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FEDSM2007-37690 - Fluid Kinetic Energy Based Limits in The Design of Control Valves
FEDSM2007-37690 - Fluid Kinetic Energy Based Limits in The Design of Control Valves
FEDSM2007-37690
FLUID KINETIC ENERGY BASED LIMITS IN THE DESIGN OF CONTROL VALVES AND VALVE-
RELATED SYSTEMS
Valves:
How these specifications are met is a matter of valve Valves with high internal velocities:
selection and design. There are many different configurations
of valves to begin, some of which are illustrated in Figures 1 High internal velocities in valves are undesirable because
and 2. The experience of the users and designers plays a major they can result in potentially damaging phenomena; it is the
role in selection of the valve type for specific applications. The most common mark of severe service applications. Robustness
rules that are used for selection and sizing generally reflect to withstand, and perform, under severe operating conditions is
good prior experience, or what has worked, within the envelope always an overriding requirement from an overall systems
of the operating parameters. One recurring theme among such perspective. Since the energy dissipation in the control valve is
rules is the limits on fluid velocity, with separate limits for the source of energy for the damaging phenomenon, it becomes
liquids and gases; the separate limits, in a way, recognize that a useful parameter for control in addressing all the problematic
density has a role too. Accurate and versatile tools have been issues related to it. As an illustration, the effectiveness of
developed over time for design. These have generally evolved kinetic energy criteria in addressing control valve vibrations is
from a limited portion of the full spectrum of applications. described in References 1-4. It is easily calculable and
They include many implicit assumptions and empirical verifiable, as shown in References 5 and 6, which makes it
relationships; the empiricism, and their limitations, often is not useful in practice.
visible. In the end, these rules do not provide any simple, and
uniform means of identifying the potential for problems in ENERGY DISSPATION IN CONTROL VALVES
service.
Pressure drop:
Pinlet
Inlet Velocity
Vinlet Voutlet
Velocity
Vapor Poutlet
Pressure Figure 4. Flow-path with many stages for pressure reduction (24
Pressure stages in this illustration).
Cavitation occurs in this
pressure-recovery region
Figure 3. Velocity and pressure variation for a single stage pressure
reduction. VALVE
Inlet
Outlet
Control valves are often modeled as variable-area orifices
Inlet
because of similarity in their characteristics. Indeed, traditional Pressure
Pinlet
control valves are just that – in-line orifices whose area can be
controlled. Pressure drop, when there is flow through the valve,
can be expressed in a form,
Voutlet
Velocity
1 Inlet
∆P = (K ) ρV 2 (1) Velocity
2
Pressure
Vapor
Typically, V is a characteristic velocity at some point in the Pressure
flow such as vena contracta; K is a constant which depends on
the geometry. Looking at the term 1/2 ρ V2, it has units of
pressure. It also represents the kinetic energy of the fluid at a Figure 5. Velocity and pressure variation for a valve with a large
point per unit volume. number of stages for pressure reduction.
The discussion in this section describes the connection High levels of forced vibrations are common in severe
between the fluid kinetic energy and the damaging phenomena service control applications because the energy dissipated is
referenced previously. It is most relevant in severe applications high. For example, the rate of energy dissipation in a 4 inch
because high energy dissipation increases the intensity of these control valve in boiler feed-pump recirculation service, with
phenomena and the risk of poor performance 3000 psi (~ 20 MPa) drop and flowing 2000 gpm (~7500l/m) of
water, approaches 2.6 Megawatts. Even a small fraction of this
Cavitation: is capable of creating tremendous vibrations in conventional
valves. Dissipation of fluid energy takes place through
The onset of cavitation in flowing liquids is expressed in turbulence downstream of the throttling area in the valve. This
terms of an incipient cavitation index, defined as, generates unsteady forces that are the root cause of the
vibrations.
(P1 − Pv )
σ= (2) The solution in this case lies in dissipating most of the
(ρV 2 / 2) energy within the boundaries of the static element in the valve.
This results in significant reduction of flow turbulence and
The potential for cavitation increases as the cavitation associated unsteady forces acting on the valve plug and the
index gets closer to 1 for a given geometry. The role of kinetic valve body.
energy is thus evident in the denominator; the higher the kinetic
energy, the greater is the potential for cavitation. Further,
cavitation may be completely suppressed if the kinetic energy is
kept sufficiently low.
V = V+v (3a)
Figure 6. Cavitation regimes for valves, with and without fluid
kinetic energy control. P =P+p (3b)
Measured Prediction
4.E-04 R2 = 0.9893
The erosion rate can then be related to pressure drop, since
3.E-04 it is proportional to (Vp)n and ‘n’ is close to 2:
2.E-04 ∆P
Erosion rate ~ Vp 2 ~ (11)
1.E-04 N
The fluid velocity depends on the number of stages of OTHER VALVE-RELATED SYSTEMS
pressure reduction; specifically,
Fluid kinetic energy plays an important role in other valve-
∆P related systems as well. Two phenomena are discussed below:
Vf ~ (7) piping vibration and secondary break-up of sprays.
N
Piping vibration
Over short distances, such as those encountered in valves,
and for a given application, the particle velocity varies with the In the design of power plants and process systems, a
fluid velocity, i.e. number of factors are considered in sizing of the pipes. One of
the important considerations, especially when choosing the
Vp ~ Vf (8) smallest size possible, is the pressure drop that is permissible.
Another constraint that is commonly applied is a maximum
Again, for a given application, which means for the same velocity limit, which is driven by concerns regarding vibration,
amount of erodent through a valve, the erosion would be noise and erosion.
proportional to (Vp)n. Since ‘n’ is close to 2 and based on
Equation (8), However, there are many situations when pressure drop is
not a consideration; an example of this is bypass systems. In
such cases, the maximum velocity limits alone do not take into
Erosion rate ~ (Vf )2 (9) account the fluid density. It seems logical that density also
plays, or should play, a role when it comes to pipe vibration.
This relationship suggests that the erosion due to solids is Following the same line of reasoning similar to that for
roughly proportional to fluid kinetic energy of the flow carrying vibration due to unsteady forces in valves, it is intuitive that
these particles, if all other conditions remain the same. limiting the fluid kinetic energy (1/2 ρ V2) in the pipe can limit
the potential for piping vibration as well.
It is not possible to set generic limits on fluid kinetic
energy in the case of solid particle erosion because of strong Pittard et al (Reference 9] studied pipe vibrations and
dependencies on additional variables. Foremost among these is correlated it to Reynolds number; the flow was fully developed
the amount of solids, which varies over a very wide range. and turbulent in their experiments. Assuming that the
Then, the proportionality of particle velocity to fluid velocity is turbulence intensity (v’/V) is constant, which is nearly so for
dependant on the corresponding density ratio as well as details fully developed flows in pipes, their data correlate well with the
of the flow-path; also, the erosion material properties play an fluid kinetic energy based on mean velocity in the pipe
important role. Yet, the relationships are useful in comparing (1/2 ρ V2) as shown in Figure 10.
design options for a given service when many of these other
factors remain the same. This is possible by estimating the
A review of many different systems in operation suggests
connection, even on a relative basis, between the particle
that the piping vibration due to fluid turbulence is not a
velocity Vp and the pressure drop. problem when the magnitude of fluid kinetic energy is below
10 psi (68 kPa).