 1.

Pump
 2 Control Valve-Pump Discharge Circuits
1.0 Pump
1.1 Introduction
 The common types of pumps used in oil & gas industry are
centrifugal and positive displacement.
 CENTRIFUGAL PUMP

 Modern practice is to use centrifugal pumps because they are

usually less costly, require less maintenance, and less space.
 Conventional centrifugal pumps operate at speeds between
1200 and 8000 rpm.
 Very high speed pumps, which can operate up to 23000 rpm
and higher, are used for low capacity and high head
applications.
 Most centrifugal pumps will operate with an approximately
constant head over a wide range of capacity.
POSITIVE DISPLACEMENT PUMP

 Positive displacement pumps operate with approximately

constant capacities over wide variation in head, and hence they
are usually installed for services which require high head at
moderate capacities.

 A typical application of small reciprocating pump is for

injection of fluids ( e.g. methanol and corrosion inhibitors) in
to process streams where their constant capacity characteristic
is desirable.

 For procurement of a pump, it is necessary to furnish all

pertinent process information.

 Based on this information, Rotating Equipment group

specialist will prepare pump specifications for pump vendor.
1.1.1 Different types of pumps and criteria for selection
1.1.1.1 Different types of pumps
Pumps used are generally of following category:
 centrifugal

 positive displacement -They are of two types:

-Reciprocating - piston, plunger or diaphragm type

-Rotary - Gear, Screw or lobe type
 The problem is to select the size and type that most nearly fits
the service in question.
 Centrifugal pumps are most widely used in chemical industry.
For these pumps, there is a distinct relationship between head
developed and capacity discharged for a centrifugal pump.
 Positive displacement pump produces what ever head is
imposed upon them. A safety valve is always required at
discharge of the pump ( PSV is always in vendor’s scope of
supply) .
 1.1.1.2 Selection of Pump Type
 Though several parameters go in to the selection of type of
pump, capacity, head and viscosity are the major parameters,
based on which a process engineer can decide the type of pump
 It is further fine tuned with close cooperation between vendor
and rotating equipment specialist.
 Preliminary selection is however done by process engineer.
Figure-12.3 from GPSA should be referred for selection of
pump type based on head-capacity requirements.
 Centrifugal pumps can handle liquids having viscosity up to
200 C S. For higher viscosity, specify screw, gear or
reciprocating pumps.
 Past commissioned jobs are best reference for selection of
pumps.
 Another important criteria which dictates selection of pump is
NPSHA.
 For low NPSHA, special pump like Sundyne or equivalent or
vertical barrel pump are used. Major features of different types
of pumps are given as Table-1.
 In spite of centrifugal pumps being most preferred, Rotating
Equipment group’s, input on availability of centrifugal pump
should be obtained.
 References of centrifugal pumps handling fluids of viscosity up
to 4000 CS are available.
 When solids are present in the pumped fluid, internal
passages should have adequate dimensions and hence type of
pump should be finalized after interactions with Rotating
Equipment group and feedback based on past jobs.
 Past commissioned jobs are best reference for selecting such
type of pump.
 1.2 Procedure to fill each item on the pump data sheet
 1.2.1 Item No. As in equipment list/ PFD
 A/B or A/B/C- to be added if operating philosophy is (1+1) or
(n+ m) respectively.
 Number of pumps in operation/ stand by is decided based on
following factors:
 Availability of pumps based on required capacity / head.
 Multiple operation when one case requires one pump where
as another case needs multiple pumps in operation
 Turndown requirements
 For (n + m) pumps, n pumps in operation & m pumps as stand
by . The capacity indicated is total capacity to be delivered by
n pumps operating in parallel. Up to 3 pumps in operation one
pump is taken as stand by and with 4 and more pumps, two
pumps are taken as stand by.

1.2.2 Service
 Name of pump as given in Equipment List / PFD
 1.2.3 Type Centrifugal / Metering / Reciprocating / Screw /
Vertical submerged centrifugal , etc
 Metering pumps are small reciprocating pumps which can
deliver variable capacity by stroke adjustment.
 Large reciprocating pumps ( generally flow above 5 m3/ hr or
high discharge pressures ) are constant capacity pumps and
any requirement of variation in flow will have to be handled
outside the pump by spill back control.
Where to use metering or reciprocating pump
 Metering pump is specified where variable capacity is required
and reciprocating type is specified where fixed capacity is
required.
1.2.4 Liquid handled
 If service indicates type of fluid like naphtha/diesel/sour water
then hydrocarbon / water should be mentioned.
 If service does not indicate type of fluid but mentions main
fractionators reflux / Debutanizer reflux / Absorber reflux then
Naphtha / LPG/Light hydrocarbon are mentioned.
 Information on internals / type of seal is required by rotating /
vendor to decide type of pump.
1.2.5 Pumping Temperature
 The normal temperature is to be indicated.
 Range needs to be indicated when there is wide variation.
 Process engineer to review start up, shut down, pump out
cases w. r. to change in temp, fluid, and source/destination.
 A note indicating name of fluid, temp, properties, vapor
pressure, capacity, discharge pressure, suction pressure,
NPSH, and duration envisaged is to be provided by process
engineer.
 Capacity or pump discharge pressure is left to be decided by
rotating group / vendor because various cases to be considered
are not rigid case of operation e.g. pump out can take longer
time hence discharge pressure is must but capacity can be
less or during start up, capacity requirement is rigid but
discharge pressure can be low due to lower circuit pressure
drop.
 However requirement of both capacity and discharge pressure
as judged by process engineer should be mentioned with note
that “Rotating Equipment to confirm”.
 1.2.6 Viscosity at pumping temperature
 Range (if variation is wide) / viscosity at pumping
temperature from simulation / curves.
 For highly viscous fluids where screw pumps have been
specified, lowest viscosity envisaged is very important as
problems of low efficiency, slippage, etc occur.

1.2.7 Vapor Pressure at pumping temperature

 For liquids in equilibrium with vapor, pumps taking
suction from columns, flash vessels, etc, the operating
pressure of vapor above the pumped liquid is the VP at
pumping temperature.
 For sub cooled liquids like in feed surge drum and blanketed
drums, VP shall be estimated from simulations /curves.
 Process to ensure sufficient margin in calculation/ estimation
of vapor pressure.
 For slightly sub cooled liquids in reflux drums (like naphtha
splitter reflux drum, crude fractionator reflux drum) or in
column bottom(vacuum column or Visbreaker fractionator
bottoms due to quench) , VP is operating pressure of vapor
above pumped liquid and should not to be lowered for
slight sub cooling

 Vapor pressure for water being pumped from reflux drum

boot/feed surge drum/compressor inter stage KOD shall be VP
of water at operating temp from steam table / simulation and
not at the operating pressure.
1.2.8 Liquid density at pumping temperature
 Shall be taken from simulation/curves/pure component
properties. If range is wide, both high and low values shall
be reported.
1.2.9 Presence of corrosive / toxic components
 If present, “yes” shall be filled and a note indicating type
and quantity ( if known) is to be added. If absent, “Absent”
shall be filled
 The general corrosive / toxic components encountered are
sulfur / H2S / NH3 / phenols / sulfides/cyanides etc. Quantity
of corrosive / toxic present should be taken based on past
pump data sheet / past experience.
1.2.10 Solids in suspension
 If present, “yes” shall be filled and a note indicating type of
particles e. g. de-generated products, coke, etc and size of
particles based on past similar job / as identified in
Technology manuals shall be added in data sheet.
1.2.11 Flow Rate
 Normal flow rate shall be filled based on material balance
and considering multiple cases of operation along with
operational flexibility required

 Maximum flow rate shall be indicated based on standard over

design factor ( 110% for feed and products, 115 % for pump
around and 120 % for reflux, re-boiler service, and compressor
inter stages.

 Minimum flow shall be indicated based on turn down

requirements for the unit as given in design basis / as
required from process angle for the specific pump.
The Automatic Recirculation Control (ARC ®) Valve
This valve provides bypass flow control, pressure
reduction, and reverse flow pump protection all within a
single unit. This single valve combines the functions of
the check valve, pressure reducing orifice, pipe tee,
control instrumentation flow meter, and bypass control
valve that are all required in the instrumented control
loop bypass system. Valves can be designed to provide
either “Modulated” or “On-Off” bypass control. The
operation of all
Centrifugal pumps
 Generally a turndown of 30% of rated capacity is achievable. If
required is less then 30% then add minimum flow provision
and a note in data sheet.
 For other cases of min flow >30%, add min flow provision
based on old jobs / rotating group input and add a note to that
effect in the data sheet.
 When head required is very high but capacity very low, such
pumps are not easily available and there may be case when
pump selected would be such that minimum continuous bypass
flow is greater than max flow required.
Caution: In such pumps continuous bypass is required. For
such pumps based on rotating input, pump suction / discharge
hydraulics including NPSHA calculations should be redone
based on Rotating groups input on pump MCF. To prevent
heating of liquid due to circulation, bypass should be put up
stream of cooler / condenser.
Reciprocating Pumps
 They are constant flow pumps so only max flow is specified.
Any turn down / variation is taken care by providing spill
back.
 For normal and minimum flow, a note is put on the pump
data sheet that provision for spill back is required to take
care of normal / minimum flow requirements.
Metering Pumps
 Generally 20-100 % variation in flow by stroke adjustment
(Automatic / manual) is possible. Less than 20% is possible
but with loss of accuracy.
1.2.12 Suction Pressure
 Suction pressure = Source pressure +static head –(∆P in pump
suction side)
where
 Source pressure = operating pressure above liquid level in
the source vessel / column / tank
 Static head = static pressure difference due to liquid
head between pump center line(normally one meter) and vessel
/column BTL
 For source vessel / columns, where there is no process
requirement for elevation and ‘min for piping” is indicated in
P&ID / Data Sheet, then 1 meter for vessels, 2 meters for
columns and 6 meters for column when max suction pressure
calculation is required and BTL of vessel is not known.
 ∆P in pump suction = ∆P in suction line + ∆P in suction
strainer + ∆P in suction control valve / heat exchangers / other
instruments if any in suction side.
 ∆ P in suction line = line loss in suction line
 For estimating line loss, equivalent length should be calculated
based on proposed location of source vessel and pump.
 Charts 1,2,3 may be used to estimate equivalent lengths
between two equipments or between an equipment and
instrument.
Caution
 -While estimating suction ∆P in very high pressure services,
the line thickness / rating correction should be applied since
pipe thickness for higher rating is quite significant.
 For critical pumps like column bottom-high temp pumps,
Process to review and approve isometrics.
 ∆P in suction strainer For basket strainers, the allowable ∆P
as per process data sheet is too less ( say 0.05 kg/cm2) then
process to check its availability from mechanical group.
 ∆P in Heat Exchangers / Control valves / instruments
 As reported / proposed to be reported in respective process
data sheets
 1.2.13 Maximum Suction Pressure
 Centrifugal Pumps
 Maximum suction pressure = ----kg/cm2g
 Required for the purpose of pump shut off pressure
calculation.
 For positive displacement pumps Maximum suction pressure
= ---- kg/cm2g
 To be used as max back pressure for safety valve at pump
discharge.
 Maximum suction pressure = Maximum source pressure +
static head
 where
 Maximum source pressure = Design pressure of source
vessel / column bottom.
 For column bottom
 Top design pressure + tray DP + static head (HLL) in bottom
section.
 Reflux pump, reflux drum and condenser are designed with
column top design pressure.
 For vessels open to atmosphere, design pressure is
atmospheric
 Static head = static pressure difference due to liquid
head between source vessel/column HLL and pump center
line. If two cases are reported, higher density should be used.
 For a pump taking suction from an upstream pump discharge,
maximum suction pressure = upstream pump shut off pressure
 1.2.14 Discharge pressure, Differential pressure &
Differential head
 Discharge pressure = Destination pressure + static head
+ (∆P in pump discharge circuit) + contingency
 where
 Destination pressure = B/L pressure for run down circuits,
operating pressure of destination vessel/ column etc
 For pumps whose destination point is another pumps discharge,
estimation of destination pressure should take in to
consideration the max pressure possible say at turn down.
 For pumps pumping to a vessel/column through a feed
distributor, the distributor ∆P to be considered and confirmed
from specialist department.
Static Head = static pressure due to liquid head between final
destination point and grade.
 For product run down circuits where destination pressure is B/L
pressure, static head should not be considered.
 For static head of vessel/column, height up to HLL
 For static head of destination vessel/column where no process
requirement for elevation and min for piping is indicated in
P&ID/data sheet, BTL of 6 meters should be considered and
counter checked with lay out.
 For circuits where static head of final destination is lower than
static head of an intermediate point e.g. final destination is
vessel at grade and air cooler at intermediate point, it should be
ensured that pressure at intermediate point (pump discharge-
circuit loss till that intermediate point) is sufficient from process
considerations i.e. above vapor pressure.
 ∆P in pump discharge = ∆P in discharge line + ∆P in flow
instruments + ∆P in heat exchangers + ∆P in control valves +
∆P in any other item
 Where, ∆P in pump discharge line =line loss in discharge line.
For estimating line loss, equivalent length shall be calculated
based on proposed lay out.
 Charts 1,2,3 shall be used to estimate equivalent lengths
between two equipments or between an equipment and
instrument.
 ∆P in Heat Exchangers/flow =As reported / process data sheets
 ∆P in control valves = As per pump calculations for varying
flow rates
 Contingency = 1.0 kg/cm2 to take care of any unforeseen
additional requirement of ∆P in discharge circuit.
 Differential pressure = Discharge pressure – suction pressure
where
 Differential head = [Differential pressure in kg/cm2)/ (in meters
) (density in kg/m3)]x 104 .
 If for multiple cases of operation, hydraulic pressures are not
very different, a single discharge pressure can be considered.
Since centrifugal pump develops fixed head for a given flow, it
is advisable to report head based on lower density.
 If for two different cases of operation, hydraulic pressure drops
in the circuit are very different, (due to large variation in
viscosities) two separate circuit hydraulic calculations are to be
performed & differential head calculated based on density of
respective cases.
1.2.15 NPSHa
 NPSHa = [source pressure –vapor pressure-suction losses +
elevation of liquid level- pump centre line] in meters of liquid
 =[(suction pressure-vapor pressure) in kg/cm2] / [Density in
kg/m3] x 104
 NPSHa (reported in data sheet) should be 0.5 meter less than
calculated figure. If NPSHa is greater than 8 meters then write
> 8 meters.
 NPSHa reported should be consistent with past jobs.
 Typical min NPSHa for centrifugal pump is 3 meters except
for water pumps where 2 meters is acceptable (also for flare
KOD pump, NPSHa of 2 meters is acceptable). The source
vessel/column BTL elevation shall be adjusted to ensure this.
 Suction line size may be increased to achieve required NPSHa,
over sized suction line leads to excessive loads on
piping/pump and should be avoided. If suction line size
increase is only option because BTL elevation can not be
increased (revamp ) then higher size only for initial portion
(i.e. towards the source vessel/column )and a reduced line size
towards pump.
 For positive displacement pumps:
 The following note must be added in all positive displacement
data sheets.
 NPSHa reported does not include acceleration head loss.
Suction line straight length = -- meters, suction line size = --
inches and suction line equivalent length = -- meters.
Straight length and equivalent length are based on proposed
lay out.
For vertical submerged centrifugal pumps:
 Flooded shall be written e.g. for CBD pumps. Vertical
submerged centrifugal pumps are pumps whose impeller is in
horizontal plane.
Vertical barrel pumps:
 Where NPSH is very low, vertical barrel pumps may be
considered. These pumps are similar to vertical submerged
centrifugal pumps but with in built barrel against an
independent vessel.
 NPSH estimated by process will stay, and additional NPSH
due to depth of barrel would be estimated by Rotating group /
vendor.
 1.16 Capacity Control for Volumetric Pumps
 It is for metering pumps i.e. for small reciprocating pumps
which can deliver variable capacity by stroke adjustment.
1.16.1 Continuous/Discontinuous/Manual/Automatic
 Manual is specified when stroke adjustment is by manual
means
 Automatic is specified if stroke adjustment is automatically
achieved by signal from say level of source vessel.
 Continuous/Discontinuous is never specified.
1.16.2 Type
 Where automatic is specified, a note shall be added indicating
type of automatic control e.g. stroke adjustment by level
signal from LT/LIC ---(tag no)
1.16.3 Range
 20-100% shall be specified as 0-100% is not accepted.
 1.16.4 Precision at min rate To be left blank
 1.17 Mechanical Data:
 1.17.1 Design Pressure:
 Design pressure is maximum discharge pressure that pump can
develop at pump shut off.
 For Centrifugal pumps
 Design pressure = Max suction pressure + Max Differential
Pressure(DP)
 where
 Max Suction Pressure = As above
 Max Differential Pressure (single stage pumps) = 1.2 x DP
 Max DP (For multi stage pumps) = 1.3 x DP
 Max DP (For variable speed pumps) = 1.32xDP
 For positive displacement pumps
 Design Pressure = 1.1 x Discharge Pressure (in kg/cm2g)
 or (Discharge Pressure +2.0) whichever is higher
1.17.2 Design Temp
 Design temp of source vessel/column
 For quenched columns (DCU quench column, main
fractionators of Delayed Coker / FCC, etc ) and Column
bottom pumps = pump operating temp + 25 0C

1.18 Casing/Impeller material

 Shall be reported as suggested by Material specialist/ past jobs
/ Material Flow Diagram.
 If CI (Cast IRON) casing / impeller is specified as MOC then
reconfirmation from Rotating Equipment group is to be
obtained as CI pumps are generally not available.

1.19 Seal Type

 It shall be single / double mechanical seal for hydrocarbon
service and packing for slurry services and positive
displacement pumps.
 Type of seal shall be revised based on pump specialist input.
 Refer API-610 for various types of seal flush plans.
 For external seal flushing (dirty / congealing pump fluids),
following note is added
 ----(name of flushing fluid like HGO,HVGO) is available at
 --- 0C and ---kg/cm2g for seal flush. Density and viscosity at
operating T,P is -----kg/m3 and -----cp/cst respectively.
 Input from Rotating Equipment on pressure required for seal
flush fluid.
 1.20 Line Rating
 Pump suction and discharge line rating shall be reported based
on suction and discharge design pressure and temperature e.
g. 150# / 300# (Though pump suction and discharge nozzle
rating would both be 300#).
1.21 Driver
 It is usually decided during design basis.
 Motor or steam turbine shall be specified for centrifugal or
positive displacement pumps.
 Steam turbines are specified where greater reliability is
required e.g. BFW pumps or steam balance calls for steam
turbine drive. Extraction type turbine is normally provided due
to less space requirement.
1.22 Steam Turbine data: Inlet and outlet steam pressure
levels shall be as decided in design basis.
1.22.1 Inlet pressure
 Minimum steam pressure as in design basis - ISBL losses.
Normal/Max steam pressure as in design basis shall be
reported. The following note shall be added:
 The pressure reported is upstream of governor (control valve,
which is in vendor scope). Minimum pressure shall be used to
calculate steam requirement.
1.22.2 Inlet Temperature
Min/nor/max temp to be reported
1.22.3 Design Pressure As per design basis
1.22.4 Design Temperature As per design basis
1.22.5 Exhaust pressure
 Max pressure plus ISBL loss up to exhaust steam header,
normal/min are also reported.
 1.22.6 Line rating-For both in and out, the rating shall be
reported as a control valve at the outlet of turbine will be there
and rating would be reduced only downstream of this valve.
 1.2 Notes
Apart from the notes that are mandatory as highlighted, the
following notes shall be included where applicable.
 Pour Point A note” Pour point of pumping fluid = ---0C” shall
be added for all pumps whose pour point is greater than or
near ambient temp. It shall be taken from crude assay / pilot
plant runs / as indicated in respective units
 Auto Start Requirement
 For pump which require auto start, following note is added.
“Pump/motor to be designed for auto start with discharge
open”. It is generally required for BFW, seal flush fluid
pumps, etc
 Discharge Dampeners
 For positive displacement pumps where discharge dampeners
are required from process angle, the following note shall be
added. “Discharge dampener to be provided “.
1.24 Typical Sample Calculations
 Typical process data sheet for pump duly filled and calculation
sheet are enclosed as ready reference
 2.0 Control Valve-Pump Discharge Circuits
 2.1 Purpose
 This guideline will cover how differential pressure across
control valve, in pump discharge circuits, at min/nor/rated
flow shall be specified.
 Scope: To estimate pressure drop for control valve circuits in
pump discharge. The min/nor/rated flows and the properties ,
temperature, pressure and other parameters are outside the
scope of this guideline and shall be specified based on
PFD/material balance/design basis/pump or other equipment
data sheet.
 2.2 Definitions
Qrated = Rated flow in m3/hr
Q nor = Normal flow in m3/hr
Qmin = Minimum flow in m3/hr
 del PCVmin = Control valve del P at rated flow in kg/cm2
 del PCvnor = Control valve del P at normal flow in kg/cm2
 del PCvmax = Control valve del P at minimum flow in kg/cm2

 del Prated = Pump differential pressure at rated flow kg/cm2

 del Pnor = Pump differential pressure at normal flow kg/cm2
 del Pmin = Pump differential pressure @ mini. flow kg/cm2
 del Pckt rated = Circuit dynamic frictional losses at rated flow
in kg/cm2 , i.e. not including static head, control
valve del P and contingency. (The dynamic losses are
frictional losses which vary with flow through the circuit)
 del Pckt nor= Circuit dynamic frictional losses at normal
flow in kg/cm2
 del Pckt min = Circuit dynamic frictional losses at minimum
flow in kg/cm2
 Cvmax = 1.17 x Qmax {(Density at op.temp.)/(del PCV min)}1/2
 Cvmin= 1.17 x Qmin {(Density at op.temp.)/(del PCV max)}1/2

2.3 Procedure
 Control valves in pump discharge circuits broadly fall under the
following categories:
 (Types A to G, and J, K are on centrifugal pump discharge while
H & I are on positive displacement pump discharge)
 A -Control valve in the governing circuit (from pump
differential pressure requirement angle) e.g. FV-1203 in Fig-1.
 B -Control valve in parallel circuit to a different destination i.e.
not in governing circuit e.g. FV-1202 in Fig 1.
C Control valve in a parallel circuit i.e. not in the governing
circuit, but to same destination. e. g. FV-1401 in Fig 2.
D Control valve in series with main control valve in
the governing circuit. e. g., FV-1502 A in Fig 3.
E Control valve in parallel in a part of the circuit. e. g.,
FV-1502 B in Fig 3.
F Pump minimum flow control valve for centrifugal pump.
e.g. FV-1201 in Fig.1.
G 3-way valve. e.g., TV-1701 in Fig 4.
H Control valve at positive displacement (constant flow)
pump discharge. e. g., FV-1601 in Fig 5, LV-1601 in Fig 5.
I Spill back control valve for positive displacement pump.
e. g., PV-1601 in Fig 5.
J Pressure control valve for fuel oil to furnace
K Back pressure control valve in fuel oil circulation line
L Control valve at pre heat inlet like FV-1801/ HV-1801
in Fig 6
M Control valve at heater pass inlet like FV-1901 Fig 6
N Pressure control valve on pump discharge as in
pipeline application. e. g., PV-2001 in Fig 7.
O Mixing valves e. g., at desalter / caustic wash inlet
 2.4 Estimation of del PCV min
 del PCV min is estimated as part of pump hydraulic calculations.
 del PCV min is taken as 0.7 kg/cm2 as an initial estimate.
 NOTE:- del PCV min for any control valve shall be 0.7 kg/cm2
minimum. However this may be relaxed for special cases, like
revamp jobs if pump discharge rating increases only due to
control valve del P. Engineering confirmation on availability
of control valve needs to be obtained before finalizing pump in
such cases.
 Step-1:
 del Pckt is proportional to Q2 ---------------1
 del Pckt + del PCV = constant -----------------2
 From equations 1 and 2 above, since del Pckt max and del Pcv min
are known from pump hydraulic calculations, del Pckt min , del
PCVmax , del Pckt nor and del P CV nor can be calculated.
Step 2:
 However above equation-2 does not consider that pump
discharge pressure increases with decrease in flow for a
centrifugal pump. Hence del PCV max and del PCV nor calculated
in step1 above is to be corrected for this extra head developed
by the pump.
 A 20 % higher head is considered to be developed at shut off
i. e., at zero flow, del P developed at normal /minimum flow
can be estimated as given below assuming linear relation
between flow vs head developed.
 del Pnor = del Pnor+ 0.2 x del P rated (Qrated – Qnormal)/Qrated

 del Pmin = del Pmin + 0.2 x del P rated (Qrated – Qmin)/Qrated

 The increased control valve inlet pressure due to higher head
developed at normal/minimum flows is also to be estimated
and reported in the process datasheet.
Step 3:
 Using the corrected del PCV max as estimated in step 2 and
del PCVmin , Cv max and Cv min are calculated.
 Generally Cv selected for control valve is around 110 % of Cv max
. To ensure controllability of the valve the following two
criteria are to be met.
Criterion 1: Cv max/Cv min is lower than 13
Criterion 2: del PCV nor is greater than or equal to
0.3 x del Pckt nor i. e. , 30 % of dynamic losses in the circuit at
normal flow (does not include static head, control valve del P
and contingency)
 If the above two criteria are met ,del PCV max, del PCV nor and del
PCV min can be reported in the datasheet. Otherwise del PCV min is
to be increased to such a value and steps 1 to 3 are to be
repeated till the above two criteria are met. Generally criterion 1
is fulfilled with a del PCV min = 0.7 kg/cm2 where del PCV max is
less than 5 kg/cm2.

If there are multiple cases, del PCV min reported in data sheet
shall be corresponding to that case which gives max Cv max .and
del PCV max reported in data sheet shall be corresponding to that
case which gives the minimum C v min. del PCV nor reported shall
be that corresponding to the case which is a more probable
normal operating case.
 Caution: If flashing occurs at control valve outlet, the
following data are to be included in process data sheet:
Weight % vapor at outlet, temperature at outlet, vapor
properties at outlet, vapor pressure and liquid critical
pressure.
sample calculations for pump discharge control valve circuit-
Case-II
del PCVmin = 0.7 (initial estimate)
del Pckt rated =1.88(LL) + 0.60 (3 FE ) + 6.00 (3 HE) = 8.48
del Pckt nor = 8.48 x (86.1/94.7)2 =7.0
del PCvnor =8.48+ 0.7-7.0 =2.18 or 2.2
del Pckt min = 8.48 x (43/94.7)2 =1.75
del PCvmax = 8.48+ 0.7- 1.75 =7.43 or 7.4

Correction for pump discharge pressure

del PCvmax = 7.4+0.2 x 11.7 x{(94.7- 43)/94.7} =7.4+1.28 =8.68 or 8.7
del PCvnor = 2.2 + 0.2 x11.7x {(94.7- 86.1)/94.7} =2.2+0.2 =2.4
Cvmax =1.17x 94.7x (968/0.7)0.5 =4120.3
Cvmin=1.17x 43x (968/8.7)0.5 = 530.7
Calculation for LV (case-1)
From pump calculation sheet
del PCVmin =4.77 or 4.8
del Pckt rated = 3(For two HE)+0.6 (For two FE ) +0.4 (For line loss) =4.0
del Pckt nor =4 x (90.6/99.7)2 =3.3 del
PCvnor =4+4.77-3.3 = 5.47 or 5.5
del Pckt min = 4 x (45.3/99.7)2 =0.826
del PCV max =4+4.77-0.826 =7.94 or 7.9
Correction for pump discharge pressure
del PCvnor = 5.5 + 0.2 x 11.1 x {(99.7-90.6) / 99.7} =5.71 or 5.7
del PCvmax =7.9+0.2 x 11.1x { (99.7-45.3) /99.7} = 9.11 or 9.1
Cvmax = 1.17 x 99.7 x {(920)/(4.8)}1/2 =1615
Cvmin= 1.17 x43 x {(920)/(9.1)}1/2 =506
Check Criteria
Cvmax case 2 / Cvmin case 1 =4120.3 / 506 = 8.14 < 13
del PCvnor case 2 / del Pckt nor case 2 = 2.4 / 7.0 = 0.34 >0.3
OK
del PCVmin =0.7
del PCvnor =2.4
del PCV max =8.7
Check Criteria
Pump Calculation with 3-way valve & Heat
Exchangers
del PCVmin = 0.7 (initial estimate)
del Pckt rated =1.1(LL) +0.3 ( FE ) =1.4
( Del P of both HE’s and 3-way valve not to be included as
variation in HE del P due to flow is to be taken care by
respective 3-way valve main port del P )
del Pckt nor =1.4 x (350.2/420.2)2 =0.97
del PCvnor = 1.4+0.7-0.97 =1.13 or 1.1
del Pckt min = 1.4 x (159.2/420.2)2 =0.2
del PCvmax = 1.4+0.7-0.2 =1.9
Correction for increased pump discharge pressure with
decreased flow
Corrected del PCvnor =1.1+ 0.2x6.6x{(420- 350./420} =1.32 or
1.3
del PCvmax = 1.9+0.2 x6.6 x {(420.2- 159.15)/420.2} =2.72 or 2.7
Check of criteria
Cvmax = 1.17 x {257( normal flow through FV) x 1.2} x { 694 /
0.7 }1/2
=11361.4
Cvmin= 1.17 x {253.5x 0.5} x {704/ 2.7}1/2 = 2394.6
Cvmax / Cvmin =4.74 which is less than 13
del PCvnor/ del Pckt nor =1.3/0.97 = 1.34 > 0.3

del PCVmin =0.7

del PCvnor =1.3
del PCV max =2.7
 Type A control valves: Estimation of del PCV min , del PCV nor ,
del PCV max are as presented in sample calculations.

 Type B & C valves: For control valves not in the governing

circuit , the del PCV min is to be increased by the difference in
discharge pressure required for the two circuits.
Subsequent steps for estimation of del PCV min , del
PCV nor and del PCV max are same as for type A control valves.

 Type D control valves: Procedure shall be similar to three

way valves

 Type E control valves: Procedure shall be similar as for

bypass port of three way valves
 Caution: control scheme where only a control valve in the
exchanger bypass and no control valve upstream or
downstream of the exchanger is provided as it is difficult to
match exchanger and control valve pressure drops.

 Type F control valves: Procedure shall be similar as for type B

and C control valves given above.

 Type G control valves: The normal flow through main port

is to be same as flow through the exchanger.

 The minimum flow through bypass port is to be 10 / 20 %

of flow through exchanger.

 Caution: The exchanger is to be specified considering only

90/80 % of flow available to take in to consideration the
10/20 % of flow through the bypass port.
 The rated flow for both main and bypass ports shall be the
available rated flow for the exchanger circuit (to take care of
total exchanger bypass). For the bypass port normal flow and del
PCV nor need not be furnished.
 The frictional losses through the exchanger circuit and
bypass circuits across points C and D are always equal
irrespective of flow.
 del PCV min bypass port or del PCV max bypass port
= del P ckt max + del PCVmin main port
assuming negligible line losses in the bypass circuit.
 Type H control Valves: Positive displacement pumps
develop a discharge pressure equivalent to the back
pressure at its rated (constant) flow.
 Caution: Positive displacement pumps are fixed capacity
machines unless provided with auto capacity control like
stroke adjustment. If a control valve is envisaged in the
positive displacement pump discharge (either through a FIC or
LIC or both) a spill back control valve (normally a PIC)
should be provided to prevent pump PSV from lifting. The
spill back control is provided upstream of any control
valve in the pump discharge circuit. This spill back control
valve should be capable of pumping back the flow equivalent
to rated flow of the pump.
 a. For control valve where the pump discharges to a single
destination:-
 The del P through the control valve for all flows is to be
specified as 0.7 kg/cm2 and the same 0.7 kg/cm2 should be used
in pump hydraulic calculations.
b. For two different control valves in two different circuits
discharging to two different destinations: e.g., FV-1601and
LV-1601 in Fig-5.
---For the control valve in the governing circuit
del Pcv min / nor / rated shall be 0.7kg/cm2
---For the control valve in the not governing circuit
the del Pcv min / nor / rated shall be 0.7 +Difference in
(destination pressures + frictional losses + static
heads in the two circuits)
 If there is a possibility of only one circuit being in operation
at a time, then since the pump would develop only the back
pressure, the del Pcv min for the control valve in each circuit
shall be 0.7 kg/cm2.
 Warning: There have been instances of vibration problems
when control valve has been provided in positive displacement
pump discharge, and hence should be avoided if the system
design permits.
 Type I control valves: The spill back control valve for
reciprocating pumps is a pressure control valve.
 The maximum flow shall be indicated equal to the pump rated
flow rate in the control valve data sheet and a note -“this
control valve shall be normally in closed position“ shall be
added. No normal flow/ delP shall be indicated.
 The circuit frictional loss is only the line loss.
 del Pcv = pressure upstream of control valve –line loss in spill
back line - (source pressure at suction vessel + static head as
in pump suction pressure calculation)
 Pressure upstream of control valve is the pump discharge
pressure less FE loss, if any , upstream of the control valve.
 Suction line loss is not considered as it can be negligible
during turn down etc.
Pdischarge rated = Destination pressure + del Pckt max +discharge
side static head + contingency
 Pdischarge min = Destination pressure + del Pckt min+ discharge side
static head.
 Pressure upstream of control valve shall be estimated based on
both Pdischarge rated and Pdischarge min and two del Pcv figures shall
be reported for both rated and min flows.
 Type J control valves: Since pressure control valve for fuel oil
to furnace involves pressure requirements at burner during
turndown, etc.
 Type K control valves: Procedure shall be similar as for type B
and C control valves given above.
 Type L control valves: Procedure shall be similar as for type A
control valves given above but Pckt shall be frictional
dynamic losses up to FV-1901 inlet only as it is intended to
ensure a fixed pressure of 2-3 kg/cm2 above bubble pressure
of liquid at FV-1901 inlet to prevent 2-phase at control valve
inlet which is not desirable for control.
 Type M control valves: Procedure shall be similar as for type
A control valves given above but del Pckt shall be the
frictional dynamic losses downstream of FV-1901 only. But
control valve upstream pressure is constant and variation in
pressure with pumped flow is not to be compensated as it will
be absorbed in FV-1801/HV-1801.

 Type N valves: Procedure shall be similar as for type A control

valves given above.

 Type O control valves: del P at min/nor/max flows shall be the

same and based on process requirement. This control valve
del P being constant with flow, should not be included in
del Pckt for estimating del P for the other control valve in
the circuit.
THANKS