4/5/2017 Cavitation in Restriction Orifices and Valves – Neutrium

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CAVITATION IN RESTRICTION ORIFICES AND VALVES

SUMMARY
Restriction orifices and control valves are commonly used for pressure
reduction and measurement of flow rates, however for a liquid system,
excessive pressure drop across these items of equipment may result in
cavitation. This article describes methods of predicting cavitation across
restriction orifices and valves and proposes designs which may be used to
avoid cavitation.

1. DEFINITIONS

Ci : Cavitation Index (often σ)

P1 : Upstream Pressure (absolute)
P2 : Downstream Pressure (absolute)

Pv : Fluid Vapour Pressure

ΔPp : Permanent Pressure Loss
ΔPr : Recoverable Pressure Loss

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2. INTRODUCTION
Cavitation occurs in liquid systems and is the result of rapid formation and
collapse of vapour bubbles in the liquid. Cavitation must be avoided or
controlled as the collapse of vapour bubbles releases significant energy at the
location of the bubble collapse. The consequences of this energy release are
typically loud noise and pitting damage to contact surfaces, which over time
may result in significant damage to or failure of equipment such as pumps or
valves.

Cavitation occurs at a region where the pressure is lower than the fluid
vapour pressure, such as the pump suction, or where a large pressure
reduction takes place. In this article we consider control valves and restriction
orifices, which are commonly used as pressure reduction steps in a liquid
system.

Cavitation may occur in a pressure reduction system even if the final system
pressure is the above vapour pressure of the liquid. This is because the
intermediate pressures may fall below the final pressure.

In the case of a simple concentric restriction orifice the fluid is accelerated as

it passes through the orifice, reaching the maximum velocity a short distance
downstream of the orifice itself (the Vena Contracta). The increase in velocity
comes at the expense of fluid pressure resulting in low pressures in the Vena
Contracta. Downstream of the Vena Contracta in the recovery zone, the fluid

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decelerates converting excess kinetic energy into pressure energy as it slows.

Therefore the intermediate pressure in the Vena Contracta is lower than the
final system pressure and thus the highest chance of experiencing cavitation
as demonstrated in the figures below.

It is difficult or often impossible to measure the lowest pressure of the system,

for example in the Vena Contracta, particularly for complex designs of control
valves. Additionally, variability in flow stability, system vibration and other
external factors can all influence the whether cavitation occurs.

Due to the difficulty in predicting or measuring the systems lowest pressure

equipment may be placed in a test rig where the cavitation through the device
may be characterised in terms of a Cavitation Index.

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3. PREDICTING CAVITATION AND THE CAVITATION INDEX

The cavitation index is the ratio of the pressure differential between the
equipment inlet pressure and the fluid vapour pressure to the pressure
differential pressure across the equipment. The equation for calculating the
cavitation index is shown below:

P1 − Pv
Ci =
P1 − P2

The above equation allows the cavitation index for a particular device and
application to be determined. The value of Ci above is compared against

acceptable values for particular equipment and applications to indicate the

likelihood of cavitation occurring. For example in the case of a typical square-
edged concentric orifice plate a Ci of 2 or above would be unlikely to cause

cavitation, whereas values below 2 would indicate cavitation or incipient

cavitation are likely.

The cavitation index is a heuristic method for analysis of restriction orifice

plates and valves, and the acceptable Ci will depend on the several factors

including, flow stability, piping geometry near the orifice and the particulars
of the orifice design. Some typical Ci values for restriction orifice and valves

are presented in the table below:

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Ci Ci
Restriction Type
Typical Range

Square-edged Concentric 2 1.8 - 6

Multi-hole orifice plate - 1.2 - 4

Globe Valve 2 1.7 - 2.0

Globe Valve with anti-cavitation trim - 1.2 - 1.7

Globe Valve with multi-stage anti-cavitation control trim - 1 - 1.3

Butterfly Valve 4 >2.5

Ball Valve 3.5 -

4. AVOIDING CAVITATION
Avoiding cavitation for pressure reduction in liquid is achieved in one of three
ways: multiple steps, tortuous paths, or controlled cavitation. Alternatively
designers may choose to accept some cavitation and use hardened trim control
valves. Each method has pros and cons, such as turn-down, costs, minimum Ci

achievable and physical size of equipment.

4.1 Multiple Steps

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4.1 Multiple Steps

Multiple step reductions may involve multiple restriction orifices, control
valves or combinations of both. A typical set up may include a control valve
with a restriction orifice downstream. The restriction orifice then provides the
back pressure on the control valve to prevent cavitation through the valve.
However the restriction orifice itself must also be correctly sized to prevent
cavitation.

The advantage of this arrangement is that it is relatively cheap, particularly if

multiple restriction orifices are used in series. Disadvantages of this
arrangement are a larger physical size and poor turn-down performance,
particularly for orifice only arrangements.

4.2 Controlled Cavitation

Controlled cavitation arrangements generally work by allowing cavitation to
occur and controlling the location of the cavitation. This may be achieved via

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a control valve which directs jets of fluid at each other, allowing them to
combine and cavitate away from the metal surfaces of the valves.

The disadvantages of this design are that narrow pathways are normally used
and they will be susceptible to plugging. Additionally these valves are not
suitable for use in systems with very low Ci values.

4.3 Tortuous Path

Tortuous path control elements may use a variety of designs such as zig-zags,
bends, etc., to reduce the pressure of the fluid over a longer path and thereby
reduce the likely hood of cavitation. The long path allows the pressure loss
and recovery steps to be essentially simultaneous, removing the pressure dip
of the vena contracta.

Tortuous path arrangements can achieve very low Ci values, with some

manufacturers advertising values as low as 1.001. This allows for a single

compact valve to perform large pressure reductions steps.

The disadvantages of this technology are plugging and cost. The small
pathways of the valve are susceptible to plugging unless the fluid is clean.
Complicated manufacture and proprietary design mean these valves will also
have a relatively high cost.

4.4 Hardened Trim

Using hardened trim control valves does not attempt to avoid cavitation, but
instead attempts to provide equipment better protected against the damage
resulting from cavitation. This may be suitable for situations where cavitation

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is infrequent or very mild. It is not usually suitable for sustained or violent

cavitation as even hardened trim valves will be rapidly damaged in these
situations. Furthermore the use of these control valves will not mitigate any
other symptoms of cavitation such as noise and vibration.

Using this type of valve may be appropriate where fluid is fouling (preventing
the use of tortuous path designs) and turn-down or space considerations
prevent the use of a multiple stage pressure reduction.

5. FURTHER READING
1. Flow Measurement Engineering Handbook

2. Instrument Engineers' Handbook, Vol. 1: Process Measurement and

Analysis

3. Valve Handbook 3rd Edition

Article Created: August 17, 2012    

ARTICLE TAGS

Cavitation Control Valve Flow Orifice Fluid Flow Pressure Drop

Pressure Loss Restriction Orifice Vapour Pressure Vena Contracta

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