CFD analysis results of Gate valve DN 200 by use of
FLUENT ANSYS software
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E-Mail faraj.khalikov@gmail.com Table of contents Table of contents .................................................................................................... 2 Introduction ............................................................................................................. 3 1 Theory ................................................................................................................. 4 3 Geometry ............................................................................................................. 5 2 Boundary conditions ............................................................................................ 7 3 Results................................................................................................................. 8 4 FEM Analysis ..................................................................................................... 12 5 Conclusion ......................................................................................................... 19 Appendix............................................................................................................... 20 Introduction Pressure losses in gate valve systems are point of interest in this report. Reducing the pressure loss is important in order to reduce the costs. Additionally flow coefficient, torque and force are derived from CFD simulation. For the optimization of gate valves, CFD simulation is a proven state of the art design and simulation tool. Consequently this technique offers everything that is required to calculate the flow coefficients of gate valve in dependence of overall pressure difference (flow rate) and fluid temperature. 1 Theory Since there is a demand to get pressure loss across the gate valve at different flow rates, the results of the simulation is presented in relation of pressure loss to opening angle of disk. Using non-dimensional parameters reduces the number of experiments and simulations to be performed. Reynolds number is given below: 𝑢𝜌𝑑 𝑅𝑒 = 𝜇 𝑢 – velocity of the fluid in m/s 𝜌 – density of the fluid in kg/m3 𝑑 – hydraulic diameter of the component in m 𝜇 – dynamic viscosity in Pa s Reynold number is 1 000 000 for all the cases. Resistance coefficient calculation (Wagner,1990) is given below: 2Δ𝑝 𝜁= 𝑢2 𝜌 Δ𝑝 – pressure loss across the component in Pa 𝑢 - velocity of the fluid in m/s 𝜌 – density of the fluid in kg/m3
Flow coefficient calculation is given below:
𝑆𝐺 𝑐𝑣 = 𝑄√ ∆𝑝
Δ𝑝 – pressure loss across the component in kPa
Q – flow rate across the component in m3/h SG – specific gravity 3 Geometry Gate valve geometry is shown in Figure 1.
Figure 1 Gate valve at 52.5 % opening.
Figure 2 Gate valve at 52.5 % opening. 2 Boundary conditions Velocity inlet with speed of 4 m/s, which is taken from EN 593 standard, is used as inlet boundary condition. Eddy viscosity is calculated automatically by ANSYS FLUENT at Intensity 1% and hydraulic diameter 0.2 m. Outflow condition is set as outlet boundary condition. Flow speed 4 m/s Viscosity 0.000001 m/s^2 Density 1000 kg/m^3 Temperature 20 C Hydraulic diameter 0.2 m Intensity 1 % Model Spalart Allmaras
Table 1 Sample boundary conditions example.
Spalart allmaras and k-e turbulence models are used. Mesh used for simulation is medium mesh. Better mesh will be applied when workstation will be available. In order to calculate the flow coefficient, pressure difference of 16 bar, which is testing pressure, is given as boundary condition between inlet and outlet. 3 Results Pressure loss at 4 m/s flow speed is derived by use of ANSYS FLUENT. At fully open position there is 1 kPa pressure loss, which enables us to use several Gate valves in a serial connection. In open position the main pressure loss is due to the wall friction on the pipe walls. Critical pressures are observed to be at angles below 50 % openings. In real case flow speed is reduced by reducing opening angle. It can be observed on Graph 4 that the flow rate is low at lower angle of opening. Closing speed of the gate is important parameter since cavitation and water hammer effects have to be balanced to be negligible when closing the valve.
Graph 1 Pressure loss of butterfly valve at different opening angles.
Torque curve is shown on Graph 2. Torque is zero at fully open position and torque is critical only for gate opening less than 50 %. Torque was calculated with respect to gland, connecting bonnet to the stem, position.
Graph 2 Torque values at 4 m/s flow speed and different opening
percentages. Force curve is given in Graph 3.
Graph 3 Force values for different angles at 4 m/s flow speed
Flow coefficient is derived by keeping inlet pressure constantly at 16 Bar.
Graph 4 Flow coefficient graph
4 FEM Analysis Fine mesh with 3 mm size was used for FEM analysis.
Figure 3 FEM analysis mesh.
Figure 4 Stress distribution in Pa. 25 Bar pressure was applied inside part of the Gate valve. Fully isotropic elastic model was used for simulation. From stress contours it can be seen that maximum stress occur at the flange connection part of the valve. Maximum stress occurs at flange connection parts and it is above the yield strength, 250 MPa. Since maximum stress occur pointwise, it was decided to neglect them. (Tunc) Secondary high stress areas are seen on the ribs, bonnet and body, which are equal to 180 MPa. Since stresses are below 250 MPa, it is acceptable solution. Figure 5 Deflection distribution in m. Figure 6 Stress distribution in Pa. Figure 7 Deflection distribution in m. Figure 8 Stress distribution in Pa for one sided pressure application. Figure 9 Deflection in mm for one sided pressure application. 5 Conclusion Throughout project, the results of ANSYS FLUENT will be validated by experimental data, which is going to be obtained in the future work. The mesh used for simulation is medium. Better mesh will be generated when workstation will be available. Cavitation analysis showed that at 5 mm opening there is cavitation at the bottom of the valve. Inserting a hole before and after wegde should be considered in order to avoid cavitation hazards. Pressure losses are negligible when the valve is fully open. Flow coefficient, Graph 4, curve will be added to the catalogue of Gate Valve DN 200 PN 16. FEM analysis show that the butterfly valve is safe for use and enhancements can be applied in future. Appendix Simulations are performed for cases with Re = 800 000. Cavitation is observed at the bottom of the disk.
Figure 10 Pressure field for open state
Figure 11 Velocity contours for open state
Figure 12 Pressure contour for 52.5 % opening.
Figure 13 Velocity contour for 52.5 % opening.
Figure 14 Vector field for 52.5 % opening.
Figure 15 Streamlines for 52.5 % opening.
Figure 16 Pressure field for 2,5 % opening.
Figure 17 Velocity contour for 2,5 % opening.
Figure 18 Velocity vector field for 2,5 % opening.