27.5. VALVE SEAT LEAKAGE |
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27.5Valve seat leakage
In some process applications, it is important that the control valve be able to completely stop fluid flow when placed in the “closed” position. Although this may seem to be a fundamental requirement of any valve, it is not necessarily so. Many control valves spend most of their operating lives in a partially-open state, rarely opening or closing fully. Additionally, some control valve designs are notorious for the inability to completely shut o (e.g. double-ported globe valves). Given the common installation of manual “block” valves upstream and downstream of a control valve, there is usually a way to secure zero flow through a pipe even if a control valve is incapable of tight shut-o . For some applications, however, tight control valve shut-o is mandatory.
For this reason we have several classifications for control valves, rating them in their ability to fully shut o . Seat leakage tolerances are given roman numeral designations, as shown in this table9:
Class |
Maximum allowable leakage rate |
Test pressure drop |
|
|
|
I |
(no specification given) |
(no specification given) |
II |
0.5% of rated flow capacity, air or water |
45-60 PSI or max. operating |
|
|
|
III |
0.1% of rated flow capacity, air or water |
45-60 PSI or max. operating |
IV |
0.01% of rated flow capacity, air or water |
45-60 PSI or max. operating |
|
|
|
V |
0.0005 ml/min water per inch orifice size per PSI |
Max. operating |
VI |
Bubble test, air or nitrogen |
50 PSI or max. operating |
|
|
|
The “bubble test” used for Class VI seat leakage is based on the leakage rate of air or nitrogen gas past the closed valve seat as measured by counting the rate of gas bubbles escaping a bubble tube submerged under water. For a 6 inch valve, this maximum bubble rate is 27 bubbles per minute (or about 1 bubble every two seconds):
Class VI seat leakage test
(Fully closed)
Compressed
air supply
Water in cup
It is from this leakage test procedure that the term bubble-tight shut-o originates. Class VI shut-o is often achievable only through the use of “soft” seat materials such as Teflon rather than
9Data in this table taken from Fisher’s Control Valve Handbook.