Cage Trim Valves

The Weir Group PLC
Cage Trim Control Valves
BLAKEBOROUGH CONTROL VALVES
Cage Trim Control Valves
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This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 2
Why are Control Valves Used?
 Control valves are higher technology, higher specification and overall more
expensive than other types of valves, so why are they used and how are the
features selected.
 Control valves have low pressure recovery values

 Less potential for noise
 Less potential for cavitation
 More resistance to flashing flows.
 More resistance to erosion
The Weir Group PLC
Dealing with Pressure Recovery
Division.
Flow Path through a Control Valve - Analogy
 A control valve is
simply a
restriction in a
pipe.
 The restriction
causes a drop in
pressure.
 Pressure
reduces to the
point of the vena
contract.
 Beyond the vena
contracta the
pressure Minimum
Geometrical Vena Contracta
recovers Streamlines Contract as (Minimum Flow Area)
Flow Area
Flow Approaches Restriction
Variation in Pressure and Velocity
 As the pressure drops

through the valve P1
energy is generated
which can damage
the valve.
Pressure
Velocity P
 If the pressure drop at Variation
the vena contracta is
Variation
reduced the energy
generated will be
reduced and therefore
P2
the potential for
erosion will in turn be
reduced.
 As a consequence of
dropping the pressure
the velocity of the Valve Trim Valve
fluid increases Inlet Trim Exit Vena Outlet
 The graph represents Inlet Contracta
the pressure drop
through a single stage
trim.
Single Stage Pressure Letdown

 Think of the pressure drop in terms of the size of a water fall, if the water fall is very high
then the water will hurt anyone stood beneath the water
Dealing With High Pressure Drops
 So if there is a high pressure drop, the potential for damage to the control valve
will increase.
 Pressure drops are generally limited to a maximum of 50 bar (although there are
exceptions) for a single stage trim.
 What do we do for higher pressure drops?
 High pressure drops on liquid applications can cause erosion
 High pressure drops on gas applications can cause high noise levels.
Multistage trims
 Multistage trims are used to portion the drop in pressure across multiple stages of
pressure letdown (in the cases below 3 stages of pressure reduction)
In liquid applications the fluid is incompressible and therefore the pressure

drop stages can be equal in area.
Gas expands and compresses due to the flow through a multi stage orifice and
therefore the gas should be allowed to expand.
 Reducing the P1
pressure in multiple
stages means there is
less energy generated
at the vena contracta. Pressure
Velocity ΔP
Variation
 As a consequence of Variation
controlling the drop in
pressure, the velocity
across the trim is P2
reduced.
 The potential for
erosion is reduced
due to the reduced
drop in pressure
across each stage of Valve Trim Valve
the trim and the Inlet Trim Exit Vena
reduced velocity Outlet
Inlet Contracta
Multi Stage Pressure Letdown

 Think of the pressure drop in this case of a waterfall with steps in the flow, in this case
the pressure drops more gradually and therefore there is less potential for damage at
the end of the waterfall
Pressure Recovery
 The best style of trim

to handle higher
pressure drops is the
valve with a low
recovery trim.
 The cage guided
valve has the lowest
pressure recovery of
any type of valve on
the market. P
 Therefore the cage
valve has less
potential for damage Low
and a longer service Recovery
life.
High
Recovery
The Weir Group PLC
Valve Features
Division.
Control Valve Selection Guide

Valve Model
Cage Trim Globe Contour Trim Valves
 BV502 Casting, upto 1” BV800 Double Seated Push Down to Close
 BV504 Forged, upto 1” BV801 Double Seated Push Down to Open
 BV500 150 lb to 600 lb BV802 Single Seated Push Down to Close
 BV990 Above 900 lb BV803 Single Seated Push Down to Open
Cage Trim Angle
 BV503 Casting, upto 1” Desuperheaters
 BV505 Forged, upto 1”  BV985 Variable Probe
 BV501 150 lb to 600 lb  BV986 Spray Ring
 BV992 Above 900 lb  BV987 Desuperheater Pipe
3-Way  BV988 Fixed Area Probe
 BV830 Mixing & Diverting  BV994 Combined- Globe
 BV831 Diverting  BV995 Combined- Angle
The Weir Group PLC
½” to 1” BV502 & BV503 Valves
Division.
Contour Trims
Suitable for most general flow applications

with relatively low pressure drops
Flow characteristic formed by the contour of
the nose of the plug.
Available in metal to metal and soft faced
constructions.
Flow is from under the plug
Available in 8 trim sizes.
Soft Faced
Trim
Spline Trims
Suitable for low flow applications. Spline Trim
The plug and seat are manufactured as a
matched pair to prevent leakage around the
circumference of the plug nose.
Where body impingement is a concern then a
seat diffuser can be provided.
Available Cv’s from 3.2 to 0.001
Flow characteristic is always modified =%
Available in metal to metal and soft faced
constructions.
Flow is from over the plug.
Spline With
Diffuser
Multi Flow Plug

The Multi-flow plug is used on higher
pressure drop applications where the contour
trim is not suitable
Flow is broken into small jets by the cage.
On gas service additional 15 to 20dBA noise
reduction achieved by fitting the multi-flow
trim.
Available Cv’s from 12 to 3.2.
Flow characteristic is linear or =%
Flow is from over the plug the achieve jet
impingement.
Multi Stage Splines

2 Stage Spline
Trim
On small valves with low Cv’s it is not
practical to control high pressure drops with
small Cv’s through a multi-stage cage
Multi stage spline trims are used to give
accurate control at low Cv’s
Multi stage splines are used on high pressure
drop applications to absorb the pressure drop.
Available in Cv’s from 3.2 to 0.001
Fitted with a diffuser to prevent valve body
erosion.
Flow is from over the plug
3 Stage Spline
Trim
The Weir Group PLC
Cage Trim Valves

1.1/2” Sizes and Above
Division.
Trim Components Stem Nut
 The valve trim is the area of the

valve that is required to control Stem Pin Stem
valve pressure drop. It therefore
has to operate under highly
erosive conditions.
 The valve features: Balance
Ring
 Cage
 Plug
 Seat
 Stem
Cage
Seat Plug
Features
Valve
Globe or angle style body
High integrity cast body and bonnet
Low pressure recovery trim giving reduced down time.
Clamped seat ring for easy service
Stable cage guiding, anti vibration
Cavitation resistant trim
Flashing erosion control
Noise reduction trim
Multi stage trims available within the same body configuration
Top entry - valve can be serviced without removal from the line
Pressure balanced trim for stable pressure control.
Designed for use with standard, intermediate and severe service cages.
Small hole technology gives the most efficient pressure control of any type
of valve currently on the market
Actuator
Spring return diaphragm actuator with inherent fail safe operation
Actuator removal without disturbance to the valve packing
Actuator mounting for pneumatic diaphragm, piston, hydraulic or electic
actuator.
Single spring or multi spring actuators available depending on space
constraints
Single Stage Cage Design
The cage trim valve is usually supplied as a

globe design, but they can also be angle
design.
Sizes from ½” to 36”

Globe or Angle formats
Ratings Class 150 to Class 4500lb
Can be balanced or unbalanced
Allows smaller actuators to be used.
Can handle higher pressure drops.
Easy maintenance due to top entry of the
valve.
Dealing with High Velocity Impingement

 The reason why cage valves are
superior is because the erosive energy
of the fluid is broken down by the
multiple holes in the valve cage.
 The flow then collides with the flows
from around the circumference of the
cage and ensures the damaging effects
of the pressure drop are maintained
within the centre of the cage
 Directs the erosive jets into each other
to dissipate the energy
 Avoids sudden changes in the flow
direction through he valve inlet and
outlet
 Hardened materials are used to reduce
the rate of erosion.
Cascade Trim
Pressure drop is staged by

increasing the flow area
through each successive
sleeve. Energy is dissipated by
jet impingement, flow division
and by turning the flow
through 90 degrees in the trim
galleries
Characteristic
100
Quick Open
80
%
60
Design Cv
Cv
40
20
0
0 20 40 60 80 100
% Valve Travel
Globe/Angle - Cage Guided Valves
The valve can be supplied in globe or angle format

Used to turn the process 90 deg
For highly erosive conditions where flow does not
contact the body wall.
Bonnet Forms
 Bonnets are specified according to the

operating temperature and the process
fluid.
 The standard bonnet is used for
temperatures below 3150C and above -
290C.
 For higher/lower temperatures an
extended normalising bonnet is used to
lift the packings further away from the Standard
main process flow. The normalising
bonnet also allows space for the valves
to be lagged.
 For valves that are used on hazardous
fluids then a bellows seal bonnet is
used. The bellows is welded to the
Bellows – Leak
valve stem and is therefore leak free.
Proof Sealing
Normalising (Extended)
Temps Above 315 deg C
and Below -29 deg C
Cryogenic Bonnets Forms
 Cryogenic bonnets are used on low

temperatures, below -1010C
 The bonnet is extended to lift the
packings further away from the process
 The extra height of the bonnet ensures
that the valves can be lagged.
 Cryogenic bonnets are often tested to
ensure operation at leak tightness at
sub-zero temperatures.
 Valves can also be supplied for cold
box applications. In these applications
the valve can be serviced from outside Cryogenic – Low
the cold box. Temperature
Applications
Standard Packings
Supagraf Packings (Low Emissions)
PTFE Chevron
Up to 232 deg C
Graphite
Above 232 deg C
The Weir Group PLC
SEVERE SERVICE VALVES

Liquid Applications
Liquid Sizing
Division.
What is a Severe Service Application ?
Stage Static Pressure Drop Exit Kinetic Energy

Trim Exit Velocity Velocity Head
Severe Service Not

Severe Service
Pressure Recovery Multi Stage

Cage Trim
 The graph gives a
basic indication of the
levels of pressure
recovery associated
with different valve
styles.
 But when more stages
of pressure letdown
are required, how is
this handled?
Single
Stage Cage
Trim
Contoured
Trim Valve
P1
Pressure DP
Variation
P2
Velocity
Variation
Valve Trim Trim Vena Valve

Inlet Inlet Exit Contracta Outlet
Disc Stack Trim with Labyrinthine Flow Path

Typical labyrinth trim supplied by RED = High velocity
our competition BLUE = Low velocity
Direction of fluid flow
Example of Disc Stack Trim with CFD Simulation of Fluid Velocity

Labyrinthine Flow Path
Problems with Labyrinthine Flow Path
RED = High velocity

BLUE = Low velocity
Areas of re-circulating
flow in which solid
debris can become
trapped & the
premature onset of
cavitation
High velocity flow

separation creates
large undesirable
pressure gradients
increasing potential
for flow erosion
CFD Simulation of Fluid Velocity
Disc Stack Arrangement

The X-StreamTM Trim
Detail of an X-StreamTM Trim

CFD Simulation of
X-StreamTM
CFD Simulation of Fluid Velocity  Close proximity of cylinders minimise
areas of re-circulating flow & pressure
RED = High velocity
gradient across path
BLUE = Low velocity
 eliminates premature onset of cavitation
due to areas of re-circulating flow
 Reduction in cylinder diameter towards

outlet of path
 reduces pressure recovery in areas of
high cavitation potential.
 Natural anti-clogging flow path

 no points at which debris could become
trapped
 Full 3D understanding of fluid flow

 better prediction of fluid parameters and
therefore performance
3D Sizing - The Principal
 More even distribution of static pressure and

velocity levels.
Plot of Velocity Vectors Plot of Static Pressure

3D Sizing - The Principal
Partial Image Velocimetry was used

to validate the CFD modelling. PIV is
used for determining velocity fields in
a liquid flow stream. Camera
The flow stream is seeded with
minute light reflecting particles.
Following the testing and the CFD
modelling sizing equations were Laser Working
developed. Section
Frame 001  28 Oct 2002  D:ExperimentsKarenVectorKaren00000.vec | D:ExperimentsKarenVectorKaren00001.vec | D:ExperimentsKarenVectorKaren00002.vec | D:ExperimentsKarenVectorKaren00003.vec | D:ExperimentsKarenVectorKaren00004.vec | D:ExperimentsK
KarenAvg.
Vel Mag
25 0.841035
0.672828
0.504621
20
0.336414
Y mm
0.168207
15
0
10
10 20 30
X mm
Plot of Velocity Contour Plot

Vectors of Velocity
Application Example
Pump Minimum Flow Duty on a Boiler
Feedwater Application.
The existing valve had experienced

high levels of noise and mechanical
vibration, and the internal parts had 135 bara
been replaced due to erosion.
The temperature of the feedwater was
such that the vapour pressure was
very close the outlet pressure, giving a
high potential for cavitation.
Vapour pressure = 3.8 bara
An X-Stream flow path based on the
valves specific operating conditions
was produced and used for the
application. 4 bara
Mechanical vibration was totally
eliminated, and noise levels reduced to
acceptable levels. In fact, the power
plant were so happy with the
performance of the valve that they
made a recommendation to their
design institute for it to be used on
future plants.
The Weir Group PLC
SEVERE SERVICE VALVES

Gas Application
Division.
3D Gas Sizing
3D Gas Sizing – the Approach taken
 The basic problem with gas applications is the aerodynamic noise resulting from pressure fluctuations
induced by turbulence and unsteady flow.
 This particular problem required the evaluation of a different solution.
 Research information available within the public domain
 Manufacture and test sample flow paths
 Evaluate and run CFD models
 Validate models
3D Gas Sizing
 Size Matters!
 Position affects performance!
In his PhD thesis “Wall Pressure Fluctuations
and Flow losses in Control Valve Models”
Jonathan Lodge concluded that the size of the
holes used in both single and multi-stage cage
arrangements had a significant effect on the
aerodynamic noise performance of the valve.
He also found that the position of the holes

relative to one another around the circumference
of the sleeves also played an important part in
contributing to the overall noise level generated by
the valve.
3D Gas Sizing
The holes in the final element of the trim have a profound effect on the aerodynamic noise
generated by the valve trim. If adjacent jets are allowed to coalesce they produced larger
noise generating shock cells.
shock cells
fluid jets
Outlet jets with holes in
Outlet jets with holes well close proximity to each
spaced. Result in lower other. Result in higher
noise levels noise levels
3D Gas Sizing
To prevent the jets from coalescing, he introduced a course “mesh” after the final stage of the valve
trim. His observations showed that the “mesh” disrupted jet formation, eliminated shock cell
formation, and reduced noise by approximately 15 dBA.
It should be noted that the “mesh” had no effect on flowrate
Standard
Sleeve =
+
Mesh
15 dBA
Noise reduction
3D Gas Sizing
•Four test samples were prepared.
•The first was a straight flow path with no cylinders designed to represent a single stage trim, and
act as a baseline for the test results.
•The second contained was an X-Stream flow path designed for liquid flow.
•Flow path three contained two rows of cylinders to define the flow rate with then an additional row
of smaller cylinders and to control the formation of the jets at the outlet of the flow path. This
sample represented the course mesh define by David Kirkwood
•The final sample comprised the X-stream flow path of test sample B with a final row of small
cylinders as sample C
•Each sample contained 4 plates stacked one on top of the other
Path A Path B Path C Path D

Blank Flow Path X-StreamTM Liquid 2 Rows + “Mesh” X-StreamTM + “Mesh”
3D Gas Sizing
The samples were laboratory tested at Manchester University’s Barton facility. The test rig was
designed to ensure that choked flow was achieved across each of the test samples with sonic velocity
at its outlet. The rig was designed to be used in two different configurations.
downstream upstream settling
working upstream
pipe upstream voltage chamber silencer control valve
section pipe measurement
transducer
amplifiers
data
collection
computer
manometer
oscilloscope
3D Gas Sizing
In the first, precise pressure fluctuations were recorded by measuring the wall pressure
fluctuations upstream and downstream of the pipe. A number of pressure sensors were used
to measure the static pressure vibrations produced by the acoustic field downstream of the
test piece. Noise readings were taken using a pre-calibrated noise meter.
Pressure Sensing Transducers
upstream settling
pipe chamber
P10 P9 P8 P7 P6 P5 P4 P3 P2 P1
downstream working
pipe section
manometer connection
3D Gas Sizing
Noise reduction compared to Blank flow path
 X-StreamTM liquid (path B) 25-28 dBA
 2 rows + Mesh (path) 20 dBA
 XstreamTM liquid + mesh (path D) 35-40 dBA

3D Gas Sizing
 After the completion of the first series of tests, the outlet section was removed
so that tests using the Scherlieren technique could be undertaken.
 This process is used as a means of flow visualisation of compressible fluids.
Its primary use is to identify the formation of important flow features such as
vortices, jet formations and shock cells.
3D Gas Sizing
Scherlieren technique light source

mirror
The visualisation works by highlighting changes
in density within the fluid flow, which deviate Fluid flow
the light rays passing through the boundaries. Image
Light is provided by a high intensity light source, directio pipe
and the image it creates is reflected into a camera n lens
using a mirrors and a knife edge. Knife
edge
As the following video clips will show, it was the field of
view
Scherlieren activity that gave the most interesting
part of the test study. image mirror
focusing
box
camera
3D Gas Sizing
As we look at the film of the blank flow path, you will note the growth and profile of the jet.
As the flow chokes, bright diamond shapes will appear. These are noise generating shock
cells.
The test piece also emits a high pitched squealing noise.
A
Blank Flow Path
Flow Vertical Plane

3D Gas Sizing
The X-stream liquid path formed four independent parallel jets. These coalesce downstream
without producing large shock cells, although there are bright spots indicating much smaller shock
cells. You will alsoBnote the reduction in noise compared to the previous path.
X-StreamTM Liquid Path
Flow Horizontal Plane

3D Gas Sizing
Path C introduces the row of small columns representing the mesh suggested by David
Kirkwood’s work. As we play the film you will note the formation of a single jet at the outlet
of the section with no apparent shock cell formation. The noise generated is again much lower
than the initial sample.
C
2 Rows of Cylinders + “Mesh”
Vertical Plane
Flow
3D Gas Sizing
Finally, the X-Stream Liquid path plus a small row of columns. As with path B, four
independent and parallel jets are formed. This time they coalesce downstream without any
discernable shock cells being present. The reduction in noise was such that measurements could
be comfortably taken without using ear protection.
D
X-StreamTM Profile + “Mesh”
Flow Horizontal Plane

3D Gas sizing – Conclusions
Path D forms the basis of

X-Stream Gas Low noise trim

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The Weir Group PLC

Cage Trim Control Valves

BLAKEBOROUGH CONTROL VALVES

Cage Trim Control Valves

Why are Control Valves Used?

 Control valves have low pressure recovery values

Dealing with Pressure Recovery

Flow Path through a Control Valve - Analogy

Variation in Pressure and Velocity

 As the pressure drops

Single Stage Pressure Letdown

Dealing With High Pressure Drops

In liquid applications the fluid is incompressible and therefore the pressure

Variation in Pressure and Velocity

Multi Stage Pressure Letdown

 The best style of trim

Control Valve Selection Guide

½” to 1” BV502 & BV503 Valves

Suitable for most general flow applications

Multi Flow Plug

Multi Stage Splines

Cage Trim Valves

Trim Components Stem Nut

 The valve trim is the area of the

Single Stage Cage Design

The cage trim valve is usually supplied as a

Sizes from ½” to 36”

Dealing with High Velocity Impingement

Pressure drop is staged by

Globe/Angle - Cage Guided Valves

The valve can be supplied in globe or angle format

 Bonnets are specified according to the

Cryogenic Bonnets Forms

 Cryogenic bonnets are used on low

SEVERE SERVICE VALVES

What is a Severe Service Application ?

Stage Static Pressure Drop Exit Kinetic Energy

Severe Service Not

Pressure Recovery Multi Stage

Variation in Pressure and Velocity

Valve Trim Trim Vena Valve

Disc Stack Trim with Labyrinthine Flow Path

Direction of fluid flow

Example of Disc Stack Trim with CFD Simulation of Fluid Velocity

Problems with Labyrinthine Flow Path

RED = High velocity

High velocity flow

Disc Stack Arrangement

The X-StreamTM Trim

Detail of an X-StreamTM Trim

 Reduction in cylinder diameter towards

 Natural anti-clogging flow path

 Full 3D understanding of fluid flow

3D Sizing - The Principal

 More even distribution of static pressure and

Plot of Velocity Vectors Plot of Static Pressure

3D Sizing - The Principal