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NUMERICAL ANALYSIS OF PERFORMANCE

CHARACTERISTICS OF GLOBE VALVE


A PROJECT REPORT
SUBMITTED BY

AJAY PRABHAKAR
NISHANTH G.L
SARATH V.J
VINAYAK V SHENOY

CB.EN.U4MEE09003
CB.EN.U4MEE09018
CB.EN.U4MEE09046
CB.EN.U4MEE09064

In partial fulfillment for the award of the degree


of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

AMRITA SCHOOL OF ENGINEERING

AMRITA VISHWA VIDYAPEETHAM


COIMBATORE 641112
May, 2013

AMRITA SCHOOL OF ENGINEERING


AMRITA VISHWA VIDYAPEETHAM, COIMBATORE 641112.
DEPARTMENT OF MECHANICAL ENGINEERING

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.

Asst. Prof. A. S. Prakash


Project Advisor
Dept. of Mechanical Engineering,
Amrita School of Engineering.

Dr. V. Ratna Kishore


Project Co-Advisor
Dept. of Mechanical Engineering,
Amrita School of Engineering.

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

AMRITA SCHOOL OF ENGINEERING


AMRITA VISHWA VIDYAPEETHAM, COIMBATORE
641112.
DEPARTMENT OF MECHANICAL ENGINEERING

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.

hereby declare that the project work entitled

Numerical Analysis of Performance Characteristics of Globe Control Valve, is


the record of the original work done by us, under the guidance of

A.

S. Prakash, Asst. Professor, Department of Mechanical Engineering and Dr. V.


Ratna Kishore, Professor, Department of Mechanical Engineering, Amrita School
of Engineering, Coimbatore. To the best of my knowledge, this work has not
formed the basis for the award of any degree/ diploma/ associateship/ fellowship
or a similar award to any candidate in any University.
AJAY PRABHAKAR

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

List of Symbols, Abbreviations & Nomenclature

vii

Introduction

1.1

Valve

1.2

Classification of Valve

1.3

Control Valves

1.4

Terminology of Globe Control Valve

Literature Survey

2.1

Terminologies

2.2

Literature on Numerical Analysis of

10

Control Valves
2.3
3

Literature Survey Conclusion

15

Development of Numerical Model

16

3.1

Governing Equation

16

3.2

Valve Geometry 3D Design

18

3.3

Computational Domain and Grid

20

3.4

Boundary Conditions and Numerical

24

Simulation
3.5
4

Calculation of Flow Rate

24

Results and Discussions

28

4.1

Validation of Numerical Model

28

4.2

Turbulence Modelling

30

Independence

32

and Grid

4.3

Effect of flow direction on flow

32

coefficient ( Cv)
4.4

Effect of Number of Holes on The

33

Cage
4.5
5

Effect of Scaling Globe Valves


Conclusion

35
40

5.1

Conclusions Arrived

40

5.2

Scope of Future Work

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

Cross sectional view of globe valve

2.1.1

Equal percentage plug

2.1.2

Linear plug

2.1.3

Flow direction along globe valve

10

3.2.1

Designed 3D geometry of valve

18

3.2.2

Cross sectional view of designed valve

18

3.2.3

Development drawing of 8 hole cage

19

3.2.4

Development drawing of 12 hole cage

19

3.2.5

Development drawing of 24 hole cage

20

3.3.1(a)

Computational domain front view

20

3.3.1(b)

Computational domain top view

20

Test valve for code validation

21

3.3.3(a)

Grid structure of computational domain

22

3.3.3(b)

Regions meshed with dead curvature

22

3.3.2

parameters
3.3.3(c)

Grid structure of valve numerical analysis

23

model along a central plane


3.3.3(d)
4.1.1

Grid structure showing prism layers

23

Validation of Numerical Models

29

34

4.2.1(a)

Verification of Turbulence Model

30

4.2.1(b)

Verification of Grid Independence

31

4.4.1

Effect of number of holes on FTC & FTO

34

4.4.2

Flow areas for different openings

34

4.5.1

Relationship between Cv and size of valves

35

for FTC & FTO


4.5.2

Relationship between Cv/Af and size of

38

valves for (a) FTC & (b) FTO


4.5.3

Relationship between Cv/Af for different %

38

stroke openings
A.A.1

Experimental Setup CAD Drawing

42

A.A.2

Schematic Experimental Diagram

44

A.B.1

Cage Design: 8 hole cage,12 hole cage, 24

45

hole cage
A.B.2

Components of valve assembly

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)

Flow to Open Validation of 3 inch 12 hole

29

valve
4.1(b)

Flow to Close Validation of 3 inch 12 hole

29

valve
4.2(a)

Turbulence Modelling

30

4.2(b)

Grid Independence

31

Comparison of mass flow rate through holes

32

4.3

of 12 hole cage
4.4(a)

Effect of Cv for Flow to Open

33

4.4(b)

Effect of Cv for Flow to Close

33

4.5(a)

Effect of Scaling for FTO

36

4.5(b)

Effect of Scaling for FTC

37

A.A.1

Bill of Materials

43

36

LIST OF ABBREVIATIONS AND NOMENCLATURES


SYMBOL

DESCRIPTION

CFD

Computational Fluid Dynamics

Cv

Flow Coefficient

Volume flow rate in m3/hr

FTO

Flow to Open

FTC

Flow to close

Fp

Piping Factor

Gf

Specific Gravity

P1

Inlet Pressure

P2

Exit Pressure

PIV

Particle Image Velocity

SIMPLE

Semi-Implicit Method for Pressure Linked Equation

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

Flow Area mm2

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.

1.2 Classification of Valves

1.2.1 Multi-turn or linear motion valves


1.2.1.1Globe Valve
A globe valve is a multi-turn valve in which closure is achieved by means
of a disk or plugs that seals or stops the fluid on a seat generally parallel to the
flow.
1.2.1.2Gate Valve
A gate valve is a multi-turn valve in which the port is closed by a flatfaced vertical disk that slides at right angles over the seat.
1.2.1.3 Needle Valve
A needle valve is type of valve which has a port and threaded needle
shaped plunger which precisely regulates fluid flow.
1.2.1.4 Diaphragm Valve

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A multi-turn valve in which the open-close element is a diaphragm.

39

Fig 1.2.1 Globe Valve

Fig 1.2.2Gate Valve

40

Fig 1.2.3 Needle Valve

Fig 1.2.4 Diaphragm Valve

1.2.2 Quarter-turn or rotary valves


1.2.2.1 Ball Valve
A ball valve is a valve in which a drilled ball rotates between seats,
allowing straight through flow in open position and shutting off when rotated 90
and blocks the flow passage.
1.2.2.2 Butterfly Valve
A butterfly valve is a quarter-turn valve that controls flow by a circular
disk pivoted at its central axis.
1.2.2.3 Plug Valve
The plug valve is a quarter turn valve which controls flow by means of a
cylindrical or tapered plug with a hole through the centre, which can be positioned
from open to close by a 90 turn.

Fig 1.2.5 Ball Valve

41

Fig 1.2.6 Plug Valve


1.2.3 Special purpose valves
1.2.3.1 Safety Valves
A valve, when actuated above a predetermined level, opens and allows the
gas or vapour to escape out, bringing the valve back to the original state.
1.2.3.2 Pressure regulator
A pressure regulator is a valve that automatically cuts off the flow of a
fluid at a certain pressure.

42

Fig 1.2.7 Butterfly Valve

Fig.1.2.8 Safety Valve

Valves may be operated manually, either by a handle, lever, pedal or


wheel. Valves may also be automatic, driven by changes in pressure, temperature,
or flow. These changes may act upon a diaphragm or a piston which in turn
activates the valve.

1.3 Control Valves


Control valves are valves that are used to control flow variables such as
mass flow, pressure, temperature, and liquid level. The controlling is achieved by
fully or partially opening or closing of the plug in response to signals received
from controllers. The controller compares a "setpoint" to a "process variable"
whose value is provided by sensors that monitor changes in such conditions.
A control valve consists of three main parts in which each part exist in several
types and designs:

Valve's actuator

Valve's positioner

43

Valve's body

The advantages of using globe valves are:

Efficient throttling with minimum wire drawing or seat erosion.

Accurate flow control.

Available in multi-ports.

Short disk travels and fewer turns to operate, saving time and wear on
stem and bonnet

1.4 Terminology of a globe control valves

Fig. 1.4.1 Cross-sectional view of a globe control valve


1.4.1 Body
The body is the main pressure containing structure of the valve that
provides a provision for connecting pipes, flow passageway, and supports the
seating surfaces and the valveclosure member.

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

2.1.1 Flow Coefficient (CV)


The valve flow coefficient is an inherent parameter which measures the
valve capacity. It depends on valve type, diameter of valve, opening rate of valve
and operating fluids.
CV is defined as the flow in cubic meter per hour of water at a temperature
0

5-40 C with a pressure drop across the valve of 1 bar.

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.

2.1.2 Valve Characteristics


The valve characteristic is a plot of the CV versus percentage opening of
the valve. The plot is indicative of how the flow rate will change with a change in
percentage opening of the valve. The percentage opening of the valve is a measure
of how far the plug is stroked relative to its maximum stroke length.
Characterization is used in control applications to better linearize the control loop.
The two most commonly used characteristics are the linear, where flow
rate increases linearly with valve plug travel, and equal percentage, where flow
rate increases exponentially with valve plug travel. Linear characteristics are used
in applications where the majority of the system pressure drop occurs at the valve
and equal percentage characteristics are used where the pressure drop across the
valve could vary significantly.

48

Fig 2.1.1 Equal Percentage

Fig 2.1.2Linear

2.1.3 Flow Direction


There are 2 types of control valve flow directions:
2.1.3.1 Flow to Close (FTC)
When the fluid flows over the plug, it gives a closing action to the plug.
This is called as FTC type flow direction. The effects of cavitation are less and it
requires more break away torque to open and less closing torque. This is mainly
used for low pressure applications.
2.1.3.2 Flow to Open (FTO)
When the fluid flow goes through and faces the plug directly, it gives an
opening action to the plug. This is called as FTO type flow direction. This
requires more closing torque and less opening torque and is mainly used for high
pressure applications.

49

Fig 2.1.3Flow direction along globe valves


2.1.4 Piping Factor (FP)
The FP factor is the ratio of the flow rate through a control valve installed
with attached fittings to the flow rate that would result if the control valve was
installed without attached fittings and tested under identical conditions which will
not produce choked flow in either installation. The piping geometry factor FP is
necessary to account for fittings attached upstream and/or downstream to a control
valve body.

2.2 Literature on Numerical Analysis of Control Valves

A generalised idea regarding control valves, its applications and


importance has been gained. To obtain the depth of work that has been done in
the analysis of control valves, different journal papers were surveyed.
Davis et al. [1] studied performance analysis of globe valves using
axisymmetric flow models for numerical analysis. Three globe control valves of
both linear and equal percentage valves with Cd ranging from 2.5 to 13 were

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

other to check the influence of these on design variables of valve performance.


They concluded that there was no much difference in valve performance between
single and double disk type butterfly valves, except that double disk type showed
more complex flow pattern and recirculating eddies at the rear of valve disk
compared to single disk type.
S.K.Kang et al. [7] discusses the effect of attached fitting on valve flow
coefficient by both numerical and experimental investigation. Experiments and
simulations were done for L, T, Y, and + type fittings under steady state
conditions. The pressure loss appeared to be 10% greater. This increase in the
pressure loss results in low performance of the valve and thus decreases the valve
flow coefficient. It was found out that valve flow coefficient must be corrected by
a piping geometry factor of 0.81 irrespective of the type of fitting used.
S.W.Kim et al. [8] investigated hydrodynamic characteristics of butterfly
valves and compared analysis results by PIV and CFD. Experimentation on
difficult conditions like cryogenic cargo transfer system is almost impossible to
conduct and analyse. This paper supports the usefulness of computational analysis
as a powerful tool for numerical analysis. Comparison of both analysis, PIV &
CFD using water, respectively vector velocities and pressure loss coefficients
have shown similar characteristic pattern.

Thus the numerical analyses are

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

Oza et al. [10] analysed performance of a globe valve in high pressure


oxygen environment using CFD. They used simplified axisymmetric numerical
model and predicted inherent valve characteristics using both k- and k-
turbulence models. The results showed that the k- turbulence model values
predicted higher values of velocity and turbulent kinetic energy than the k-
model since the latter captures lesser recirculation and is more suitable for
boundary level flow. It was found that k- model is more suitable for free stream
simulations.
Daines et al. [11] performed computational analysis of cryogenic flow
through a control valve. Study was done on the effect of change in plug/seat
region of the valve prior to testing.

All the numerical values were verified

experimentally and the modelled results compared well qualitatively with


experimental trends. During verification process, they analysed that it was better
to use double precision accuracy and non-integer grid ratios to make coarser grid
and thereby to reduce computational time. Thus the grid dependence of the
solutions was quantified using CFD verification techniques which yielded a grid
convergence index, an indication in the error bounded on the numerical solution
and an extrapolated grid independent value for Cv at various plug positions.
Soorya et al. [12] studied the valve deformation and valve performance
which are obligatory for material and product design integration. CFD analysis
was carried out on ball and gate valves with different fluids. Pressure distribution
along the valve body was analysed. This study helps in product design of the
control valves which makes the use of CFD very prominent. With the help of
CFD, product design and material design were able to be integrated in valve
manufacturing in an economical and faster way.
Yang et al. [13] aims at detailed CFD analysis of the three dimensional
flow fields in the chambers of the stop valve. The model was simulated and
observedfor flow patterns and to obtain valve flow coefficient and flow
fluctuations when stop valves with different flow rate and uniform incoming
velocity were used in a valve system. RNG k- turbulence model was used to

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.

2.3 Literature Survey Conclusion

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

3.1 Governing Equation

The governing equations of fluid flow represent mathematical statements


of conservation law of Physics:

The mass of the fluid is conserved.

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.

A steady incompressible flow without heat addition is assumed, thus energy


equation is not considered in the present work. The governing continuity and
momentum equations are:

..(1)

..(2)
where

stands for the divergence of the stress tensor. Considering the above

equation, the number of unknowns are 13 (velocity components, pressure and


stress field), making it difficult to solve. To overcome this difficulty NavierStokes equations are consider, where the stress field is related to the fluid
viscosity. Thus Reynolds-averaged form of the Navier-Stokes equations is
typically used for solving engineering flows problems.

57

The widely used numerical procedure to solve Navier-Stokes Equations is


SIMPLE (Semi-Implicit Method Pressure Linked Equations) algorithm. An
approximation of the velocity field is obtained by solving the momentum
equation. The pressure gradient term is calculated using the pressure distribution
from the previous iteration or an initial guess. The pressure equation is formulated
and solved in order to obtain the new pressure distribution. Velocities are
corrected and a new set of conservative fluxes is calculated.
The solution of the governing equations in case of laminar or inviscid
flows can be easily solved. However the solution of turbulent flows presents a
significant problem. In order to predict the effects of turbulence, a turbulence
model has to be considered. The commercial CFD code FLUENT offers a wide
range of turbulence models, standard k- model is selected for the simulations in
this work, based on studied result.
The k- Standard model is a two- equation model which has two extra
transport equations apart from the governing equations. These extra equations are
used to find turbulence kinetic energy and turbulence dissipation rate.
The turbulence kinetic energy is the mean kinetic energy per unit mass is
associated with turbulent flow. It is governed by the equation,

..(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)

RNG k- model can be used to verify turbulence model independence. In


this model, the unknown Reynolds stresses are related to the known mean strain
rate via a turbulent viscosity which is calculated as:
..(5)

58

Specification of this viscosity requires solution to two additional modelled


transport equations for the turbulent kinetic energy and the dissipate rate.

59

3.2 Valve Geometry 3D Design


Globe control valve of 3 inch (80NB) was modelled for a 12 hole cage
profile using SolidWorks. The 3D geometry and cross sectional view of the valve
modelled are shown below:

Fig 3.2.1 Designed 3D geometry of globe valve

Fig 3.2.2 Cross Sectional View of designed globe valve.

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.

3.2.1 Design of 8-hole and 24-hole cages


The experimentally validated 3 inch globe control valve with 12-hole cage
was used as a reference in this project. Cages with 8 and 24 holes respectively
were designed (within an error of 13%) by matching the flow areas at various
stroke lengths with the data from the 12 hole cage. These cages replaced the 12
hole cage in the test section. And the plug was positioned at vertical heights to
obtain 20, 50, 70 and 100 percentage opening for both FTO and FTC
configuration. The flow paths of all the designed test sections were extracted
using the commercial software ANSYS Workbench. (Details in appendix 1).

Fig 3.2.3 Development Drawing of 8 hole Cage

61

Fig 3.2.4 Development Drawing of 12 hole Cage

Fig 3.2.4 Development Drawing of 24 hole Cage

3.3 Computational Domain and Grid


The numerical grid for the valve body and upstream and downstream pipes
was generated by means of StarCCM software. The Computational domain of the
model is shown in Fig.3.3.a.
Along with structured grid, unstructured grid was also used, owing to
the complex nature of the geometry. The distinguishing feature of structured grid
is that, the computational space is mapped in a unique manner by the grid points
in the physical space. Unstructured grids mainly comprises of triangles in case of
2D and tetrahedral in case of 3D. The grid size for the computational domain of
12-hole caged globe valve was obtained in the range of 1.6 to 2.0 million cells.
Fig 3.3.b shows the test valve for code validation. Fig 3.3.c shows the grid
structure of valve numerical analysis model.

62

Fig 3.3.1(a) Computational Domain Front View

Fig 3.3.1(b) Computational Domain Top View

63

Fig 3.3.2 Test valve for code validation

64

Fig. 3.3.3(a) Grid structure of computational domain

65

Fig. 3.3.3(b) Regions meshed with dead curvature parameters

66

Fig. 3.3.3(c) Grid structure of valve numerical analysis model along a central
plane

Fig. 3.3.3(d) Grid structure showing prism layers

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;

For Normal(Coarse) Grids


No. of prism layers

68

Prism layer thickness :

0.2mm

Size of cell

Maximum

2.5 mm

Target

5mm

For Finer Grids


No. of prism layers

Prism layer thickness :

0.2mm

Size of cell
Maximum

2 mm

Target

5mm

3.4 Boundary Conditions and Numerical Simulations

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

3.5 Calculation of Volume flow rate


The computational codes of commercial CFD software ANSYS FLUENT
14.0 were used.
Firstly, the numerical model for globe control valve was validated with
experimental results, for both FTC and FTO configuration. Then, the gird
independence and turbulence model were verified. This was done only for FTO
type valves.
3.5.1 Validation of experimental results
The numerical models for 3 inch globe control valve with 12-hole cage
were validated using the experimental results (courtesy FCRI Ltd., Kanjikode).
The volume flow rates of the numerical model for 30%, 40%, 50%, 60%, 70%,
80%, 90% and 100% opening were used to calculate corresponding flow
coefficients (CV) and compared with the experimental data.

3.5.2 Grid Independence


For verifying, grid independence, numerical model of 12-hole cage was
remeshed to finer grids. The volume flow rate of these numerical models was
calculated using the computational codes of ANSYS FLUENT 14.0 with standard
k- turbulence model and the same boundary conditions. The corresponding CV
values thus obtained were compared with the CV values of the numerical models
with coarser mesh.

3.5.3 Turbulence Model


So far, the turbulence model chosen was standard k- model. Now, by
choosing RNG k- model the volume flow rates of the same numerical model
(only the ones with coarser mesh) was calculated. The corresponding C v values
were also noted down. These values were compared with that of the
corresponding numerical models in which standard k- was used.

70

In the standard k-epsilon model the eddy viscosity is determined from a


single turbulence length scale, so the calculated turbulent diffusion occurs only at
the specified scale, whereas in reality all scales of motion will contribute to the
turbulent diffusion. The RNG approach, which is a mathematical technique, is
used to derive a turbulence model similar to the k-epsilon, resulting in a modified
form of the epsilon equation which attempts to account for the different scales of
motion through changes to the production term.

3.5.5 Effect of number of holes


The numerical models with 8-hole and 24-hole cages were used to find
their corresponding volume flow rates. The volume flow rates and their
corresponding CV values of 20%, 50%, 70% and 100% openings were calculated.
The turbulence model used was standard k- model. The analysis was performed
for both FTO and FTC type configuration.
3.5.6 Effect of Scaling
The numerical models of 3 inch globe control valves for different
percentage openings were scaled to 4 inch, 5 inch and 6 inch. The volume flow
rates and corresponding CV values of these models were also found and a
relationship between CV and flow areas were tried to obtain.

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.

4.1 Validation of numerical models


The CV values of the numerical models for 20%, 50%, 70% and 100%
openings of the 3 inch globe control valve with 12-hole cage are in close
agreement with the experimental results within an error of 7%. The following
graphs (Fig.4.1.1) would be helpful in explaining the above statement clearly. The
results for both FTC and FTO are illustrated in these graphs.

72

Table 1(a): Validation of numerical models for FTO


% Stroke Opening

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

Table 1(b): Validation of numerical models for FTC


% Stroke Opening

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

4.2 Turbulence modelling and grid independence


The numerical models simulated with standard k- model and RNG k-
model yielded similar results within an error of 2% as shown in the graph
(Fig.4.2.1(a)). This proves that the effects of turbulence models are negligible.
Table 2(a): Turbulence Modelling
% Opening

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

Fig. 4.2.1(a) Verification of Turbulence Model

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

Fig.4.2.1(b) Verification of Grid Independence

75

76

4.3 Effect of flow direction on flow coefficient ( Cv)


It is interesting to note that the flow coefficient values obtained for FTO
and FTC configuration vary by a certain degree, for large percentage openings
(above 50%). This variation was found to be arising due to the difference in mass
flow rates of fluid flowing through the holes in the cage. The mass flow rate
through each hole in both the configuration for 50% and 100% was computed
using CFD-Post (Post Processor). It was observed that for 50% opening of cage
the difference between the mass flow rates through each hole for FTO and FTC
were almost zero. At 100% opening a significant difference was observed for
these values between FTC and FTO conditions. The tabulated results shown in
Table (4.3) enumerates the above statements clearly. Hence, it can be concluded
that, these variations arise due to the difference in the nature of flow in both flow

Table 4: Comparison of mass flow rate through holes of 12 hole cage


100% mass flow rate
Hole No.

FTO

FTC

mass flow mass flow

50% mass flow rate

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

directions (FTO and FTC).

4.4 Effect of number of holes on the cage


The CV values for the numerical models with 8-hole and 24-hole cages for
various plug openings yielded results which matched with the corresponding CV
values of the numerical models of 12-hole cage within an error of 10%. Therefore,
it can be inferred that the effect of number of holes on the cage has little
significance on the CV values. The following tables (Table 4.4) and graphs
(Fig.4.4.1) illustrate these results for both FTO and FTC.
Table 4(a): Effect of cage design on Cv for FTO
Computed Cv

% 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

Table 4(b): Effect of cage design on Cv for FTC


Computed Cv

% 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

Fig 4.4.2 Flow areas for different openings


It can be observed that the graph (Fig 4.4.1) follows the same pattern as
that of the above graph (Fig.4.4.2) except at lower plug openings. At lower
percentage openings the effect of velocity fluctuations are dominant owing to the
transient nature of the flow. Since, steady state flow was assumed in this present
work, the errors due to these factors got added up while calculating the Cv values.

4.5 Effect of scaling globe control valve


The numerical models of 3 inch globe control valve were scaled to 2 inch,
4 inch, 5 inch and 6 inch for 20%, 50%, 70% and 100% plug openings. A
comparative study of these scaled models for 50% and 100% plug openings for
both FTC and FTO is illustrated in Fig 4.5.1.

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

Table 4.5(a) Effect of Scaling for FTO


3 inch

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

Flow area, Af(mm2)

Cv / A f

Computed Cv

Flow area, Af(mm2)

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

Table 4.5(b) Effect of Scaling for FTC


3 inch

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

Flow area, Af(mm2)

Cv / A f

Computed Cv

Flow area, Af(mm2)

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

Fig 4.5.3 Relationship between Cv/Af for different % stroke openings

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

5.1 Conclusions Arrived


The numerical models for 3 inch globe control valve for both FTO and FTC were
qualitatively matched with the experimental results within an error of 6%. The effect of
turbulence model was found to be negligible by comparing results of numerical models
simulated with standard and RNG k- model. The grid independence was established by
comparing the results of numerical models simulated with fine and coarse meshes. Further,
the effect of number of holes of cage on flow coefficient (Cv) was found to be very less,
within an error of 10%. Scaling of 3 inch numerical models to 2 inch, 4 inch, 5 inch and 6
inch highlighted on the relationship between size of valve, flow area and C v. It was found that
for a specific plug opening, Cv/Af is a constant for different valve sizes. Another observation
was that Cv /Af values for FTC were more than that of FTO for all the plug openings except
for 50% plug opening, where the values were equal. Owing to the small computational
domain, there were discrepancies in the results obtained for 2 inch globe control valve.
Therefore, results obtained for scaling in this present study are valid only between the 3 inch
and 6 inch valve sizes.

5.2 Scope of future work


In this project, all the analyses were confined to globe control valve. As a scope for
future work, these analyses can be performed for other types of control valves as well.
Cavitation study and analysis of streamlines can be done for all these numerical models.
Further, scaling can be done for valve sizes above 6 inch for globe control valve. Also, a
better computational analysis can be followed for the scaling of 2 inch and other lower valve
sizes to obtain more accurate results. Additionally, studies can be conducted with different
working fluids as well. Further, CFD analysis can be supplemented by finite element
modelling in a more detailed way, and the results would help predict the behaviour of flow in
a more detailed and accurate manner.

APPENDIX A

1. Fabrication of Experimental Loop


As part of this present work, an experimental loop was proposed to be set up in the
Fluid Lab of Amrita School of Engineering, Coimbatore. But due to some unforeseen
circumstances the fabrication was not completed on time for the experiments to be conducted
for this project. So, the experimental results obtained from FCRI (Fluid Control Research
Institute), Kanjikode were used to validate the present numerical models. The details of the
experimental loop are explained briefly here.

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.

Table A.A.1 Bill of Materials


Fig. A.A.1 Experimental Setup CAD Drawing

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

Nut & Bolt

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

3 bar/ 30m , 3, 2500lpm,


Submersible Monoblock

TEXMO
Industries

Differential
Pressure Gauge

Pneumatically
Actuated Control
Valve

Triplee
Engineering
Equipments
Enterprises.
CIRCOR

3 Globe Style- CIRCOR D


SERIES

Fig. AA.2 Schematic Experimental Diagram

APPENDIX B

1. Design of 8-hole and 24-hole cages


In this section, the design of 8-hole and 24-hole cages using the already available 12hole cage is discussed. In the 12-hole cage, one of the holes was assumed as the reference and
the angles of the other holes were measured with this reference. These angles, in radians,
along with the arc lengths were used to make the development drawing of the12-hole cage.
This development drawing was used to make the development drawings of 8-hole and 24hole cages as shown in chapter 3 (Fig 3.2.3-3.2.4), by matching the flow areas at 10, 20, 30,
40, 50, 60, 70, 80, 90, and 100 percentages plug openings. By this trial and error method, the
flow areas of all the three development drawings were matched within an error of 4%. The
development drawings were then converted into 3D models. The 3D models are shown in the
Fig A.B.1.

(a)

(b)

(c)

Fig A.B.1 Cage designs of (a) 8 hole cage (b) 12 hole cage (c) 24 hole cage

2. Valve Assembly Design

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.

Fig. A.B.2 Components of valve assembly


Steps followed for valve assembly design:
1. A reference plane was made at the base of the seat ring.
2. The maximum height to which the plug can be moved was fixed to be 50.8 mm. So,

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.

Fig. A.B.3 Valve Assembly

3. Procedure for Extraction of Fluid Path


The fluid path was extracted in ANSYS 14.0 Workbench. The steps followed for the
extraction process are given below.
1. The Geometry tool was selected from Components Systems.
2. On right clicking the Geometry, a drop box was displayed from which Import was

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

units. Millimetre was selected as the unit.


4. The Operation Type was made as Add Frozen and the path was generated using

Generate from the menu bar.


5. After generating, filling was done by Select-> Tools->Fill. From the window which

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.

Fig A.B.4 Flow path extract from ANSYS Workbench

REFERENCES

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[12] K. Soorya Prakash, S.S. Mohamed Nazirudeen, M. Joseph Malvinraj and T. Manohar,
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[14] Young Joon An, Byeong Jin Kim and Byeong Rog Shin, 2008, Numerical analysis of
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[15] Brian C. Kuo and Nesrin Sarigul-Klijn, 2010, Conceptual study of micro-tab device in
airframe noise reduction: (II) 3D computation, Aerospace Science and Technology.
[16] ISA-75.01.01-2007 (60534-2-1 Mod) Flow Equations for Sizing Control Valves.
[17] Catalogue 12, 2012, Introduction and Sizing Valves for Liquids, ANSI/ISA/IEC Valve
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