.Result report after Mass Calculation

9.1.2 Mass Editing


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Any value of a sizing can be used for mass editing. Start mass editing by selecting sizings

where the mass edit is wanted to apply. After that, change any sizing input field and select

Edit|Mass Editing

Figure 35.Apply to all selected? -dialog

Figure 36.Mass Editing Ready

9.2 Adapters

Like the Bernie adapter, there are already some other "std" adapters that can be used toexport or import data in data format between different systems and Nelprof. The below

std adapters are available by default and optionally you can create your own adapter forexample by using the std adapters as an example for the mapping of parameters.

An old mapping can be used as base for creating new.


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Figure 37. Screen after selecting File|Export/Import|Advanced


49/81

Figure 38. Mapping of the parameters in the adapter

9.3 Importing data to quotation (for Metso users only)

Control valve process and sizing data can be uploaded to a quotation in Metso sales system.Select your sizings with a selection in the box of the project tree. Then export selected tags

using Bernie adapter by File|Export/Import|Export Bernie file. Save the exported file to

your temp directory, where Bernie reads it automatically when import function is used inBernie.

10 SIL calculation tool


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10.1 Introduction

Nelprof 6 SIL module is a tool to estimate the average probability of failure on demand

(PFD ) for final element subsystem. PFD for final element subsystem is calculatedaccording to IEC 61508. Final element subsystem considered in this SIL tool consist of

valve, actuator and accessories including all necessary linkages. Accessories might includecomponents such as partial stroke test device, solenoid valves or quick exhaust valves. SILtool cover complete final element subsystem supplied by Metso, other subsystems (e.g.

sensors or PLC) are not considered.

Architecture of the final element subsystem including individual components (e.g.solenoids) is limited to single channel architectures 1oo1 and 1oo1D, where refers to

diagnostics tests.

SIL tool is intended for use in quotation and pre-selection phases. In case of final SIL

calculation approved by Metso is needed, calculation must be accepted by Metso

authorized persons.

Failure rate values for valves, actuators and accessories in the tool are based on product

certifications provided by 3rd parties such as TUV, Exida or Lloyds or generic databasessuch as Exida and OREDA. Contact Metso in case more detailed information is needed.

10.2 SIL calculation

SIL tool consist of two pages : SIL edit page and Remarks page. SIL calculation is done at

SIL edit page (see figure below) and remarks or notes can be added into calculation at the

Remarks page.


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Figure 39.

New SIL calculation can be created by selecting Create | New SIL from the menu orclicking the New SILbutton on the tool bar. SIL calculation can be created only under

valve Tag. Enter or select all input parameters from top to bottom in all sections at SIL edit

page and press Calculate button to perform SIL calculation for complete final element.Input parameters are located in final element setup, test intervals, valve, actuator and

accessories section. Notice that SIL tool shows next and/or missing input parameter with

yellow color.

The results can be printed by selecting File | Print or clicking Print button in tool bar. SILcalculation sheet is printed by selecting Sizings in print menu.

10.2.1 Final element setup

Figure 40.


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(1) Safety position. Safety position of the final element when demand from the safetysystem occurs. Select either open or close safety position.

(2)Architecture. Architecture of the complete final element subsystem. Only 1oo1 or

1ooD voting are available. 1oo1 architecture consists of single channel without diagnostictests between proof tests. 1oo1D architecture consists of single channel with diagnostics

tests such as partial stroke tests. Select either 1oo1 or 1oo1D.

(3) Diagnostic coverage. Diagnostic coverage of the final element provided by possible

partial stroking testing. Diagnostic coverage is equal to 0 if 1oo1 architecture is selected. In

case of 1oo1D architecture, the diagnostic coverage factors provided by Metso ValvGuard(VG) or typical manual partial stroke device can be selected. Safety position close and open

has different diagnostic coverage.

10.2.2 Test intervals

Figure 41.

(4)Full stroke test. Enter full stroke (proof test) interval of the final element in months.

12 months corresponds 365 days (8760 hours). The default value is 24 months.

(5) Partial stroke test. Enter partial stroke interval of the final element in months or days.

12 months corresponds 365 days (8760 hours). The default value is 3 months.

(6) Pneumatic test. Pneumatic test is ValvGuard internal diagnostic test which is not

moving the valve assembly and affect only average probability of failure on demand for

ValvGuard. Enter pneumatic test in days or select Disabled if pneumatic diagnostic test isnot used.

Note, in case of 1oo1 voting only full stroke test interval is required, partial stroke test andpneumatic test intervals are not shown in user interface.

10.2.3 Valve and actuator

Figure 42.

(7) Valve. Select valve for the final element PFD calculation from available valve list e.g.

D-SERIES (METAL SEAT). Dangerous failure rates (lambda D) in the database areconservative values. Soft seated valves values are for relatively clean service, and metal


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seated valve values can be used also for severe service. Note, that valve selection and

installation must be always be suitable for application and done according tomanufacturers instruction in order verify reliable estimation of the probability of failure on

demand. Contact Metso in case more information is needed regarding failure rate values.

(8) Actuator. Select actuator for the final element PFD calculation from the availableactuator list e.g. B-SERIES. Dangerous failure rates (lambda D) are conservative values for

Metso pneumatic actuators. Note, that actuator selection and installation must be always be

suitable for application and done according to manufacturers instruction in order verifyreliable estimation of the probability of failure on demand. Contact Metso in case more

information is needed regarding failure rate values.

(9) MTTR. Mean time to repair. An average time required to repair failed valve or

actuator. Enter MTTR in hours. The default value is 24 hours.

(10) PFD. An average probability of failure on demand for valve (actuator) component inthe final element subsystem. The value depends on lambda D, MTTR, diagnostic coverage,

architecture and test intervals (see equation in chapter 10.2.6).

10.2.4 Accessories

Figure 43.

(11) Intelligent PST. Select intelligent partial stroke device from the list : Metso

ValvGuard VG800 (Hart), VG9000H (Hart) and VG9000F (Foundation Fieldbus).Dangerous failure rates (lambda D) are conservative values. Note, that device selection and

installation must be always be suitable for application and done according to

manufacturers instruction in order verify reliable estimation of the probability of failure on

demand. Diagnostic coverage provided by pneumatic diagnostic test for ValvGuard isautomatically taken into for PFD calculation for VG. Contact Metso in case more

information is needed regarding failure rate values.

Note, intelligent PST device menu is available only for 1oo1D architecture.

(12) Instru. Select necessary instrumentation for the final element PFD calculation fromthe available instrumentation list. Dangerous failure rates (lambda D) are provided by

instrument manufacturer or generic databases such as Exida or OREDA. Note, that device

selection and installation must be always be suitable for application and done according tomanufacturers instruction in order verify reliable estimation of the probability of failure on

demand.Contact Metso in case more information is needed regarding failure rate values.


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Abbreviations :

SOV_xxx = Solenoid valve from different manufacturer

SOV_xxx (DTT) = Solenoid valve, de-energized to trip.

SOV_xxx (ETT) = Solenoid valve, energized to trip.

SOV_xxx (DOUBLE) = Versa 316 solenoid, double solenoid version

SOV_GENERIC 3-WAY = Generic 3/2 solenoid valve.

AOV = Air operated valve, generic value.

QEV = Quick exhaust valve, generic value.

BOOSTER = Volumetric booster, generic value.

QEV WITH DC = Generic quick exhaust valve with diagnostic coverage provided by

partial stroke test

BOOSTER WITH DC = Generic booster with diagnostic coverage provided by partial

stroke test.

RCI9H FOR VG9000H = Remote control interface unit for VG9000H. RCI9H should be

selected for only VG9000H in case connected to SIS system with digital output (DO). In

case

VG9000H is connected to SIS with analog output RCI9H is not needed (see examples

below)

(13) MTTR. Mean time to repair. An average time required to repair failed component.

Enter MTTR in hours. The default value for PST device and instrumentation is 4 hours.

(14) PFD. An average probability of failure on demand for VG and selected

instrumentation components. The value depends on lambda D, MTTR, diagnostic coverage,

architecture

manual de usuario nelprof 6

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