VALVESTAR® - Manual

The Safety Valve

®
VALVESTAR
Version 6.3

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The Safety Valve

Contents

Contents .............................................................................................................................. - 2 -
1 Introduction....................................................................................................................... - 4 -
2 Installation of VALVESTAR® ............................................................................................ - 5 -
2.1 Systemrequirements.................................................................................................. - 5 -
2.2 Installation.................................................................................................................. - 5 -
2.3 Uninstallation ............................................................................................................. - 5 -
2.4 Contents of the CD .................................................................................................... - 6 -
3 Terms ............................................................................................................................... - 7 -
3.1 Projects...................................................................................................................... - 7 -
3.2 Sizings ....................................................................................................................... - 7 -
3.3 Valves and Configurations......................................................................................... - 7 -
4 Usage of VALVESTAR® ................................................................................................... - 8 -
4.1 Projects...................................................................................................................... - 8 -
4.1.1 The Initial Screen ................................................................................................ - 8 -
4.1.2 Create a new Project........................................................................................... - 8 -
4.1.3 Save a Project..................................................................................................... - 9 -
4.1.4 Rename a Project ............................................................................................... - 9 -
4.1.5 Additional Information and Text .......................................................................... - 9 -
4.2 Sizings ..................................................................................................................... - 10 -
4.2.1 AD 2000:A2 / TRD 421 ..................................................................................... - 11 -
4.2.1.1 Gases and Steam....................................................................................... - 11 -
4.2.1.2 Saturated Steam......................................................................................... - 15 -
4.2.1.3 Manually Enter Isentropic Exponent........................................................... - 16 -
4.2.1.4 Superheated steam .................................................................................... - 16 -
4.2.1.5 Liquids ........................................................................................................ - 16 -
4.2.1.6 Viscosity ..................................................................................................... - 17 -
4.2.1.7 Backpressure in the Outlet Pipe ................................................................. - 17 -
4.2.1.8 Pressure Drop in the Inlet Pipe................................................................... - 18 -
4.2.1.9 Noise .......................................................................................................... - 18 -
4.2.2 ASME VIII.......................................................................................................... - 18 -
4.2.2.1 Gases and Steam....................................................................................... - 19 -
4.2.2.2 Saturated steam ......................................................................................... - 19 -
4.2.2.3 Superheated steam .................................................................................... - 20 -
4.2.2.4 Liquids ........................................................................................................ - 21 -
4.2.2.5 Noise .......................................................................................................... - 21 -
4.2.3 API 520 ............................................................................................................. - 21 -
4.2.3.1 Gases and Steam....................................................................................... - 22 -
4.2.3.2 Saturated steam ......................................................................................... - 24 -
4.2.3.3 Superheated steam .................................................................................... - 24 -
4.2.3.4 Liquids ........................................................................................................ - 24 -
4.2.3.5 Viscosity ..................................................................................................... - 24 -
4.2.3.6 Noise .......................................................................................................... - 25 -
4.2.4 Two-Phase-Flow ............................................................................................... - 25 -
4.2.4.1 Sizing for Hot Water ................................................................................... - 25 -
4.2.4.2 Auslegung nach VdTÜV 100/2 ................................................................... - 25 -
4.3 Valves ...................................................................................................................... - 25 -
4.3.1 Construction ...................................................................................................... - 25 -
4.3.1.1 Lift Restriction............................................................................................. - 26 -
4.3.1.2 Connections................................................................................................ - 27 -
4.3.1.3 Part List ...................................................................................................... - 27 -
4.3.1.4 Dimensions................................................................................................. - 28 -

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4.3.2 Certifications and Inspections ........................................................................... - 29 -

4.3.3 Settings ............................................................................................................. - 29 -
4.3.3.1 Units ........................................................................................................... - 29 -
4.3.3.2 Constants ................................................................................................... - 30 -
4.3.4 Translation ........................................................................................................ - 31 -
4.3.5 Datasheets ........................................................................................................ - 31 -
4.3.5.1 Print a Project or Sizing .............................................................................. - 32 -
4.3.5.2 Print Valve .................................................................................................. - 33 -
4.3.6 Drawing ............................................................................................................. - 35 -
4.3.6.1 Sectional Drawings..................................................................................... - 35 -
4.3.6.2 Focus Drawing............................................................................................ - 35 -
4.3.6.3 Part List ...................................................................................................... - 35 -
4.3.7 Media ................................................................................................................ - 35 -
4.3.7.1 Gases ......................................................................................................... - 35 -
4.3.7.2 Liquids ........................................................................................................ - 35 -
4.3.7.3 Thermodynamical Properties of Water ....................................................... - 36 -
5 Outlook to future Releases............................................................................................. - 37 -
5.1 Performance ............................................................................................................ - 37 -
5.2 Functionality............................................................................................................. - 37 -
5.3 Translation ............................................................................................................... - 37 -
6 Terms of License............................................................................................................ - 38 -
7 Appendix ........................................................................................................................ - 39 -
7.1 Examples ................................................................................................................. - 39 -
7.1.1 Example 1 1: ..................................................................................................... - 39 -
7.1.2 Example 2: ........................................................................................................ - 40 -
7.1.3 Example 3: ........................................................................................................ - 41 -
7.1.4 Example 4: ........................................................................................................ - 42 -

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1 Introduction
Welcome to the new sizing-software VALVESTAR® version 6.2. VALVESTAR® is the
new tool to size safety valves from LESER.

The development-process has been influenced by project-engineers, who combine

several sizings together to a project. On the other hand the unexperienced users have
been mentioned which are guarded during a sizing from a Wizard. Several input data will
be checked and warnings will be generated.

The projects may be saved on disk and You can open the projects again. It is also
possible to save settings like standard-units. You can save different settings for customers
or countries. At least nearly all valves are included in VALVESTAR® with sectional
drawings and partlists.

Please read the terms of license carefully.

Other information is written in this manual.

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2 Installation of VALVESTAR®
2.1 Systemrequirements
Please find below the requirements listed:

Operation-System:
- WINDOWS 98
- WINDOWS ME
- WINDOWS NT with Servicepack 6
- WINDOWS 2000
- WINDOWS XP

Hardware:
- Pentium I Minimum, Pentium III strongly recommended
- 64 MB RAM, better 128 MB RAM or more
- 40 MB free space on Your harddisk

2.2 Installation
Put in the VALVESTAR® -CD in Your CD-drive and run the setup.exe from the explorer.

Choose a language and follow the instructions. According to Your system it may be
nessecary to reboot the system.

Hint: If You use WINDOWS 2000, WINDOWS NT, You need local
administrator privilege to install VALVESTAR® .

Hint: We strongly recommend to uninstall any previous VALVESTAR® -

version.

2.3 Uninstallation
Select in Settings->Control Panel -> Add / Remove Programs and select VALVESTAR® .
Then click Uninstall to remove it. Just follow the Wizard.

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2.4 Contents of the CD

The CD contains the following files:

No. Path Description

1 /doc/Manual_de.pdf this manual in German as pdf-file
2 /doc/Manual_en.pdf this manual
3 /readme.txt latest information (English)
4 /liesmicht.txt latest information (German)
5 /Acrobat/acroread_e Acrobat-Reader (English)
6 /Acrobat/acroread_d Acrobat-Reader (German)
7 Distributors.pdf Distributor list
8 setup.exe VALVESTAR® -Setup-Program

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3 Terms
This chapter shall introduce You the main terms which are used in VALVESTAR® .

3.1 Projects
Projects are the folder which contain the sizings. All project-dependent information is
stored and available here. Also You can add or edit text which must be equal on all
printouts. Besides an input-field for internal usage which is not printed.

3.2 Sizings
Sizings comprise medium-data and service-conditions. They differ depending from the
code and the medium.They are also the container for the chosen valves.

3.3 Valves and Configurations

One or more valves may be added to a sizing. On the one hand they have the
characteristics for the calculation (depending from the code). On the other hand valves
may include technical information concerning the design. E.g. You can choose a steel-
bellow or an O-ring-disc. These configurations may influence the calculation (e.g. lift
restriction).

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4 Usage of VALVESTAR®
4.1 Projects

4.1.1 The Initial Screen

VALVESTAR® creates after the startup always a project with the name "Single sizing”
(Fig. 1). The screen is divided into two parts. On the left one You can see the tree-view
of the current project. This main-screen is called Valve-Explorer. Below there is a
screen for warnings and error-messages. You can change text about the project in the
upper right corner, which will be printed on the data-sheet. You can also fill in
comments for internal usage in the textfield in the right bottom.

The title of the project may be changed in the textfield in the headline. Below the menu
You’ll find a toolbar. Only those icons are activated, which have a function in the
context of the project.

The right part of the screen changes depending from the element which is chosen in
the tree-view. If You have selected a sizing You can see service-condition and medium-
data. The calculation will be shown if You have selected a valve.

Fig. 1 – The initial screen

4.1.2 Create a new Project

There are three ways to create a project:

1) Click in the toolbar on

2) Select in the menu Project->New
3) Right-click on an existing project in the tree-view

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Afterwards a new project will be created. VALVESTAR® asks You whether You would
like to save the old project. Then the wizard starts which guides You step by step to the
valve. The first screen is identical to the right part of the screen in fig. 2. Here You can
enter what You need and know - all data may be changed at any time.

Fig. 2 – Create a project with the wizard

4.1.3 Save a Project

There are two possibilities to save a project:

1) Select Project->Save or Project->Save as from the menu. Use „Save as“ if You want
to save the project with a different name
2) Click in the toolbar

4.1.4 Rename a Project

The project-name is displayed in the right top of the screen. A change will apply directly
to the tree-view.

4.1.5 Additional Information and Text

In the right part of the window are additionally information displayed. If You enter text
into these text-fields then there will be those fields printed on each printout.

You can change the names of the text-fields so that they match Your requirements.
Therefore choose in the menu Options->Texts. A new dialog will open (Fig. 3). The text
can be selected in the upper listbox. The corresponding text can be changed directly in
the textbox below. A lot of different languages are available because VALVESTAR®
is an internationalized product. You have to translate the text in those languages which
You need for the printout.

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Fig. 3 - Adaptation of additional text

4.2 Sizings
When the wizard has created a project and the next step is the sizing. Once again there
are three choices to add a sizing:

1) Rightclick on the project and select "New sizing".

2) Choose in the menu Sizing->New sizing.
3) Click on the symbol in the toolbar

Independent from the choice You will see the window like in fig. 4. Select the code in the
combobox in the right top area. In the part "sizing" please select Sizing or Calculation.
In the part medium one has to select the type of medium.

In the case of AD 2000:A2-sizings an in- and outlet-calculation is also possible. At least

the reactionforce may be calculated with checking the Checkbox.

The part "Additional fields" is independend from the code and contains:
- Text-fields which are specific for the sizing (Button Fields). These text-fields may be
changed similar to the project text in the menu Options->Texts.
- Free text, which can be edited and will be printed in the section "sizing" on the
datasheet.

The window with service-condition and medium data opens with Next > .

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Fig. 4 – Select sizing

4.2.1 AD 2000:A2 / TRD 421

Please find in the following sections the description of the sizings according to AD
2000:A2 / TRD 421.

Fig. 5 – Select AD 2000:A2 / TRD 421

4.2.1.1 Gases and Steam

The service-condition and the medium (Fig. 5) must be specified in the next screen.
Temperature, set pressure and back pressure must be specified. Normally
VALVESTAR® changes the overpressure according to the code for You. With a click
on You can choose between „No overpressure“ and „Enter manually
overpressure“.

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Fig. 6 – Service condition for gases and steam

VALVESTAR® checks the input and informs You if there are any problems. Left
beneath in the combobox for gases You’ll find the button , which is used for:

- Adding a medium within a sizing

- Change a medium name only for the current sizing (Fig. 7).

Fig. 7 – Change gas

You should enter the name for all the languages in which You generate printouts.
Each physical quantity which has units is selected with the standard units (see
chapter Settings - units). When You change the unit VALVESTAR® recalculates the
value directly. Therefore You have to change the unit before You enter the value.

Please note that You can use the arrow-keys ↑ and ↓ to switch between the input-
fields.

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Fig. 8 – Select valve

Choose once again Next > to reach the valve-selection (Fig. 8). The window is
divided in to three parts:
- Top Selection of the valve-type. The listbox right beneath contains
additional information.
- Middle Select body-material and lifting device.
- Bottom All valves of this type which match Your condition are shown (if the set
pressure is outside of the approved pressure-range the valve will be
hidden).

Fig. 9 – Construction view

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Select a valve in the listbox "Valve" by mouseclick and click on Next >. The
construction-window appears (Fig. 9) after some seconds. VALVESTAR® selects all
data like partlists, connections and drawings from the database. The features of this
window will be explained in the chapter Valves / Construction. Just click Finish to
complete Your first sizing. Well done – the first sizing is finished.

We recommend to save Your work frequently with Project->Save or click in the

toolbar. The files are saved in a vsp-Format – a special VALVESTAR®-format.

If You want to print a sizing there are several ways:

- Click in the menu Project->Print
- Click in the tree-view the Project or the sizing and then on in the toolbar.

A new window (Fig. 10) is shown. The checkboxes are used to define the contents of
the datasheet. You can select whether the
- the part list
- the sectional drawing
- the focus drawing (detail drawing)
- warnings

If You select in the tree-view instead a valve and click on a different window (fig.
11) will arise. With a click on Preview one can proof the printout on the screen. Click
Print to start the printout.

Fig. 10 – Print project / sizing

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Fig. 11 – Print valve

4.2.1.2 Saturated Steam

Only two physical quantities are nessecary to size a valve (Fig. 12):
- Set pressure
- Required masslow (if sizing instead of calculation has been chosen)

The temperature and isentropic exponent is calculated by VALVESTAR® based on

the steam table of the IAWPS from 1997.

The selection of valves is absolutely similar to the sizing of gases.

Fig. 12 – Saturated steam

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4.2.1.3 Manually Enter Isentropic Exponent

The isentropic exponent may be changed manually, if You don’t want to use the
actual steam table. The AD A2000:A2-Code is based on the steam table from 1956
and uses the value 1.13. This value is near the values of wet steam. The calculation
with the values from the actual steam table assumes dry saturated steam.
Hint: As a result of a smaller k-value one obtains a bigger required area.

4.2.1.4 Superheated steam

There is no difference between saturated and superheated steam except the
temperature (Fig. 13). The isentropic exponent will be calculated. If the temperature is
to low it will be corrected automatically to the saturation temperature. Please keep in
mind that VALVESTAR® calculates the saturation temperature and isentropic
exponent from the sum of set- and overpressure.

Fig. 13 – Superheated steam

4.2.1.5 Liquids
The following input data are required for liquid sizing:

- Density
- Optionally viscosity
- Set pressure
- Back pressure
- Required massflow

The input is similar to all other sizings. The medium data (see gases) may be
changed.

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Fig. 14 - Liquids

4.2.1.6 Viscosity
There exists no German code for viscosity. Therefore VALVESTAR® uses a
calculation according to API 520. This code is inconsistent for the calculation of the
real massflow. Please see the example in the appendix.

4.2.1.7 Backpressure in the Outlet Pipe

There exists also no code for this type of calculation. LESER uses formulas from G.
Naue, which are taken from a formula booklet from Goßlau and Weyl (BASF).

Please note that this calculation is only valid for pipes with a constant diameter.

You can add (Fig. 5) in the combobox "Outlet" the calculation or You select a valve
and click in the toolbar. There are three different calculations available:
- "Backpressure in the outlet-pipe" calculates the real dynamic backpressure
- „Maximum length of the outlet-pipe“ leads to a maximum length for a given
back pressure and diameter
- “Minimum diameter of the outlet-pipe" calculates for a given length and back
pressure the minimum diameter

VALVESTAR® recognizes whether a stainless steelbellow is chosen or not.

Length and diameter must be specified (if they are not to be calculated). One can
additionally specify the pipe components. Therefore select in "Available pipe
components" the required bends etc. There are a lot of different components
included. A component is added if is clicked. To delete a component select it and
click .

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The calculated dynamic back pressure is printed below the constant back pressure.
You can change the pipe in the Valve-Explorer at any time. The pressure will be
recalculated after You click again on the valve. Warnings will be shown in the Valve-
Explorer and on the datasheet.

Hint: To achieve the diameter of a pipe just click on a bend with the nominal
diameter. This value is reasonable size for the pipe.

At least it should be stated that values like pipe-roughness strongly influence the
calculation. These parameters change because e.g. pipes will rust. This calculation is
just a model of the physical world. We recommend large-scale design of the inner
diameter of the pipes.

4.2.1.8 Pressure Drop in the Inlet Pipe

Two different methods of pressure drop-calculations are implemented:
- AD A2000:A2 / TRD 421
- SVTI

The pipe must be specified first (see backpressure in the outlet pipe). Then
VALVESTAR® calculates the real pressure drop and maximum length of the inlet
pipe with and without pipe components. You will find the real pressure drop and
warnings also in the Valve-Explorer.

The real massflow may be also reduced by the pressure drop.

Please note that the pressure drop from the inlet stub must not be mentioned by
LESER-valves. Result: No inlet stub must be added in the pipe components.

Hint: It is very often useful to try a lift-restriction (see chapter Valve /

Construction) which minimizes the pressure drop. This may result in a
smaller inlet pipe compared to the situation without a lift restriction.

4.2.1.9 Noise
Noise is calculated according to VDI 2713. Calculation is only available for gases and
steam.

4.2.2 ASME VIII

The calculations according to ASME VIII are based on the ASME-Code. But for
calculations for superheated steam or liquids with viscosity are correction-factors from
the API 520 used.

In difference to the API 520, which is based on nominal diameters and nominal
discharge coefficients, are real diameters and certified discharge coefficients in the
ASME VIII-calculations used. The valve-selection is therefore based on the certified
massflow and not on the orifice designation letter.

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The differences are clearly stated in the example in the Appendix. The features of the
User-Interface are described in the chapter AD 2000:A2 / TRD 421 / Gases and steam.

4.2.2.1 Gases and Steam

The sizing is absolutely similar to AD A2000:A2 / TRD 421 - sizings. The variable
backpressure is the only diffrence (Fig. 14). The valve-selection appears after Next >
is clicked. The same data like in AD 2000:A2 has to be specified:
- Valve-type
- Bodymaterial
- Lifting device

The capacity is listed below. Select a valve and click Next > to configure the valve in
the construction-window.

The printout can be done as described in the AD A2-chapter.

Fig. 15 - ASME VIII for gases and steam

4.2.2.2 Saturated steam

The ASME uses correction factors for the steam-calculation. Therefore must be only
the set pressure and the required massflow defined.

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Fig. 16 - Sattdampf according to ASME VIII

4.2.2.3 Superheated steam

Beneath in the required data for saturated steam is the temperature for sizings with
superheated steam necessary (Fig. 16). The temprerature is compared with the
temperature of saturated steam.

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Fig. 17 – Superheated steam according to ASME VIII

4.2.2.4 Liquids
The sizing for liquids is nearly identical to the AD A2000:A2 / TRD 421 - sizing (Fig.
17). The difference of set- and back pressure determines the massflow. The API 520-
approach is used for viscous liquids.

Fig. 18 – Liquids according to ASME VIII

4.2.2.5 Noise
The noise calculation is implemented according to API 521. The L-value in the
diagram is not interpolated für higher ratios of setpressure and backpressure. Any
type of interpolation leads to unreasonable noise-levels. Please see also the example
in the Appendix.

4.2.3 API 520

The API 520 together with the API 526 is the basis for the API sizing of safety valves. It
has been founded to size safety valves independent from the valve manufacturers.
Therefore an Orifice-Letter has been introduced. The API describes the capacity of
safety valves with letters between D and T. The discharge area, the connections and
materials are listed in the API 526. The sizing follows always the same way:

- Calculate a required discharge area AReq based on a nominal discharge coefficient

(Gases, steam KD=0,975, liquids KD=0,65)
- Determine the next Orifice by comparing the nominal with the required area.

In the valve-selection is now the required orifice displayed.

LESER has a since 2002 a complete API-Program (Type 526) product range. But it is
also allowed to size valves according to API (e.g. Type 441) even if it is not an API

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valve. The orifices of these valves are only derived from the capacity of the valve. The
flange-connections are mostly not according to the API 526.

If You need an API-valve with connections and design according to API 526 then the
Type 526 must be chosen.

4.2.3.1 Gases and Steam

There are some substantial differences between the API-sizing and other code, which
will be explained in this chapter. Fig. 19 shows that the service condition and medium
data look as You are used to from the other chapters.

The valve-selection, which arises when Next > is clicked, looks like the ASME-
Selection. An additional information is given – the required orifice. Besides is the
valve characterized by "Nominal diameter inlet" "Orifice" "Nominal diameter outlet"
(Fig. 20). As nominal diameter is the standard-connection chosen. This can be a
flange or a screwed connection.

Fig. 19 Gases and steam according to API 520

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Fig. 20 - Selection chart - Button

After selecting Type 526 button one can see a button Selection chart (Fig. 20). If You
click this Button then a new windows will open with the pressure-temperature-chart
according to API 526. Additionally data of the ASME B16.34 have been integrated in
this chart. This chart helps You to select the bodymaterial of the valve.

The required and the selected orifice will be printed later on the datasheet. The
capacity-exceed and the real massflow will be also printed. The required discharge
area is based on the nominal discharge-coefficients.

According to the back pressure is a correction factor KB calculated. This factor is acc.
to API only for valves with bellows. We apply this factor in VALVESTAR® for valves
without bellow too, because the valves may be set to the differential pressure. This
factor will be only different from 1 for pressure ratios of 15% and more based on the
set pressure.

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Fig. 21 - Selection chart

4.2.3.2 Saturated steam

There are no differences to the ASME VIII-window. The valves can be selected as
described in 4.2.3.1.

4.2.3.3 Superheated steam

See saturated steam.

4.2.3.4 Liquids
The sizing looks like ASME VIII (Fig. 18). As nominal discharge coefficient is KD=0,65
assumed. You can see the real massflow in the Valve-Explorer. Printout is
generated as usual.

4.2.3.5 Viscosity

The sizing for viscosity is complicated and needs some explanation. The algorithm is
as follows:
- Calculation of the required area without viscosity A0,Req.
- Selection of the next larger orifice
- Calculation of A0,Req*=A0,Req/KV
- Check whether the calculated value is smaller than the selected Orifice. Else one
has to select a larger valve and restart the calculation.

Some open points remain:

1) It is always assumed that the valve can discharge the required volume flow
2) if viscosity gets to big (>2500cps) the KV-factor may be outside of the definition
range (KV,Min=0,3)
3) The real valve don’t have that nominal diameters and nominal discharge
coefficients. Therfore will be different Kv-factors for sizing and calculation.

The following algorithm is used to calculate the real volume flow

1) Calculate QNo Viscosity

2) Iterate Q between 0 and QNo Viscosity

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3) Use Q in the formulas for the Reynoldsnumber and KV

4) Stop if Q=QNo Viscosity*KV is fulfilled

This is the reason why we have sometimes differences between calculation acc. to
ASME VIII and sizing acc to API 520. Please ask LESER if You have to size a valve
for media with Kv-values below 0.3.

4.2.3.6 Noise
See ASME VIII.

4.2.4 Two-Phase-Flow

All in VALVESTAR® implented formulas are based on simplified assumptions. A

minimum of data is needed for this calculation.

Caution: We recommend in special cases (e.g. chemical reactions) a sizing

from two-phase-experts like BASF or DIERS-Institute.

4.2.4.1 Sizing for Hot Water

The sizing is described in the LESER-Catalogue 20/50. Only the set pressure and the
massflow needs to be specified. The temperature must be below the temperature of
saturated steam – else would it be no two-phase-flow. The ratio of liquid and gas
phase is derived from the thermodynamical properties of steam. These properties are
calculated by VALVESTAR® . The pressure medium coefficients will be printed also
om the datasheet.

4.2.4.2 Auslegung nach VdTÜV 100/2

This sizing is implemented from formulas according to the German VdTÜV 100/2.
This sizing is valid for gases in a liquified state in the range of 3 to 150 bar-g.

For some media is the logarithm of the Leung-function linear. It is also assumed that
the pressure drop in the inlet is 3% based on the set pressure, which is used from the
medium to evaporate. Examples for media are liquid propane, butane etc.

We copied all gases for this sizing. LESER can not decide without further information
whether these media fulfil the criteria for this sizing.

Please check in the VdTÜV 100/2 whether Your medium fits the criteria for this
sizing.

4.3 Valves
Nearly all valves are included in VALVESTAR®. Data for calculation and design (part list,
drawing) are part of the database. Please read the following chapters to us
VALVESTAR® to learn more about the entire features.

4.3.1 Construction
There are three ways to open the construction-view:

- In the wizard if You click Next > in the select-valve-window

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- Select the valve in the Valve-Explorer and click

- Select the valve in the Valve-Explorer and click in the menu Valve->Construction

Afterwards the construction window appears (Fig. 22).

Fig. 22 Konstruktion

4.3.1.1 Lift Restriction

Lift restriction is used if the capacity of the valve has to be set exactly to the
requirements of the process. The required mass flow is used to obtain the lift. The
discharge coefficient of the valve will change. To restrict the lift, click in the section
"Lift restriction" (Fig. 23) the button Calculate. With a click on Standard will be the lift
reset to the standard. It is additionally possible to enter manually a lift.

Important:
- Dynamic back pressure changes the pa0/p0-Correction. This can not be
obtained analytically. It may be necessary to edit the lift manually.
- Lift restriction is not for all LESER-valves allowed. VALVESTAR® shows in
this case the standard lift.

Fig. 23 – Lift restriction

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4.3.1.2 Connections
The connections of the valve can be changed in the part in- and outlet (Abb. 24).
Select the code of the flange in the ComboBox at the top. The other ComboBoxes will
change due to Your selection. If You select a flange-class then will be the standard-
facing chosen. These values are not overwritable because VALVESTAR® uses this
information to check the pressure-temperature-range of the flange.

Hint: Not all combination of flanges are for (normally) threaded valves
allowed. This will not be checked by VALVESTAR® .

Fig. 24 – Select flanges and screwed connections

4.3.1.3 Part List

Depending from the valve are additional accessories available. They can be selected
in "Available configurations" and may be selected with (Fig. 25). The part list will
be changed according to Your selection. A conflict arises if a configuration is chosen
which changes a part list-position that holds already a configured position. Only one
configuration can be valid under these circumstances. VALVESTAR® will inform You
in that case.

Click List of parts to look at the part list (Fig. 26).

Fig. 25 – Konfigurationen

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Fig. 26 – The partlist

4.3.1.4 Dimensions
The database contains for nearly all valves dimension data. To view or change them
click Dimensions (Fig. 27).

Mostly are the standard dimensions filled in. These can be overwritten, if changes are
needed for special connections. This applies also for the weight. VALVESTAR®
changes the dimensions if a bellow is selected.

Hint: Please use always the dimensions from the catalogue.

Fig. 27 – Dimensions

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4.3.2 Certifications and Inspections

It is possible to add certifications and inpections as free text or as text macro to the
sizing. Click in the Valve-Explorer on the valve and then on or in the menu on
Valve->Inspection. Other text may be entered in the two textboxes (Fig. 28). If You
check the boxes then the text will be added.

Fig. 28 – Inspections and certifications

4.3.3 Settings
VALVESTAR® offers a lot of presettings which You can use to optimize Your work.

4.3.3.1 Units
You may adapt the units in the menu Options->Units for Your requirements. There it
is possible to change the standard units and the precision for the input and the
printouts (Fig. 29). After You closed the window it is necessary save the changes in
Options->Save options. After a restart of VALVESTAR® Your changes will be
applied.

Unfortunately changing or loading setting-files require a restart of VALVESTAR® to

apply the changes.

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Fig. 29 – Units

4.3.3.2 Constants
It is in Options -> Constants possible to select standard unit and precision of the
environmental pressure (Fig. 30) and Your favourite sizing-code (Fig. 31). Click on
Valves and You are able to choose for each Type the bodymaterial and the lifting
device which VALVESTAR® will preselect in each sizing (Fig. 32).

Fig. 30 – Set environmental pressure

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Fig. 31 – Standard sizing

Fig. 32 – Standard bodymaterial and lifting device

4.3.4 Translation
VALVESTAR® is implemented in several languages. The languages are all in English
to prevent problems with fonts and misunderstandings. Remarkable is the language
"Neutral". This is an English version without any special symbols. Choose "Neutral" if
no other language works without error messages. This may be helpful e.g. by Asian or
Arabian installations.

Fig. 33 – Select language

4.3.5 Datasheets
VALVESTAR® includes a comfortable and powerful report-system.

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4.3.5.1 Print a Project or Sizing

After You select a project or a sizing in the Valve-Explorer and click on in the
toolbar the following window opens (Fig. 33). All elements which belong to the tree-
element will be printed. You can choose the content of the sheet:

- Output-language – select language

- Print to – choose printer or pdf-file
- Valve – part list
- Drawing – print sectional drawings
- Focuses – detail drawings which
- Warnings – warnings from VALVESTAR® which are shown in the Valve-
Explorer in the bottom left corner.

If You select "Print to" pdf-file then the ComboBox offers two options:

- "Automatic save reports" – The sizing will be saved in a selected folder with automatic
generated names.
- "Manual save reports" - The program asks You for each sizing for a name.

Fig. 34 – Print project or sizing

Fig. 35 – Print to pdf-file

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4.3.5.2 Print Valve

If You select a valve in the Valve-Explorer and click the button from the toolbar
then a new windows appears (Fig. 35). The language and the target for the printout
can be changed. The button Print leads to a message box which allows the selection
of the content (Fig. 36). It is also possible to view the report before printing in by
clicking Preview (Fig. 37). To export the sheet in different formats click in the
toolbar (Fig. 38). Please note that only the pdf-format is nearly identical to the
printout.

Fig. 36 – Print valve

Fig. 37 – Select report content

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Fig. 38 – Preview

Fig. 39 - Export in different formats

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4.3.6 Drawing

4.3.6.1 Sectional Drawings

The database of VALVESTAR® contains for each valve several drawings. Even
bellows and heatings jackets are displayed.

4.3.6.2 Focus Drawing

Not all details are visible in the sectional drawings (e.g. connections of heating jacket,
O-ring-disc...). In this cases are focus-drawings used.

4.3.6.3 Part List

VALVESTAR® contains a (primitive) product-configurator which allows a technical
specification of the valves. This specification may result in a changed part list which
can be printed on the datasheet.

4.3.7 Media

4.3.7.1 Gases
An extensive database with media is included in VALVESTAR®. This database is
customizable in the menu Medium->Edit gas file (Fig. 40). You can add, change and
delete media. The upper listbox contains all gases which are already in the database.

After a gas is selected one can see the translations and the data below. The section
„gas data“ contains the data (isentropic exponent, molar mass, realgas-factor and
chemical formula).

Click New to add a gas. Before the window is closed You will be asked whether the
changes shall be applied. The changes are visible in each new sizing.

Fig. 40 – Edit gas file

4.3.7.2 Liquids
The usage of this functionality is absolute similar to that for gases.

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4.3.7.3 Thermodynamical Properties of Water

The window Medium->Thermodynamical properties of water (Fig. 41) offers the
possibility to calculate the properties of water like entropy, inner energy etc. After
pressure and temperature are entered into the edit fields click Calculate. Then
calculates VALVESTAR® the thermodynamical properties. If You enable the
checkbox „Saturated steam“ both phases will be calculated.

Fig. 41 – Thermodynamical properties of water

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5 Outlook to future Releases

5.1 Performance
LESER works already on release 7. This version is a result of an iterative approach. A
lot of features have been added during the development process. The additional
functionality decreased the performance. The next version will use the resources more
carefully.

5.2 Functionality
The next release will be extended by the following features:

- API 520 – Calculation of two phase flow according the omega-method

- API 520 / ASME VIII – Multiple valve installation
- API 520 – Fire case for gases and liquids

5.3 Translation
VALVESTAR® supports the following languages:

- English
- German
- French
- Spanish
- Portuguese
- Italian
- Russian
- Swedish
- Turkish
- Croatian
- Norwegian

Please note that each language needs special local settings. This is the reason why not
all languages may be shown correctly on Your system with Your locale. The text for the
user-interface and the report are stored as textfile in "Language.lng" and
"Language_reports.lng". E.g. "Italian.lng" and "Italian_reports.lng" contain the italian
translation.

Changes in these files influence directly VALVESTAR® .

Caution: Never change the "language_references"-files. A result might be

absolute wrong reports.

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6 Terms of License
Please note the terms of License which You accepted with the installation.

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7 Appendix
7.1 Examples

7.1.1 Example 1 :

Sizing acc. to AD 2000:A2 for Gases

Medium: Air

M = 29
k = 1,4
Z =1

Service Condition:

Set pressure p = 10 bar - g = 11 bar

Back pressure pa = 0 bar - g = 1 bar
Temperaturr T = 20° C = 293,15 K
Req. massflow qm,ab = 10000 kg/h % = 1 bar
Overpressure dp= 10 % = 1 bar

Safety Valve: αw = 0,7 (Type 441)

=> p0 = 12 bar
=> pa0 = 1 bar
k 1, 4
pa 0  2  k −1  2  0, 4
= 0,0833   =   = 0,528
p0  k +1  2,4 

Calculation of ψ :
k
pa0  2  k −1
Because <   is true the flow is critical. That means
p0  k +1
1 1
k  2  k −1 1,4  2  0, 4
ψ = x   = ⋅  = 0,48418.
k +1  k +1 2,4  2,4 

And consequently the following calculation arise:

q m, ab T ⋅Z
A0,erf = 0,1791 ⋅
ψ ⋅α w ⋅ p 0 M
10000 293,15 ⋅ 1
A0,erf = 0,1791 ⋅ = 1400,09 mm2.
0,48418 ⋅ 0,7 ⋅12 29

Select 4412.4544
d2
d0 = 46 mm => A0 = π = 1661,9 mm2
4
ψ ⋅ α w ⋅ p 0 ⋅ A0 M
Certified massflow qm,rv = ⋅
0,1791 T ⋅M

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0,48418 ⋅ 0,7 ⋅12 ⋅1661,9 29

qm,rv = ⋅ = 11869,97 kg/h.
0,1791 293,15 ⋅ 1
 pm , rv 
And at least the capacity exceed:  − 1 ⋅100 = 18,7% .
 pm , ab 

7.1.2 Example 2:

Sizing acc. AD 2000:A2 for Liquids

Medium: Water (H2O)

Density:
ρH2O = 998 kg
m3

Service Conditions:

Set pressure p = 10 bar-g

Back pressure pa = 2 bar-g
Overpressure dp = 10 %
Temperature T = 20° C
Discharge coefficient αw = 0,45 (Type 441)
Req. Massflow kg
qm,ab = 20000
h

Safety Valve: αw = 0,7 (Type 441)

p0 = p ⋅1,1 + pu = 10 ⋅1,1 + 1 = 12bar

pao = pa + pu = 2 + 1 = 3bar
qm,ab
A0,erf = 0,6211 ⋅ mm2 with dp = p0 - pao
α w ∆p ⋅ ρ H O2

=> ∆p = 12 bar – 3 bar = 9 bar

20000
=> A0,erf. = 0,6211 ⋅ mm2 = 291,27 mm2
0,45 ⋅ 9 ⋅ 998

Select valve 4411.4384 with d0 = 23 mm. It follows for the necessary discharge area
and massflow:
d2
A0 = π = 415,48 mm2
4

A0 ⋅ α w ∆p ⋅ ρ H 2O kg
qm = .
0,6211 h

415,48 ⋅ 0,45 ⋅ 9 ⋅ 998 kg kg

qm = = 28529,07
0,6211 h h

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 pm , rv 
And at least the capacity exceed: =  − 1 ⋅100 = 42,65% .
 pm, ab 

7.1.3 Example 3:

Sizing acc. AD 2000:A2 for Saturated Steam

Medium: Saturared Steam

Isentropic exponent: K = 1,29

Specific volume: m3
v = 0,1632
kg

Service Conditions:

Set pressure p = 10 bar - g

Back pressure pa = 0 bar – g
Overpressure ∆p = 10 %
Temperature T = 187,96° C
Req. massflow kg
qm,ab = 15000
h

Safety Valve: αw = 0,7 (Type 441)

Scrutinize the type of flow:

p0 = p ⋅1,1 + pu = 10 ⋅1,1 + 1 = 12bar

pao = pa + pu = 2 + 1 = 3bar

p ao 1bar
=> = = 0,0833
p0 12bar

k 1, 29
 2  k −1  2  0, 29
  =   = 0,5475
 k +1  2,29 

k
p  2  k −1
0,0833 < 0,5475, -> ao <  
p0  k +1

=> Overcritical flow

1 1
k  2  k −1 1,29  2  0, 29
=> ψ = ⋅   = ⋅   = 0,4705
k +1  k +1 2,29  2,29 

Required discharge area:

x ⋅ q m ,ab p0 ⋅ v
A0,erf = with x = 0,6211
α w ⋅ p0 ψ

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12 ⋅ 0,1632
=> x = 0,6211 ⋅ = 1,8474
0,4705

1,8474 ⋅ 15000
A0,erf. = mm2 = 3298,93 mm2
0,7 ⋅ 12

Select 4412.4564 mit d0 = 74 mm. And the massflow amounts to:

d2
A0 = π = 4300,84 mm2
4

A0 ⋅ α w ⋅ p0 4300,84 ⋅ 0,7 ⋅ 12 kg
qm = = = 19555,62
x 1,8474 h

 pm , rv 
And at least the capacity exceed:  − 1 ⋅100 = 30,37% .
 pm, ab 

7.1.4 Example 4:

Sizing acc. to ASME VIII /API 520 for liquids with viscosity

Medium: Machine oil

Viscosity: 400cp
Density
ρOil = 910 kg
m3

Service Condition:

Set pressure p = 100 psig

Back pressure pa = 20 psig
Overpressure dp = 10 %
Temperature T = 100° C
Discharge coefficient K = 0,578 (Type 526)
Req. volumeflow USGal
qm,ab = 1000
min

Safety Valve: αw = 0,7 (Type 441)

p1 = p ⋅1,1 = 100 ⋅1,1 = 110 psig

p2,const = 20 psig

Q G
A0,Req = ⋅
38 ⋅ K D ⋅ KW p1 − p 2

With G=910/998=0,912 follows:

1000 0,912
=> A0,Req,ASME = ⋅ =4,5832 sqinch
38 ⋅ 0,578 ⋅1 110 − 20

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1000 0,912
=> A0,Req,API = ⋅ =4,0755 sqinch
38 ⋅ 0,65 ⋅1 110 − 20

A Orifice N with 4,34 sqinch (API-Calculation is needed). Select 5262.5903.

d2
A0 = π = 5,3 sqinch
4

Calculate Reynoldsnumber Re:

2800 ⋅ Q ⋅ G
Re =
µ ⋅ A0

That leads to:

API: Re=2800*1000*0,912/400/sqrt(4,34)=3064 >> KV=0,96 and

AReq=4,27 sqinch
ASME VIII: Re=2800*1000*0,912/400/sqrt(5,3)=2773 >> KV=0,95 and
AReq=4,82 sqinch

p1 − p2
Q = 38 ⋅ K D ⋅ KW ⋅ KV ⋅ A0 ⋅
G

To calculate KV Q must be known. Valvestar® iterates Qm and Kv, which results in

Qm= 1101,6 USgal/min.

As evidence:

API + ASME VIII with certified discharge coefficient:

Re=2800*1101,6*0,912/400/sqrt(5,3)=3055. >> KV=0,94, Valvestar® calculates

internally with 0,952 because the value is derived from a polynome.
110 − 20
Q ASME = 38 ⋅ 0,578 ⋅1⋅ 5,3 ⋅ 0,952 ⋅ = 1100,9 USgal/min
0,912

 pm , rv 
And at least the capacity exceed:  − 1 ⋅100 = 10,1% .
 pm, ab 

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