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Cavitation
Prevention
Written by Cla-Val Technical Products Department
Pumps & Systems, October 2008
In water distribution systems where high pressure differentials and high flow rates are
present, valves, piping and equipment really take a beating. When automatic control valves
are exposed to such conditions, they will often exhibit vibration and excessive noise, letting
the operator know that the pressure differentials and high flow rates are taking their toll.
When these "symptoms" appear, they are clear indications that cavitation is occurring and
will be followed by diminished performance and failure.
Cavitation in valves occurs when the velocity of the fluid at the seating area becomes
excessive, creating a sudden, severe reduction in pressure below the vapor pressure level
and causing the formation of thousands of tiny bubbles. As fluid velocity subsequently
decreases, the pressure level rises, causing the vapor bubbles to collapse and release a
substantial amount of energy that literally eats away the metal surfaces of the valve interior.
This can eventually result in multiple performance issues, including loss of flow capacity and
erosion damage. The rule of thumb is: with relatively low downstream pressure conditions,
the higher the pressure drop across the valve, the greater potential for damage.
It is not pretty. In fact, it is startling what the force of the vapor bubbles impinging on a
valve's metal surfaces can do. The collapse of vapor bubbles can cause local pressure waves
of up to 1,000,000-psi, causing deterioration of any surface with which they come in contact.
The noise and vibration that accompany the valve damage are also a concern, posing a
potential safety hazard for personnel working in close proximity to the cavitating valve.
The first step in avoiding this commonly occurring problem is to analyze the system to
measure the potential for valve cavitation. Analysis should take into account parameters such
as pipe and valve size, maximum and minimum flow rates, static/dynamic inlet and outlet
pressure, water temperatures and elevation above sea level. This analysis can be performed
using commercially available software or another approach such as the analytical method
described in Hydraulics of Pipelines: Pumps, Valves, Cavitation, Transients by J. Paul Tullis of
Utah State University (copyright 1989 by John Wiley & Sons, Inc.).
Following Tullis' methodology, flow tests are conducted to determine a Sigma curve for the
valve. Sigma is defined as a cavitation index that identifies the level of cavitation that will
occur with various flow and pressure conditions through a restriction device (such as a valve).
To further clarify, the conditions causing cavitation are directly proportional to the kinetic
energy of fluid, which is related to delta P (see Figure 1).
Once the potential for cavitation in a system is understood, the next step is determining the
best method to prevent it from occurring. Some of the most common and effective measures
are:
Installing two valves in series will effectively mitigate the incidence of cavitation. An added
benefit is that the second valve acts as a backup in the event the first valve fails, ensuring at
least some level of pressure-reducing functionality in the application. The negative in this
scenario is that space at valve installations is often limited and there simply is not enough
room to install two valves. In addition to these concerns, there is also the cost of the second
valve to consider.
Orifice Plates
An obvious benefit of using orifice plates as backpressure devices to reduce cavitation's effect
is the relatively low cost to purchase and install them in the pipeline. Unfortunately, when
orifice plates are used in this way, they are only effective within a narrow flow range and will
cause a reduction of flow capacity within the system.
Another negative is that orifice plates can actually cause cavitation to occur, creating the
potential for damage to downstream fittings and valves.
Several automatic control valve manufacturers offer products that are designed to reduce or
eliminate cavitation. By nature, any anti-cavitation device will result in reduced flow capacity.
Fortunately, the negative effects can be minimized when the valve is properly sized for the
application. This is achieved by performing comprehensive and thorough flow testing with a
sizing program to ensure that the right size valve is chosen to provide cavitation protection.
Despite this caveat, using an anti-cavitation valve is generally considered the most effective
approach, especially if an existing, installed valve can be retrofitted with anti-cavitation trim.
It is important to note that there are occasionally applications where a system's pressure and
flow rates are so extreme that the only effective measure against cavitation is a combination
of a valve outfitted with anti-cavitation trim, installed in conjunction with orifice plates.
Fortunately, this scenario is not the norm.
In the best-case scenario, distribution systems would be designed with cavitation prevention
measures as an integral part of the system. It goes back to taking that all-important first step
of performing a complete cavitation study before valves are selected, purchased and installed
in a pipeline. Engineers and consultants can provide a significant value to their customers by
considering cavitation when designing their systems.
They can provide further value by consulting with valve manufacturers and specifying valves
that are properly sized and equipped with anti-cavitation trim or other options. The long-term
benefits are significant: lower maintenance costs; fewer equipment failures; less downtime
associated with valve replacements; and a system that performs with optimum efficiency.
In the case of an existing pipeline, the most direct approach to minimizing or even
eliminating cavitation is either replacing existing valves with cavitation-fighting valves or
retrofitting them with anti-cavitation trim.
Whichever avenue the water company chooses, operating a water distribution system with
little or no cavitation is possible. It is just a matter of which approach will work best with the
company's operational and financial parameters.