Manufacture of a valve trim for reducing valve noise

Abstract

A valve trim configured to reduce noise within a control valve. These configurations can include a cage having a flow path with a spiral design or layout. This flow path can direct flow around a central bore. A plug may be within this bore. This plug can move longitudinally to change parameters of the flow through the control valve. In one implementation, the spiral design can split the flow inside the cage. This feature can extend the travel of the flow without increasing the size of the cage (or the valve trim itself). The use of additive manufacturing can further maintain these components within a specific design envelope as these techniques create unique flow geometries within an integral or monolithic body. In this way, the valve trim of the present disclosure can maintain or even reduce the cost of the control valve while simultaneously simplifying the overall structure of the valve device.

Description

Background Art

[0001] Flow control devices play a major role in many industrial facilities. For example, power plants and industrial processing facilities use different types of flow control devices to manage the flow of materials, typically fluids, throughout an extensive network of pipes, tanks, generators, and other equipment. Due to the pressure changes that occur as the flow passes across the device, it is common in these facilities for flow control devices, such as control valves, to generate significant noise during operation. This aerodynamic noise can far exceed 100 dBA or at least exceed the set limits necessary to provide a safe working environment for engineers and other workers in the facility.

Summary of the Invention

[0002] The subject matter of the present disclosure relates to improvements in the manufacture or structure of valves that can attenuate this noise to a safe and acceptable level. Of particular interest are embodiments that direct the flow through a serpentine flow path. These embodiments gradually impose a pressure drop within the components of the valve device. This feature can maintain the fluid velocity at a reasonable level while the noise level remains well within the specifications or standards.

Brief Description of the Drawings

[0003] This specification refers to the following drawings.

Figure 1

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Figure 3

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[0004] These drawings and any descriptions in this specification represent examples that may disclose or illustrate the present invention. These examples include the best mode and enable the implementation of the present invention, including a person skilled in the art making and using any device or system and performing any incorporated method. The drawings are not to scale unless otherwise specified in the description. Elements in each example may appear in one or more of several figures or in a combination of multiple figures. The drawings may use similar reference numerals to indicate identical or corresponding elements. Each method is merely illustrative and may be modified, for example, by reordering, adding, deleting, and / or changing individual steps or stages. In this specification, such steps, as well as any part, component, element, or function, may sometimes be identified in the singular using the words "a" or "an". However, this should not exclude the plural form of such designations unless the specification explicitly describes or explains such an exclusion. Similarly, references to "one embodiment" or "one implementation form" should not be construed as excluding the existence of additional embodiment or implementation forms that also incorporate the recited features.

Mode for Carrying Out the Invention

[0005] Next, the features of each example shown in the above drawings will be described. These examples are aimed at reducing noise in industrial or commercial valves. This noise is a cause for concern because, if left unmitigated, it can create a work area that is unsafe or even dangerous for operators or technicians. The design proposed in this specification can implement a meandering path to a quiet valve on-site. These paths maximize the ratio of the total pressure drop induced by shear action and boundary layer turbulence in the flowing fluid. Other embodiments are within the scope of this disclosure.

[0006] Figure 1 shows an example of a trim 100. This embodiment is typically found in a distribution network 102 designed to convey a material 104 throughout a network of conduits 106. The trim 100 may be part of a flow control device 108 having a valve body 110 connected in series with the conduit 106. The device may also have an actuator 112. A valve stem 114 may extend from the actuator 112 and position a closure member 116 in proximity to a seat 118. In one embodiment, the trim 100 may include a cage 120 that receives the closure member 116 therein.

[0007] Generally, the trim 100 may be configured to attenuate noise. These configurations can incorporate components that can address noise sources within the device. These components can have, for example, structures that change the direction of the flow, often when the flow moves radially from the inside to the outside through the component. This structure may adopt geometries that are useful for the use of additive manufacturing due to complex curves, bends, or other features that are not amendable with conventional machining techniques.

[0008] The distribution system 102 may be configured to deliver or move resources. These configurations can embody extensive infrastructure. The material 104 can also include gases, liquids, solids, or mixtures. The conduits 106 can often include pipes or pipelines connected to pumps, boilers, etc. The pipes may also be connected to tanks or reservoirs. In many facilities, this equipment forms a complex network.

[0009] The flow control device 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 within such a device is often made of cast or machined metal. This structure can form flanges at the openings I, O. The adjacent pipes 106 can be connected to these flanges. The actuator 112 may use compressed or pressurized air and may generate a load together with a piston, spring (or springs), or a flexible diaphragm. The valve stem 114 can form an elongated cylinder or rod that guides this load to the closing member 116, which is often a cylindrical block or plug. The position of the plug can be controlled by the load to prevent flow through the opening in the seat 118.

[0010] The cage 120 can be configured to be present in proximity to the seat 118. These configurations may include being "porous" or having a design that allows the material to flow from the inside to the outside of the device. This feature can smooth the pressure drop due to serpentine or tortuous paths that direct the fluid in various directions within the material of the cage 120. These paths reduce or attenuate noise. As described above, the design of this specification maximizes the path length without unnecessarily increasing the size of the cage 120.

[0011] Figure 2 shows a schematic plan view of a cross-section of an exemplary structure of the cage 120. This structure can embody a cylinder 122 with a body having a bore 124 with a central axis C. The body may also have an outer surface 126. The flow structure 128 may be incorporated into the body. The configuration of the flow structure 128 can direct the flow F of the material 104 through one or more meandering or serpentine paths. These paths can include flow channels 130 that extend through the body and terminate, for example, at openings 132 seen in the bore 124 and the outer surface 126, respectively. The flow channels 130 may have a circular cross-section. However, other cross-sections such as square or rectangular may be equally preferred. Its surface may be textured, for example, with bumps or a circumferential ring. This texture may be configured to add friction or drag to the flow F. The flow channels 130 may take on a geometry having a design or layout that dissipates the pressure of the flow F along its length. This design can extend or maximize the movement of the material 104 through the body. This feature can induce a pressure drop and reduce noise, for example, when the flow F exits the cylinder 122 at the opening 132 of the outer surface 126. In one design, the passage 130 can be serpentined with a continuous or gradually widening curve that at least partially surrounds the bore 124. This curved design or "helical" layout can follow a radius R that increases according to the angular position α, both measured from or around the central axis C. The advantage of the helical design is that an appropriate pressure drop is achieved within the set dimensions of the cylinder 122, that is, within its outer diameter, such that the overall dimensions of the flow control device 108 are maintained within the design specifications.

[0012] FIG. 3 shows a plan view of a cross-section of an exemplary structure of the cylinder 122. The flow path 130 can incorporate a junction 134. This feature can split the flow from the "internal" opening 132 in the bore 124 into one or more branches 136, so that the length of the pressure dissipation structure can be extended. Each of the branches 136 may terminate at a separate "external" opening 132 on the outer surface 126. In one embodiment, the flow path 130 may include a valve 138 that can contribute to the pressure drop. The valve 138 may include a loop 140 with an inlet 142 and an outlet 144. The loop 140 can receive a portion of the flow F from the branch 136 at the inlet 142. This portion can form an auxiliary flow F1. The geometry of the loop 140 can be oriented to return the auxiliary flow F1 to the branch 136 at the outlet 144. In one implementation, the auxiliary flow F1 flows in a direction opposite to the flow F or at an angle to the flow F. This feature can further reduce the velocity or flow rate and then smooth the pressure drop that can reduce noise when the flow F exits the path 132 at the opening 130 of the outer surface 126, and can block the flow F.

[0013] Figure 4 shows an elevation view of an example of cylinder 122. The body has a length L that includes several flow dissipation sections 146. Each of the sections 146 can incorporate a flow structure 128 having an opening 132 present in the outer surface 126. In one implementation, additive manufacturing techniques (i.e., 3D printing) can be useful for manufacturing or embedding a serpentine path (or a flow channel 130 having a helical layout) or other complex geometries within each section 146. These techniques are also useful for manufacturing the sections 146 together such that the body of the cylinder 122 forms a single or monolithic device. In other implementations, the sections 146 can form individual "plates" that are stacked on top of each other. This collective stack can form the cylinder 122. However, the present disclosure recognizes that the use of additive techniques makes it possible to avoid the need to stack "plates" and thus provides a better solution as it is less costly, less complex, or offers other benefits than a design where plates are stacked.

[0014] FIG. 5 shows an elevation view from the side showing an exemplary structure of the trim 100. The cylinder 122 may be present within a casing 148 made of metal (or a material having suitable properties). The casing 148 can have a flow path 150 that terminates in a flanged opening 152. The flow path 150 can receive the material 104 from an adjacent conduit 106 attached to the casing at the flanged opening 152. The closure member 116 can embody a movable plug 154 present within the bore 124 of the cylinder 122. The valve body 110 can include a bonnet 156 that is inserted within the casing 148. The bonnet flange 158 may be coupled to the casing 148 and thus fixes the bonnet 156 in place. Fasteners F such as nuts and bolts may function for this purpose. The valve stem 114 may extend through the bonnet 156. In one implementation, a packing 160 can fit over the valve stem 114. The packing 160 allows movement of the valve stem 114 but is useful to prevent the flow control device 108 from discharging escaping emissions.

[0015] The following examples include specific elements or sections for explaining embodiments contemplated within the scope of this specification. These elements may also be combined with other elements and sections for explaining embodiments. This specification includes and contemplates other examples that may occur to those skilled in the art. These other examples are within the scope of the claims if, for example, they have structural elements that do not differ from the literal language of the claims, or if they have equivalent structural elements with no substantial difference from the literal language of the claims.

Claims

1. A valve comprising a valve trim having a cage forming a bore, said cage incorporating a flow path following a pattern having a radius increasing according to the angular position around said axis.

2. The valve according to claim 1, wherein said pattern forms a helix.

3. The valve according to claim 1, wherein said flow path has an opening in said bore.

4. The valve according to claim 1, wherein said flow path has an opening in the outer surface of said cage.

5. The valve according to claim 1, wherein said flow path is configured to enable flow through said cage.

6. The valve according to claim 1, wherein said flow path forms branches terminating at different openings in the outer surface of said cage.

7. The valve according to claim 1, wherein said flow path divides the flow into two separate outflow streams.

8. The valve according to claim 1, wherein said flow path has a junction inside said cage that divides the flow into two different branches.

9. The valve according to claim 1, wherein said flow path has a loop that generates an auxiliary flow in a direction opposite to the flow in said flow path.

10. The valve according to claim 1, wherein said cage has a monolithic structure.

11. A valve comprising: a cage having a bore; a closing member movable within said bore; and a seat fixed to said cage, wherein said cage has a body for directing fluid through a flow path following a pattern having a radius increasing according to the angular position around said bore.

12. The valve according to claim 11, wherein said body has at least two flow dissipation sections, each flow dissipation section having at least one of said flow paths.

13. The valve according to claim 11, wherein said body has at least two flow dissipation sections, each flow dissipation section having at least one of said flow paths and being longitudinally spaced apart from each other along said bore.

14. The valve according to claim 11, wherein said body forms a cylinder having a monolithic structure.

15. The valve according to claim 11, wherein said body has a monolithic structure having at least two flow dissipation sections, each flow dissipation section having at least one of said flow paths.

16. The valve according to claim 11, wherein the body has a monolithic structure having at least two flow dissipation sections, each dissipation section having at least one of the flow paths and being longitudinally spaced from each other along the bore.

17. A valve, wherein the valve trim directs the flow in a spiral pattern from the inside to the outside.

18. The valve according to claim 17, further comprising a plurality of flow paths adopting the spiral pattern.

19. The valve according to claim 17, further comprising a plurality of flow paths adopting the spiral pattern, the plurality of flow paths being longitudinally spaced from each other along the axis of the valve trim.

20. The valve according to claim 17, further comprising a plurality of flow paths adopting the spiral pattern, each of the plurality of flow paths dividing the flow within the valve trim.

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