A Study of Turbulence Induced Forces Acting on a Globe

Control Valve Operating at Small Opening

A. Hassan1. and A. Sharara2

Abstract - Under certain opening conditions and partial opening of control valves, the piping
systems occasionally suffer large vibrations. To understand the valve instability that is responsible
for such vibrations, experiments and CFD simulations were performed. As a result of the study of
the turbulence flow through a single seat globe valve operating at small openings, it was found
that a complex three-dimensional flow structure (valve attached flow) sets up in the valve region
leading to high pressure variations in the valve trim region. CFD calculations showed how a jet
may impinge on the roof of the valve body and cause a large-scale recirculation region in the pipe
downstream of the valve. Moreover, it was found that the smaller valve opening, the larger the
exciting force acting on the valve stem. The harmful effect of the fluid flow forces (exciting forces)
is very much pronounced at relatively smaller valve opening. The simulation results for turbulent
flow with k   model were more accurate than the k   model. In addition, k   model was
simpler and faster in convergence than the k   model.

Keywords: Control valves – Turbulent – Simulation – Computational fluid dynamics.

I. Introduction attempt to avoid a host of valve problems, Miller [1]

Control valves are used to control volumetric flow
rates and keep the regulated process variable as close
as possible to the desired set point. One of the most
common types of control valves is the single seat globe
valve. It consists of three main components: body, trim
(which made up of the plug and seat), and actuator.
The trim of the control valve is responsible for the
inherent valve flow characteristics. Different flow
conditions require different shapes of the plug and seat
to achieve optimum flow control. In severe service
applications; control valves are equally crucial for
safely dissipating high process fluid energy levels to
avoid valve and piping damage from acoustic noise,
vibration, cavitations and erosion. To varying degrees,
all of these potentially damaging phenomena scale with
flow velocities in the valve and valve trim, leading
some valve manufactures to recommended specific
limits to fluid kinetic energy (K E) in the valve trim.
More recently, designers of fluid handling equipments
are using CFD simulation for product development
and optimization. In the present study, CFD has been
combined with experimental work to analyze the flow
through globe control valve with a flat-faced plug,
operating at small opening.
II. Literature Review
Despite of the importance of control valves, a little
research work has been published on control valve
design, especially for the globe control valves. In an
proposed applying valve trim maximum K E criteria
including component vibration, breaking parts,
excessive aerodynamic noise, trim and/or valve pitting
and erosion caused by liquid cavitations or flashing and
surface erosion by solid particulate. Based on
operational experience, Miller and Stratton [2]
presented an allowable trim K E limit for a given
control valve application that depends on the
application service conditions. The criterion involves
limits on the fluid K E existing from the valve’s trim.
They advocate a 485 kPa limit to a clean flowing
process fluid, but suggested a 275 kPa limit for
cavitating and multiphase trim flows. Hardin et al [3]
studied three different plug design cut off, concave and
hybrid to eliminate the flow-induced instability of
steam turbine control valves. They used a steady state
CFD model and found that the hybrid plug design is
the most convenient shape for the presented case.
Wojtkowiak and Oleśkowicz-Popiel [4] carried out
numerical and experimental investigation on the flow
characteristics of butterfly valves. Flow patterns and
pressure distribution in the disk vicinity were obtained.
The computational results, obtained from the standard
k-ε turbulence model, agree qualitatively with the
results of the experimental study. It is likely that more
sophisticated turbulence model will yield quantitatively
more accurate values. Using the FLUENT code, Kim
[5] investigated a three dimensional numerical
simulation to analyze an incompressible flow through
the partially-opened thin-flap disk butterfly valve.
Chern and Wang [6], conducted a 3D numerical
simulations and experiments were conducted to
observe the flow patterns and to measure performance
coefficients when V-ports with various angles were
used in a piping system. Three V-ports with angles 30
deg, 60 deg, and 90 deg were studied. It was found that
V-ports with angles 30 deg and 60 deg make the flow
rate proportional to the valve opening. However, V-
ports increase the pressure loss between the inlet and
the exit of a ball valve. Davis and Stewart [7] studied
the performance of a single seated globe valve by
applying Fluent CFD code. They showed that the
valve characteristics could be accurately predicted
using axisymetric flow models over most of the plug
travel. Hong et al [8] performed a numerical simulation
for the cavitating flow in hydraulic conical valves. The
structure of the valve was simplified as two
dimensional axisymmetric model. They found that the
cone shape have a considerable effect on the intensity
of the cavitation. Amirant et al [9] studied theoretically
flow forces on an open center directional control valve.
The results showed that the flow force increases with
increasing the flow rate. Oza et al [10] presented a
CFD model for a globe valve in oxygen applications.
They used both k   and k   models of turbulence
through the numerical computations. The simplified
axisymmetric model was used to predict the inherent
valve characteristic. Their results showed that the
k   turbulent model is more suitable for boundary
level flow.
In the present study, the fluid flow around a single
seat globe valve will be treated as a three-dimensional
flow to focus on the details of the flow variations in the
valve region. An experimental study and CFD
simulation are conducted to understand the cause of the
fluctuations. The fluid flow force acting on the valve
stem is measured and compared with the obtained
values from the numerical study to verify the numerical
model.
III. Experimental Facility
An experimental test rig was designed on the basis
of closed loop flow system. The test setup in Fig.1 is
driven by a 7.5 hp centrifugal pump and is capable of
providing 48 m 3 hr of water flow. The test rig
generates 400 kPa (4 bar) across the test valve at flow
rates up to 30 m³/hr. the rotational speed of the pump
may be adjusted via a frequency inverter to obtain a
desired value of the water flow rate. The test section is
situated at the fully developed flow area and the back
pressure can be controlled using a butterfly valve
downstream of the test section. A calibrated orifice
flow meter is used to measure the flow rate during the
experiments. Pressure transducers, which can
distinguish millisecond fluctuations, are mounted
upstream and downstream the globe valve to measure
the pressure fluctuations caused by the valve. The
upstream pressure P1 and downstream pressure P2 are
measured from static wall tapings located 5 pipe
diameter upstream and 11 pipe diameter downstream
of the valve. The mounting of the pressure transducers
needed special attention to avoid an influence to the
flow field [11]. The bonnet of the tested valve was
modified from a standard type (Fig.2-a) to an extended
type (Fig.2-b) which included an S-type load cell to
measure the flow net force acting on the valve and to
transmit it to the valve body. The sensing elements of
the load cell, those subjected to bending moments.
Bending elements offer high strain level at relatively
low force, which makes them ideal for low capacity
load cells. In the proposed design of the load cell, there
are two surfaces subjected to equal strains of opposite
sign. This offers convenient means for implementing a
full bridge circuit, while temperature compensation is
relatively easy. Bending as a measuring principle offers
excellent linearity of the S-type load cell, which was
used in the experiments to measure the flow net force.
Using CIO-EXP-GP signal conditioning board, the
time history signals have been collected and
transformed to DAS08-AO data acquisition card via a
37 pin connector cable.
III.1. Test Conditions
The hydraulic test and measurements have been
made at room temperature with flow rate up to
40 m3 / hr and a valve opening up to 40%. The
opening of the control valve was set using a dial gauge
indicator, which has a resolution of 0.01 mm. The
valve’s opening was 5, 10, 20, 30, and 40 %;
respectively, and the maximum valve travel was 23
mm. The maximum pump outlet pressure was 5.7 bar,
while the minimum back pressure of the valve was 0.3
bar.
III.2. Valve Characteristics
There are two important control valve parameters,
the overall flow coefficient Cv and the relative valve
capacity Cd . The flow coefficient Cv is a measure of
valve capacity. It is given by the ISA standard S75.01
[12] for incompressible, fully turbulent, noncavitating
and nonflashing flow as
Gf
C v  11.6 Q (1)
P
where G f is the specific gravity of the fluid. In the SI
system of units, the units of Cv are
((m3 / hr ) /(kPa )0.5 ) . Equation (1) is applicable to fully
turbulent flow field for which valve parameters
becomes independent of the Reynolds number. The
relative valve capacity factor Cd is a measure of the
 Tested Butterfly
Globe Valve
Valve
Entrance Pipe

Upstream Downstream Flexible

Pressure Pressure
Transducer Transducer
Joint

Water
Tank

Isolation Ball Valve

Flexible
Joint

Long
Radius Pump Filter Isolation Ball Valve
Orifice
Bend
Meter
(a) Outline of experimental apparatus

(b) Overhead view of the test loop

Fig. 1. The experimental test rig.

valve capacity relative to its nominal pipe size D p , it is
given by
Cv
Cd  (2)
(0.0394 D p ) 2
and has units of (m 3 / hr ) /(kPa ) 0.5 /(mm 2 ) . Values of
Cd do not normally exceed 11, see [7]. The inherent
valve characteristic is a plot of Cv versus percent
opening of the valve, which represents an indication
for how the flow rate will change with a change in
percent opening of the valve. The percent opening of
the valve is a measure of how far the plug is stroked
relative to its maximum stroke length. The flow
coefficient Cv is experimentally determined for
different valve openings or positions. For a constant
valve opening, ten test runs were made for turbulent
flows at high Reynolds numbers such that the flow
coefficient should remain constant, R e  1  10 5 . Runs
were made at levels of heavy cavitation were avoided
because of the effect of cavitation on Cv . The flow
coefficient was then calculated from the average of the
test runs at a constant valve opening, after excluding
the largest and smallest values. Valve position is
expressed in terms of percentage of full opening
 1- Valve Body
2- Seat
3- Plug
4- Stem
5- Bonnet
6- Side Rod
7- Load Cell
8- Lower Square Plate
9- Rigid Spacer
10- Nut
11- Side Guide
12- Upper Square Plate
13- Handle
14- Dial Gauge

(a) Standard (b) Modified

Fig. 2. Bonnet design of tested valve

(23 mm) . For the purpose of test repeatability, valve valve to a given position. The experimental results
opening was always set and measured by opening the illustrated in Fig.3 show the inherent valve
characteristic for the valve under investigation.
Accordingly, the test-valve was found to be of quick-
opening type.
Fig. 3. Inherent valve characteristics
IV. Dimensional Analysis
The flow force acting on the valve stem 'F' depends
upon the volume flow rate 'Q', the valve opening or
position 'l' , the valve diameter 'D', the upstream
pressure' P1 ', the pressure drop across the valve ' P ',
the viscosity of the fluid '  ', and mass density '  '. By
applying the Buckingham’s  -theorem, a
dimensionless expression for the flow force acting on
the valve stem may be obtained as follows,
 
F Q
2
 f  3 

(3)
P1 D  D P /(  D ) 
F The load cell had an error of 0.5 percent. Other
where is defined as the dimensionless exciting
P1 D 2
Q plug percent opening error was investigated
force Fd and is defined as the
D P /(  D )
3
dimensionless volume flow rate Qd . The experimental
results shown in Fig.4 show the variation of the
dimensionless exciting force with the dimensionless
volume flow rate. The test runs were made at high
Reynolds numbers and turbulent flow at different flow
rates and pressure drops. The dimensionless force ' Fd '
and the dimensionless volume flow rates were
calculated as the average of the test runs at a constant
valve position. The results show that the dimensionless
exciting force decreases as the valve opening increases,
see Fig.5. For small valve opening values, a little
change in the plug position yields to a significant
variation in the value of the exciting force which
means that the effectiveness of valve position becomes
very much pronounced for small values of valve
opening. Based on the experimental results an
approximating equation may be obtained as follows,
Fd  0.109049 log Q d  1.41356 (4)
Formula (4) was established with the least-square-error
technique of fit using the experimental data, and
automated curve fitting software.
Fig. 4. The variation of the dimensionless exciting
force with the dimensionless volume flow rate
V. Experimental Uncertainty
Experimental uncertainty in the present work has
several sources. The most obvious and easiest to
quantify is the error associated with the
instrumentation. This includes the pressure transducers,
the orifice flow meter, and load cell. The uncertainty
for pressure measurements was  0.1 percent. The
flow meter had an error of one percent of the reading.
sources of error in the study included the plug percent
opening and the errors caused by plug centering. The
experimentally using repeated measurements and
applying statistical arguments. The measurements were
taken using a dial indicator that gave an error of one
percent of the valve percent opening. The uncertainty
associated with plug percent opening error was
negligibly small. Centering the plug with equally
spaced was investigated. This was verified
experimentally by rotating the valve stem after the
setting of the valve opening, while taking
measurements in the load cell. The results showed that
the flow force acting on the plug (valve stem) could
vary by a maximum of 4 percent depending on the
valve opening percentage and the plug's rotation. The
experimental uncertainty changed with valve opening.
When calculated as a percent of the measured Cv , the
experimental uncertainty ranged from a minimum
value of 1.66 percent error to a maximum value of 7.21
percent error.
VI. Computational Fluid Dynamics (CFD)
Using FLUENT 6.3, a three dimensional model of
the valve body and connecting pipes shown in Fig.6 is
created to investigate the flow. The valve was modeled
with the plug positioned at different percent openings.
The converged flow field was used with Equation (1)
to calculate the valve Cv . Also, the converged pressure
was used to calculate the flow net force acting on the
valve stem.
Geometry: The fully dimensioned valve was modeled
and the plug and seat region was well represented.
Upstream of the seat, the inlet pipe length divided by
L
the valve diameter   was 5, and downstream of the
 D
seat, the outlet pipe length divided by the valve
diameter was 11.
Grid: The grid used in the numerical study was made
up of tetrahedral cells, the nodes of grid were clustered
in the plug and a seat region since this was the area of
largest flow gradients. In addition, an effort was made
to reduce the grid distortion. Fig 5-a shows an extended
view of the grid and Fig.5-b shows the expanded view
of the grid.
Boundary conditions: All solid boundaries were
represented as walls with no slip velocity conditions
and log well turbulence conditions. Inlet conditions
were represented by a uniform total pressure. The
treatment of pressure inlet boundary condition can be
described as a loss-free transition from stagnation
conditions to the inlet conditions. For incompressible
flows, this is accomplished by application of the
Bernoulli equation at the inlet boundary. The outlet
boundary conditions were set as a uniform static
pressure. The boundary conditions at inlet and outlet
sections of the domain of solution were obtained from
the laboratory experiments. Turbulence intensity and
turbulence length scale at the entrance cross section
were set as I  0.16 R e 1 8 and L  0.0175 d h [13],
where dh is the hydraulic diameter. Test cases were
run with 10 and 20 percent turbulence intensity, no
significant change in the predictions was observed.
Selection of turbulence model: The choice of
turbulent model depends on consideration such as the
physics encompassed in the flow, the established
practice for a specific class of problem, the level of
accuracy required, the available computational
resources, and the time available for the simulation.
Two equation turbulence models have become the
most popular, since they are relatively simple to
program and place much lower requirements on
computer resources than other more complex models
(Algebraic and Reynolds stress models). The k  
model relates the turbulence viscosity,  t (Pa s) , the
turbulence kinetic energy, k (m 2 s 2 ) , and the
turbulence dissipation rate,  (m 2 s3 ) . The k  
turbulence model is similar to the low Reynolds
number k   model, with  replacing  , which
represents the specific dissipation rate (s 1 ) .
Researchers have developed many turbulence models
provided results with major differences and
contradictions in some cases. The model used in this
study was the two-equation k   model. The Standard,
RNG, and Realizable k   models are investigated.
Other turbulence models (Standard and Shear Stress
Transport, SST k   ) were used in an attempt to
obtain the best convenient model for the present study.
All turbulence models were used with the standard
parameters.
Numerical accuracy: All conservation equations are
discretized in FLUENT using a finite volume
formulation with second order spatial accuracy. The
continuity is satisfied using a SIMPLE (semi-implicit
pressure linked equations) algorithm. Normalized
residuals were used for the convergence criteria, which
was set at three orders of magnitude.
The numerically tested valve was geometrically
similar to that applied in the experimental
investigations. It was assumed that the flow is three-
dimensional, steady, isothermal, turbulent, Newtonian
and incompressible. However, body forces have been
neglected. Water, at the room temperature, was applied
as the fluid passing through the valve. The flow was
governed by the system of mass and momentum
conservation equations. In turbulent flow region the
system of equations RANS (Reynolds Averaged
Navier-Stokes equations) was closed by the
introduction of the turbulence model.
(a) Extended view
(b) Close up view of grid
Fig. 5. Generated mesh for investigated geometry
 VII. Results and Discussions
The flow field was examined through the
interpretation of the post process data resulting from
the model solution. The results of the numerical study
are shown in Fig.6 through 11, and Fig.13 shows the
comparison of numerical and experimental results of
the inherent valve characteristics.
Flow field: The numerically obtained path line patterns
in a partially opened valve on the longitudinal mid
plane for 5, 10, 20, 30 and 40 percent openings are
illustrated in Fig.6. On the upstream surface of the plug
disk a stagnation region forms and outside of this
region, the flow direction is towards the edge of the
disk. In each case, the flow initially accelerates through
the plug and seat region and then flows downstream in
the form of a wall jet at the side of the valve body, and
at the open valve side. For valve opening up to
approximately 30%, flow separation from the plug with
a second recirculation zone occurs between the wall jet
and the plug surface. At valve opening greater than
30%, the results show that the flow remaining attached
to the plug surface, Fig.6-e. In addition, a large
recirculation region develops on the downstream side
of the plug at the closed valve body. As the valve
opening increases, flow separation from the valve body
with a recirculation zone between the jet and valve
body at outlet path of the flow occurs. A vena contracta
phenomenon and a hydrodynamic minimum flow area
down stream of the plug are observed. The jet flows
interact and mix downstream of the trim area and
sufficiently far from it the flow again occupies the
available flow area and approaches a fully developed
pipe flow.
Pressure contours: Fig.7 displays the numerically
modeled contours of the static pressure in a plane
placed close to the upstream surface of the plug. At
small opening value, the results show that the pressure
contours are radial relative to valve centerline, which
implies that the pressure field is primarily one
dimensional with the axial (stem) direction. As the
valve percent opening increases, the static pressure
contours become two dimensional and the gradients are
less confined to the gap between the plug and seat. In
each case, the pressure decreases in the downstream
direction with the largest pressure gradients occurring
in the plug and seat region. No significant pressure
changes are observed upstream of the seat and only
minor changes are observed downstream of the seat.
Fig.8 shows the variation of the static pressure along a
line in a longitudinal mid-plane placed close to
upstream surface of the plug. The pressure has a
maximum value corresponding to zero total velocity at
stagnant point, see Fig.9. At the plug edge the static
pressure has a minimum value while the velocity of the
fluid has a maximum value.
Fig. 6. Numerically obtained path line patterns
in a partially open valve.
 (a) (a)

(b)
(b)

(c) (c)

Fig. 7. Pressure contours at upstream plug surface. Fig. 8. Pressure distributions at upstream plug surface
(a) 5% opening (a) 5% opening
(b) 20% opening (b) 20% opening
(c) 40% opening (c) 40% opening
 (a) (a)

(b)
(b)

(c) (c)
Fig. 9. Velocity distributions at upstream plug Fig. 10. Turbulent Kinetic Energy contours.
surface. ( K-ω Turbulence Model.)
(a) 5% opening , (b) 20% opening (a) 5% opening, (b) 20 % opening
(c) 40% opening (c) 40% opening

Fig. 11. Comparison of flow forces for different Fig. 12. Comparison between experimental and
turbulent models. theoretical (CFD) values of flow force.
Turbulent kinetic energy: The constant contours for
turbulence energy are shown in Fig.10. The separated
regions of the flow where shear layers exist have the
highest magnitudes of the turbulence kinetic energy 'k'.
The magnitude of the turbulence kinetic energy in the
plug and seat region of the valve is high, this is due to
creation of large shear layer as the flow is squeezed
through this region.
Exciting force: The fluid flow forces acting on the
valve stem were obtained using different turbulent
models, as shown in Fig.11. It was noticed that no odd
discrepancy neither in the pattern nor the values of the
flow forces, for all investigated openings. Moreover,
the flow forces, computed by the k   (SST) model
for different valve's openings (5-40 %), have the less
percent of deviation with experimental results,
compared with other turbulent models. Fig.12 shows
the comparison between the experimental results and
the numerical results. The maximum percentage of
deviation was 12.81% at 40% valve opening.
VII. Conclusions
Under completion of the study, the following
conclusions are withdrawn,
1- The flow field was examined and the results show
that the valve geometry has a significant impact on
the turbulent flow passing through the valve. The
results are in good agreement with those obtained
by many researchers as pointed in [7] and [15].
2- Under the partial opening (greater than 5 %)
condition, a complex three-dimensional (3D) flow
structure set up in the valve region leading to high
pressure variations in the valve trim region.
3- The fluid flow forces that acting on the plug and
stem depends on the valve opening percentage. It
was found that the smaller valve opening, the larger
the exciting force acting on the valve stem. The
harmful effect of the fluid flow forces (exciting
forces) is very much pronounced at relatively
smaller valve opening.
4- The simulation results for turbulent flow with
k   model were more accurate than the k  
model. Moreover, k   model was simpler and
faster in convergence than the k   model. These
results are in agreement with those obtained by [10].
References
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Control Valves: Practical Guides for Measurement and control.
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Carolina
[2] Miller H., and Stratton L., 1997, " Fluid Kinetic Enrgy as a
Selection Criteria for Control Valves", ASME Fluids
Engineering Division Summer Meeting.
[3] Hardin J., Kushner F. and Koester F., 2003, "Elimination of
Flow-Induced Instability From Steam Turbine Control
Valves", Proceeding of the Thirty-Two Turbomachinery
Symposium.
[4] Wojtkowiak J., and Oleśkowicz-Popiel C,.2006,"Investigations
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Civil and Environmental Engineering, V.7, ISSN 1642-9303
[5] Kim R. H., and Huang C., 1993, "3-D Analysis Butterfly
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[6] Chern M., and Wang C., 2004, " Control of Volumetric Flow-
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[7] Davis J., and Stewart M., 2002," Predicting Control Valve
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[8] Hong G., Xin F., and Huayong Y., 2000, "Numerical
Simulation Of Cavitating Flow In Hydraulic Conical Valve" ,
A project supported by SRF for ROCS, SEM and National
Natural Science Foundation of China (59835160).
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Evaluation of the Flow Forces on an open Center Directional
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of Globe Valves for Oxygen Application", Proceeding of the
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[11] Au-Yang MK, Jordan KB, Nucl Eng Dec.1980,"Dynamic
pressure inside a PWR-a study based on laboratory and field
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[12] Research Triangle Park, North Carolina: Instrument Society of
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Equations",
[13] Fluent 6.3 User's Guide, Fluent Inc. 2005.
[14] Launder B. E. and Spalding D. B., 1972,"Mathematical
Models of Turbulence", London, Academic Press.
[15] Bernard, S., Muntean, S., Susan-Resiga, R. and Anton, L.,
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Acknowledgements
The authors want to express their great thanks and sincere gratitude
for both Prof. Zakria Ghoneim (Mechanical Engineering Department,
Faculty of Engineering, Ain Shams University) and Prof. El-Sayed
Saber (Mechanical Engineering Department, College of Engineering,
AASTMT) for their continuous guidance and help during the
execution of the present research work.
Authors’ information
1
Amr Hassan was birthed on 21-07-1966. A
master degree in mechanical engineering was
obtained in 1994 from faculty of engineering,
Alexandria University – Egypt. A PhD was
obtained in 2002 from School of Mechanical,
Materials, Manufacturing Engineering and
Management, University of Nottingham,
Nottingham, UK.
He conducted previous research studies in the fields of windshield
defrosting and demisting in automotive. He is now interested in the
using computational fluid dynamics in flow simulation.
Dr. Amr is member of Society of Automotive Engineers, SAE and
IMarEST (The Institute of Marine Engineering, Science and
Technology)
2
Ashraf Sharara was birthed on 05-01-1970.
A master degree in mechanical engineering
was obtained in 1997 from faculty of
engineering, Alexandria University – Egypt.
Currently , a PhD student at faculty of
engineering, Ain Shams University – Egypt.
He conducted previous research studies in the fields of applied
mechanics. He is now interested in studying the phenomenon of flow
induced vibration in fluid valves.