Plug valve vs. butterfly valve for manual balancing
I had always heard that a plug valve should be used for manually balancing hydronic systems instead of a butterfly valve due to the poor throttling ability of the butterfly valve. However, I am noticing more and more valve manufacturers offering and manual balancing valve with venturi and P/T ports utilizing a butterfly valve. Have butterfly valve's throttling characteristics changed over the years or are these just more sub-par products offered up by companies trying to save a buck?
There seem to be a lot of manufacturers trying to shoehorn Butterfly
valves into every posible niche. They are pretty lousy block valves for
the most part, they've always been really terrible throttle valves, so
manufacturers are spending a bunch of R&D money to try to fit them
SOMEWHERE.
I won't use the new butterfly valves for throttling
service, there are too many good products on the market to use a
marginal valve.
That being said; there is no application on this
earth where I would recommend a plug valve. I know someone will follow
this post with examples of where plug valves are the perfect answer and
they may even be right, I've just spent way
too much time with a 36-inch pipe wrench, 20 ft cheater, 12 lb hammer,
and a whole roustabout crew to try to shut plug valves that haven't been
serviced in a couple of decades. I know that the problem could have
been mitigated with a bit of PM, but I find that in bad times the valve
service program is the first thing cut and then it is slow to be
re-implemented. An unserviced plug valve is a disaster.
If you
want to throttle a process why not use a throttle valve? Globe valves,
V-balls, and dozens of linear-flow chokes all work really well in
throttling service.
OK, I'll be the devil's advocate.
Things that EVERYBODY knows:
1.Butterfly valves are bad for throttling.
2.Plug valves are bad for throttling.
3.The earth is flat.
5.There is a vast international conspiracy from the trilateral commission.
6. Engineers wear calculators on their belts and have tape on their glasses
1.
Butterfly valves have an equal-percentage characteristic out to about
60 degrees open. They throttle just fine BUT THEY ARE LIMITED IN THEIR
APPLICATION. (Every valve has limits)
Butterfly valves have a huge
Cv for their size. Thus they have a reputation for having a quick-open
characteristic. They don't- but if you just slap a line-size butterfly
valve in a line without benefit of the thought process, you will likely
swamp the system and say "Dagnabit! I tol' y'all them butterfly valves
wasn't no good" or other similar intellectual analysis. If a typical
globe valve for control is a size smaller than the line it is in, isn't
it reasonable to expect that a much higher capacity valve would be even
further reduced?
Limitations of butterfly valves: They have a low
value of Fl- also characteristic of other high-capacity valves. Put too
much differential pressure across them in water service and they are
likely to begin cavitating before a globe valve would. Is this a
problem in a balancing valve? Probably not-since a balancing valve is
just for...balancing, which is just creating a small restriction to
match a similar small restriction elsewhere in the system.
Rangeability
can be similar to a globe valve, but it is necessary to use a gear
operator..A handle with a 10-notch plate doesn't really allow for much
fine tuning. Automated valves neet to hae the actuator torque
characteristic matched to the valve's torque characteristic. And a
rubber-seated butterfly valve (typical for a balancing application)
requires a lot of torque to break the vane out of the seat. I mentioned
60-degrees earlier: a good place to stop opening the valve for reasons
other than capacity. There is a dynamic torque peak at about 75 degrees
where the flow becomes attached to the vane. The center of pressure is
ahead of the shaft-so the valve wants to close. Don't open past 60
degrees for modulating servixe and this won't be a problem. Past the
torque peak the torque drops off rapidly to zero at 90 degrees open.
Some sources report this as a torque "reversal" but the reversal occure
in the first derivative of the torque function. If your actuator is
too "soft" it is possible to overshoot and go into a nasty
dynamic. Hence few butterfly valves offered with 3-15 pneumatic
diathragm actuators these days, since a diaphragm actuator has the
dynamics of a waterbed. Nice stiff rack and pinion, Scotch yoke, or
electric actuators work fine for butterfly valves. High-Performance
(aka double-offset) butterfly valves have reduced breakout torque as
well as reduced dynamic torque. Triple offset valves have even less
breakout torque but require huge seating loads to compress the metallic
seal ring. The big advantage of a triple offset valve is that there are
no elastomers in the valve so it can withstand extended temperature
range.
Plug valves:
You did not mention that there are 2
types of plug valves: Lubricated and nonlubricated. "Lubricated" plug
valves have a metallic plug that bears directly against the inside of
the metallic body. High-pressure sealant (almost universally referred
to as "grease" is stored inside the valve, and injected between he plug
and body by turning a screw BEFORE ATTEMPTING TO TURN THE PLUG. The
sealant acts as a lubricant and the high pressure causes the plug to
float clear of the body so it can be turned. The sealant should be
selected so that it is both compatible with and non-contaminating to
whatever is flowing through the valve. Leave a lubricated plug valve in
place without stoking it for a long time, and corrosion products of
system mung can render it very, very difficult to break loose when you
do want to reposition it. Lubricated plug valves are intended for
isolation and I know of no vendor who offers them for throttling.
"NONLUBRICATED"
plug valves are actually better lubricated that the lubricated
types. In a nonlubricated plug valve the plug rides in a (usually) PTFE
sleeve. Set-torque of a nonlubricated plug valve peaks at around 72
hours, as the TFE sleeve cold-flows to match whatever microscopic
imperfections exist in the surface of the plug. Set-torque is around
double run-torque. Lubricated plug valves ARE offered with
characterized ports for throttling, and the port capacity is comparable
with a globe valve of the same size. Characterized plugs have
equal-percentage characteristics. Rangeability can exceed that offered
by a globe valve. THere is NO effect of pressure on the torque required
to turn a nonlubricated plug valve. THe torque is known, actuator
sizing addresses the torque, so automated plug valves can be offered to
modulating applications and can meet the ENTECH dynamic specifications.
Limitations
of Nonlubricated plug valves: Also low Fl, therefore can begin to
cavitate at lower pressure drops than globe valves. Limited pressure
drop for modulating to around 100 psid due to exposure of the TFE sleeve
to the pressure drop. Limited temperature range due to elastomers in
contact. Is it good as a balancing valve? Sure! Better resolution and
rangeability than a butterfly, matches the line size better for a given
Cv, and tends to stay where you leave it because of the friction of the
plug in the sleeve.
Nobody mentioned them, but Gate valves
really are unsuitable for mudulating in all but a very tightly defined
applications window.
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