Manufacturing valve trim for eliminating valve noise

Abstract

A valve trim configured to cancel noise in a control valve. These configurations may include a cage with a flow path having an inner opening and an outer opening. The holder may also have a bore to receive a closure member or a "plug". The stopper may be longitudinally advanced to vary a parameter of flow through the control valve. In one embodiment, the inner opening and the outer opening are vertically offset or spaced apart from each other along the axis of the bore. In one embodiment, the external opening is located in a section of the cage that is generally not exposed to flow. This feature may increase the density of noise cancelling features within a given size of the cage (or the valve trim itself). The use of additive manufacturing may help (even necessary) create these portions within certain design ranges, since these techniques may create unique flow geometry within one-piece or unitary bodies. In this manner, the valve trim of the present disclosure may maintain or even reduce the cost of the control valve, while it may simplify the overall configuration of the valve apparatus.

Description

Background Art

[0001] Flow control devices play an important role in many industrial facilities. For example, power plants and industrial process facilities use different types of flow control devices to manage the flow of materials (usually fluids) throughout a vast network of pipes, tanks, generators, and other equipment. Since pressure changes occur as the flow travels across the devices, significant noise is typically generated during operation in these facilities for flow control devices such as control valves. This pneumatic noise can reach well above 100 dBA, or at least exceed the set limit necessary to provide a safe working environment for technicians and other workers at the facility. Summary of the Invention

[0002] The subject matter of the present disclosure relates to improvements in the manufacture or construction of valves that can attenuate such noise to a safe and acceptable level. Particular interest lies in embodiments that direct flow through a flow path having openings vertically spaced from each other. These embodiments can utilize portions of the valve components that are not typically subjected to or exposed to the flow. Without increasing the size of the underlying component structure, this results in an increased density of pressure-reducing structures such as the flow path. As an additional benefit, multiple flow paths force a gradual pressure drop to occur within the valve device. This feature can maintain the velocity of the fluid at a reasonable level while keeping the noise level well within the specifications or standards. Brief Description of the Drawings

[0003] This specification refers to the following drawings:

[0004] Figure 1 A schematic diagram depicting an exemplary embodiment of a valve internals;

[0005] Figure 2 Depicting Figure 1 a front view of a cross-section of an example of the valve internals;

[0006] Figure 3 Depicting Figure 1 a perspective view of an example of the valve internals;

[0007] Figure 4 Depicting Figure 1 a front view of an example of the valve internals;

[0008] Figure 5 Depicting Figure 1 a front view of a cross-section of an example of the valve internals;

[0009] Figure 6 Depicting Figure 1 a front view of a cross-section of an example of the valve internals; and

[0010] Figure 7 a front view of an exemplary structure of a flow control device.

[0011] These figures and any description in this document represent examples that may disclose or explain the invention. These examples include the best mode and also enable any person skilled in the art to practice the invention, including manufacturing and using any device or system and performing any combined method. Unless otherwise stated in the discussion, the figures are not drawn to scale. Elements in the examples may appear in one or more of several views or in a combination of several views. The figures may use similar reference numerals to denote the same or corresponding elements. The methods are merely exemplary and may be modified, for example, by reordering, adding, deleting, and / or changing individual steps or stages. This specification may use the singular words "a" or "an" to identify such stages as well as any parts, components, elements, or functions; however, this should not exclude the plural forms of any such names unless the specification expressly recites or states such an exclusion. Similarly, any reference to "an embodiment" or "a particular implementation" does not exclude the existence of other embodiments or particular implementations that also incorporate the described features. Detailed Description

[0012] The features of the examples shown in the above figures will now be discussed. These examples are intended to eliminate noise in industrial or commercial valves. Such noise is a concern because if not mitigated, it can create a work area that is unsafe or even dangerous for operators or technicians. The designs presented herein enable tortuous flow paths to silence the individual valves in the field. These paths maximize the percentage of the total pressure drop in the flowing fluid caused by shear action and boundary layer turbulence. Other embodiments are within the scope of this disclosure.

[0013] Figure 1 An example of a valve internals 100 is depicted. This example exists in a distribution network 102 that is typically designed to transport a material 104 through a network of conduits 106. The valve internals 100 can be part of a flow control 108 that has a valve body 110 connected in series with the conduit 106. The device may also have an actuator 112. A valve stem 114 can extend from the actuator 112 to position a closure member 116 in proximity to a seat 118. In one embodiment, the valve internals 100 can include a cage 120 that receives the closure member 116 therein.

[0014] Generally, the valve internals 100 can be configured to attenuate noise. These configurations can incorporate parts that address the noise sources in the device. These parts can, for example, have a structure that generally changes the direction of the flow as the flow moves radially from the inside to the outside through the part. As noted, this structure can utilize most of the available surface area of the part. This feature can improve or increase the pressure drop because it provides a greater flow path density within the existing dimensions of the part.

[0015] The distribution system 102 can be configured to convey or move resources. These configurations can manifest as massive infrastructure. The material 104 can also include gases, liquids, solids, or mixtures. The conduit 106 can include pipes or pipelines that are typically connected to pumps, boilers, etc. The pipe can also be connected to a tank or reservoir. In many facilities, this equipment forms a complex network.

[0016] The flow control 108 can be configured to regulate the flow of the material 104 through the conduit 106 in these complex networks. These configurations can include control valves and similar devices. The valve body 110 in such devices is typically made of cast or machined metal. This structure can form flanges at the openings I, O. Adjacent conduits 106 can be connected to these flanges. The actuator 112 can use compressed air or pressurized air and, together with a piston, one (or more) springs, or a flexible diaphragm, generate a load. The valve stem 114 can form an elongated cylinder or rod that directs this load to a closure member 116, which is typically a cylindrical block or plug. The load can manage the position of the plug within the valve internals 100 to regulate the flow of the material 104 through the opening in the seat 118. The position of the plug may expose certain parts of the valve internals 100, for example, allowing flow to the outlet O. However, due to its size or other considerations, the plug may not expose other parts of the valve internals 100 at all.

[0017] The cage 120 can be configured to reside near the seat 118. These configurations can include a "porous" design or a design that enables the material to flow from the interior of the device to the exterior of the device. Since the paths direct the fluid in all directions within the material of the cage 120, this feature can be beneficial for achieving a pressure drop. These paths reduce or attenuate noise. As noted, when the cage 120 is in place within the valve body 110, the paths can have openings that are vertically offset from each other. Since the openings can reside in areas where the plug is not typically exposed to the flow, this arrangement can utilize the "full" surface area of the cage 120.

[0018] Figure 2A front view depicting a cross-section of an exemplary structure of a cage 120 is shown. The structure may be embodied as a cylinder 122 having a body that includes a bore 124 with a central axis C. The body may also have an outer surface 126. A flow-through structure 128 may be filled within the body. The configuration of the flow-through structure 128 may convey a flow F of a material 104 through one or more tortuous or winding paths. These paths may include flow-through passages 130 that extend through the body and terminate, for example, at openings 132, each opening being present at the bore 124 and the outer surface 126. The cross-section of the flow-through passage 130 may be circular. However, other cross-sections, such as square or rectangular, may also be employed. Its surface may be textured, for example, with bumps or dimples. Such a texture may be configured to increase the friction or resistance of the flow F. Along its length, the flow-through passage 130 may present a geometric structure having a design or layout that dissipates the pressure of the flow F. Such a design may extend or maximize the travel of the material 104 through the body. For example, when the flow F exits the cylinder 122 at the opening 132 on the outer surface 126, this feature may cause a pressure drop to reduce noise.

[0019] One design may position the openings 132 of the flow-through passage 130 in different portions of the cylinder 122. As shown, the openings 132 may be vertically offset from each other along the axis C. This arrangement positions the openings 132 in different sections 134, 136 of the cylinder 122. The sections 134, 136 may correspond to the height of the closure member 116 relative to, for example, the seat 118. In one particular implementation, the first section 134 may reside near the seat 118. The closure member 116 may move to positions found within the first section 134. These positions may expose a certain number of the openings 132 to allow the flow F to pass through the flow-through passage 130. This feature manages the outflow of the material 104 from the device. The second section 136 is above the first section 134. It may start at a maximum height M E that defines the travel limit of the closure member 116. This travel limit may not allow the closure member 116 to move to a position that may expose the area of the second section 136 to the flow of the material 104.

[0020] Figure 3Depicts a perspective view of a partially cut-away top of an example of a cylinder 122. The example includes a set of separate flow-through paths 130, typically identified by the letters A, B, C. Flow-through paths A, B, C terminate at internal openings A1, B1, C1 and external openings A2, B2, C2, respectively. Internal openings A1, B1, C1 reside in a first or "lower" section 134 of the cylinder 122. External openings A2, B2, C2 reside in a second or "upper" section 136. In one particular implementation, the flow-through paths 130 connecting the openings 132 can adopt a geometry that "winds" tortuously through the body of the cylinder 122. This tortuous geometry can create axial flow (i.e., along axis C) as well as angled, radial, or helical flow within the body of the cylinder 122. It can also offset the openings 132 of each flow-through path A, B, C from one another. For example, in addition to the vertical offset described herein, a radial offset 140 can define the degree or amount of offset or "radial asymmetry" that the design employs between the internal openings A1, B1, C1 and the external openings A2, B2, C2 about the central axis C.

[0021] Figure 4 Depicts a front view of an example of the structure of the cylinder 122. The structure adopts a tortuous geometry that results in an asymmetry ASY between the openings 132. Since any complex curves, bends, or other features in the tortuous geometry are not modifiable by traditional machining techniques, the asymmetry can lend itself to the use of additive manufacturing techniques such as 3D printing. These techniques can help to fabricate or embed the tortuous path 130 or other complex geometries within the body of the cylinder 122, particularly such that the body of the cylinder 122 is a single or monolithic structure or device. In other particular implementations, separate "plates" can be stacked on top of one another. This assembly stacking can form the body of the cylinder 122. However, the present disclosure recognizes that the use of additive techniques can obviate the need to stack "plates", thereby providing a better solution as it is less costly, simpler, or achieves other beneficial effects over the stacked-plate design.

[0022] Figure 5 and Figure 6 Depicts a front view of a cross-section of an exemplary structure for a cage 120. Additional flow-through paths 138 can also fill the lower section 134 of the cylinder 122. In Figure 5 this, the flow-through path 138 can be embodied as a through-hole 140 that directs flow substantially radially from the interior of the device. The through-hole can penetrate the lower section 134 in any number or arrangement as needed. As best shown in Figure 6 this, the path 138 can be embodied as a large-diameter through-hole 142.

[0023] Figure 7Depicts a front view seen from the side showing an exemplary structure of the valve internals 100. The cylinder 122 may reside within a housing 144 made of metal (or a material with suitable properties). The housing 144 may have a flow path 146 that terminates at a flange-like opening 148. The flow path 146 may receive the material 104 from an adjacent conduit 106, which is attached to the housing at the flange-like opening 148. The closure member 116 may be embodied as a movable plug 150 residing within the bore 124 of the cylinder 122. The valve body 110 may include a valve bonnet 152 fixed to the housing 144. Fasteners F such as nuts and bolts may be used for this purpose. The valve stem 114 may extend through the valve bonnet 152. In one embodiment, a packing 154 may be adapted above the valve stem 114. The packing 154 may be used to enable the valve stem 114 to move but prevent the flow control 108 from discharging fugitive emissions.

[0024] In view of the foregoing, improvements can generally optimize the use of surface area for noise cancellation in valves or flow controls. The design can maximize the flow through the cage walls due to additional flow paths available to direct the flow from the interior of the cage to the exterior. Additive manufacturing can provide a degree of flexibility to achieve layout complexity.

[0025] The following examples include certain elements or clauses that describe embodiments contemplated within the scope of this specification. These elements may be combined with other elements and clauses to further describe embodiments. This specification may include and contemplate other examples that occur to those skilled in the art. If these other examples have structural elements that are identical to the literal language of the claims, or if they include equivalent structural elements that are not materially different from the literal language of the claims, then these other examples fall within the scope of the claims.

Claims

1. A valve, the valve comprises: a closing member; and a cage that surrounds at least a portion of the closing member, the cage including a bore having an axis, the cage being coupled to a flow passageway that terminates in openings, the openings each being present on an inner surface of the bore and an outer surface of the cage, the openings being offset along the axis such that the openings on the inner surface are located in a first section of the cage that is within a maximum stroke of the closing member, and the openings on the outer surface are located in a second section of the cage that is outside the maximum stroke of the closing member.

2. The valve according to claim 1, wherein the openings are angularly offset from each other.

3. The valve according to claim 1, wherein the openings are vertically aligned with each other.

4. The valve according to claim 1, wherein the flow passageway is configured such that the openings are angularly offset from each other.

5. The valve according to claim 1, wherein the flow passageway is configured to direct flow through the cage in axial and radial directions relative to the axis of the bore.

6. The valve according to claim 1, wherein the flow passageway is configured to direct flow through the cage in a helical direction relative to the axis of the bore.

7. The valve according to claim 1, wherein the flow passageway has a tortuous geometry.

8. The valve according to claim 1, the valve further comprises: a through-hole in the cage, the through-hole having an axis perpendicular to the axis of the bore.

9. The valve according to claim 1, the valve further comprises: a through-hole in the cage, the through-hole having an axis perpendicular to the axis of the bore and having a diameter larger than a diameter of the openings on the inner side of the bore.

10. The valve according to claim 1, the valve further comprises: a plurality of through-holes in the cage, each through-hole having an axis perpendicular to the axis of the bore.

11. A valve, the valve comprises: a cage having a bore; a closing member that is movable within the bore; and a support that is stationary relative to the cage, wherein the cage includes a body that internally directs flow along the bore from a first section located below a maximum position of the closing member to a second section located above the maximum position of the closing member.

12. The valve according to claim 11, wherein the body includes openings above and below the maximum position of the closing member.

13. The valve according to claim 11, wherein the body includes an opening for fluid to exit, the opening being located above the maximum position of the closing member.

14. The valve according to claim 11, wherein the body includes an opening for fluid to enter, the opening being located below the maximum position of the closing member.

15. The valve according to claim 11, wherein the body is penetrated by a through-hole perpendicular to the bore.

16. The valve according to claim 11, wherein the body is penetrated by a through-hole perpendicular to the orifice below the maximum position of the closing member.

17. A valve, the valve comprising: a valve internals having a first section for radially receiving a flow and a second section for radially discharging a flow; and a closing member residing in the valve internals, wherein the first section is below the maximum stroke of the closing member and the second section is above the maximum stroke of the closing member.

18. The valve according to claim 17, wherein the first section and the second section are coupled by a flow passage.

19. The valve according to claim 17, wherein the first section and the second section are coupled by a flow passage having a tortuous geometry.

20. The valve according to claim 17, wherein the first section and the second section are coupled by a flow passage that axially and radially guides the flow within the valve internals.

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