Beruflich Dokumente
Kultur Dokumente
AJAY PRABHAKAR
NISHANTH G.L
SARATH V.J
VINAYAK V SHENOY
CB.EN.U4MEE09003
CB.EN.U4MEE09018
CB.EN.U4MEE09046
CB.EN.U4MEE09064
BONAFIDE CERTIFICATE
This is to certify that the thesis entitled Numerical Analysis of Performance
Characteristics of Globe Control Valve submitted by AJAY PRABHAKAR
(CB.EN.U4MEE09003), NISHANTH G.L (CB.EN.U4MEE09018), SARATH V.J
(CB.EN.U4MEE09046), VINAYAK V SHENOY (CB.EN.U4MEE09064) for the award
of the Degree of Bachelor of Technology in Mechanical Engineering is a bonafide
record of the work carried out under my/ our guidance and supervision at Amrita School of
Engineering, Coimbatore.
Dr. K. Rameshkumar
Chairman
Dept. of Mechanical Engineering,
Amrita School of Engineering
This report was examined and the candidates underwent Viva-Voce examination
on
14th May 2013
Internal Examiner
External Examiner
DECLARATION
We, AJAY PRABHAKAR (Reg. No.CB.EN.U4MEE09003), NISHANTH G.L
(Reg.
No.CB.EN.U4MEE09018)
No.CB.EN.U4MEE09046)
No.CB.EN.U4MEE09064)
SARATH
VINAYAK
V.J
SHENOY
(Reg.
(Reg.
A.
NISHANTH G.L
28
SARATH V.J
SHENOY
Place: Coimbatore 112
Date:
VINAYAK V
COUNTERSIGNED
Prof. Dr. V. Ratna Kishore
Prakash
Project Co-Advisor
Dept. of Mechanical Engineering,
Engineering
Amrita School of Engineering.
Engineering
Asst.
Prof.
A.
S.
Project Advisor
Dept. of Mechanical
Amrita
School
of
ACKNOWLEDGEMENT
Our whole hearted thanks to our project guide Mr. A. S. Prakash (Asst. Professor)
for giving us an opportunity to work on this project and for being supportive
throughout the project. He was a good friend to us and we have learnt a lot from
his guidance.
This project would not have been a success without the invaluable inputs and
suggestions by Dr. V. Ratna Kishore. It was his suggestions and practical
experience that had helped us to overcome most of the obstacles. We have learned
a lot from him and owe him a lot for developing passion in us for Computational
Fluid Dynamics.
Our sincere thanks to Dr.K.Rameshkumar, Chairman of Mechanical Engineering,
for motivating and providing support in all our efforts.
We would also like to express our thanks and gratitude to Mr. Vignesh (Fluid Lab
Asst.), Mr. Gireesh Kaimal (Fluid lab Asst.), Mr. Ravikumar (CAD lab Asst.) and
Mr. Venkitesh (CAD lab Asst.) for extending their helping hands whenever
needed.
We are indebted to Dr. M. Elangovan for reviewing and providing much useful
suggestions on our project report. We also take this opportunity to thank him for
permitting and ensuring that full facilities needed are well reached.
29
We would be failing in our duties if we do not thank the review panel for their
constructive comments which proved crucial at various stages.
We feel honored to have been part of Amrita School of Engineering that made our
B.Tech programme a highly memorable one.
30
ABSTRACT
A control valve is the most important single element in any fluid handling
systems, because it regulates the flow of fluid to the process. The comprehension
and better management of these hydraulic control valves along with
computational fluid dynamics (CFD) techniques have acquired a growing
significance due to their common usage in many automatic and manual industrial
processes. One of the most common types of control valves is the single seat
globe valve. Over the past few years, there has been an intense effort for knowing,
classifying, and analysing the characterization and classification of these valves.
In this work, the numerically predicted inherent valve characteristic of the 3 inch
globe control valve is qualitatively matched with the experimentally determined
characteristic. Also, the relationship between CV and the size of the valve will also
be analysed. The computational codes of the commercial CFD software FLUENT
14.0 and the validated standard results for a 3 inch globe control valve will be
used in the analysis. In addition, the influence of the turbulence model and grid
size will also be investigated. The knowledge of these effects on CV has an
enormous potential impact on the selection and performance of these control
valves.
31
TABLE OF CONTENTS
SL. NO
TOPIC
PAGE NUMBER
Acknowledgement
Abstract
ii
List of Figures
List of Tables
vi
vii
Introduction
1.1
Valve
1.2
Classification of Valve
1.3
Control Valves
1.4
Literature Survey
2.1
Terminologies
2.2
10
Control Valves
2.3
3
15
16
3.1
Governing Equation
16
3.2
18
3.3
20
3.4
24
Simulation
3.5
4
24
28
4.1
28
4.2
Turbulence Modelling
30
Independence
32
and Grid
4.3
32
coefficient ( Cv)
4.4
33
Cage
4.5
5
35
40
5.1
Conclusions Arrived
40
5.2
40
Appendix A
41
Appendix B
45
References
49
33
LIST OF FIGURES
FIGURE
DESCRIPTION
PAGE NUMBER
NUMBER
1.2.1
Globe valve
1.2.2
Gate valve
1.2.3
Needle valve
1.2.4
Diaphragm valve
1.2.5
Ball valve
1.2.6
Plug valve
1.2.7
Butterfly valve
1.2.8
Safety valve
1.4.1
2.1.1
2.1.2
Linear plug
2.1.3
10
3.2.1
18
3.2.2
18
3.2.3
19
3.2.4
19
3.2.5
20
3.3.1(a)
20
3.3.1(b)
20
21
3.3.3(a)
22
3.3.3(b)
22
3.3.2
parameters
3.3.3(c)
23
23
29
34
4.2.1(a)
30
4.2.1(b)
31
4.4.1
34
4.4.2
34
4.5.1
35
38
38
stroke openings
A.A.1
42
A.A.2
44
A.B.1
45
hole cage
A.B.2
46
A.B.3
Valve Assembly
47
A.B.4
Flow
path
extract
Workbench
35
from
ANSYS
48
LIST OF TABLES
Table Number
Description
Page Number
4.1(a)
29
valve
4.1(b)
29
valve
4.2(a)
Turbulence Modelling
30
4.2(b)
Grid Independence
31
32
4.3
of 12 hole cage
4.4(a)
33
4.4(b)
33
4.5(a)
36
4.5(b)
37
A.A.1
Bill of Materials
43
36
DESCRIPTION
CFD
Cv
Flow Coefficient
FTO
Flow to Open
FTC
Flow to close
Fp
Piping Factor
Gf
Specific Gravity
P1
Inlet Pressure
P2
Exit Pressure
PIV
SIMPLE
NB
Nominal Bore
RNG
Re-Normalized Group
Velocity in x-direction
Velocity in y-direction
Velocity in z-direction
Density kg/m3
Divergence Vector
Stress Tensor
Af
37
Chapter 1
INTRODUCTION
1.1 Valve
A valve is a device that regulates, directs or controls the flow of a fluid
(gases, liquids, fluidized solids, or slurries) by opening, closing, or partially
obstructing various passageways. They are found in virtually every industrial
process, including water & sewage processing, mining, power generation,
processing of oil, gas & petroleum, food manufacturing, chemical & plastic
manufacturing and many other fields.
38
39
40
41
42
Valve's actuator
Valve's positioner
43
Valve's body
Available in multi-ports.
Short disk travels and fewer turns to operate, saving time and wear on
stem and bonnet
44
1.4.2 Bonnet
Bonnet is the portion of the valve that contains the packing box and stem
seal. Packing maintains the seal between the bonnet and the stem during valve
cycles. Stem is the part that connects the actuator to the plug. The bonnet guides
the stem and provides a leak-proof closure for the valve body .
1.4.3 Ports
Ports are openings in the body for fluid to flow in or out. The ports may be
oriented straight across from each other or anywhere on the body oriented at any
angle (such as 90).
1.4.4 Actuator
Actuator is a component which is used to control the position of the plug
or piston in a valve. The actuators can be classified based on the source of
mechanism which are mainly hydraulic, pneumatic, manual, solenoid and motor.
1.4.5 Plug
Plugs are the closure member of the valve. Plugs are connected to the stem
which is slid or screwed up or down to throttle the flow.
1.4.6 Seat
The seat ring provides a stable, uniform and replaceable shut off surface.
Seat rings are usually held in place by pressure from the fastening of the bonnet.
Thus pushing the cage down on the lip of the seat ring and holding it firmly to the
body of the valve.
Seat rings may also be threaded and screwed into a thread cut in the same
area of the body. This makes removal of the seat ring during maintenance difficult
if not impossible. They may also be bevelled at the seating surface to allow for
some guiding during the final stages of closing the valve.
1.4.7 Stem
45
The stem serves as a connector between the actuator and the inside of the
valve. The stem must be straight and have low run out, in order to ensure good
valve closure. It should also be able to withstand high compression and tensile
strengths. Stems are either smooth or threaded.
1.4.8 Cage
The cage is part of the valve that surrounds the plug and is located inside
the body of the valve. Typically, the cage is one of the greatest determiners of
flow within the valve. As the plug is moved up, the openings in the cage are
exposed thus increasing flow. The design and layout of the openings can have a
large effect on fluid flow. Cages are also used to guide the plug to the seat of the
valve for a good shutoff, substituting the guiding from the bonnet.
46
CHAPTER 2
LITERATURE SURVEY
2.1 Terminologies
Cv
q
N1 * Fp *
P1 P2
Gf
Where,
q is the volume flow rate in m3/hr
P1 and P2 are inlet and outlet pressures
Gf is the specific gravity
Correction Factor, Fp=1
Numerical Constant, N1 = 0.862
For example, CV value of 12 means the valve has an effective port area in
the full open position such that it passes 12gpm of water at a pressure difference
47
of 1 psi. The use of the flow coefficient offers a standard method of comparing
valve capacities and sizing valves for specific applications that is widely accepted
by industry.
48
Fig 2.1.2Linear
49
50
modeled. This simplified flow model predicted the Cv values and inherent valve
characteristics for all the three globe control valves accurately over most of the
plug opening. It was found that Cv values differed the most from the experimental
data in the final plug openings of control valves. The details of the flow field such
as pressure at a discrete point and jet behaviour are also studied. This study
demonstrates and proves the usefulness of simplified CFD analysis for relatively
complex three dimensional flows.
Davis et al. [2]also conducted performance analysis of globe control
valves experimentally to analyse the differences in axisymmetric flow modeling
and three dimensional flow field modeling. Experimental results were obtained by
conducting an axisymmetric flow field experiment. This models actual
applications were then tested to actual three dimensional control valves by
studying the pressure and flow field through a three dimensional control valve.
The results of the experiment revealed that control valve have a predominantly
axisymmetric flow field for most of their plug travel, which makes them suitable
for the model.The agreement between the experimental and modelled values was
better at lower percentage opening.
Salvador et al. [3] emphasize the importance of proper 3D modelling for
analysing control valve performances in their study with CFD. Mike and Stewart
had said in their paper that axisymmetric modelling and geometric simplification
will yield to lower Cv values and accuracy. Thus they modelled in full 3D with
geometric smoothening to analyse the differences in accuracy. The velocity fields,
pressure distributions, and flow separations and reattachments in all piston
positions were studied. Comparison was carried out between numerical results
and experimental data using different piston positions.. A 2inch double chamber
globe control valve was studied in an experimental setup for different flow rates
ranging from 0 l/s to 20 l/s and for pressure differences from 0 MPa to 14 MPa.
With the experimental data the CFD model was validated within the error of 6%.
Certain geometrical modifications were made in the original geometry and it was
observed that the area distorted by turbulence was reduced. The valve
characteristics were obtained with better accuracy than from axisymmetric model.
51
In 3D modelling, even in 100% opening the values was matching with an error of
less than 4%. The CFD simulation reports that the Cv for the original geometry
was lower than the Cv for modified geometry for all percentage opening. This
reaffirms that original geometry produced larger distorted area and thus larger
pressure drop. This confirms that turbulence flow behaviour inside a control valve
is better predicted by 3D model.
Hailing et al. [4] studied flow along a co-axial control valve by both
experimental
and
computational
investigation
for
various
plug
piston
configurations. Valve characteristics were obtained and were compared for two
different plug geometries. The results obtained prove that, axial flow valve with
both piston configurations performs more efficiently than the conventional valve,
resulting in less energy loss. Numerical analysis was successfully done using
commercially available CFD code such as FLUENT.
Kiesbaueret al. [5] conducted a set of experiments to determine the flow
coefficient of a control valve using numerical simulation methods. A geometric
model with proper calibrations was set up and flow coefficient was measured.
Then the same setup was modeled in a software program with appropriate
boundary conditions and the flow coefficient was determined. Two methods are
available for calculation of flow coefficient. In the first method, pressure at the
inlet and the outlet of the valve was defined and mass flow rate was used as the
converging parameter. In the second method inlet pressure and outlet mass flow
rate was defined and outlet pressure was used as the converging parameter.
Second method is applied when the first method fails to converge. The results
indicated that the values obtained from the simulation were within the 5%
tolerance. However, the result was obtained by using an optimal mesh and not a
rough mesh, which increased the error to 20%.
Jeon et al. [6] discuss the numerical analysis on butterfly valves using
commercial CFD code FLUENT. A comparative study was done on different
kinds of butterfly valves. The flow coefficient, loss coefficient and pressure
distribution of valves according to valve opening rate were compared to each
52
verified as a higher accurate tool and could be used for various applications for
analysis of flow fields in marine and industrial processes.
Moncalvo et al. [9] studied the flow of non-Newtonian fluids using
computational methods. Shear thinning fluids like aqueous solutions of polyvinylpyrrolidine in LESER type safety valve were analysed. The calculations were
carried out assuming laminar, turbulent and transitional flows. The predicted mass
flow rates using CFD were close to each other and to the measured values, except
at relieving pressure close to ambient. This deviation is thought to be because of
the entrainment of air bubbles which makes for additional shearing in the
solutions.
53
54
simulate turbulent flows in valve body. This model was chosen since the flow
inside a hydraulic valve is characterised by the co-existence of free shear flows
due to the flow jet at the exit of the metering section and wall bounded flows
which are strongly influenced by wall effects. From this paper it was understood
that when the fluid flows in the throat path between the piston and its seat,
circulation area diminishes quickly, due to which fluid pressure falls and fluid
here has more velocity magnitude.
Young et al. [14] studies the flow characteristics of control valves with
complex flow fields including pressure drop, cavitation effect, and variation of
flow coefficient and correlation of discharge coefficient. Numerical analyses of
three dimensional turbulent flows with high pressure drop were modelled in CFDACE code. After analysing the pressure distribution, velocity flow fields and
cavitation inception points, certain design changes was done in a new model at the
trim region, valve chamber, valve inlet and outlet and were simulated. The newly
designed valve model showed reduced cavitation and was found to be better than
conventional one resulting in superior friction of anti-cavitation trim.
The literature survey highlights the fact that determination and verification
of flow coefficient of a valve can be done by designing a numerical model and an
experimental setup respectively. The analysis can be extended further by studying
the pressure fields, thus, giving an insight on the cavitation effect in the valve.
The pressure losses resulting due to the addition of various fittings in the
experimental setup should also be accounted by considering the piping geometry
factor, Fp. Since the flow through pipes and control valves are generally boundary
layer problems, in most cases k- standard turbulence model are used. Whereas,
RNG k- turbulence model is used for free shear flow and wall bounded flow
conditions. It was also understood that flow coefficient can be calculated by two
methods, either by defining pressure at the inlet and the outlet of the valve and
55
mass flow rate was used as the converging parameter or by considering inlet
pressure and outlet mass flow rate and then using outlet pressure as the
converging parameter. Second method is applied when the first method fails to
converge. Most of the published papers prominently support the use of
computational fluid dynamics, such as commercial CFD code by FLUENT, as a
powerful robust tool for detailed flow analysis across control valves.
56
CHAPTER 3
DEVELOPMENT OF NUMERICAL MODEL
The rate of change of momentum equals the sum of the forces on a fluid
particle (Newtons second law).
The rate of energy is equal to the sum of the rate of heat addition to and
the rate of work done on a fluid particle.
..(1)
..(2)
where
stands for the divergence of the stress tensor. Considering the above
57
..(3)
The turbulence dissipation rate is the rate at which the turbulence kinetic
energy is converted into thermal energy. It is governed by the equation,
..(4)
58
59
60
The test section includes the inlet pipe, outlet pipe, valve body, plug, cage
and seat ring. The length of the inlet and outlet pipes is 18inch and 30inch
respectively. The design was done for both flow directions (FTO and FTC) of the
control valves. The 3D cad model for various plug openings at 20%, 50%, 70%
and 100% were also modelled by moving the plug in vertical direction.
61
62
63
64
65
66
Fig. 3.3.3(c) Grid structure of valve numerical analysis model along a central
plane
67
Initially, the grid size function was used to refine the grid in the area
where sudden changes occur, to ensure an adequate grid size where the maximum
velocity and pressure gradients occur. In particular, the grid is significantly
refined in the valve body section. Certain areas in the geometry where the flow
does not occur were termed as dead curvature. Those sections were given a coarse
mesh.
The surface remesher is used to re-triangulate an existing surface in order
to improve the overall quality of the surface and optimizes the volume mesh
model. The re-meshing is primarily based on a target edge length of a cell.
Localized refinements based on boundaries are defined.
The prism layer mesh is used in conjunction with a core volume mesh to
generate orthogonal prismatic cells near wall boundaries. In typical boundary
layers, the flow is aligned with the wall and the gradients vary largely normal to
the wall. When only tetrahedral cells are present, the gradients exist across the
tetrahedral cell leading to inaccuracy in the resolution of the boundary layer
phenomena across the cell. The inclusion of prismatic layers resolves this problem
by aligning the gradients along the mesh.
Tetrahedral model is preferred due to its following advantages:
For a given number of cells, tetrahedral mesh occupies less memory due to its
lesser number of faces per cell and for the same reason, it consumes lesser
computational time. Though polyhedral mesher can yield meshes with lesser cells,
it would compromise on the accuracy of the solution. The smoothness, i.e., the
difference in size between any two tetrahedral cells is also lesser compared to
other models.
The mesh parameters used are given below;
68
0.2mm
Size of cell
Maximum
2.5 mm
Target
5mm
0.2mm
Size of cell
Maximum
2 mm
Target
5mm
The second order upwind scheme was used to discretizes the governing
equations in a collocated grid node to ensure the accuracy of the simulation
results. Regarding the inlet and outlet boundaries (6D from the inlet and 10D
outlet of the valve), pressure conditions was specified. The inlet and outlet
pressure specified were 3 bar and 2 bar respectively. Water, at standard pressure
and temperature was chosen as the working fluid. A proper estimation of turbulent
phenomena has great importance to determine the valve flow features.
In particular, the flow inside a hydraulic valve is characterized by the
coexistence of free shear flows, due to the flow jet at the exit of the metering
section, and wall bounded flows, which are strongly influenced by the wall
effects. The most suitable turbulence model for this kind of problem appears to be
the Standard k- model. This model gives a reliable estimation of the turbulent
quantities upstream and downstream of the restricted sections and is able to
estimate properly both the free jet and the wall bounded region.
69
70
71
CHAPTER 4
RESULTS AND DISCUSSIONS
Chapter Overview
This chapter explains in detail about the results obtained for the various
numerical models that were simulated.
Initially, the numerical models of 3 inch globe control valve with 12-hole
cage for various percentage openings are validated with the experimental data
obtained from FCRI, Kanjikode. This was done for both FTO and FTC flow
directions. Further, the results obtained for turbulence modelling and grid
independence verification are discussed. This is followed by the comparison of CV
values for the numerical models with 8-hole and 24-hole cage, with that of the
numerical models with 12-hole cage. Scaling effects of 3 inch globe control valve
to 4 inch, 5 inch and 6 inch are discussed in detail at later stages of the chapter.
72
Computed Cv`
Experimental Cv
Error (%)
20
8.69
8.86
-1.9
30
21.3
20.33
4.9
`50
58.45
58.21
0.4
70
94.73
100.35
-5.6
100
111.7
114.39
-2.3
Computed Cv
Experimental Cv
Error (%)
20
9.20
9.39
-2.0
40
41.07
41.59
-1.2
50
60.05
61.53
-2.4
70
102.46
100.03
2.4
100
132.78
142.10
-6.6
(a) FTO
(b) FTC
Fig. 4.1.1 Validation of Numerical Models for (a) FTO & (b) FTC
73
k- Model Cv
RNG k- Model Cv
Error (%)
20
8.62
9.36
-0.74
50
58.90
58.74
0.16
70
97.54
98.17
-0.63
100
110.50
112.42
-1.92
74
For grid independence, the numerical models with coarser and finer
meshes yielded equal CV values for corresponding percentage openings within an
error of 3%. Therefore, the effect of mesh size can be regarded as negligible. The
following graph (Fig.4.2(b)) illustrates these results.
Table 2(b): Grid Independence
% Opening
Computed Cv
Error (%)
Original
Refined
20
8.60
8.62
-0.02
50
58.45
58.90
-0.45
70
94.73
97.54
-2.81
100
111.70
110.50
1.20
75
76
FTO
FTC
FTO
FTC
mass flow
mass flow
1.228
3.090
1.862
4.274
4.610
0.336
1.500
1.691
0.192
0.000
0.000
0.000
0.615
1.166
0.551
0.000
0.000
0.000
1.672
2.987
1.315
2.006
2.129
0.123
1.122
1.454
0.332
0.000
0.000
0.000
2.639
2.384
-0.255
0.000
0.000
0.000
3.310
3.108
-0.202
4.756
4.718
-0.038
4.034
3.656
-0.378
0.000
0.000
0.000
2.709
2.225
-0.484
0.000
0.000
0.000
10
3.611
3.471
-0.140
2.075
2.113
0.038
11
2.053
1.656
-0.397
0.000
0.000
0.000
12
2.142
2.951
0.809
0.000
0.000
0.000
77
% Opening
Error (Cv)
Error (%)
12hole
8 hole
24 hole
8 hole
24 hole
8 hole
24 hole
20.00
8.71
7.26
6.62
1.45
2.09
16.65
24.00
30.00
21.33
19.74
19.15
1.60
2.18
7.48
10.22
50.00
58.45
58.71
60.19
-0.26
-0.26
-0.44
-0.44
70.00
94.73
93.46
98.72
1.27
-3.99
1.34
-4.21
100.00
114.85
113.31
113.86
1.54
1.54
1.34
1.34
% Opening
Error (Cv)
Error (%)
12hole
8 hole
24 hole
8 hole
24 hole
8 hole
24 hole
20.00
9.20
7.58
7.05
1.62
2.15
17.61
23.37
30.00
22.37
20.96
19.19
1.41
3.18
6.30
14.21
50.00
60.05
58.26
60.95
1.79
-0.90
2.98
-1.50
70.00
102.46
93.93
107.50
8.53
-5.04
8.33
-4.92
78
100.00
132.78
129.71
129.64
3.07
(a) FTC
3.14
2.31
2.36
(b) FTO
Fig 4.4.1 Effect of number of holes on (a) FTC & (b) FTO
The discrepancies observed are due to the errors which had occurred in the
flow area comparison performed for cage design. Since, the cage was designed by
trial and error method (within an error of 6%) as explained in the previous
chapter, these unavoidable errors got reflected in the calculation of CV values as
well. In the following graph (Fig 4.4.2), the flow area for different plug openings
are plotted for 8-hole, 12-hole and 24-hole cages.
79
80
(a) FTC
(b) FTO
Fig 4.5.1 Relationship between Cv and size of valves for (a) FTC & (b) FTO
From the graph, a linear relationship can be approximated for both the
percentage openings, within the limits of computational error.
The obtained values for FTC and FTO are tabulated in the following tables
(Table4.5).
81
2 inch
%
opening
4 inch
Computed
Cv
Flow area,
Af(mm2)
Cv /
Af
Computed
Cv
Flow area,
Af(mm2)
Cv /
Af
Computed
Cv
Flow area,
Af(mm2)
Cv /
Af
3.838
9.540
26.454
32.13
42.877
50.141
96.240
217.814
643.969
892.293
1309.053
2521.867
0.040
0.044
0.041
0.036
0.033
0.020
8.734
21.331
58.451
18.250
94.732
114.845
149.487
397.340
1302.928
1814.201
2484.575
5386.406
0.058
0.054
0.045
0.042
0.038
0.021
15.369
37.972
107.077
134.711
177.622
202.737
266.398
706.220
2314.154
3222.056
4416.233
9570.688
0.058
0.054
0.046
0.042
0.040
0.021
20
30
50
60
70
100
5 inch
% Opening
20
30
50
60
70
100
6 inch
Computed Cv
Cv / A f
Computed Cv
Cv / A f
23.885
59.319
166.345
211.005
283.826
334.105
414.431
1103.927
3621.920
5043.446
6902.600
14968.669
0.058
0.054
0.046
0.042
0.041
0.022
33.140
80.980
237.501
305.778
402.933
489.661
6.5173E+02
1.5894E+03
5.3017E+03
7.2568E+03
9.9383E+03
2.1546E+04
0.051
0.051
0.045
0.042
0.041
0.023
2 inch
%
opening
4 inch
Computed
Cv
Flow area,
Af(mm2)
Cv /
Af
Computed
Cv
Flow area,
Af(mm2)
Cv /
Af
Computed
Cv
Flow area,
Af(mm2)
Cv /
Af
4.082
9.939
26.446
32.795
45.199
55.033
96.240
217.814
643.969
892.293
1309.053
2521.867
0.042
0.046
0.041
0.037
0.035
0.022
9.196
22.369
60.047
75.164
102.458
132.775
149.487
397.340
1302.928
1814.201
2484.575
5386.406
0.062
0.056
0.046
0.041
0.041
0.025
16.230
39.555
105.893
130.227
183.551
227.276
266.398
706.220
2314.154
3222.056
4416.233
9570.688
0.061
0.056
0.046
0.040
0.042
0.024
20
30
50
60
70
100
5 inch
% Opening
20
30
50
60
70
100
6 inch
Computed Cv
Cv / A f
Computed Cv
Cv / A f
25.287
61.636
165.570
202.212
288.232
359.186
414.431
1103.927
3621.920
5043.446
6902.600
14968.669
0.061
0.056
0.046
0.040
0.042
0.024
35.593
90.176
226.902
69.112
397.432
531.093
651.731
1589.362
5301.690
7256.815
9938.319
21545.622
0.055
0.057
0.043
0.040
0.040
0.025
Further, it was found that for different valve sizes, CV is a multiple of a constant and
flow area for a specific percentage opening. The CV / Af values are plotted against different
valve sizes, for 50% and 100% plug openings as shown in graph (Fig 4.5.2). Also, the CV / Af
values for different percentage openings for both FTO and FTC are shown in graph (Fig
4.5.3).
It can be observed that CV / Af values for FTO are more than that of FTC except at
50% opening were the values are equal.
(a) FTC
(b) FTO
Fig 4.5.2 Relationship between Cv/Af and size of valves for (a) FTC & (b) FTO
It is interesting to note from the graph (Fig 4.5.2) that, for 2 inch valve models, CV/Af
values deviate from their counterparts. This may be due to the small computational domain of
2 inch valve model and the present criteria being insufficient for the analysis. Therefore, it
can be concluded that, the results obtained in the present section is valid only for valve sizes
between 3 inch and 6 inch, supported by verified numerical results for 3 inch, 4 inch, 5 inch
and 6 inch numerical models.
CHAPTER 5
CONCLUSION
APPENDIX A
2. Design
The experimental loop was designed to measure the flow coefficient of 3 inch valve is
shown in figure (Fig. A.A.1). Various components used in the loop are labelled in the figure
appropriately. The design was done in the commercial CAD modelling software SolidWorks
12.0.
3. Market Survey
A market survey was conducted to find about the available manufacturers and dealers
of pumps, pipes, fittings, gate valves etc. The prices of the all these items by different
manufacturers were compared. A bill of materials, thus prepared is given in Table A.A.1.
4. Schematic Diagram
All the components of the experimental loop are shown in this schematic diagram
(Fig. A.A.2) using the standard symbols.
DATE: 13/12/2012
Sl.No. Item
Specifications
Manufacturer Quantity
Pipe
Scheduled 40 Steel
Jindal Steels
Pvt. Ltd.
3 (x5m)
Manual Valves
(Upstream and
Downstream)
ANSI CLS150
Jindal Steels
Pvt. Ltd.
Flanges and
Gaskets
ANSI CLS150
Jindal Steels
Pvt. Ltd.
10
ANSI CLS150
Jindal Steels
Pvt. Ltd.
40
Pipe Bends
ANSI CLS150
Jindal Steels
Pvt. Ltd.
Flow meter
3 (80NB),
ANSI B 16.5 150
Frehnig
Instruments
and Controls
Ltd.
Submersible
Pump
TEXMO
Industries
Differential
Pressure Gauge
Pneumatically
Actuated Control
Valve
Triplee
Engineering
Equipments
Enterprises.
CIRCOR
APPENDIX B
(a)
(b)
(c)
Fig A.B.1 Cage designs of (a) 8 hole cage (b) 12 hole cage (c) 24 hole cage
The valve assembly consists of valve body, seat, plug, cage and a bonnet as shown in
fig.A.B.2. It was designed and assembled using the design software SolidWorks 2012.
for 20% percentage opening, the plug was positioned at a distance of 10.16 mm
(50.8*(20/100)) from the base of the seat ring.
3. Similarly, numerical models were created for all the other required percentage
openings with the appropriate distances from the base of the seat ring.
4. A pipe of length 6*Diameter(D) (458.7mm) was placed upstream of the valve while a
pipe of length 10D (763.5mm) was placed downstream. The upstream and
downstream pipe lengths were given these values so as to attain a fully developed
flow.
5. Then, the pipe openings were covered with a cap. The caps were placed so as to
extract the fluid path fig.5 in ANSYS Workbench, which is discussed in the next
section. The design files were saved as Parasolid files.
selected. The required Parasolid file was chosen from the window appeared.
3. The Geometry was double-clicked and a new window appeared for the selection of
opened, By Cavity was changed to By Caps and No was selected for Preserving
Solids.
6. The generation of path was done again by clicking Generate. Thus, the fluid path was
fully generated. The file was saved as a Parasolid text file. The generated path is
shown in the fig.6. This file was then used for meshing.
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