Aerodynamic noise reduction element and control valve comprising same

Abstract

The control valve includes a valve body defining an inlet and an outlet. A valve closure member is also coupled with the valve body, the valve closure member being displaceable relative to the valve body between a first closed position and a second fully open position. The aerodynamic noise reduction element is arranged in the valve body and comprises a plurality of flow channels. The plurality of flow channels include a first flow channel and a second flow channel. The first flow channel extends along a first flow axis from an open first end to an open second end. The first flow channel comprises a first expansion cavity. The second flow channel extends along a second flow axis from an open first end to an open second end. The second flow channel is provided with a second expansion cavity.

Description

Technical Field

[0001] The present disclosure relates generally to control valves and, more particularly, to aerodynamic noise reduction elements for use with control valves that control compressible fluids. Background Art

[0002] Control valves are commonly used in processes to control the flow of fluids (such as gases, liquids, etc.) or any other substances through pipes and / or containers connected thereto. Control valves typically include one or more fluid inlets and fluid outlets, and control valves may also include fluid control elements or components (such as spherical elements, rotating elements, valve gates, pistons, valve plugs, control components, etc.) that operate to control the flow of fluid through a passage that couples the inlet and outlet fluids. The control component is typically configured to engage with a sealing structure (such as a valve seat) that surrounds a flow path through the valve.

[0003] Generally, control elements (including fluid control members, valve seats, cages or other fluid passages) are referred to in the art as "valve trims" or "trim assemblies". In some cases, it may be necessary to characterize the fluid flowing through the valve, for example, to reduce pressure and / or reduce cavitation. In these cases, a trim assembly can be used, which includes an element having a plurality of openings, passages or channels for fluid flow. The size and shape of these openings, passages, or channels can be designed to be suitable for characterizing the fluid flow as the fluid flows through these openings, passages, or channels, for example, by reducing pressure as the fluid moves through the valve trim. This characterization or depressurization process can produce undesirable noise.

[0004] In certain valves, such as ball valves, the fluid flowing through the valve may experience rapid changes in pressure. Such rapid pressure changes in the fluid may result in the formation of undesirable aerodynamic noise. More specifically, when the fluid pressure drops due to an increase in fluid velocity, turbulence is generated, resulting in undesirable noise and vibration. In high-speed fluid flows, especially in fluids experiencing high-pressure drops, sonic flow is generated, resulting in the development of shock waves, which produce undesirable high-frequency noise and vibration.

[0005] In valve embodiments, the aerodynamic noise control device may be disposed in or near the inlet such that when the ball valve is in an open position, fluid flows from the inlet to the outlet through the aerodynamic noise control device.

[0006] In typical aerodynamic noise control device components (such as In the V260 or V260A), a dome can be placed before the inlet ball valve to grade the pressure drop. The dome includes a plurality of machined holes, which limits the size of the holes and thus the number of holes that can be included. In addition, the shape of the holes is also limited.

[0007] In other aerodynamic noise control device components (such as Vee-Ball TM In a conventional valve, a flow control device such as a spherical element may include separate flow channels that receive fluid flow when the flow control device is in an open position. These separate flow channels are machined into the spherical element, or the spherical element is cast as a single piece and the holes are machined into the separate pieces, or the spherical element is made of multiple welded pieces that include machined flow channels. In any case, the size and shape of the flow channels are limited, similar to the domes discussed above, and the manufacturing process is time-consuming and expensive. Summary of the invention

[0008] According to an exemplary aspect, a control valve includes a valve body defining an inlet and an outlet. A valve seat is coupled to the valve body. A valve closing member is also coupled to the valve body, and the valve closing member is displaceable relative to the valve body between a first closed position and a second fully-open position. In the first closed position, a sealing portion of the valve closing member is sealingly engaged with a sealing portion of the valve seat to prevent the flow of a compressible fluid from the inlet of the valve body to the outlet of the valve body. In the second fully-open position, the sealing portion of the valve closing member deviates from the sealing portion of the valve seat to allow the flow of the compressible fluid from the inlet of the valve body to the outlet of the valve body. An aerodynamic noise reduction element is disposed in the valve body, and the aerodynamic noise reduction element includes a plurality of flow channels. The plurality of flow channels include a first flow channel and a second flow channel. The first flow channel extends from an open first end to an open second end along a first flow axis. The first flow channel includes a first fluid expansion chamber. The second flow channel extends from an open first end to an open second end along a second flow axis. The second flow channel has a second expansion chamber.

[0009] According to another exemplary aspect, an aerodynamic noise reduction element is suitable for use with a valve assembly. The valve assembly has a valve body defining an inlet and an outlet, a valve seat coupled to the valve body between the inlet and the outlet, and a valve closing member coupled to the valve body. The valve closing member is displaceable between a first closed position and a second fully open position relative to the valve body. In the first closed position, a sealing portion of the valve closing member is sealingly engaged with a sealing portion of the valve seat. In the second fully open position, a sealing portion of the valve closing member is offset from a sealing portion of the valve seat. The aerodynamic noise reduction element includes a plurality of flow channels. The plurality of flow channels include a first flow channel and a second flow channel. The first flow channel extends from an open first end to an open second end along a first flow axis. The first flow channel has an inner surface defining a first flow area. The inner surface of the first flow channel has a first cross-sectional shape normal to the first flow axis. The first flow channel has a first expansion chamber. The second flow channel extends from an open first end to an open second end along a second flow axis. The second flow channel has an inner surface defining a second flow area. The inner surface of the second flow channel has a second cross-sectional shape normal to the second flow axis. The second flow channel has a second expansion cavity.

[0010] Further according to any one or more of the aforementioned exemplary aspects, the control valve or the aerodynamic noise reduction element may also include one or more of the following preferred forms in any combination.

[0011] In a preferred form, the first flow passage includes a plurality of first expansion chambers arranged in series.

[0012] In another preferred form, the expansion lumens of the first plurality of expansion lumens are discrete and separated from each other.

[0013] In another preferred form, the expansion lumens of the plurality of first expansion lumens are continuous to form a single expansion lumen with increasing stepped volumes.

[0014] In another preferred form, the second flow channel includes a plurality of second expansion chambers arranged in series.

[0015] In another preferred form, the two expansion lumens of the first expansion lumen have different expansion volumes.

[0016] In another preferred form, the expansion volume increases along the first flow axis from the first end to the second end.

[0017] In another preferred form, the first flow axis and the second flow axis are parallel to each other.

[0018] In another preferred form, the cross-sectional shape of the first flow channel is the same as the cross-sectional shape of the second flow channel.

[0019] In another preferred form, the cross-sectional shape of the first flow channel and the cross-sectional shape of the second flow channel both have a polygonal shape.

[0020] In another preferred form, the polygonal shape is one of a hexagon, a diamond or a rhombus.

[0021] In another preferred form, the valve closing member is a spherical member that rotates along a closing axis between the first closed position and the second fully open position. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is an isometric and partial cross-sectional view of an exemplary embodiment of a rotary valve assembly with the valve closing member in a fully open position.

[0023] Figure 2 yes Figure 1 Isometric and partial cross-sectional views of embodiments.

[0024] Figure 3 yes Figure 1 Isometric and partial cross-sectional views of an embodiment with the valve closing member in a closed position.

[0025] Figure 4 yes Figure 3 A partially cutaway top view of an embodiment.

[0026] Figure 5 is a front view of an embodiment of an aerodynamic noise reduction element;

[0027] Fig. 6A yes Figure 5 A side cross-sectional view of a flow channel assembly of an aerodynamic noise reduction element.

[0028] Figure 6B Is has Fig. 6A First-class channel components Figure 5 Side cutaway view of the aerodynamic noise reduction element.

[0029] Figure 6C Is has Fig. 6A Multiple flow channel components Figure 5 Side cutaway view of the aerodynamic noise reduction element.

[0030] Figure 7 is an alternative embodiment of a flow channel assembly comprising Figure 5 Side cutaway view of the aerodynamic noise reduction element.

[0031] Figure 8is a front view of an alternative embodiment of an aerodynamic noise reduction element having a hexagonal flow channel cross section.

[0032] Fig. 9 is a side cross-sectional view of an alternative embodiment of a runner assembly.

[0033] Fig.10 is a side cross-sectional view of an alternative embodiment of a control valve assembly having an aerodynamic noise reduction element located downstream of the valve trim. DETAILED DESCRIPTION

[0034] Although a detailed description of exemplary methods, devices and / or articles is disclosed below, the legal scope of the property rights is defined by the claims. Therefore, the following detailed description should be interpreted as exemplary only, and does not describe every possible example, because it would be impractical, if not impossible, to describe every possible example. Numerous alternative examples can be implemented using current technology or technology developed after the filing date of this patent. Such alternative examples will still fall within the scope of the claims.

[0035] The valves described herein advantageously provide aerodynamic noise reduction within a control valve with minimal flow restriction. Thus, the disclosed valves are very effective in reducing aerodynamic noise. The disclosed valve components can be significantly smaller and / or lighter than current components having aerodynamic noise reduction devices. Thus, the disclosed valves can have a smaller valve body than current valves.

[0036] Although the aerodynamic noise reduction element is described herein for a ball valve, the aerodynamic noise reduction element may also be used in other types of valves, such as rotary valves, globe valves, sliding stem cages, diffusers upstream or downstream of a control element.

[0037] In addition, the aerodynamic noise reduction elements in the disclosed valves can be customized for specific applications by adjusting the size and shape of the internal cavity and / or the number of chamber stages. In addition, the disclosed valves can also be combined with more traditional noise suppression devices (such as noise reduction trim) to achieve more comprehensive noise reduction.

[0038] The disclosed aerodynamic noise reduction element is particularly advantageous for reducing aerodynamic noise of a compressible fluid in a control valve. By splitting the fluid flow into multiple flow paths and forcing the compressible fluid to flow through a flow channel having multiple graded internal pressure drop characteristics, the corresponding fluid expansion caused by the pressure drop is accommodated by increasing the flow area of ​​the flow channel between the inlet and the outlet. By grading the pressure drop through the flow channel, the total energy of the compressible fluid is gradually reduced, thereby reducing the aerodynamic noise generated by turbulence and / or shock waves in the valve system.

[0039] While the aerodynamic noise reduction elements described herein are particularly useful in reducing unwanted aerodynamic noise in compressible fluids, in other embodiments, the aerodynamic noise reduction elements disclosed herein may be used to control cavitation in fluid control valves.

[0040] Unless otherwise stated, any features or characteristics of any one embodiment of the valve disclosed herein may be combined with features or characteristics of any other embodiment of the valve.

[0041] like Figure 1-Figure 4 As shown, the valve assembly 10 includes a valve body 12 defining an inlet 16 and an outlet 14. A valve seat 18 is defined by or coupled to the valve body 12 between the inlet 16 and the outlet 14. A valve closing member 20 is coupled to the valve body 12, and the valve closing member 20 is in a closed (first) position (eg, Figure 3 and Figure 4 ) and the fully open (second) position (as shown Figure 1 and Figure 2 As shown) can be shifted between. Figure 3 In the closed (first) position shown, the sealing portion 22 (shown in phantom) of the valve closing member 20 is sealingly engaged with the sealing portion 24 of the valve seat 18 to prevent the flow of fluid from the inlet 16 to the outlet 14. Figure 1 and Figure 2 In the fully open (second) position shown, the sealing portion 22 of the valve closing member 20 is deflected from the sealing portion 24 of the valve seat 18 to allow fluid flow from the inlet 16 to the outlet 14 .

[0042] like Figure 2 As shown, the valve assembly 10 also includes an aerodynamic noise reduction element 26, which includes a plurality of flow channels 28. The plurality of flow channels 28 include a first flow channel 28a extending from an open first end 32a to an open second end 34a along a first flow axis 30a. The plurality of flow channels 28 also include a second flow channel 28b extending from an open first end 32b to an open second end 34b along a second flow axis 30b.

[0043] By forming the first flow channel 28a and the second flow channel 28b (and in some embodiments, each flow channel in the plurality of flow channels 28 and / or all aerodynamic noise reduction elements 26) as a single unitary structure (e.g., formed, created, or manufactured using any additive manufacturing process or technique described in the following paragraphs), the geometry of the cross-sectional shape of the first flow channel 28a and the second flow channel 28b can be precisely manufactured to optimize the flow therethrough. This optimized flow geometry is difficult or impossible to achieve using conventional machining / casting processes. The optimized flow geometry enables the walls between adjacent flow areas to be thinner and stronger than conventional tubes, thereby reducing material costs. In addition, the optimized flow geometry can also produce an effective pressure drop with minimal noise.

[0044] The disclosed aerodynamic noise reduction element 26 advantageously reduces noise generated by turbulence and / or shock waves by grading a plurality of smaller pressure drops through the first flow channel 28a and the second flow channel 28b, and splitting the compressible fluid flow into a plurality of flow paths, for example, one flow path through the first flow channel 28a and another flow path through the second flow channel 28b. By grading a plurality of smaller pressure drops and splitting the fluid flow into a plurality of flow paths, the disclosed aerodynamic noise reduction element 26 can disperse the energy loss in the pressure reduction process to a larger area in the flow path, which generates smaller turbulent vortices and reduces or eliminates sonic flow, thereby reducing or eliminating noise generated by shock waves.

[0045] Due to thinner walls and / or optimized geometry, the number of fluid passages can be increased in the same area, so the flow capacity of the fluid flowing through the aerodynamic noise reduction element 26 is increased while reducing the pressure drop of the compressible fluid distributed over many fluid flow paths, which helps reduce aerodynamic noise.

[0046] The optimized geometry also allows for precise control of the overall shape of the aerodynamic noise reduction element 26. The optimized geometry can also grade the pressure drop through each individual flow channel (e.g., each flow channel 28) by, for example, continuous expansion and / or diffusion of the cavity 38 and communication to other flow cavities 38 with larger volumes. In addition, the aerodynamic noise reduction element 26 (or portions of the aerodynamic noise reduction element 26) can be formed as an assembly, thereby reducing the production cost of fixing each of the multiple flow channels 28. Unlike conventional devices, the material can also significantly reduce the weight of the aerodynamic noise reduction element 26. The material can be corrosion resistant, so further manufacturing steps may not be required.

[0047] Turning to the valve assembly 10 in more detail, Figure 1An embodiment of a valve body 12 is shown, the valve body 12 defining an inlet 16 and an outlet 14, and the inlet 16 and the outlet 14 may each extend along a valve body longitudinal axis 43. An inlet flange 44 may be disposed at a first end of the valve body 12, at or adjacent to the inlet 16 of the valve body 12, and the inlet flange 44 may be adapted to connect the inlet 16 to a portion of an upstream pipeline (not shown) in any known manner. An outlet flange 42 may be disposed at a second end of the valve body 12, at or adjacent to the outlet 14 of the valve body 12, and the outlet flange 42 may be adapted to connect the outlet 14 to a portion of a downstream pipeline (not shown) in any known manner. The inlet flange 44 and the outlet flange 42, as well as the portion of the valve body 12 defining the inlet 16 and the outlet 14, may be formed symmetrically about the valve body longitudinal axis 43. In the disclosed embodiment, fluid may flow through the valve body 12 from the inlet 16 to the outlet 14 or from the outlet 14 to the inlet 16.

[0048] Valve seat 18 (in Figure 2 and Figure 3 , but for clarity Figure 1 The valve seat 18 may be disposed between the inlet 16 and the outlet 14 and may have an annular shape that may be formed symmetrically about the valve body longitudinal axis 53. All or part of the valve seat 18 may be integrally formed with the valve body 12, or all or part of the valve seat 18 may be coupled to the valve body 12. Figure 3 As shown, the valve seat 18 may include a sealing portion 24, which may have an annular shape and when the valve closing member 20 is in the Figure 3 When the valve closure member 20 is in the closed first position, the sealing portion 24 may be adapted to sealingly engage with the sealing portion 22 of the valve closure member 20. All or part of the sealing portion 24 may be made of an elastic material or a rigid material.

[0049] The valve closing member 20 is coupled to the valve body 12, and the valve closing member 20 is in a first closed position (eg, Figure 3 ) and a fully open second position (as shown Figure 1 and Figure 2 The valve closing member 20 can also be shifted to a third partially-open position between the first closed position and the second fully open position.

[0050] The valve closing member 20 may have any shape and / or configuration to prevent fluid from flowing from the inlet 16 to the outlet 14 (or from the outlet 14 to the inlet 16) when in a closed first position, and to allow fluid to flow from the inlet 16 to the outlet 14 or between the inlet 16 and the outlet 14 (or from the outlet 14 to the inlet 16 or between the outlet 14 and the inlet 16) when in a fully open second position. For example, Figure 4As shown, the valve closing member 20 can be a spherical member 21, which includes a spherical member body 45 having a convex sealing surface 46. The sealing surface 46 can be any suitable shape, so that when the valve closing member 20 is in the closed first position, the sealing portion 22 of the valve closing member 20 is sealed and engaged with the sealing portion 24 of the valve seat 18 (to prevent the flow of the fluid from the inlet 16 to the outlet 14, or vice versa). For example, the sealing surface 46 can have (or substantially have) the shape of a partial sphere. In other embodiments, as described below, the sealing surface 46 can be a complete sphere with a through hole. The spherical member body 45 can also have a concave inner surface 48 opposite to the convex sealing surface 46, and the shape of the inner surface 48 can correspond to the sealing surface 46, so that all or part of the spherical member body 45 can selectively have a uniform or substantially uniform cross-sectional thickness. For example, the inner surface 48 can have (or substantially have) a partial spherical shape with a radius smaller than the sealing surface 46.

[0051] The spherical member 21 may also have a first stem portion 50 and a second stem portion 52 extending along a pivot axis 54, and the first stem portion 50 and the second stem portion 52 may each be coupled to a portion of the spherical member body 45. The first stem portion 50 may extend into a blind hole 56 formed in the valve body 12, and a middle portion of the second stem portion 52 may extend through a stem hole 58 formed through the valve body 12 so that an end 60 of the second stem portion 52 is disposed outside the valve body 12. The end 60 of the second stem portion 52 may be adapted to be coupled to a valve actuator (not shown), and the valve actuator may be any suitable actuator capable of rotating the valve closing member 20 between a first closed position and a second fully open position. The pivot axis 54 may extend normal to the valve body longitudinal axis 53 and may intersect the valve body longitudinal axis 53.

[0052] When the valve closing member 20 (such as the spherical member 21) is in Figure 3 In the closed first position shown, the convex sealing surface 46 of the spherical member 21 can be positioned relative to the valve seat 18 so that the sealing portion 22 of the spherical member 21 is in sealing engagement with the sealing portion 24 of the valve seat 18. Figure 1In the fully open second position shown, the actuator (not shown) rotates the second rod portion 52 about the pivot axis 54 by an appropriate rotational distance (e.g., 90 degrees) so that the entire sealing surface 46 of the spherical member 21 is disposed away from the valve seat 18, and so that any portion of the spherical member 21 does not impede or substantially impede the flow of fluid from the inlet 16 to the outlet 14 (or vice versa). In other words, in the fully open second position, the sealing portion 22 of the spherical member 21 is not in sealing engagement with the sealing portion 24 of the valve seat 18, thereby allowing fluid to flow from the inlet 16 to the outlet 14 (or vice versa). In some embodiments, when the fluid flows from the outlet 14 to the inlet 16 (and when the fluid flows from the inlet 16 to the outlet 14), the fluid pressure on the inner surface 48 of the spherical member 21 when the spherical member 21 is in the first closed position provides additional force when the sealing portion 22 of the spherical member 21 is in sealing engagement with the sealing portion 24 of the valve seat 18.

[0053] To displace the ball member 21 to the partially open third position, an actuator (not shown) rotates the second lever portion 52 about the pivot axis 54 by an appropriate rotational distance (e.g., 30 to 60 degrees) so that a portion of the entire sealing surface 46 of the ball member 21 can be disposed away from the valve seat 18, but a portion of the ball member 21 blocks or substantially blocks fluid flow from the inlet 16 to the outlet 14 (or vice versa). One of ordinary skill in the art will recognize that fluid flow from the inlet 16 to the outlet (or vice versa) can be adjusted by rotating the ball member 21 about the pivot member by a desired rotational distance between the closed first position and the fully open second position.

[0054] In some embodiments, the spherical member 21 (e.g., the spherical member body 45) can also translate along the longitudinal axis 53 of the valve body (e.g., through the action of a cam not shown) so that when the spherical member 21 is in the first closed position, the sealing portion 22 of the spherical member 21 is sealingly engaged with the sealing portion 24 of the valve seat 18.

[0055] like Figure 2 As shown, the valve assembly 10 also includes an aerodynamic noise reduction element 26, which includes a plurality of flow channels 28. The aerodynamic noise reduction element 26 may include any suitable number of flow channels 28 to reduce the pressure of the compressible fluid flowing from the inlet 16 of the valve body 12 to the outlet 14 (or vice versa). The flow channels 28 in the drawings are not necessarily drawn to scale. More specifically, in order to facilitate discussion of the flow channels 28, the flow channels 28 shown in the drawings are relatively large. In some embodiments, the flow channels 28 may be quite small and more numerous. Figure 2 As shown, the plurality of flow channels 28 include a first flow channel 28a and a second flow channel 28b. Any number of additional flow channels 28 may be included, such as a third flow channel, a fourth flow channel, a fifth flow channel, etc.

[0056] The first flow channel 28a can extend along a first flow axis 30a from an open first end 32a to an open second end 34a, and the first flow axis 30a can be linear and parallel to the valve body longitudinal axis 43. The inner surface defining the flow channel 28a (or defining a hole that defines the first flow channel 28a) can have any suitable first cross-sectional shape or combination of shapes that are normal to the first flow axis 30a. In some embodiments, the first cross-sectional shape of the first flow channel 28a can be uniform from the first end 32a to the second end 34a. In other embodiments, the first cross-sectional shape can vary from the first end 32a to the second end 34a of the first flow channel 28a. For example, as Figure 1 and Figure 8 As shown, the cross-sectional shape can be a polygon, such as a hexagonal opening shape as shown. In other examples, the cross-sectional shape can be a circle, such as Figure 5 Circular opening shape shown.

[0057] like Figure 2 As shown, the plurality of flow channels 28 include a second flow channel 28b extending from an open first end 32b to an open second end 34b along a second flow axis 30b. In some embodiments, the second flow axis 30b can be linear and parallel to the first flow axis 30a and / or the valve body longitudinal axis 53. The inner surface defining the second flow channel 28b (or defining a hole that defines the second flow channel) can have any suitable second cross-sectional shape (or combination of shapes) that is normal to the second flow axis 30b. In some embodiments, the cross-sectional shape of the second flow channel 28b can be the same as the cross-sectional shape of the first flow channel 28a described above, and the corresponding dimensions of the cross-sectional shape of the second flow channel 28b can be the same as the corresponding dimensions of the first cross-sectional shape of the first flow channel 28a, so that the area of ​​the second flow channel 28b can be equal to the area of ​​the first flow channel 28a. In other embodiments, the cross-sectional shape of the second flow channel 28b may be the same as the cross-sectional shape of the first flow channel 28a, but one or more corresponding dimensions of the cross-sectional shape of the second flow channel 28b may be larger than (or smaller than) one or more corresponding dimensions of the cross-sectional shape of the first flow channel 28a, so that the area of ​​the cross-sectional shape of the second flow channel 28b may be different from the area of ​​the cross-sectional shape of the first flow channel 28a.

[0058] In some embodiments (not shown), the cross-sectional shape of the second flow channel 28b can be different from the cross-sectional shape of the first flow channel 28a. In these embodiments, the cross-sectional shape of the second flow channel 28b can be uniform from the first end 32b to the second end 34b of the second flow channel 28b. In other embodiments, the cross-sectional shape of the second flow channel 28b can vary from the first end 32a to the second end 34a of the second flow channel 28b. Figure 1As shown, the cross-sectional shape of the second flow channel 28b can be a non-circular shape, such as a polygonal shape. For example, in some embodiments, the polygonal shape can be a hexagon, a pentagon, an octagon, or a diamond / rhombus. In other embodiments, the cross-sectional shape of the first flow channel 28a can be a circle (such as Figure 5 as shown) or oval.

[0059] As previously described, any number of additional flow passages 28 may be included in the plurality of flow passages 28 (e.g., a third flow passage, a fourth flow passage, a fifth flow passage, etc.). Any and all of the additional flow passages 28 may extend from the open first end 32 to the open second end 34 along a corresponding (e.g., a third, fourth, fifth, etc.) flow axis 30, and the corresponding flow axis 30 may be parallel to the valve body longitudinal axis 53.

[0060] like Figure 4 As shown, the plurality of flow passages 28 of the aerodynamic noise reduction element 26 may be laterally bounded by an imperforate circumferential wall 74, which may have a first portion 76 (which may be cylindrical or partially cylindrical) disposed adjacent the flange 72. The first portion 76 may be formed symmetrically about the valve body longitudinal axis 43, or a portion of the first portion 76 may be formed symmetrically about the valve body longitudinal axis 43.

[0061] The circumferential wall 74 may also have a second portion 82 (which may be cylindrical or partially cylindrical) that may extend from the first portion 76 away from the flange 72. The second portion 82 may be formed symmetrically about the valve body longitudinal axis 53, or a portion of the second portion 82 may be formed symmetrically about the valve body longitudinal axis 53. The diameter of the second portion 82 (or the cylindrical portion of the second portion 82) may be smaller than the diameter of the cylindrical portion of the first portion 76. In some embodiments, the length of each flow channel 28 in the outer group of the plurality of flow channels 28 located in the first portion 76 may be shorter than the length of any or all of the flow channels 28 in the inner group of the plurality of flow channels 28 located in the second portion 82. The length and position of the second ends 34 of the flow channels 28 in the outer group may depend on the internal geometry of the valve body 12 and / or the closing member 20. For example, the second ends 34 of some of the flow channels 28 in the outer group may be configured to minimize the gap between the second ends 34 and the first stem portion 50 and / or the second stem portion 52 to improve pressure drop.

[0062] In some embodiments, the entire aerodynamic noise reduction element 26 can be integrally formed as a single unitary structure. That is, the first flow channel 28a, the second flow channel 28b, and the third flow channel 28c (and any additional flow channels, such as the fourth flow channel, the fifth flow channel, the sixth flow channel, etc.) can be integrally formed as a single unitary structure. The flange 72 and / or the circumferential wall 74 can also be integrally formed with the first flow channel 28a, the second flow channel 28b, and the third flow channel 28c (and any number of other flow channels 28) to form a single unitary structure.

[0063] In some embodiments, the first flow channel 28a, the second flow channel 28b and the third flow channel 28c can be integrally formed using additive manufacturing technology or additive manufacturing processes. The additive manufacturing process can be any additive manufacturing process or technology that builds a three-dimensional object by adding successive layers of material to a material. The additive manufacturing process can be performed by any suitable machine or combination of machines. The additive manufacturing process can generally involve or use a computer, three-dimensional modeling software (such as computer-aided design, or CAD, software), a machine device, and layered materials. Once the CAD model is generated, the machine device can read the data from the CAD file and (for example) stack or add successive layers of liquid, powder, or sheet materials in a layered manner to manufacture a three-dimensional object.

[0064] The additive manufacturing process may include any of a variety of processes, such as, by way of example only, a three-dimensional printing process, a stereolithography ("SLA") process, a fused deposition modeling ("FDM") process, a multi-jet modeling ("MJM") process, and a selective laser sintering ("SLS") process. In some embodiments, the additive manufacturing process may include a laser powder bed fusion process. Any suitable material may be used to form the aerodynamic noise reduction element 26, such as a high-strength, low-weight material such as a metal or a metallic material.

[0065] In some embodiments, two or more portions of the aerodynamic noise reduction element 26 may be manufactured using an additive manufacturing process and the two or more portions of the aerodynamic noise reduction element 26 may be coupled (eg, by welding) to form the aerodynamic noise reduction element 26 .

[0066] In some embodiments, all or part of the aerodynamic noise reduction element 26 may be disposed in the outlet 14 of the valve body 12, or downstream of the valve body 12, such as by connecting the flange 72 to the outlet flange 42 of the valve body 12 and / or a flange of a portion of the downstream conduit (see Fig.10) to secure the aerodynamic noise reduction element 26 to the valve body 12 and / or the downstream conduit. In other embodiments, when the aerodynamic noise reduction element 26 does not have the flange 76, all or part of the aerodynamic noise reduction element 26 can be disposed in the outlet 14 of the valve body 12, and the aerodynamic noise reduction element 26 can be coupled or supported in the outlet 14 and / or in a portion of the downstream conduit ( Fig.10 ) to maintain a desired position of the aerodynamic noise reduction element 26 relative to the valve body 12 and / or downstream piping.

[0067] One of ordinary skill in the art will recognize that, using any of the above methods, all or part of the aerodynamic noise reducer 26 can be inserted into the inlet 16 and / or a portion of the upstream duct (not shown). In addition, two or more aerodynamic noise reducers 26 (not shown) can be used, such as a first aerodynamic noise reducer 26 disposed on one side of the valve seat 18 and a second aerodynamic noise reducer 26 disposed on the other side of the valve seat 18. The first and second aerodynamic noise reducers 26 can be the same or different. For example, the cross-sectional shape of the flow channel 28 of the first aerodynamic noise reducer 26 can be different from the cross-sectional shape of the flow channel 28 of the second aerodynamic noise reducer 26 to increase the total length of the duct for further pressure grading. In some embodiments, the first aerodynamic noise reducer 26 can be disposed in the upstream duct and / or in the inlet 16, the second aerodynamic noise reducer 26 can be disposed in the downstream duct and / or in the outlet 14, and the first aerodynamic noise reducer 26 can have a larger flow area than the second aerodynamic noise reducer 26 to further grade the pressure drop in the fluid.

[0068] Now turn to Fig. 6A , an aerodynamic noise reduction component 27 is shown. The aerodynamic noise reduction component 27 can be constructed according to any of the above-mentioned additive manufacturing techniques. The aerodynamic noise reduction component 27 includes a first flow channel 28a and a second flow channel 28b. As described above, the first flow channel 28a and the second flow channel 28b can have the same shape and / or size, or the first flow channel 28a and the second flow channel 28b can have different shapes and / or sizes. In any case, each of the first flow channel 28a and the second flow channel includes an expansion chamber (e.g., a first expansion chamber 38a and a second expansion chamber 38b). The first expansion chamber 38a is located between the first end (e.g., inlet) 32a of the first flow channel 28a and the second end (e.g., outlet) 34a of the first flow channel 28a along the first flow axis 30a. The second expansion chamber 38b is similarly located in the second flow channel 28b.

[0069] In the following description, the first flow passage 28a and the first expansion chamber 38a will be discussed in more detail. Unless otherwise specifically stated, the description of the first flow passage 28a (and any element of the first flow passage 28a) is also applicable to the second flow passage 28b (and any other flow passages).

[0070] The first expansion chamber 38a includes a first nozzle 41a and a first expansion inlet 43a. The first expansion inlet 43a leads to an increased volume portion 47a of the first expansion chamber 38a. When the fluid enters the increased volume portion 47a, the fluid velocity is reduced, the fluid pressure drops, and the fluid expands. When the fluid flows along the first flow axis 30a, multiple expansion chambers 38 can be arranged along the first flow axis 30a to further reduce the fluid pressure. Continuous pressure drop grading reduces cavitation and noise of the fluid flowing through the valve by reducing the size and intensity of turbulent eddies in the fluid by dispersing the pressure drop over a larger distance. In the illustrated embodiment, the size of the expansion chamber 38 is constant (such as Figure 6A-6C ) or the size increases along the fluid flow path (e.g. Figure 2 , Figure 4 , Figure 7 , Fig. 9 and Fig.10 ). Regardless, a portion of the fluid energy is extracted from each expansion chamber 38, which extracts energy from the fluid flow, leaving less energy to generate turbulent vortices that generate aerodynamic noise.

[0071] Once the aerodynamic noise reduction assembly 27 is manufactured, the aerodynamic noise reduction assembly 27 can be attached to the valve closing member 20, such as Figure 6B The spherical valve member 23 shown in FIG. The aerodynamic noise reduction assembly 27 can be attached to the inner hole 51 of the spherical valve member 23 by any attachment technique, such as welding, brazing, gluing, interference fit, fasteners, clamping, etc. Alternatively, the spherical valve member 23 can also be manufactured as a single integral part with the aerodynamic noise reduction assembly 27, for example, by any of the above-mentioned additive manufacturing techniques.

[0072] Now turn to Figure 6C In an alternative embodiment, a plurality of aerodynamic noise reduction components 27a, 27b, 27c may be manufactured separately and assembled in the spherical valve member 23. Figure 6C In the embodiment, the aerodynamic noise reduction components 27a, 27b, 27c, when assembled in the spherical valve member 28, form a flow channel 28 having a plurality of expansion chambers 38. For example, the first flow channel 28a may include a first expansion chamber 38a1, a second expansion chamber 38a2, and a third expansion chamber 38a3.

[0073] Now turn to Figure 7 , shows an alternative embodiment of the ball valve member 23 and an alternative embodiment of the aerodynamic noise reduction assembly 28d. The aerodynamic noise reduction assembly 27d includes a first flow passage 28a having a first expansion chamber 38a1 and a second expansion chamber 38a2. Figure 7The expansion chambers 38a1 and 38a2 in the embodiment are different from the previous embodiment in that the first expansion chamber 38a1 and the second expansion chamber 38a2 are continuous. In other words, the first expansion chamber 38a1 and the second expansion chamber 38a2 form a single expansion chamber with a stepped increasing volume.

[0074] Now turn to Fig. 9 , shows another embodiment of an aerodynamic noise reduction component 27e. The aerodynamic noise reduction component 27e includes a first flow channel 28a having a first expansion chamber 38a1, a second expansion chamber 38a2, and a third expansion chamber 38a3. The volume of the first expansion chamber 38a1 is smaller than the volume of the second expansion chamber 38a2, and the volume of the second expansion chamber 38a2 is smaller than the volume of the third expansion chamber 38a3. Therefore, the first flow channel 28a has discrete, graded, and increasing volume expansion chambers 38.

[0075] The disclosed aerodynamic noise reduction assembly advantageously includes an expansion chamber arranged along an axis that is parallel to the flow axis of the fluid when the valve is in a fully open state.

[0076] More expansion chambers can advantageously reduce wear of the trim material by producing a greater fluid pressure reduction and by reducing cavitation. In general, as the pressure differential across the trim increases, more expansion chambers are advantageous. Conversely, if the pressure differential across the trim is smaller, fewer throttling stages can reduce manufacturing complexity, thereby improving economic feasibility.

[0077] The disclosed aerodynamic noise reduction elements are advantageously used to reduce aerodynamic noise of compressible fluids. However, the disclosed aerodynamic noise reduction elements may also be used with other fluids, such as non-compressible fluids, to reduce cavitation and the noise generated thereby.

[0078] Furthermore, the disclosed aerodynamic noise reduction element advantageously achieves flow channels having smaller diameters, longer lengths, and tighter spacing than known aerodynamic noise reduction elements. The smaller diameters, longer lengths, and tighter spacing of the flow channels allow the disclosed aerodynamic noise reduction element to achieve greater pressure grading and greater noise reduction than known aerodynamic noise reduction elements, while also packing many flow channels closely together to create higher flow capacity.

[0079] The above listed aspects reflect various embodiments explicitly contemplated by the present disclosure. It will be readily appreciated by those skilled in the art that these aspects are neither limiting the embodiments disclosed herein nor exhaustive of all embodiments contemplated from the above disclosure, but are intended to be exemplary in nature.

Claims

1. A valve assembly, comprising: a valve body defining an inlet and an outlet; a valve seat coupled to the valve body; a valve closing member coupled to the valve body, the valve closing member being displaceable relative to the valve body between a first closed position and a second fully open position, wherein in the first closed position a sealing portion of the valve closing member sealingly engages a sealing portion of the valve seat to prevent flow of a compressible fluid from the inlet of the valve body to the outlet of the valve body, and in the second fully open position the sealing portion of the valve closing member deviates from the sealing portion of the valve seat to allow flow of the compressible fluid from the inlet of the valve body to the outlet of the valve body; An aerodynamic noise reduction element, wherein the aerodynamic noise reduction element comprises a plurality of flow channels, wherein the plurality of flow channels comprises: a first flow passage extending along a first flow axis from an open first end to an open second end, the first flow passage having a first fluid expansion chamber; A second flow passage extends along a second flow axis from an open first end to an open second end, the second flow passage having a second expansion chamber.

2. The valve assembly according to claim 1, wherein: The first flow channel includes a plurality of first expansion chambers arranged in series.

3. The valve assembly according to claim 2, wherein: The expansion lumens of the plurality of first expansion lumens are discrete.

4. The valve assembly according to claim 2, wherein: The expansion lumens of the plurality of first expansion lumens are continuous to form a single expansion lumen with increasing graded volumes.

5. The valve assembly according to claim 2, wherein: The second flow channel includes a plurality of second expansion chambers arranged in series.

6. The valve assembly according to claim 2, wherein: The two expansion cavities in the first expansion cavity have different expansion volumes.

7. The valve assembly according to claim 6, wherein: The expansion volume increases along the first flow axis from the first end to the second end.

8. The valve assembly according to claim 1, wherein: The first flow axis and the second flow axis are parallel to each other.

9. The valve assembly according to claim 1, wherein: The cross-sectional shape of the first flow channel is the same as the cross-sectional shape of the second flow channel.

10. The valve assembly according to claim 1, wherein: A cross-sectional shape of the first flow channel and a cross-sectional shape of the second flow channel both have a polygonal shape.

11. The valve assembly according to claim 10, wherein: The polygonal shape is one of a hexagon, a diamond or a rhombus.

12. The valve assembly according to claim 1, wherein: The valve closing member is a spherical member that rotates along a closing axis between the first closed position and the second fully open position.

13. The valve assembly of claim 1 further comprising a compressible fluid flowing through the aerodynamic noise reduction element.

14. An aerodynamic noise reduction element adapted for use with a valve assembly having a valve body defining an inlet and an outlet, a valve seat coupled to the valve body between the inlet and the outlet, and a valve closing member coupled to the valve body and displaceable relative to the valve body between a first closed position and a second fully open position, wherein: In the first closed position, the sealing portion of the valve closing member is sealingly engaged with the sealing portion of the valve seat, and in the second fully open position, the sealing portion of the valve closing member is offset from the sealing portion of the valve seat, the aerodynamic noise reduction element comprising: A plurality of flow channels, the plurality of flow channels comprising: a first flow channel extending from an open first end to an open second end along a first flow axis, the first flow channel having an inner surface defining a first flow region, the inner surface of the first flow channel having a first cross-sectional shape normal to the first flow axis, the first flow channel having a first expansion chamber; A second flow channel extends along a second flow axis from an open first end to an open second end, the second flow channel having an inner surface defining a second flow area, the inner surface of the second flow channel having a second cross-sectional shape normal to the second flow axis, and the second flow channel having a second expansion chamber.

15. The aerodynamic noise reduction element according to claim 14, wherein: The cross-sectional shape of the first flow channel and the cross-sectional shape of the second flow channel are polygonal shapes.

16. The aerodynamic noise reduction element according to claim 15, wherein: The polygonal shape is one of a hexagon, a diamond or a rhombus.

17. The aerodynamic noise reduction element according to claim 14, wherein: The cross-sectional shape of the first flow channel and the cross-sectional shape of the second flow channel are non-circular shapes.

18. The aerodynamic noise reduction element of claim 14, further comprising a compressible fluid flowing through the first flow passage and the second flow passage.

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