Wear indicator device for flow control valve

Abstract

A flow control device includes a valve body with an inlet, an outlet, and a flow path connecting the inlet and the outlet. Flow vanes are coupled to the valve body and disposed in the flow path to divide the fluid flow through the valve body. The flow vanes have a first surface, a second surface, and corrugations formed on at least one of the first and second surfaces. A control element is disposed in the flow path and movable within the valve body between an open position and a closed position.

Description

Technical Field

[0001] This disclosure generally relates to flow control valves, and more specifically, to flow vanes of flow control valves. Background Technology

[0002] In some control valves, undesirable noise is generated by undulating pressure waves caused by the fluid flowing through the valve. For example, hydrodynamic noise can be caused by cavitation, which is the formation and rupture of vapor chambers in a flow subjected to rapid pressure changes. When vapor chambers in the fluid are subjected to higher pressures, they burst and generate strong shock waves, which can damage internal parts of the valve or produce audible noise. Damage from cavitation occurs gradually, and if detected early, valve components can be replaced to prevent leaks and / or valve failure. Summary of the Invention

[0003] According to a first exemplary aspect, a flow control device may include a valve body having an inlet, an outlet, and a flow path connecting the inlet and the outlet. Flow vanes may be coupled to the valve body and disposed in the flow path to divide fluid flow through the valve body. The flow vanes may have a first surface, a second surface, and corrugations formed on at least one of the first and second surfaces. A control element may be disposed in the flow path and movable within the valve body between an open position and a closed position.

[0004] According to a second exemplary aspect, a valve body may include an inlet, an outlet, and a flow path connecting the inlet and the outlet. A valve port may be disposed between the inlet and the outlet. An outlet channel may connect the valve port and the outlet. A flow vane may be coupled to the valve body and disposed in the outlet channel. The flow vane may be corrugated, the corrugation being disposed at a first end of the flow vane.

[0005] According to a third exemplary aspect, a method for determining wear due to cavitation may include: providing a flow control device having a valve body having an inlet, an outlet, and a flow path connecting the inlet and the outlet. A control element may be disposed in the flow path and movable within the valve body between an open position and a closed position. A flow vane may be coupled to the valve body and disposed in the flow path to divide fluid flow through the valve body. The flow vane may have a first surface, a second surface, and corrugations formed on at least one of the first surface and the second surface. The method may include: measuring the size of the flow vane at a location along the length of the flow vane; and comparing a first measurement and a second measurement of the size of the flow vane obtained at the location. Finally, the method may include: determining wear of the flow vane based on a comparison of the first and second measurements of the size.

[0006] Further, according to any one or more of the first, second or third aspects mentioned above, the flow control device, valve body, or method for determining wear can include one or more of the following preferred forms.

[0007] In a preferred embodiment, the flow vane may be disposed between the control element and the outlet.

[0008] In a preferred embodiment, the corrugations may include ridges arranged parallel to the flow direction.

[0009] In a preferred embodiment, the corrugations may include ridges that are arranged perpendicular to the flow direction.

[0010] In a preferred embodiment, the ripples may include raised peaks.

[0011] In a preferred embodiment, the corrugations may include indentations.

[0012] In a preferred embodiment, the flow vane may be integrally formed with the valve body.

[0013] In a preferred embodiment, the flow vanes can be removably coupled to the valve body.

[0014] In a preferred embodiment, an ultrasonic transducer may be coupled to the valve body and configured to measure the thickness of the flow blades.

[0015] In a preferred embodiment, the sensor may be coupled to the control element to measure the distance between the control element and the first end of the flow blade.

[0016] In a preferred embodiment, the corrugations may include a plurality of raised bumps.

[0017] In a preferred embodiment, the corrugations may be formed on the first and second surfaces of the flow blades.

[0018] In a preferred embodiment, the flow vane may be integrally formed with the valve body.

[0019] In a preferred embodiment, the flow vanes can be removably coupled to the valve body.

[0020] In a preferred embodiment, an array of sensors may be coupled to the valve body and configured to measure the thickness of the flow blades.

[0021] In a preferred embodiment, each sensor may be arranged along the length of the flow blade.

[0022] In a preferred embodiment, the sensor may be coupled to the flow blade to measure the thickness of the flow blade.

[0023] In a preferred embodiment, the sensor can be coupled to the flow blade to measure wear on the flow blade.

[0024] In a preferred embodiment, measuring the thickness may include using an ultrasonic transducer to measure the thickness of the flow blade at the location. Attached Figure Description

[0025] Figure 1 This is a side sectional view of a first exemplary flow control valve assembled in accordance with the teachings of this disclosure, having a first exemplary valve body and flow vanes.

[0026] Figure 2 yes Figure 1 A perspective sectional view of the valve body and flow vanes of a flow control valve.

[0027] Figure 3 This is a perspective cross-sectional view of a second exemplary valve body and flow vanes of a flow control valve assembled in accordance with the teachings of this disclosure.

[0028] Figure 4 This is a perspective sectional view of a third exemplary valve body and flow vanes of a flow control valve assembled in accordance with the teachings of this disclosure.

[0029] Figure 5 This is a perspective cross-sectional view of a fourth exemplary valve body and flow vanes of a flow control valve assembled in accordance with the teachings of this disclosure.

[0030] Figure 6This is a side sectional view of a fifth exemplary valve body and flow vanes of a flow control valve assembled in accordance with the teachings of this disclosure; and

[0031] Figure 7 This is a top cross-sectional view of a second exemplary flow control valve assembled in accordance with the teachings of this disclosure, having a fifth exemplary valve body and flow vanes. Detailed Implementation

[0032] This disclosure provides detection equipment and methods for detecting wear caused by cavitation or corrosion on flow control valve components. Figure 1 In this context, a first exemplary flow control device 10 is constructed to indicate wear caused by cavitation, based on the teachings of this disclosure. The flow control device 10 is a sliding rod type control valve (e.g., The HP series valve includes a ball valve body 14 that defines an inlet 18, an outlet 22, and a flow path 26 connecting the inlet 18 and the outlet 22. The valve body 14 includes a valve port 30 defined between the inlet 18 and the outlet 22, an inlet passage 34, an outlet passage 38, and a flow vane 42. The inlet passage 34 connects the inlet 18 to the valve port 30, and the outlet passage 38 connects the valve port 30 to the outlet 22.

[0033] A control element 46 is disposed in the flow path 26 and is movable between an open and closed position relative to a valve port 30 in the valve body 14 to control the flow of fluid through the valve 10. The fluid may be a gas (e.g., air, natural gas) or a liquid (e.g., water, liquefied natural gas). The control element 46 includes a valve plug 47 connected to a valve stem 48. The valve stem 48 extends through a valve cover 49 beyond the valve body 14 and may be connected to an actuator that positions the control element 46, and more specifically, positions the valve plug 47 relative to the flow path 26, to regulate the flow of fluid through the control valve 10. In other examples, the control valve 10 may be a different type of control valve, such as an upward flow valve, a rotary control valve (e.g., Vee-Ball TM V150 valve, Vee-Ball TM (e.g., V300 valve), throttle valve, isolation valve, or other control valve. Furthermore, components of the control valve 10 (e.g., valve body 14, control element 46, and valve cover 49) may differ from those depicted herein. For example, the inlet 18, outlet 22, and the fluid flow path 26 extending between them may vary in shape and / or size and still perform the intended function.

[0034] In the example shown, the control valve 10 is a downward flow valve, and a flow vane 42 is disposed in an outlet passage 38 between the control element 46 and the outlet 22. The flow vane 42 is coupled to the valve body 14 and disposed in the flow path 26 to divide the fluid flow through the valve body 14. The flow vane 42 has a first surface 50 and a second surface 54 and extends in the flow direction (as indicated by the arrows) between a first end 58 and a second end 62. The first end 58 of the flow vane 42 is located near the valve port 30 (i.e., directly downstream of the valve port 30), and the second end 62 of the flow vane 42 is located downstream of the first end 58. The flow vane 42 is attached to the wall 66 of the valve body 14 to divide the flow path 26, and more specifically, to divide the outlet passage 38, such that fluid flows on either side of the first and second surfaces 50, 54 of the flow vane 42. The flow vane 42 may be integrally formed with the valve body 14, separately formed from the valve body 14, and then permanently attached to the valve body 14, for example, by welding the vane 42 to the valve body wall 66, removably coupled to the valve body 14, and / or cast or formed by additive manufacturing. The expressions “coupled” and “connected” and their derivatives may be used to describe some embodiments. For example, the term “coupled” may be used to describe some embodiments to indicate that two or more elements are in direct physical or electrical contact. However, the term “coupled” may also mean that two or more elements are not in direct contact with each other, but still cooperate or interact with each other. The embodiments are not limited to this context.

[0035] Flow vanes 42 are used to divide and guide fluid flow through control valve 10. By dividing the fluid flow into multiple channels, as indicated by the flow arrows, flow vanes 14 prevent momentum from forcing the fluid flow along one side of the flow path instead of the other. Notably, flow vanes 14 help increase flow distribution across flow path 26, thereby increasing fluid flow through control valve 10. Flow vanes 42 also improve the pressure distribution around the circumference of valve internals 70, thus providing a more stable and controlled flow through valve 10.

[0036] Go to Figure 2 A perspective view of the valve body 14 and flow vane 42 is shown in more detail. The flow vane 42 has corrugations 74, which provide a physical indication of the wear effects caused by cavitation. In the presence of cavitating fluid, the corrugations 74 deteriorate, thus visibly changing in size (e.g., shape and size). In this example, the corrugations 74 take the form of a plurality of ridges 74 formed on the first surface 50. However, in other examples, the corrugations 74 may include a single ridge. The plurality of ridges 74 are equidistant from each other and relative to the flow direction (e.g., ...). Figure 1The ridge 74 is arranged parallel to the flow direction (as indicated by the arrow in the diagram). It extends from the first end 58 of the flow blade 42 to the second end 62. However, in other examples, the ridge 74 may extend partially and / or intermittently from the first end 58 of the flow blade to the second end 62. The corrugations 74 may be integrally formed with the first surface 50 of the flow blade 42, or in other examples, the corrugations 74 may be fixedly attached to the first surface 50 and / or the second surface 54. Although in this example the ridge 74 is parallel to the flow direction, in other examples the ridge 74 may be angled relative to the flow direction. The corrugations 74 may be machined, cast together with the flow blade 42, formed by additive manufacturing, or formed separately from the flow blade 42 and then welded or otherwise fixedly attached to one or more surfaces 50, 54 of the flow blade 42.

[0037] The operator can visually inspect the corrugations 74 for any changes to estimate the impact of cavitation on the valve body 14. To inspect the flow vanes 42, the operator can remove the valve cover 49 and control element 46 from the valve body 14 to expose the flow vanes 42 through the valve port 30. The flow vanes 42 can serve as a gauge of wear and can indicate to the operator when the valve body 14 or certain valve components need replacement. The ridges 74 can indicate wear by changes in dimensions (e.g., width, height) or shape (e.g., round, angular, sharp, etc.) compared to their original size and shape. For example, the ridges 74 may initially have sharp peaks, such that each ridge 74 has a triangular cross-section. Wear can be indicated by the rounding of the peaks or by changes in height measured from the first surface 50 of the flow vanes 42. In some cases, wear or damage to the corrugations 74 does not affect fluid flow but can indicate wear in other areas of the valve body 14 where cavitation occurs. The flow vanes 42 can also be used as a gauge to determine the flow conditions present in the valve 10. For example, damage can be identified in different forms, such as corrosion, flashing, or cavitation, and any of these forms of damage will indicate the type of flow condition currently causing damage and / or wear.

[0038] In addition to (or replacing) ripple 74, such as Figure 1 As shown, one or more sensors 51, 52 can be used in the control valve to determine damage caused by cavitation. For example, laser displacement sensor 51 can be integrally mounted in the valve plug 47 of control element 46, and / or sensor 52 can be mounted in valve stem 49. Sensors 51, 52 are configured to measure the distance from control element 46 (in the closed position) to the first end 58 of blade 42. A change in distance will indicate that the gap between control element 46 and flow blade 42 has widened, thus indicating damage to flow blade 42. Sensors 51, 52 can be coupled to a digital valve controller to automatically monitor this gap.

[0039] Go to Figure 3 The second exemplary flow vane 142 and valve body 114 are constructed according to the teachings of this disclosure. The second exemplary flow vane 142 and valve body 114 are similar to the first exemplary flow vane 42 and valve body 14, respectively, except that the surface treatment or corrugation 174 of the second exemplary flow vane 142 differs from the corrugation 74 of the first exemplary flow vane 42. Elements of the second exemplary flow vane 142 and valve body 114 that are similar to those of the first exemplary flow vane 42 and valve body 14 are indicated by the same reference numerals numbered 100. For the sake of brevity, descriptions of many of these elements are simplified or even omitted. The flow vane 142 and valve body 114 can be, for example, Figure 1 The control valve part, such as control valve 10.

[0040] In this example, the flow blade 142 has a shape formed on the first surface 150 and relative to the flow direction (e.g., Figure 1 (As indicated by the arrow in the image) A series of vertically arranged ridges 174 form a corrugation 174. The ridges 174 have sharp peaks, which become smoother over time, allowing the operator to easily determine the severity of wear on the valve body 114 or other valve components due to cavitation. In other examples, the ridges 174 may have rounded peaks or peaks of different shapes.

[0041] exist Figure 4 In this disclosure, a third exemplary flow vane 242 and valve body 214 are constructed in accordance with the teachings of this disclosure. The third exemplary flow vane 242 and valve body 214 are similar to the second exemplary flow vane 142 and valve body 114, respectively, except that the surface treatment or corrugations 274, 276 of the third exemplary flow vane 242 differ from the corrugation 174 of the second exemplary flow vane 142. Specifically, a first set of ridges 274 is formed on the first surface 250 of the flow vane 242, and a second set of ridges 276 is formed on the second surface 254 of the flow vane 242. Elements of the third exemplary flow vane 242 and valve body 214 that are similar to those of the second exemplary flow vane 142 and valve body 114 are indicated by the same reference numerals incremented by 100. For the sake of brevity, descriptions of many of these elements are simplified or even omitted.

[0042] In this example, the corrugations 274 and 276 of the flow blade 242 are formed on both the first surface 250 and the second surface 250, and the ridges 274 and 276 are relative to the flow direction (e.g., Figure 1(As indicated by the arrow in the diagram) They are set vertically. Ridges 274 and 276 have sharp peaks that become smoother over time, allowing the operator to easily determine the severity of wear on valve body 214 or other valve components due to cavitation. In other examples, ridges 274 and 275 may have rounded peaks or peaks of different shapes, and corrugations 274 and 276 may extend completely or partially on one or both of the surfaces 250 and 254 of the flow vane 242.

[0043] exist Figure 5 In this disclosure, a fourth exemplary flow vane 342 and valve body 314 are constructed in accordance with the teachings of this disclosure. The fourth exemplary flow vane 342 and valve body 314 are similar to the third exemplary flow vane 242 and valve body 214, respectively, except that the surface treatment or corrugations 374, 376 of the fourth exemplary flow vane 342 differ from the corrugations 274, 276 of the third exemplary flow vane 242. Elements of the fourth exemplary flow vane 342 and valve body 314 that are similar to those of the third exemplary flow vane 242 and valve body 214 are indicated by the same reference numerals incremented by 100. For the sake of brevity, descriptions of many of these elements are simplified or even omitted.

[0044] The corrugations 374 of the flow blade 342 are defined by a plurality of grooves and / or ridges forming a grid. On the first surface 350 of the flow blade 342, the plurality of grooves are positioned relative to the flow direction (e.g., Figure 1 The corrugations 376 are arranged parallel and perpendicular to each other (as indicated by the arrows in the diagram). Between the parallel and perpendicular grooves, multiple peaks or raised protrusions are formed in the grid. On the second surface 354, the grid lines of the corrugations 376 are defined by ridges arranged parallel and perpendicular to the flow direction, such that the grid of recesses 376 or pits is formed on the flow blades 342. Although the example shown depicts a grid of peaks 374 on the first surface 350 and a grid of recesses 376 on the second surface 354, in other examples, peaks 374 may be formed on the second surface 354, and recesses 376 may be formed on the first surface 350. Furthermore, the corrugations 374, 376 can be constructed in patterns other than rows and columns to form the grid, and may include a recess, a protrusion, or a combination of recesses or protrusions, and may completely or partially cover one or more of the first surface 350 and the second surface 354.

[0045] Now go to Figure 6 The second exemplary control valve 410 is constructed according to the teachings of this disclosure. The control valve 410 is similar to the first exemplary control valve 10, except that the second exemplary control valve 410 is an upward-flow control valve 410 and the fifth exemplary flow vane 442 is disposed in the inlet channel 434 instead of the outlet channel 438, for example... Figure 1The first exemplary control valve 10. Wear on the flow vanes 442 of the upward-flowing valve 410 can indicate damage caused by corrosion (e.g., in sludge or wet steam services).

[0046] The flow vane 442 has a first end 458 and a second end 462, the first end 458 being located proximal to the valve port 430 (i.e., directly upstream relative to the valve port 430), and the second end 462 being located upstream relative to the first end 458. For wear due to corrosion, to visually inspect the flow vane 442, the operator can remove the valve cover 449 fixed to the valve body 414 and measure the wear of the corrugations 474 located at the first end 458. As shown in this example, the corrugations 474 do not extend completely from the first end 458 to the second end 462, but rather are locally located at both ends, leaving a smooth surface 480 on the central portion 484 of the flow vane 474. In other examples, the flow vane 442 may have different corrugations, for example... Figures 2-5 Any one of the ripples 74, 174, 274, 276, 374, or 376 depicted in the text.

[0047] exist Figure 7 In another example shown, a fifth exemplary valve body 514 and flow vane 542 are constructed in accordance with the teachings of this disclosure. The valve body 514 can be used for, for example... Figure 1 In a downward-flowing control valve such as the downward-flowing control valve 10. However, in another example, the fifth exemplary valve body 514 can be used in, for example... Figure 6In an upward-flowing control valve such as control valve 410, the flow vane 542 has no ripples on either the first surface 550 or the second surface (hidden from view). Instead, to determine wear due to cavitation on the valve body 514 and / or components of the control valve, a sensor 588 (e.g., an ultrasonic transducer) can be used to measure wear due to cavitation of the flow vane 542 (or corrosion in the upward-flowing valve). In the example shown, an array of sensors 588 is embedded or mounted in or on the wall 592 of the valve body 514 (e.g., between the inner and outer surfaces of the valve body 514, on the inner surface of the valve body 514, on the outer surface of the valve body 514), and spaced apart along the length L of the flow vane 542. At each location along the length L, the ultrasonic transducer 588 can measure the thickness T or width W of the flow vane 542. Additionally, one or more additional sensors 588 can be mounted or embedded in the flow vane 542 for measuring the thickness T of the vane 542 along its length L. Acquiring multiple measurements at each location over time will provide data to the operator to determine the rate or severity of wear due to cavitation, which may affect valve body 514 and / or components of the control valve. Wear due to cavitation will primarily manifest at the edge 596 of the first end 558, and the edge 596 will move in the D direction over time (due to wear). Wear on the flow vane 542 can be measured by determining the change in position of the edge 596 in the D direction. For example, an initial measurement obtained by ultrasonic transducer 588 is compared with a second measurement obtained by ultrasonic transducer 588. The change in value between the first and second measurements will indicate a change in the distance or position of the outer edge 596. As damage progresses, the change in the distance or position of the outer edge 596 will increase. These diagnostics can be automated in systems with digital valve controllers, which is discussed further below. In one example, one or more of the flow vane 542 and valve body 514 may provide a sensor 588 for measuring wear. In yet another example, a combination of sensors may be embedded or mounted in the blade 542, valve body 514, and / or other valve components to measure wear or perform other diagnostics on the valve.

[0048] The impact of cavitation on control valves 10 and 410 can also be determined by measuring the stroke changes of control elements 46 and 446. As mentioned earlier, flow vanes 42, 142, 242, 342, 442, and 542 improve the flow conditions and stability of valves 10 and 410, thereby increasing efficiency. Therefore, any damage to flow vanes 42, 142, 242, 342, 442, and 542 will reduce the efficiency of valves 10 and 410. Typically, changes in the flow coefficient cause valves 10 and 410 to adjust the stroke of control elements 46 and 446 accordingly. This change in stroke can be measured and tracked to determine the performance of valves 10 and 410.

[0049] Any of the flow vanes 42, 142, 242, 342, 442, 542 and valve bodies 14, 114, 214, 314, 414, 514 can be used in an upward or downward flow control valve according to the teachings of this disclosure. Furthermore, combinations of the various devices or methods disclosed herein can be used to determine deterioration or wear caused by cavitation or corrosive fluid flow. For example, any of the previously described valve bodies 14, 114, 214, 314, 414, 514 and / or flow vanes 42, 142, 242, 342, 442, 542 can be paired with one or more sensors (e.g., ultrasonic transducers, laser displacement sensors, vibration sensors, etc.) to measure damage caused by cavitation or corrosion. A sensor or an array of sensors may be placed on or embedded in the wall of valve bodies 14, 114, 214, 314, 414, 514, or in other examples, one or more sensors may be coupled to control elements 46, 446 (e.g., embedded in valve plugs 47, 447 or valve stems 48, 448).

[0050] In other examples, each of the process control valves 10, 410 disclosed herein may be coupled to actuator 104 and communicatively coupled to a digital valve controller (“DVC”). The DVC may be... FIELDVUE TM DVC 6200 digital valve controller FIELDVUE TM The DVC6000 digital valve controller, or another type of digital valve controller (e.g., a digital valve controller manufactured by Fisher or another company), includes a processor, memory, communication interface, computing logic, I / P converter, and pneumatic relays housed within a module base. Those skilled in the art will understand that the digital valve controller may also include other components, such as analog-to-digital converters, digital-to-analog converters, amplifiers, and meters, not explicitly shown herein.

[0051] The processor can be a general-purpose processor, digital signal processor, ASIC, field-programmable gate array, graphics processing unit, analog circuit, digital circuit, or any other known or later-developed processor. The processor operates according to instructions stored in memory. It provides a communication interface (which may be, for example...) Interface, FOUNDATION TM Fieldbus interface An interface (or some other port or interface) is used to enable or facilitate electrical communication between the digital valve controller and the process controller, and between the digital valve controller and other components of the process control equipment (e.g., valve 10 and actuators). This electrical communication can occur through any known communication protocol, such as... Communication protocol Fieldbus communication protocol Communication protocol, or any other suitable communication protocol.

[0052] The logic includes one or more routines and / or one or more subroutines, embodied as computer-readable instructions stored in memory. A digital valve controller, particularly its processor, can execute logic to cause the processor to perform actions related to the operation (e.g., control, regulation), maintenance, diagnosis, and / or troubleshooting of control valve components (e.g., control valve 10, actuator, and / or components thereof). The logic, when executed, can cause the processor to obtain data associated with and instructing the operation of control valve 10. In this application, the data associated with control device 10 may relate to changes in the thickness T of the flow vane 42, the distance between the valve plug 47 and the flow vane 42, and changes in pressure, valve stroke, and flow rate.

[0053] The processor can acquire data indicating characteristics or properties of, for example, valve body 14 or flow vane 42 at a single point in time (e.g., current time, previous time). For example, the processor can acquire data indicating changes in the thickness T of flow vane 42, the distance between valve plug 47 and flow vane 42, pressure, valve stroke, and flow rate at a single point in time. For example, the data can be measured or collected by one or more sensors (e.g., ultrasonic transducers, laser displacement sensors, vibration sensors, etc.). Data can be automatically sent to the processor (i.e., automatically acquired by the processor) and / or acquired in response to a request sent by the processor. In addition to acquiring data measured at a single point in time, the logic can also, when executed, cause the processor to acquire or collect data over a period of time (e.g., a week, a month, etc.). This typically involves acquiring data associated with control valve 10 at two or more different points in time, as described above. The acquired data can be measured at predetermined intervals (e.g., every 5 seconds), such that the two or more different points in time are separated by the predetermined interval. Once the data is acquired, it can be stored in memory or another memory. Furthermore, the processor can aggregate, accumulate, or sum some or all of the acquired data.

[0054] To assess the condition of one or more components, data can be compared with other data and / or quality factors or thresholds. Other data may include, for example, empirical data and / or expected data (e.g., expected values). Empirical data may be or include previous flow vane thickness data, flow vane length data, flow rate data, and / or pressure data associated with one or more components of control valve 10. Any data deviating from previous data may indicate that one or more components are not functioning effectively and / or are exposed to different levels of cavitation fluid, particulate matter, contaminants, and / or humidity than before, which may affect the health and / or effectiveness of one or more components. Expected data may be or include average or expected flow vane thickness data, flow vane length data, flow rate data, and / or pressure data generally expected for control valve 10. Any data deviating from expected data may indicate that one or more components are exposed to abnormal cavitation, particulate matter, contaminants, and / or humidity, and are therefore not currently in good health and / or are unlikely to function effectively for an extended period. Factors or thresholds may be, for example, the maximum threshold to which aggregated data does not exceed (e.g., maximum variation in flow vane thickness, maximum variation in stroke, etc.). For example, when the thickness data of the flow blade 42 indicates that the flow blade has deteriorated to a thickness below the minimum thickness threshold due to wear, it can be determined that one or more components may need to be replaced as soon as possible.

[0055] By monitoring data and / or analyzing its changes as described herein, performance problems (e.g., leakage) and / or anomalies in control valve 10 can be quickly identified or predicted and corrected. By assessing the condition of one or more components as described herein, faulty or otherwise ineffective components can be identified and removed or repaired, and the future effectiveness and / or health of components can be estimated, thereby improving the performance of control valve 10.

[0056] Based on the foregoing, undesirable cavitation effects can be identified and avoided. The disclosed equipment and methods can help monitor the flow conditions of process fluids and inform operators of the effects of cavitation, thereby indicating whether maintenance or replacement is required for valve bodies 14, 114, 214, 314, 414, 514, or other components of control valves 10, 410. Figures 1-6 In the example shown, each flow blade 42, 142, 242, 342, 442 provides a visual indication of wear due to cavitation, and... Figure 7 In the example, wear caused by cavitation can be determined without disassembling the control valve.

[0057] The accompanying drawings and descriptions provided herein depict and illustrate preferred embodiments of the flow vanes and control valves for illustrative purposes only. Those skilled in the art will readily recognize from the foregoing discussion that alternative embodiments of the components shown herein can be employed without departing from the principles described herein. Therefore, upon reading this disclosure, those skilled in the art will understand alternative structures and functional designs for the flow vanes used in the valve body. Thus, although specific embodiments and applications have been shown and described, it should be understood that the disclosed embodiments are not limited to the precise constructions and components disclosed herein. Various modifications, alterations, and variations that will be apparent to those skilled in the art may be made to the arrangement, operation, and details of the methods and components disclosed herein without departing from the spirit and scope defined by the appended claims.

Claims

1. A flow control device, comprising: A valve body having an inlet, an outlet, and a flow path connecting the inlet and the outlet; A flow vane, coupled to the valve body and disposed in the flow path, for dividing the flow of fluid through the valve body, the flow vane having a first surface, a second surface, and corrugations formed on at least one of the first surface and the second surface; A control element is disposed in the flow path and is movable within the valve body between an open position and a closed position; as well as A sensor, coupled to the flow blade, is used to measure the wear on the flow blade.

2. The flow control device according to claim 1, wherein, The flow blades are disposed between the control element and the outlet.

3. The flow control device according to claim 1, wherein, The ripples include ridges arranged parallel to the flow direction.

4. The flow control device according to claim 1, wherein, The ripples include ridges that are perpendicular to the flow direction.

5. The flow control device according to claim 1, wherein, The ripples include raised peaks.

6. The flow control device according to claim 1, wherein, The ripples include recesses.

7. The flow control device according to claim 1, wherein, The flow vane is integrally formed with the valve body.

8. The flow control device of claim 1 further includes an ultrasonic transducer coupled to the valve body and configured to measure the thickness of the flow blades.

9. A flow control device, comprising: A valve body having an inlet, an outlet, and a flow path connecting the inlet and the outlet; A flow vane, coupled to the valve body and disposed in the flow path, for dividing the flow of fluid through the valve body, the flow vane having a first surface, a second surface, and corrugations formed on at least one of the first surface and the second surface; A control element is disposed in the flow path and is movable within the valve body between an open position and a closed position; as well as A sensor, coupled to the control element, is used to measure the distance between the control element and the first end of the flow blade.

10. A valve body, comprising: The entrance, the exit, and the flow path connecting the entrance and the exit; A valve port is disposed between the inlet and the outlet; An outlet channel that connects the valve port and the outlet; A flow vane, coupled to the valve body and disposed in the outlet channel, the flow vane having corrugations disposed at a first end of the flow vane; as well as A sensor, coupled to the flow blade, is used to measure the thickness of the flow blade.

11. The valve body of claim 10, further comprising an array of sensors coupled to the valve body and configured to measure the thickness of the flow vanes, wherein, Each sensor is arranged along the length of the flow blade.

12. A method for determining wear caused by cavitation, the method comprising: A flow control device is provided, the flow control device having a valve body, a control element, and flow vanes, the valve body having an inlet, an outlet, and a flow path connecting the inlet and the outlet, the control element being disposed in the flow path and movable within the valve body between an open position and a closed position, the flow vanes being coupled to the valve body and disposed in the flow path to divide the flow of fluid through the valve body, the flow vanes having a first surface, a second surface, and corrugations formed on at least one of the first surface and the second surface; The dimensions of the flow blade are measured at a position along the length of the flow blade; A first measurement and a second measurement of the dimensions of the flow blades obtained at the said location are compared; Wear on the flow blades is determined by comparing the first and second measurements of the dimensions.

13. The method according to claim 12, wherein, The thickness measurement includes using an ultrasonic transducer to measure the thickness of the flow blade at the location.

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