Method for constructing a bivariate structure optimization scheme for inhibiting flow corrosion of a shut-off valve
By using fluid dynamics analysis and multiple comparison methods, the structural variables of the gate valve were optimized, solving the problem of flow corrosion under high temperature and strong corrosion, and improving the stability and reliability of the valve.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-12
- Publication Date
- 2026-03-31
AI Technical Summary
Existing gate valves have not been effectively optimized based on fluid dynamics analysis under high temperature and strong corrosion conditions, resulting in severe flow corrosion problems and affecting the stability and reliability of the valves.
Using a fluid dynamics-based analysis method, two structural variables of the optimization scheme were determined by setting up an original control group, a univariate group, and a bivariate group. A three-dimensional fluid computational domain model was established, and mesh generation and fluid simulation calculations were performed to obtain flow corrosion cloud maps and maximum corrosion rate statistics. The results were compared to determine the optimal structural optimization scheme.
It significantly improves the flow corrosion suppression effect of gate valves and the accuracy of optimization schemes, enhances the persuasiveness of designs, and improves construction efficiency.
Smart Images
Figure CN117634092B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of valve technology, specifically a method for constructing a bivariate structural optimization scheme to suppress flow corrosion in gate valves. Background Technology
[0002] As a component that plays a role in shutting off and throttling in pipeline systems, gate valves exhibit different fluid dynamic characteristics than normal operating conditions when the process valve is under harsh conditions such as high temperature and strong corrosion. These characteristics include rapid flow changes, complex eddies, and strong shear stress flow, which can cause flow corrosion damage on the valve surface.
[0003] Although domestic valve manufacturers and research institutions have conducted some research and development on process valves, dissecting and analyzing some representative process valves to explore their failure modes and making design improvements, resulting in their own products, most valve structural designs are not based on fluid dynamics analysis and flow corrosion prediction, nor do they summarize the flow corrosion mechanism of valves and optimize the corrosion prevention and control structure of process valves.
[0004] Therefore, it is necessary to use a construction method based on fluid dynamics analysis to optimize the design of key components of the gate valve, such as the valve body, valve core, valve stem, and seal, in order to ensure that the process valve has high stability and reliability when conveying highly corrosive media. Summary of the Invention
[0005] The purpose of this application is to provide a method for constructing a bivariate structural optimization scheme to suppress flow corrosion of a gate valve, so as to solve the problem that the optimal scheme cannot be guaranteed when designing a bivariate structural optimization scheme to suppress corrosion.
[0006] According to an embodiment of this application, a method for constructing a bivariate structural optimization scheme to suppress flow corrosion of a gate valve is provided, the method comprising:
[0007] S1: Based on the requirement to suppress flow corrosion of the shut-off valve, determine the two structural variables of the optimization scheme;
[0008] S2: Establish the original control group, the single variable group, and the bivariate group, and number each scheme within the group;
[0009] S3: Model the valve models corresponding to each numbered scheme and establish a three-dimensional fluid computational domain model;
[0010] S4: Mesh the three-dimensional fluid computational domain model to obtain a mesh model;
[0011] S5: Perform fluid simulation calculations on the mesh model based on CFD to obtain calculation data;
[0012] S6: Perform data and image processing on the calculated data to obtain a flow corrosion cloud map and a maximum corrosion rate statistical chart;
[0013] S7: Compare the flow corrosion cloud map and the maximum corrosion rate statistical map;
[0014] S8: Determine the optimal structural optimization scheme based on the comparison results.
[0015] Optionally, the original control group is a blank control of the single variable group, and the single variable group is a control of the bivariate group. If there are multiple schemes in the single variable group or the bivariate group, the schemes in the single variable group or the bivariate group are each other's controls.
[0016] Optionally, model the valve models corresponding to each numbered scheme and establish a three-dimensional fluid computational domain model, including:
[0017] S31: Create valve models corresponding to each numbered scheme using 3D modeling software;
[0018] S32: Extract the flow channel from the valve model to obtain a three-dimensional flow channel model;
[0019] S33: Extend the inlet of the three-dimensional flow channel model by n times the valve diameter length and extend the outlet by m times the valve diameter length to obtain a three-dimensional fluid calculation domain, where n≥5 and m≥10.
[0020] Optionally, the three-dimensional fluid computational domain model is meshed to obtain a mesh model, including:
[0021] The fluid computational domain model is imported into the mesh generation software, and an unstructured mesh is used to generate the mesh model.
[0022] Optionally, fluid simulation calculations are performed on the mesh model based on CFD to obtain calculation data, including:
[0023] S51: Import the mesh model into FLUENT software and define the units in Scale Mesh under General;
[0024] S52: Define the turbulence models sequentially in the Models module:
[0025] S53: Define a single-phase liquid medium in the Material module;
[0026] S54: In the Cell Zone Conditions module, click the fluid option, and in the Material Name option, select the defined single-phase liquid medium;
[0027] S55: Define boundary conditions in the Boundary Conditions module;
[0028] S56: Set the calculation method in the Solution Methods module;
[0029] S57: Set the convergence residual in the Monitors module;
[0030] S58: In the Solution Initialization module, select the entry point from the Compute from dropdown menu, and click the Initialize option to complete the initialization;
[0031] S59: In the Run Calculation tab of the Calculation Activities module, set the number of steps and then click the Calculate option to start the calculation and obtain the calculation data.
[0032] Optionally, the calculated data undergoes data and image processing to obtain a flow corrosion cloud map and a maximum corrosion rate statistical chart, including:
[0033] S61: Import the calculated data into Tecplot software;
[0034] S62: In the Data module, click the Alter option and then click Specify Equationgs. In the pop-up window, enter the flow corrosion calculation formula in the Equation(s) box and click Compute.
[0035] S63: Select coordinate plane;
[0036] S64: Click the Zone Style button, and in the Show Zone section of the pop-up window, check the structure you want to observe;
[0037] S65: Check the Coutour option, click the Details button, and select the name of the flow corrosion calculation formula from the pop-up menu;
[0038] S66: Set the image and ruler separately;
[0039] S67: Output the configured cloud map as an image to obtain the flow corrosion cloud map.
[0040] S68: Click the Details button to record the maximum value data corresponding to max under Contour variable range, and obtain the maximum value data of the flow corrosion rate;
[0041] S69: Import the maximum flow corrosion rate data into Origin software, and use the different scheme numbers as the horizontal axis and the maximum flow corrosion rate as the vertical axis to obtain a bar chart of the maximum flow corrosion rate of the gate valve under different schemes.
[0042] The technical solutions provided by the embodiments of this application may include the following beneficial effects:
[0043] As can be seen from the above embodiments, this application is for the optimized design of the dual-variable structure of the gate valve, which greatly improves the construction efficiency and also significantly increases the upper limit of the gate valve's effect on inhibiting flow corrosion.
[0044] This application establishes an original control group, a univariate group, and a bivariate group. The original control group serves as a control for the univariate group, and the univariate group serves as a control for the bivariate group. Furthermore, different schemes within each variable group also form mutual controls, which greatly enhances the persuasiveness of the optimized scheme and the accuracy of selecting the optimal scheme.
[0045] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description
[0046] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.
[0047] Figure 1 This is a flowchart illustrating a method for constructing a bivariate structure optimization scheme to suppress flow corrosion of a shut-off valve, according to an exemplary embodiment.
[0048] Figure 2 This is a schematic diagram of the original valve structure according to an exemplary embodiment.
[0049] Figure 3 This is a valve core model diagram optimized for the first variable, as shown according to an exemplary embodiment.
[0050] Figure 4 This is a sleeve model diagram of second variable optimization according to an exemplary embodiment.
[0051] Figure 5 This is a schematic diagram illustrating all the schemes according to an exemplary embodiment.
[0052] Figure 6 This is a mesh model diagram illustrated according to an exemplary embodiment.
[0053] Figure 7 This is a flow corrosion contour map of the valve core at 1 / 3 opening, according to an exemplary embodiment.
[0054] Figure 8 This is a flow corrosion contour map of the valve seat at 1 / 3 opening, according to an exemplary embodiment.
[0055] Figure 9 This is a bar chart showing the maximum flow corrosion rate of the valve core and valve seat at 1 / 3 opening, according to an exemplary embodiment.
[0056] Figure 10 This is a flow corrosion cloud map of the valve core under full opening, according to an exemplary embodiment.
[0057] Figure 11 This is a flow corrosion cloud map of the valve core under full opening, according to an exemplary embodiment.
[0058] Figure 12 This is a bar chart showing the maximum flow corrosion rate of the valve core and valve seat under full opening conditions for various embodiments, according to an exemplary embodiment. Detailed Implementation
[0059] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.
[0060] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The singular forms “a,” “the,” and “the” used in this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.
[0061] It should be understood that although the terms first, second, third, etc., may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."
[0062] Figure 1 This is a flowchart illustrating a method for constructing a bivariate structural optimization scheme to suppress flow corrosion of a gate valve, according to an exemplary embodiment. Figure 1As shown, the method may include the following steps:
[0063] S1: Based on the requirement to suppress flow corrosion of the shut-off valve, determine the two structural variables of the optimization scheme;
[0064] S2: Establish the original control group, the single variable group, and the bivariate group, and number each scheme within the group;
[0065] S3: Model the valve models corresponding to each numbered scheme and establish a three-dimensional fluid computational domain model;
[0066] S4: Mesh the three-dimensional fluid computational domain model to obtain a mesh model;
[0067] S5: Perform fluid simulation calculations on the mesh model based on CFD to obtain calculation data;
[0068] S6: Perform data and image processing on the calculated data to obtain a flow corrosion cloud map and a maximum corrosion rate statistical chart;
[0069] S7: Compare the flow corrosion cloud map and the maximum corrosion rate statistical map;
[0070] S8: Determine the optimal structural optimization scheme based on the comparison results.
[0071] As can be seen from the above embodiments, this application focuses on the optimized design of a bivariate structure for gate valves, greatly improving construction efficiency and significantly increasing the upper limit of the effect on inhibiting flow corrosion in gate valves. Furthermore, the inclusion of an original control group, a univariate group, and a bivariate group provides multiple comparisons, greatly enhancing the persuasiveness of the optimized scheme and the accuracy of selecting the optimal solution.
[0072] In the specific implementation of S1: based on the requirement to suppress flow corrosion of the shut-off valve, two structural variables of the optimization scheme are determined;
[0073] Specifically, by reviewing relevant literature, it was found that flow corrosion of the gate valve is most severe at the valve core and valve seat. Therefore, the first structural variable was determined to be the shape of the valve core, and the second structural variable was to add a sleeve.
[0074] In the specific implementation of S2: an original control group, a single-variable group, and a bivariate group are set up, and each scheme within the group is numbered;
[0075] Specifically, the original structural design was set as the original control group; the designs that only changed the valve core without adding a sleeve and those that only added a sleeve without changing the valve core were set as single-variable groups; and the designs that changed both the valve core and added a sleeve were set as double-variable groups. Each design was also numbered, with the following designations: original flat-bottomed valve core design without sleeve, trapezoidal valve core design without sleeve, circular valve core design without sleeve, conical valve core design without sleeve, flat-bottomed valve core design with sleeve, trapezoidal valve core design with sleeve, circular valve core design with sleeve, and conical valve core design with sleeve, numbered A, B, C, D, a, b, c, d.
[0076] In the specific implementation of S3: Modeling the valve models corresponding to each numbered scheme and establishing a three-dimensional fluid computational domain model; this step may include the following sub-steps:
[0077] S31: Create valve models corresponding to each numbered scheme using 3D modeling software;
[0078] Specifically, Solidworks software was used to model the original valve, resulting in the original valve model ( Figure 2 Then, the valve core and sleeve corresponding to the optimized solution are modeled to obtain the valve core model of the optimized solution. Figure 3 ) and sleeve model ( Figure 4 Finally, according to each scheme, the structures in the original valve model are replaced and added respectively to obtain the valve models of all schemes. Figure 5 ).
[0079] S32: Extract the flow channel from the valve model to obtain a three-dimensional flow channel model;
[0080] Specifically, the original valve model and various optimized models are adjusted to 1 / 3 opening and full opening respectively to extract the three-dimensional flow channel, resulting in two sets of three-dimensional flow channel models.
[0081] S33: Extend the inlet of the three-dimensional flow channel model by 5 times the valve diameter length and the outlet by 10 times the valve diameter length to obtain the three-dimensional fluid calculation domain.
[0082] In the specific implementation of S4: the three-dimensional fluid computational domain model is meshed to obtain a mesh model;
[0083] Specifically, such as Figure 2 As shown, the three-dimensional fluid computational domain model was imported into ICEM mesh generation software for unstructured mesh generation. Then, local refinement was applied to areas such as valve body 1, valve core 2, valve cover 3, valve stem 4, and valve seat 5 to obtain the mesh model. One of the mesh model diagrams is shown below. Figure 6 As shown.
[0084] In the specific implementation of S5: fluid simulation calculations are performed on the mesh model based on CFD to obtain calculation data; this step may include the following sub-steps:
[0085] S51: Import the mesh model into Fluent software and define the units in Scale Mesh under General;
[0086] Specifically, the mesh model is imported into Fluent software, and the unit is defined as mm in Scale Mesh under General.
[0087] S52: Define the turbulence models sequentially in the Models module:
[0088] Specifically, since the calculation of flow corrosion needs to consider the effect of the fluid on the wall, the SST k-ω turbulence model is adopted.
[0089] S53: Define a single-phase liquid medium in the Material module;
[0090] Specifically, since Fluent's material library does not have a 30wt% HCl solution, I clicked Fluid in the Material module, and then customized the properties of the 30wt% HCl solution in the pop-up window. I set Density to 1146 kg / m³, Viscosity to 0.001568 kg / (m·s), and Name to HCl.
[0091] S54: In the Cell Zone Conditions module, click the fluid option, and in the Material Name option, select the defined single-phase liquid medium;
[0092] Specifically, in the Cell Zone Conditions module, click the fluid option, and in the Material Name option, select HCl.
[0093] S55: Define boundary conditions in the Boundary Conditions module;
[0094] Specifically, the inlet uses a pressure inlet and the outlet uses a pressure outlet. The inlet and outlet pressures are set according to the inlet and outlet pressures of the actual shut-off valve structure. The inlet and outlet temperature values are set according to the actual working environment of the pipeline valve. All other boundaries other than the inlet and outlet temperature values are set as no-slip boundary conditions.
[0095] In this embodiment, the inlet pressure is set to 0.5 MPa, the outlet pressure to 0.1 MPa, and the temperature to 298 K.
[0096] S56: Set the calculation method in the Solution Methods module;
[0097] Specifically, the SIMPLE algorithm was chosen as the calculation method. The gradient discretization method in the SIMPLE algorithm adopts the least squares method based on the unit volume. The pressure, momentum, turbulent kinetic energy and dissipation in the SIMPLE algorithm all adopt the second-order upwind scheme.
[0098] S57: Set the convergence residual in the Monitors module;
[0099] Specifically, the convergence residuals are all set to a value of 10. -6 .
[0100] S58: In the Solution Initialization module, select the entry point from the Compute from dropdown menu, and click the Initialize option to complete the initialization;
[0101] S59: In the Run Calculation tab of the Calculation Activities module, set the number of steps and then click the Calculate option to start the calculation and obtain the calculation data.
[0102] Specifically, the number of iterations is set to 20000.
[0103] In the specific implementation of S6: the calculated data is processed for data and image visualization to obtain a flow corrosion cloud map and a maximum corrosion rate statistical chart; this step may include the following sub-steps:
[0104] S61: Import the calculated data into Tecplot software;
[0105] S62: In the Data module, click the Alter option and then click Specify Equationgs. In the pop-up window, enter the flow corrosion calculation formula in the Equation(s) box and click Compute.
[0106] S63: Select coordinate plane;
[0107] S64: Click the Zone Style button, and in the Show Zone section of the pop-up window, check the structure you want to observe;
[0108] Specifically, the structure observed in this embodiment is the lower bottom surface of the valve core and the upper surface of the valve seat.
[0109] S65: Check the Coutour option, click the Details button, and select the name of the flow corrosion calculation formula from the pop-up menu;
[0110] Specifically, the flow corrosion calculation formula used in this embodiment is as follows:
[0111]
[0112] In the formula: CR* is the flow corrosion rate; w is the mass concentration of the corrosive medium; T is the temperature; wss is the wall shear stress; and a, b, c, i, j, and k are all constants.
[0113] S66: Set the image and ruler separately;
[0114] S67: Output the configured cloud map as an image to obtain the flow corrosion cloud map.
[0115] S68: Click the Details button to record the maximum value data corresponding to max under Contour variable range, and obtain the maximum value data of the flow corrosion rate;
[0116] S69: Import the maximum flow corrosion rate data into Origin software, and use the different scheme numbers as the horizontal axis and the maximum flow corrosion rate as the vertical axis to obtain a bar chart of the maximum flow corrosion rate of the gate valve under different schemes.
[0117] In the specific implementation of S7: the flow corrosion cloud map and the maximum corrosion rate statistical map are compared;
[0118] Specifically, when the shut-off valve is at its smallest opening (1 / 3 of its opening), such as... Figure 7 As shown, in all schemes, the valve core location in schemes c and d does not exhibit a corrosion rate exceeding 19600 g·m⁻¹. -2 ·s -1 The best results are achieved in the area; such as Figure 8 As shown, in all schemes, the valve seat positions in schemes b, c, and d do not exceed 35400 g·m. -2 ·s -1 The best results are achieved in the area; such as Figure 9 As shown, among all schemes, schemes b, c, and d have the best results because the maximum corrosion rates of the valve core and seat are basically the same and relatively small. When the gate valve is fully open, as... Figure 10 As shown, in all schemes, the valve core location in schemes C and d does not exhibit a corrosion rate exceeding 11400 g·m⁻¹. -2 ·s -1 The best results are achieved in the area; such as Figure 11 As shown, in all schemes, the valve seat of scheme d does not exceed 31500 g·m. -2 ·s -1 The best results are achieved in the area; such as Figure 12As shown, among all the schemes, the d-group scheme has the lowest maximum corrosion rate of the valve core and valve seat, and the best effect.
[0119] In the specific implementation of S8: the optimal structural optimization scheme is determined based on the comparison results;
[0120] Specifically, based on the comparison results in step S7, the scheme in group d (the scheme with the sleeve-shaped conical valve core) is determined to be the best and is the optimal structural optimization scheme among all schemes.
[0121] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the disclosure herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this application are indicated by the claims.
[0122] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.
Claims
1. A method for constructing a bi- variable structure optimization scheme for inhibiting flow corrosion of a shut-off valve, characterized by, The method comprises: S1: according to the requirement of inhibiting flow corrosion of the cut-off valve, two structure variables of the optimization scheme are determined, the first structure variable is the shape of the valve core, and the second structure variable is an added sleeve; S2: an original control group, a single variable group and a double variable group are set up, and each scheme in the group is numbered; the original control group is a blank control of the single variable group, the single variable group is a control of the double variable group, and if there are multiple schemes in the single variable group or the double variable group, each scheme in the single variable group or the double variable group is a control of each other; S3: modeling the valve model corresponding to each numbered scheme and establishing a three-dimensional fluid calculation domain model; S4: grid division is performed on the three-dimensional fluid calculation domain model to obtain a grid model; S5: fluid simulation calculation is performed on the grid model based on CFD to obtain calculation data; S6: the calculation data is subjected to data and image processing to obtain a flow corrosion cloud chart and a maximum corrosion rate statistical chart; S7: the flow corrosion cloud chart and the maximum corrosion rate statistical chart are compared; S8: the optimal structure optimization scheme is determined based on the comparison result.
2. The method of claim 1, wherein the method is characterized by: Modeling the valve model corresponding to each numbered scheme and establishing a three-dimensional fluid calculation domain model comprises: S31: a three-dimensional modeling software is used to establish the valve model corresponding to each numbered scheme; S32: a three-dimensional flow channel model is obtained by flow channel extraction on the valve model; S33: the inlet of the three-dimensional flow channel model is extended by n times the valve diameter length, and the outlet is extended by m times the valve diameter length, to obtain a three-dimensional fluid calculation domain, wherein n≥5 and m≥10.
3. The method of claim 1, wherein the method is a method of constructing a bi- variable structure optimization scheme for suppressing flow erosion in a choke valve, the method comprising: Grid division is performed on the three-dimensional fluid calculation domain model to obtain a grid model, which comprises: The fluid calculation domain model is imported into a grid division software, and non-structured grid is used for grid division on the fluid calculation domain model to obtain a grid model.
4. The method of claim 1, wherein the method is a method of constructing a bi- variable structure optimization scheme for suppressing flow erosion in a choke valve, the method comprising: Fluid simulation calculation is performed on the grid model based on CFD to obtain calculation data, which comprises: S51: the grid model is imported into FLUENT software, and a unit is defined in Scale Mesh in General; S52: a turbulent flow model is defined in the Models module in sequence; S53: a single-phase liquid medium is defined in the Material module; S54: the fluid option is clicked in the Cell Zone Conditions module, and the defined single-phase liquid medium is selected in the Material Name option; S55: boundary conditions are defined in the Boundary Conditions module; S56: calculation methods are set in the Solution Methods module; S57: convergence residuals are set in the Monitors module; S58: the inlet is selected in the Compute from drop-down option in the Solution Initialization module, and the Initialize option is clicked to complete initialization; S59: Click Calculate option in Run Calculation tab in Calculation Activities module to start calculation after setting calculation steps, and obtain calculation data.
5. The method of constructing a bi-variant structural optimization scheme for suppressing flow erosion of a shut-off valve according to claim 1, wherein, The calculation data is processed by data and image to obtain flow corrosion cloud picture and maximum corrosion rate chart, including: S61: Import the calculation data into Tecplot software; S62: Click Specify Equationgs in Alter option in Data module, input flow corrosion calculation formula in Equation(s) box in the pop-up window and click Compute; S63: Select coordinate plane; S64: Click Zone Style button, and check the structure to be observed in Show Zone column in the pop-up window; S65: Check Contour option, click Details button, and select the name of the flow corrosion calculation formula in the pop-up menu; S66: Set image and scale respectively; S67: Output the set cloud picture in the form of picture to obtain flow corrosion cloud picture; S68: Click Details button, record the maximum value data corresponding to max under Contour variable range to obtain maximum flow corrosion rate data; S69: Import the maximum flow corrosion rate data into Origin software, take different scheme numbers as abscissa and maximum flow corrosion rate as ordinate to obtain column chart of maximum flow corrosion rate of different schemes of stop valve.