Usually commercial control valves are characterized only by parameters based on steady flow states not considering the transient conditions that occur in real environments. Two performance parameters to characterize their behaviour in variable demand conditions are proposed in the present paper to improve the knowledge about different types of automatic control valves.
The study is based on experimental analyses that in part are taken from literature references (Prescott and Ulanicki 2003; Meniconi et al. 2017) and in part are performed by the authors. In the section experimental setup, the procedures of the tests performed are described.
In the following paragraphs the GVS and the standard PRV that are used in the study are briefly described, then the main parameters used in the discussion are introduced.
The GVS
The GVS is a new concept of electric actuated control valve, patented by the Politecnico di Milano (Malavasi 2013), that is able to recover part of the energy dissipated in the throttling process and reuse it to feed the actuator, the integrated system of sensors, the electronics, and the data transmission system. In this way, the device can work as a stand-alone monitoring and control station. The device is of interest in the context of water-distribution network revamping and optimization as described in (Ferrarese and Malavasi 2020). The valve was developed to assure pressure regulation with the addition of certain enabling functions that can help the transition towards smart WDN. Examples of these functions are: remote control of the valve position; real-time adjustment of the control parameters; real-time monitoring of pressure and flow rate; local energy supply. These characteristics allow the use of a single integrated device instead of a series of different devices that must be arranged to work together (e.g. pressure sensors, flow meter, communication system). Thanks to its functions and to the energy recovery capability, the GVS is an Internet of Things (IoT) system that can work without an electrical grid connection. Where an IoT system is intended as a network of physical objects embedded with sensors and connected to the internet to exchange data.
In the following the pressure control mechanism is described. The actuator, a Valpes VR with quarter turn operating time of 15 s, is controlled by a Programmable Logic Controller (PLC) installed in a control box. The logic of control is based on the pressure recorded by the pressure transducers integrated in the GVS. The control is a closed-loop in which the pressure is the control variable. The principal parameters that are used to define the control behaviour are:
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the dead-band, db, that defines the tolerance on the pressure; in the tests this parameter is kept equal to 0.15 bar in the laboratory experiments and to 0.2 in field.
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the target pressure, Pt, that is the pressure that the valve must regulate.
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The following graph shows the valve’s behaviour during a transient between two stable conditions. In Fig. 1 the main phases of valve operation are schematically indicated. An abrupt decrease of the downstream pressure is induced by increasing the demand downstream of the valve. After a short time, the valve begins to open increasing the downstream pressure until the target pressure (continuous line in Fig. 1) is again achieved.
Generally, PRV can show two states as defined in Prescott and Ulanicki (2003): a steady state when the valve does not move and pressure and flow rate are stable, and a transient state when the control valve moves and pressure and flow rate change. The transient state of the GVS is subdivided into four phases (Fig. 1):
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Phase 1: the pressure begins changing but still remains inside the dead-band. The valve does not move. No command is sent to the actuator.
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Phase 2: the pressure exits the dead-band. The system shows a dead-time in which the valve is still not moving even though the pressure is out of the dead-band.
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Phase 3: after a dead-time of the electronics’ response, the system reacts by moving the valve until the pressure is restored to a value inside the dead-band.
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Phase 4: the pressure achieves the set point and the actuator stops moving.
Pilot Operated PRV
Pilot operated PRV, otherwise referred to as Clayton type valves, are membrane pilot operated hydraulically-actuated valves. A description of the functioning of the device can be found in Khezzar et al. (1999) and Meniconi et al. (2017). The data shown in this paper is about a Cla-Val NGE 9001 DN100 from Prescott and Ulanicki (2003) and about a Cla-Val ECO 90–35 DN80 from Meniconi et al. (2017). Pilot operated valves assure an automatic behaviour based on the pressure balance between the pressure in the main valve chamber and the pressure imposed regulating the pilot valve that is installed in the control loop. The pressure to be controlled is manually set by changing the regulation of the pilot. The controlled pressure can be maintained constant in a certain range of flow rates.
Direct Acting PRV
Both pilot operated and direct acting PRV are hydraulically actuated and automatic control valves, but the latter are simpler and less expensive. The functioning mechanism is based on the balance between a spring whose compression can be tuned manually to set the target pressure, and the direct action of the flow on the valve trim. This kind of valve shows some limitations due to the limited capacity. The model shown in the present work is a CSA VRCD DN50.
Parameters of Interest
The flow coefficient \(KV\) is one of the most important performance parameters of a valve. It is a dimensional parameter that has been derived from the valve loss coefficient introduced in (Idelchik 1986) and widely used in valve sizing procedures both in European and American standards (International Society for Automation 2007; The International Electrotechnical Commission 2011). In the field of regulation, in addition to the maximum flow coefficient that expresses the maximum capacity of the valve, the characteristic curve is also of crucial importance. It expresses the flow coefficient as a function of valve opening rate. The flow coefficient is defined by international standards as the discharge that passes through the valve for a pressure drop equal to 1 bar, at a certain opening rate. In the following the flow coefficient is defined with units \(\frac{{m}^{3}}{h {bar}^{0.5}}\), thus referred to as KV and calculated as follow:
$$KV=\frac{Q}{{N}_{1}}\sqrt{\frac{\frac{{\rho }_{1}}{{\rho }_{0}}}{\Delta P}}$$
(1)
where \({\rho }_{1}\) \(\left[Kg/{m}^{3}\right]\) is the density of the used fluid, \({\rho }_{0}\) \(\left[Kg/{m}^{3}\right]\) is the reference density in standard condition (water at 15 °C and 1 atm) and ∆P [bar] is the difference between the pressure HUS measured in standard position upstream of the valve and pressure HDS measured in standard position downstream of the valve. N1 is a constant that depends on the unit used for Q and ∆P. In the following N1 is equal to 1 with Q expressed in \(\frac{{m}^{3}}{h}\) and ∆P in bar.
To allow the comparison between different valve sizes, the flow coefficient is divided by the nominal diameter of the valve to the square:
$${KV}^{*}=\frac{KV}{{D}^{2}}$$
(2)
where KV* [\(\frac{m}{h {bar}^{0.5}}\)] is referred to as the flow coefficient index, D [m] is the nominal diameter of the valve. The flow coefficient index \({KV}^{*}\) is a dimensional parameter that is widely used in industrial-valve sizing procedures to express the head loss coefficient (Idelchik 1986) of a generic size valve at certain opening rate.
The derivative of the characteristic curve is a very important index that indicates the inherent valve gain. The gain \({G}_{I}\) is defined as the ratio between the change in flow coefficient \(\Delta KV\) and the change in travel \(\Delta \delta\).
$${G}_{I}=\frac{\Delta KV}{\Delta \delta }$$
(3)
A large gain value means that the flow rate changes abruptly for a small change of the opening of the valve. In some cases a very high value of gain can indicate the possible occurrence of instability (Ulanicki and Skworcow 2014). Instability is addressed in the GVS system by an automatic parameter that regulates the motion velocity of the shutter. Some solutions to limit instability for electronically regulated valves are discussed in (Giustolisi et al. 2017; Janus and Ulanicki 2018; Galuppini et al. 2020).
When the condition of discharge changes during the test, the valve tested needs some time to react and restore the target pressure. During that time the regulated pressure reaches a peak. The difference \(\Delta {H}_{P}\) between the peak and the regulated pressure before the transient \({HD}_{V1}\) is referred to as the pressure peak index and used as a comparison term in this work to differentiate the behaviour of the different kind of valves. The subscript 1 indicates the period before the transient and subscript 2 indicates the period after the transient.
$$\Delta {H}_{P}={HD}_{VP}-{HD}_{V1}$$
(4)
After the transient, the pressure is regulated near the target within a certain accuracy. To evaluate this accuracy another comparison parameter \(\Delta {H}_{t}\) is introduced in the present work, which is defined as the difference between the target pressure imposed and the pressure effectively regulated after a transient by the valve. It is referred to as the pressure accuracy index and defined as:
$$\Delta {H}_{t}={HD}_{V2}-{P}_{t}$$
(5)
where \({P}_{t}\) is the target pressure and \({HD}_{V2}\) is the stabilized pressure after the transient.
Experimental Set-up
Tests at the hydraulic laboratory of the Politecnico di Milano have been performed on the direct acting PRV and on the GVS. A scheme of the test plant is shown in Fig. 2b. The plant is fed by a multi-stage pump that is supplied by a free surface tank. The test section, that contains the valve under test, is delimited by two control valves that are used to set the boundary condition of pressure and flow rate during the tests. The variables recorded during the tests are:
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pressures measured on the pressure taps placed in the standard positions as defined in (The International Electrotechnical Commission 2011) respectively 2 diameters upstream HUS and 6 diameters downstream HDS with relative pressure transducers by Lektra model KPT with full scale 10 bar;
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pressures measured upstream on the tested valve body HUV [bar] and downstream on the tested valve body HDV [bar] with relative pressure transducers by Lektra model KPT with full scale 10 bar.
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flow rate measured 20 diameters upstream of the test section, with an ultrasonic flowmeter VALCOM UPF-01;
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water temperature.
All the data are recorded simultaneously with a data acquisition system at the frequency of 100 Hz. In addition to the above-mentioned acquisition system a monitoring system integrated on the valve has been used for tests performed on the GVS. The integrated system is able to acquire data at a frequency of 10 Hz. The two systems are synchronized through a manual trigger. The additional data of interest for this study, recorded by the GVS built-in monitoring system, is the valve position \(\delta\) [%].
Test Procedures
The test procedures explained in the following were developed to investigate the downstream pressure control ability of the direct acting PRV and of the GVS. A preliminary series of tests was performed to define the characteristic curve of the valve under study as a function of the valve travel rate. The tests follow the procedure described in (The International Electrotechnical Commission 1997). A second series of tests was finalized to evaluate the control effectiveness of the device. A test procedure was developed to highlight how the valve behaves in the transient between two conditions of stable pressure, with particular interest to the pressure peaks generated on the regulated pressure and on the accuracy of pressure regulation. The tests consisted in a series of abrupt changes of discharge by changing the opening of a valve downstream of the test section (valve VD in Fig. 2b). The change in discharge simulates the change in water demand in field applications. In particular, if the discharge increases the valve under test partially opens to achieve the target pressure. Instead, if the discharge decreases the valve under test partially closes again to restore the target pressure. Figure 2a shows the main phases of the test procedure used for the tests on the GVS and for the test on the direct acting PRV.
GVS Test
The built-in electronic control of the GVS can be set to keep a certain target pressure upstream or downstream of the valve. For this series of tests, the valve was set to control the downstream pressure in order to compare the behaviour with that of other standard PRV that have this function. The test begins with the valve completely closed, then the valve is activated. After the valve is activated it reaches a certain opening rate to achieve the target pressure. Then the flow rate is changed abruptly several times by changing the opening of a control valve placed downstream of the valve under test. The GVS reacts to the variation of discharge by opening or closing the shutter until the target pressure is reached. The test ends with the valve closed.
Several tests of this kind have been performed to explore the functioning of the valve for a total of 35 transients that are considered in the discussion.
Direct Acting PRV Test
Initially the target pressure is set for a velocity of the flow in the pipe equal to 1 m/s, as suggested by the constructor. After the setting, the opening of the valve VD placed downstream of the test section is changed to vary the discharge. The variation causes the valve under test to open or close stabilizing the pressure to the target value.
Several tests of this kind have been performed to explore the functioning of the valve for a total of 36 transients, all of which are considered in the discussion.