Report. PIBCV Tests. Report 52724/1 Edition 2 February 2010

Transcription

1 Report PIBCV Tests This report supersedes Report 52724/1 Report 52724/1 Edition 2 February 2010 Carried out for: Danfoss Trata d.o.o. Jožeta Jame 16 SI-1210 Ljubljana Šentvid ID DDVS Slovenia Compiled by: Phil Stonard and Mike Smith Total No of pages: 51 Quality Approved:... Greg King BSc MSc M.InstR Group Manager MicroClimate, Test & Refrigeration This report must not be reproduced except in full without the written approval of an executive director of BSRIA. It is only intended to be used within the context described in the text. BSRIA Limited Old Bracknell Lane West, Bracknell, Berkshire RG12 7AH UK T: +44 (0) F: +44 (0) E: bsria@bsria.co.uk W:

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3 PIBCV TESTS PREFACE PREFACE This second edition report has been issued to clarify aspects of the testing. Specifically the FRESE Optima valve product, which at minimum setting was set the MIN position on the valve adjustment. On investigation, this position does not correspond to the manufacturer s specified minimum operating flow for the valve, which is stated in some literature at 75 l/h. To obtain this flow rate, the valve adjustment would need to be set at 0.4 (on a 0 to 4.0 scale). Other setting positions used for the tests similarly do not give a pro rata flow based on the 500l/h marked on the valve and used in determining nominal flow settings. Manufacturers data sheets give 625l/h as the maximum flow. Changes to the report are made to the Table 2, Chart 7.3 (legend) and Chart 7.9 to clarify the above. In addition, following a query on the Belimo product. A note of explanation has been added to the Chart 7.11 to indicate that the depiction is a reverse characteristic due to the mounting of the actuator relative to the ball. (which can also be mounted to give a forward characteristic). This edition is not a consequence of the first edition being faulty by purpose or negligence. BSRIA Report 52724/1 Edition 2 3 of 51

4 SUMMARY PIBCV TESTS SUMMARY This report concerns tests carried out on six small pressure independent control valves at Danfoss Slovenia. There is currently no standard test method that deals specifically with pressure independent control valves, resulting in data for various pressure ranges and characteristics being quoted by different manufacturers. The objective of the tests was to compare the response and flow characteristics of the valves when subjected to tests under the same conditions: Changing control voltage of VDC, with constant pressure drop. Changing pressure drop of kpa, across the valve with a constant valve setting. The flow pressure curves gave an indication of the range over which the pressure independent control valve worked. The range tested was greater than the manufacturers declared operating range, shown by the vertical white lines on the graph. The narrowest flow band (l/h) at each setting gave the best control stability. The flow characteristic curves showed the linearity of flow control with changing voltage. An ideal valve would show all the plot lines being straight and superimposed on top of each other, rising from zero flow, zero voltage to 100% flow at 10 volts. Details of the test methods and results are contained within the main body of this report. 4 of 51 BSRIA Report 52724/1 Edition 2

5 CONTENTS PIBCV TESTS CONTENTS 1 INTRODUCTION OBJECTIVE ITEMS RECEIVED FOR TEST EQUIPMENT USED TEST METHODS Measured Flow Flow Limitation Test kpa Control Characteristic Tests VDC Control Characteristic Tests (extra) COMMENTS/ANALYSIS RESULTS AB QM DN10 Flow Limitation Test AB QM DN15 Flow Limitation Test Frese Optima DN15 Flow Limitation Test Flowcon SME DN15 LF Flow Limitation Test Belimo R2P DN15 Flow Limitation Test Cocon Q DN15 Flow Limitation Test AB-QM DN10 LF Flow Characteristic AB-QM DN15 Flow Characteristic Frese Optima DN15 Flow Charateristic Flowcon SME DN15 LF Flow Characteristic Flowcon SME DN15 LF Flow Characteristic Belimo R2P DN15 Flow Characteristic Cocon Q DN15 Flow Characteristic APPENDICES Appendix: A Test Specification Appendix: B Photographs of Valves and test rig Appendix: C Instrument calibration certificates Appendix: D Raw test data Appendix: E Chart of Frese valve set at 78 l/h and 50kPa differential applied at BSRIA TABLES Table 1 Instrumentation... 8 Table 2 Measured flow at DP=50kPa BSRIA Report 52724/1 Edition 2 5 of 51

6 PHOTOGRAPHS PIBCV TESTS PHOTOGRAPHS Photograph 1 ABQM Photograph 2 ABQM Photograph 3 ABQM Photograph 4 Belimo Photograph 5 Belimo Photograph 6 Calibrator Photograph 7 Cocon Q Photograph 8 Cocon Q Photograph 9 Flowcon Photograph 10 Flowcon Photograph 11 Flowcon Photograph 12 Frese Photograph 13 Instrumentation Photograph 14 Small rig of 51 BSRIA Report 52724/1 Edition 2

7 PIBCV TESTS INTRODUCTION 1 INTRODUCTION This report details work carried out to compare the performance of six pressure independent control valves, when subjected to varying pressures and control signals. The work was commissioned by Danfoss, Slovenia and carried out during the period January 2009 at the Danfoss factory. The work was conducted by Andrej Jelenec, Saša Kojić of Danfoss and Phil Stonard of BSRIA. 2 OBJECTIVE The objective of the tests was to compare the response and flow characteristics of the valves when subjected to: Changing control voltage of VDC, with constant pressure drop. Changing pressure drop across the valve of kpa, with a constant valve setting. Appendix A shows the test specification. The test differential pressures, in some instances exceeded the manufacturers normal quoted operating range. 3 ITEMS RECEIVED FOR TEST Items received for test consisted of: Danfoss AB-QM DN10 LF Danfoss AB-QM DN15 Frese Optima DN15 Flowcon SME DN15 LF Belimo R215P-009 DN15 Oventrop Cocon Q DN15 Three of each of the Danfoss valves was selected from factory production stock, one of which was then selected for test, by BSRIA. Competitors valves were purchased from commercial suppliers by BSRIA and shipped to Danfoss. The original Oventrop test piece failed to arrive from the supplier before the tests and a duplicate was obtained by Danfoss from a German supplier. This was retained by BSRIA on completion of the tests for examination and comparison with the original UK purchased item. All items except for the Oventrop valve used the original equipment actuators. The Oventrop valve used the actuator that arrived with the Flowcon valve, this being a normally closed (closed at 0v) Siemens unit. BSRIA Report 52724/1 Edition 2 7 of 51

8 EQUIPMENT USED PIBCV TESTS The valves (except for the Belimo) were constructed and operated on similar principles. That is, they had three major functioning parts: The differential pressure controller within the valve. A manually adjustable flow range, using a rotating collar or similar device. A spring loaded stem, operated by the electrical actuator with a 0-10V signal that determined the percentage open or closed. These valves also had integral pressure tappings on the valve body. These were not used during the tests. The Belimo valve operated in a different manner. This had: The differential pressure controller within the valve. A rotating actuator, operating a quarter turn ball valve over a 90 degree range and driven by a 0-10V signal. Manually adjustable limit stops at each end of the valve travel. The flow setting was adjusted according to the magflo reading. Photographs of the valves and actuators are contained within Appendix B. 4 EQUIPMENT USED The equipment used consisted of two pressure transducers and a flowmeter on the Danfoss small test rig (designated as LFT small ASV ). The rig used a pressurised water system, with an inverter controlled pump. The pipe used for the test length was of steel with straight lengths of at least 18 diameters upstream and downstream of the valve. Pressure tappings were fitted to the pipe at least 2 diameters upstream and 7 diameters downsteam of the valve. This was generally in accordance with valve standards such as BS 7350 Double regulating globe valves for heating and chilled water systems. Calibration certificates for the devices used were supplied to BSRIA prior to the tests commencing. Copies are included within Appendix C of this report. Table 1 Instrumentation Test item Identifier Calibration date Siemens Magflo 3000 QT /03/04 pressure transducer PT /09/08 pressure transducer PT /09/08 Fluke process calibrator /06/08 8 of 51 BSRIA Report 52724/1 Edition 2

9 PIBCV TESTS TEST METHODS 5 TEST METHODS There is currently no specific standard test method for pressure independent control valves. The test methods used consisting of initially installing the test valve on the rig and connecting the instrumentation. A series of tests was then conducted in sequence, as detailed below to compare the performance of the various valve and actuator assemblies: 5.1 MEASURED FLOW The valve was set using the manually adjustable collar or limit stop to its minimum setting. A differential pressure of 50kPa was applied and the flow rate that was achieved noted. Where a manufacturer published a value, the test data was compared with that quoted. No actuator was fitted during this test. This was repeated for the maximum valve setting and one or two mid point settings. Nominally, settings were Minimum, 100 l/h, 200 l/h and 450 l/hr. The Danfoss AB-QM DN 10 used 30 l/h, 60 l/h and 150 l/h. The Belimo valve was set at a minimum flow by altering the mechanical stop position and manually operating the actuator using the integral clutch mechanism. However, as manufacturers characteristic data for this particular valve size was not available at the time of testing this was by experimentation using the flow meter to register when a steady flow occurred. Likewise, mid point position was determined by use of the flow meter. Therefore, there was no manufacturer declared value to compare the test data with. 5.2 FLOW LIMITATION TEST KPA Following on from 5.1, at each valve setting, the pressure was raised slowly from 0 kpa to 600 kpa and back to 0 kpa by means of the ramp setting on the pump inverter. The time taken to apply the pressure and return to zero was approximately seven minutes. Pressures and flow rates were automatically recorded every 1 second. The data was then plotted to show the valve characteristics, with a band showing the manufacturers stated minimum and maximum operating pressure differential. 5.3 CONTROL CHARACTERISTIC TESTS VDC After 5.2, the actuator was fitted to the valve. Manual valve positions were as 5.1, but in this case, differential pressure was set to 20kPa with the valve open. The valve was then driven from closed to full open and back to closed using a ramped 10v signal from the Fluke calibrator. Pressures and flow rates were automatically recorded every 1 second. The total ramp time was ten minutes. For each valve setting, this was also repeated with differential pressures of 50 kpa and 100 kpa. The flow characteristic curves were then plotted. 5.4 CONTROL CHARACTERISTIC TESTS (EXTRA) On completion of 5.3, short tests were conducted to observe the effect if the valve was driven open using the same voltage ramp as previously, but pressure was also varied from kpa. This involved some manual control. This was tried on a few of the valves. The effects observed were similar to 5.3. Consequently, this was not carried out on all the valves and the data is not reported. BSRIA Report 52724/1 Edition 2 9 of 51

10 COMMENTS/ANALYSIS PIBCV TESTS 6 COMMENTS/ANALYSIS The flow pressure curves gave an indication of the range over which the pressure independent control valve worked. The range tested was greater than the manufacturers declared operating range, shown by the vertical white lines on the graph. The flow bands were indicated by horizontal dashed white line (minimum) and solid white line (maximum).the narrowest flow band (l/h) at each setting gave the best control stability. The flow characteristic curves showed the linearity of flow control with changing voltage. An ideal valve would show all the plot lines being straight and superimposed on top of each other, rising from zero flow, zero voltage to 100% flow at 10volts. 7 RESULTS The results are shown as a table of nominal and measured flow rates at 50kPa and two graphs for each valve, showing the flow limitation test and control characteristic. Data used to produce the graphs is included in Appendix D. Table 2 Measured flow at DP=50kPa Test Sample Nominal setting Measured flow at 50kPa Deviation AB-QM DN10 LF 30 l/h 60 l/h 150 l/h AB-QM DN15 Minimum (75) 100 l/h 200 l/h 450 l/h Frese Optima DN15 Minimum 125l/h 250l/h 560l/h Flowcon SME DN15 Minimum (40) 100 l/h (107) l/h (193) 450 l/h (447) Belimo R2P DN15 Minimum 200 l/h l/h Cocon Q DN l/h 200 l/h 450 l/h 32 l/h 60 l/h 147 l/h 83 l/h 94 l/h 195 l/h 480 l/h N/A 129 l/h 247 l/h 550 l/h 79 l/h 187 l/h 276 l/h 487 l/h 90 l/h 209 l/h 400 l/h 109 l/h 162 l/h 483 l/h N/A As determined from incremental percentage clickstop settings on dial. 2. Set at approximate midpoint (no positive stop setting available) by adjustment until measured flow reached 200 l/h. Manufacturers flow vs position curve for this valve was not available during tests. 3. Note that the Frese valve was set to a Min position, this does not correspond to the setting for the declared minium flow operation range and any flow at the setting is due to leakage through the mechanism. N/A of 51 BSRIA Report 52724/1 Edition 2

11 PIBCV TESTS RESULTS 4. This second edition has amended values for the Nominal Setting for the FRESE valve that were previously stated incorrectly. In some cases, minimum setting was the same or larger than 100 l/h, hence a consequent reduction in the number of tests from four to three with some of the valves. BSRIA Report 52724/1 Edition 2 11 of 51

12 RESULTS PIBCV TESTS 7.1 AB QM DN10 FLOW LIMITATION TEST Danfoss AB-QM 10 Ramp kpa with fixed valve position kPa 350kPa Rising 30 l/h Falling 30 l/h Rising 60 l/h Falling 60 l/h Rising 150 l/h Falling 150 l/h Flow l/hr Applied pressure kpa 12 of 51 BSRIA Report 52724/1 Edition 2

13 PIBCV TESTS RESULTS 7.2 AB QM DN15 FLOW LIMITATION TEST kPa Danfoss AB-QM15 Ramp kpa with fixed valve position 350 kpa Rising Min Falling Min Rising 100 l/h Falling 100 l/h Rising 200 l/h Falling 200 l/h Rising 450 l/h Falling 450 l/h Flow l/hr Applied pressure kpa BSRIA Report 52724/1 Edition 2 13 of 51

14 RESULTS PIBCV TESTS 7.3 FRESE OPTIMA DN15 FLOW LIMITATION TEST Frese Optima Ramp kpa with fixed valve opening Rising Min stop Falling Min stop Rising 125 l/h Falling 125 l/h Rising 250 l/h Falling 250 l/h Rising 560 l/h Falling 560 l/h Flow l/hr Applied voltage 14 of 51 BSRIA Report 52724/1 Edition 2

15 PIBCV TESTS RESULTS 7.4 FLOWCON SME DN15 LF FLOW LIMITATION TEST 16kPa kPa Flowcon SME Ramp kpa with fixed valve position Rising Min Falling Min Rising 100 l/h Falling 100 l/h Rising 200 l/h Falling 200 l/h Rising 450 l/h Falling 450 l/h Flow l/hr Applied pressure kpa BSRIA Report 52724/1 Edition 2 15 of 51

16 RESULTS PIBCV TESTS 7.5 BELIMO R2P DN15 FLOW LIMITATION TEST Belimo Ramp kpa with fixed valve opening kPa 345 kpa Rising 210 l/h Falling 210 l/h Rising 400 l/h Falling 400 l/h Rising Min Falling Min Flow rate l/hr Applied pressure kpa 16 of 51 BSRIA Report 52724/1 Edition 2

17 PIBCV TESTS RESULTS 7.6 COCON Q DN15 FLOW LIMITATION TEST Cocon Q Ramp kpa with fixed valve opening kPa 400kPa Rising Min Falling Min Rising 200 l/h Falling 200 l/h Rising 450 l/h Falling 450 l/h Flow l/hr Applied pressure BSRIA Report 52724/1 Edition 2 17 of 51

18 RESULTS PIBCV TESTS 7.7 AB-QM DN10 LF FLOW CHARACTERISTIC Danfoss AB QM 10 Ramp V with fixed differential and various % opening settings Flow as % of manufacturers stated values Set 30 l/h 20kPa Set 30 l/h 50kPa Set 30 l/h 100kPa Set 60 l/h 20kPa Set 60 l/h 50kPa Set 60 l/h 100kPa Set 150 l/h 20kPa Set 150 l/h 50kPa Set 150 l/h 100kPa Applied voltage 18 of 51 BSRIA Report 52724/1 Edition 2

19 PIBCV TESTS RESULTS 7.8 AB-QM DN15 FLOW CHARACTERISTIC Danfoss AB QM 15 Ramp V with fixed differential and various % opening settings Flow as % of manufacturers stated value Set 100 l/h 20kPa Set 100 l/h 50kPa Set 100 l/h 100kPa Set 200 l/h 20kPa Set 200 l/h 50kPa Set 200 l/h 100kPa Set 450 l/h 20kPa Set 450 l/h 50kPa Set 450 l/h 100kPa Applied voltage BSRIA Report 52724/1 Edition 2 19 of 51

20 RESULTS PIBCV TESTS 7.9 FRESE OPTIMA DN15 FLOW CHARACTERISTIC Frese Optima Ramp V with fixed differential pressure and various % opening Flow as % of manufacturer stated value Set 560 l/h 100kPa Set 560 l/h 50kPa Set 560 l/h 20kPa Set 250 l/h 100kPa Set 250 l/h 50kPa Set 250 l/h 20kPa Set 125 l/h 100kPa Set 125 l/h 50kPa Set 125 l/h 20kPa Applied voltage Appendix E illustrates a BSRIA Laboratory test when set to 78 l/h and 50 kpa differential pressure 20 of 51 BSRIA Report 52724/1 Edition 2

21 PIBCV TESTS RESULTS 7.10 FLOWCON SME DN15 LF FLOW CHARACTERISTIC Flowcon SME Ramp V with fixed differential pressure and various % opening Flow as % of manufacturers stated value Set min 20kPa Set min 50kPa Set min 100kPa Set kPa Set kPa Set kPa Set kPa Set kPa Set kPa Set kPa Set kPa Set kPa Applied voltage BSRIA Report 52724/1 Edition 2 21 of 51

22 RESULTS PIBCV TESTS 7.11 BELIMO R2P DN15 FLOW CHARACTERISTIC Belimo ramp V with fixed differential pressure and various % opening Flow as % of set value Set 90 l/h 20kPa Set 90 l/h 50kPa Set 90 l/h 100kPa Set 209 l/h 20kPa Set 209 l/h 50kPa Set 209 l/h 100kPa Set 400 l/h 20kPa Set 400 l/h 50kPa Set 400 l/h 100kPa Applied voltage Note that these are reverse characteristics the actuator can be mounted to give forward characteristics. The valve is based on a quarter turn ball valve with low flow rates achieved by limiting the travel hence the limited control range. The actuator used for the tests was an LR24A-SR. Manufacturers preferred actuator for pre setting the valve position is an LR24A- MF. 22 of 51 BSRIA Report 52724/1 Edition 2

23 PIBCV TESTS RESULTS 7.12 COCON Q DN15 FLOW CHARACTERISTIC Flow % of manufacturers stated value Cocon Q Ramp V with fixed differential pressure and various valve % opening Set 130 l/h 20kPa Set 130 l/h 50kPa Set 130 l/h 100kPa Set 200 l/h 20kPa Set 200 l/h 50kPa Set 200 l/h 100kPa Set 450 l/h 20kPa Set 450 l/h 50kPa Set 450 l/h 100kPa Applied voltage BSRIA Report 52724/1 Edition 2 23 of 51

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25 PIBCV TESTSPIBCV TESTS APPENDICES APPENDICES BSRIA Report 52724/1 Edition 2 25 of 51

26 APPENDIX A PIBCV TESTS Appendix: A Test Specification SPECIFICATION OF PICV TESTS Flow limitation test (representative graph) Testing sample AB-QM DN20 Control characteristic test (representative graph) AB-QM DN15 & AME 110 NL Lin Flow (l/h) %, 1 bar 40%, 1 bar 20% 1bar 40%, 0,5 bar 100% 0,5 bar 20%, 0,5 bar Volt (V) 26 of 51 BSRIA Report 52724/1 Edition 2

27 PIBCV TESTS APPENDICES Sample/Testing specification AB-QM DN10 LF AB-QM DN15 Frese Optima DN15 Flowcon SME DN15 Belimo Rp DN15 Cocon Q DN15 Setting l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h Measured flow at dp=50 kpa Flow limitation test kpa l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h 1. Minimum l/h l/h l/h Test rig /Duration LFT Small ASV LFT Small ASV LFT Small ASV LFT Small ASV LFT Small ASV LFT Small ASV BSRIA Report 52724/1 Edition 2 27 of 51

28 APPENDIX B PIBCV TESTS Appendix: B Photograph 1 Photographs of Valves and test rig ABQM10-1 Photograph 2 ABQM of 51 BSRIA Report 52724/1 Edition 2

29 PIBCV TESTS APPENDIX B Photograph 3 ABQM15-1 Photograph 4 Belimo-1 BSRIA Report 52724/1 Edition 2 29 of 51

30 APPENDIX B PIBCV TESTS Photograph 5 Belimo-2 Photograph 6 Calibrator 30 of 51 BSRIA Report 52724/1 Edition 2

31 PIBCV TESTS APPENDIX B Photograph 7 Cocon Q-1 Photograph 8 Cocon Q-2 BSRIA Report 52724/1 Edition 2 31 of 51

32 APPENDIX B PIBCV TESTS Photograph 9 Flowcon-1 Photograph 10 Flowcon-2 32 of 51 BSRIA Report 52724/1 Edition 2

33 PIBCV TESTS APPENDIX B Photograph 11 Flowcon-3 Photograph 12 Frese-1 BSRIA Report 52724/1 Edition 2 33 of 51

34 APPENDIX B PIBCV TESTS Photograph 13 Instrumentation Photograph 14 Small rig 34 of 51 BSRIA Report 52724/1 Edition 2

35 PIBCV TESTS APPENDIX C Appendix: C Instrument calibration certificates BSRIA Report 52724/1 Edition 2 35 of 51

36 APPENDIX C PIBCV TESTS 36 of 51 BSRIA Report 52724/1 Edition 2

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50 APPENDIX D PIBCV TESTS Appendix: D Raw test data Raw test data on accompanying CD. 50 of 51 BSRIA Report 52724/1 Edition 2

51 PIBCV TESTS APPENDIX E Appendix: E Chart of Frese valve set at 78 l/h and 50kPa differential applied at BSRIA Frese Optima ramp with fixed differential of 50kPa 120 Set 78 l/h rising voltage Set 78 l/h falling voltage 100 Flow as % of manufacturers stated value Applied voltage Tested on 3 February 2010 in BSRIA laboratory BSRIA Report 52724/1 Edition 2 51 of 51