Usage of equivalent Cv equation and porous media in Cv calculation of a control valve using CFD

ABSTRACT When two components are in series, its equivalent Cv is calculated using standard equivalent Cv equation. In case of a control valve, trim and gallery are connected in series. Using CFD simulation, Cv is calculated for individual component and overall Cv is calculated using equivalent Cv equation. For validation, overall Cv of the system is also computed directly using CFD simulation. It is found that equivalent Cv equation is not predicting correct Cv of control valve. This paper explains the reason for discrepancy in Cv calculation using equivalent Cv equation. Calculating Cv of the overall system directly using CFD technique could be extremely cumbersome particularly when a trim has hundreds of individual flow paths. DRAG trim patented by Control Component Inc and TIGER TOOTH trim developed by Flowserve International could have as many as hundreds of flow channels with multiple turns in a single valve. Concept of porous media is used for reducing computational effort. This concept reduces cell size by 1/3 to 1/8 times depending on the number of turns in the flow channel. Keywords: CFD (computational Fluid dynamics), Porous media, equivalent Cv equation, control valves, DRAG disc Nomenclature Cv = flow capacity of the system Cv1 = flow capacity of sub-system 1 Cv2 = flow capacity of sub-system 2 = density Introduction In valve industry, flow capacity (Cv) is used for sizing control valves. Every company has its own in-house tool for calculating Cv of a control valve. These are empirical correlation developed over time based on experience. It is not yet an established practice in this industry to calculate flow capacity for every single valve at design stage using CAE tools like computational Fluid Dynamics (CFD) simulation. Part of the reason is time taken for such simulations. Some times it is not at all feasible to perform CFD simulation as mesh size could go in millions and simulation time will be in months! Fig-1 shows a typical DRAG disc stack of a valve developed by CCI for severe service application. A disc stack consists of many drag disc stacked together. Fig-2 shows an 8T EDM disc. As shown in figure, there are many flow channels with multiple turns in DRAG disc depending on its application and

flow capacity. Resolving flow through these channels in CFD simulation will be extremely difficult and mesh size could go in millions.

equal to Cv of one channel multiplied by number of channels in the trim. Calculating Cv of individual flow channel in isolation through CFD simulation is a simple task. Similarly Cv of valve gallery is calculated with CFD simulation. Now Cv of valve disc stack and valve gallery are known. Using Equation-1, overall Cv of control valve is computed assuming that valve disc stack and gallery are in series connection (computed as per ISA handbook).

Fig-1: Typical drag disc stack To overcome above mentioned difficulties, a new approach in CFD simulation is explored. ISA hand book for control valve provides following equation to calculate valve Cv when Cv of individual sub-systems are known:
1 1 1 = + 2 2 2 Cv Cv1 Cv

(1)

Where, Cv = Overall flow capacity Cv1 = Flow capacity of first sub-system Cv2 = Flow capacity of second subsystem. Equation 1 assumes that sub-systems are connected in series. It is a generic equation. Using equation-1, it is possible to calculate overall valve Cv with disc stack of multiple flow paths. First calculate Cv of disc stack. Valve disc consists of many flow channels of smaller cross sectional area as shown in Fig-2. These channels are in parallel. Hence Cv of overall disc is Fig-2: A drag disc To validate this approach, overall Cv is directly computed using CFD simulation when disc stack and gallery are assembled. Cv values should be equal in both the cases. But it is not happening. Calculated Cv using equation-1 is significantly higher than actual Cv of overall valve. Trim and gallery are interacting when they are assembled which leads to overall lower Cv for the system than expected. Hence Eqn-1 can

not be used as a general reliable method for computing valve Cv. Interaction phenomenon must be captured in Cv calculation. This necessitates simulation of flow through overall system (when trim and gallery are assembled) capturing interaction phenomenon if any to get correct Cv value. As discuss earlier, it is not practical all the time. Concept of porous media is widely used in simulation simulating flow through highly resistant media like sand, etc. Simulation of hot gases through catalytic converter is a typical example of flow though porous media. As theory suggests, pressure drop of any magnitude can be produced in very small distance when porous media exists. This concept is applied in current simulation to reduce mesh size or computational effort. Flow channels have multiple turns from inlet to outlet as shown in Fig-2. An equivalent channel is created with only two turns with porous media defined in the inlet region. Properties of the porous media are adjusted to create required pressure drop which exists in original channel. Hence Cv of equivalent channel with two turns matches with Cv of original channel with multiple turns. Care has been taken in creating equivalent channel to have similar flow pattern at channel outlet so that its overall interaction with gallery does not change. When equivalent channels are assembled with gallery, overall Cv does not change (as it is with original channel). This shows the concept is validate and it can be used in Cv calculation. This alternate approach is reducing computational effort significantly.

CFD Simulation Hex mesh with good mesh refinement is used for simulation. ICEMCFD software is used for meshing computational domain. CFX is used as CFD solver. SST turbulence model is used in simulation. From simulation, pressure drop across inlet and outlet is measure along with flow rate. Flow capacity is calculated using standard equation:
Cv = Q dP

(2)

Where, Q = Flow rate in Gallon per minute dP = Pressure drop in Psi Fig-3 shows CFD model of an individual channel in isolation. Pressure drop is measured across inlet and outlet of the channel

Fig-3: CFD model of 8T EDM disc channel Fig-4 shows CFD model of gallery region in isolation. Outlet of individual channels on drag disc becomes inlet boundary when flow simulation is performed for gallery as shown below.

Fig-4: CFD model of gallery region

Fig-5 shows CFD model when drag disc is assembled with gallery. Nonconformal mesh is used at interface of drag disc and gallery.

Fig-5: CFD model of overall system Advantage of symmetric boundary condition is used for modeling half section only. Results Cv calculation using formula Cv calculation using concept of porous media Conclusion

Reference: