Manufacturing valve trim to reduce valve noise

Abstract

Valve trim configured to reduce noise in control valves. These configurations may include a cage with a flow path having an internal opening and an external opening. The cage may also have a bore for receiving a closure member or "plug." The plug can move longitudinally to change the flow parameters through the control valve. In one embodiment, the internal and external openings are vertically offset or spaced apart from one another along the axis of the bore. In one embodiment, the external opening is in a section of the cage not normally exposed to flow. This feature can increase the density of noise-reducing features within a given dimension of the cage (or the valve trim itself). The use of additive manufacturing may be useful (or even necessary) to further produce these parts within a specific design envelope, as these techniques create unique flow shapes within a unitary 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

[Technical Field]

[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 vast networks of pipes, tanks, generators, and other equipment. It is common in these facilities for flow control devices, such as control valves, to generate significant noise during operation due to pressure changes that occur as flow passes across the device. This aerodynamic noise can well exceed 100 dBA, or at least exceed established limits necessary to provide a safe working environment for technicians and other workers at the facility. Summary of the Invention

[0002] The subject matter of this disclosure relates to improvements in valve manufacturing or construction that can attenuate this noise to safe and acceptable levels. Of particular interest are embodiments that direct flow through flow channels with openings that are vertically spaced apart from one another. These embodiments can utilize parts of valve components that are typically not subject to or exposed to flow. As a result, the density of pressure-reducing structures, such as flow channels, is increased without increasing the dimensions of the underlying component structures. As an added benefit, multiple flow channels create a gradual pressure drop within the valve device. This feature can maintain fluid velocities at reasonable levels while maintaining noise levels well within specifications or standards. [Brief explanation of the drawings]

[0003] This specification makes reference to the following drawings: [Figure 1] 1 shows a schematic diagram of an exemplary embodiment of a valve trim; [Figure 2] 2 shows an elevational view of a cross section of the example valve trim of FIG. 1. [Figure 3] 2 shows a perspective view of an example of the valve trim of FIG. 1. [Figure 4]2 shows an elevation view of an example of the valve trim of FIG. 1. [Figure 5] 2 shows an elevational view of a cross section of the example valve trim of FIG. 1. [Figure 6] 2 shows an elevational view of a cross section of the example valve trim of FIG. 1. [Figure 7] 1 illustrates an elevation view of an exemplary configuration of a flow control device.

[0004] These drawings and any descriptions herein represent examples that may disclose or describe the invention. These examples, including the best mode, enable one skilled in the art to practice the invention, including making and using any device or system and performing any incorporated methods. The drawings are not to scale unless otherwise noted in the discussion. Elements in the examples may appear in more than one of the figures or in combinations of the figures. The figures may use like reference numerals to indicate identical or corresponding elements. Methods are merely illustrative and may be modified, for example, by reordering, adding, removing, and / or changing individual steps or stages. Although such stages, as well as any parts, components, elements, or functions, may be identified in the singular using the word "a" or "an," this should not, however, exclude a plural form of such designation unless the specification expressly states or explains such exclusion. Similarly, any reference to "one embodiment" or "an implementation" should not exclude the existence of additional embodiments or implementations that also incorporate the recited features. DETAILED DESCRIPTION OF THE INVENTION

[0005] The features of each example shown in the above figures will now be described. These examples are intended to mitigate noise in industrial or commercial valves. This noise is a cause for concern because, if left unmitigated, it can create an unsafe or even dangerous work area for operators or technicians. The designs proposed herein may implement tortuous paths to quiet valves in the field. These paths maximize the percentage of total pressure drop that shear action and boundary layer turbulence induce on the flowing fluid. Other embodiments are within the scope of this disclosure.

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

[0007] Generally, the valve trim 100 can be configured to attenuate noise. These configurations can incorporate components that can address noise sources within the device. These components can have structures that redirect flow, for example, as flow often moves radially from inside to outside through the component. As mentioned above, this structure can utilize a large portion of the available surface area of ​​the component. This feature can improve or increase pressure drop by providing greater flow channel density within the existing dimensions of the component.

[0008] Distribution systems 102 may be configured to deliver or move resources. These configurations may embody vast infrastructures. Materials 104 may include gases, liquids, solids, or even mixtures. Conduits 106 may include pipes or pipelines that often connect to pumps, boilers, etc. Pipes may also connect to tanks or reservoirs. In many facilities, this equipment forms a complex network.

[0009] Flow control devices 108 can be configured to regulate the flow of material 104 through conduits 106 in this complex network. These configurations can include control valves and similar devices. The valve body 110 in such devices is often made of cast or machined metal. This structure can form flanges at openings I and O. Adjacent pipes 106 can connect to these flanges. The actuator 112 can use compressed or pressurized air and, in conjunction with a piston, spring (or springs), or flexible diaphragm, can generate the load. The valve stem 114 can form an elongated cylinder or rod that directs this load to a closure member 116, which is often a cylindrical block or plug. The load can govern the position of this plug in the valve trim 100 to regulate the flow of material 104 through the opening in the seat 118. The position of the plug can expose a specific portion of the valve trim 100 to the flow, for example, to allow flow to outlet O. However, due to its size or other considerations, the plug may not expose any other portion of the valve trim 100 to the flow.

[0010] The cage 120 can be configured to reside in close proximity to the seat 118. These configurations can be "porous" or include designs that allow material to flow from the inside to the outside of the device. This feature can facilitate pressure drop due to pathways that direct fluid in various directions within the cage 120 material. These pathways can also mitigate or attenuate noise. As mentioned above, the pathways can have openings that are vertically offset from one another when the cage 120 is in place within the valve body 110. This configuration can utilize the "full" surface area of ​​the cage 120, as the openings can be in areas where the plug is not normally exposed to flow.

[0011] FIG. 2 shows a schematic plan view of a cross section of an exemplary structure of the cage 120. This structure may 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. A flow structure 128 may be incorporated into the body. The configuration of the flow structure 128 may direct the flow F of material 104 through one or more serpentine or winding paths. These paths may include flow channels 130 that extend through the body and terminate at openings 132 found, for example, 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 also be preferred. The surface may be textured, for example, with bumps or stippling. The texture may be configured to apply friction or drag to the flow F. The flow channels 130 may have a geometry along their length that dissipates pressure in the flow F. This design may extend or maximize the movement of material 104 through the body. This feature may, for example, induce a pressure drop to reduce noise as flow F exits cylinder 122 at opening 132 in outer surface 126.

[0012] One design may position the openings 132 of the flow channels 130 in different portions of the cylinder 122. As shown, the openings 132 may be vertically offset from one another along the axis C. This configuration places 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 the seat 118, for example. In one implementation, the first section 134 may be proximate to the seat 118. The closure member 116 may be movable to positions found within the first section 134. These positions may expose a specific number of openings 132 for flow F to pass through the flow channels 130. This feature manages the flow of material 104 from the device. The second section 136 is above the first section 134. The second section 136 has a maximum height M that defines the travel limit of the closure member 116. E This travel limit may not allow the closure member 116 to move to a position that may expose an area of ​​the second section 136 to the flow of material 104.

[0013] FIG. 3 shows a partially cutaway, top perspective view of an example cylinder 122. This example includes a group of individual flow channels 130 generally identified by the letters A, B, and C. Flow channels A, B, and C terminate in internal openings A1, B1, and C1 and external openings A2, B2, and C2, respectively. Internal openings A1, B1, and C1 reside in a first or "lower" section 134 of the cylinder 122. External openings A2, B2, and C2 reside in a second or "upper" section 136. In one embodiment, the flow channels 130 connecting the openings 132 may adopt a serpentine "wrap" shape through the body of the cylinder 122. This serpentine shape may create axial flow (i.e., along axis C) as well as angular, radial, or spiral flow within the body of the cylinder 122. Additionally, the openings 132 of each flow channel A, B, and C may be offset from one another. For example, in addition to the vertical offset described herein, the radial offset 140 may define the degree or amount of offset or “radial asymmetry” adopted by the design between the inner openings A1, B1, C1 and the outer openings A2, B2, C2 about the central axis C.

[0014] FIG. 4 shows an elevation view of one example of the structure of the cylinder 122. This structure employs a serpentine shape that creates an asymmetry between the openings 132. The asymmetry may be suitable for use with additive manufacturing techniques, such as 3D printing, due to any complex curves, bends, or other features in the serpentine shape that are not correctable with conventional machining techniques. These techniques may be particularly useful for manufacturing or embedding the serpentine path 130 or other complex shapes into the body of the cylinder 122 so that the body of the cylinder 122 becomes a single or monolithic structure or device. In other embodiments, individual “plates” may be stacked on top of each other. This collective stack may form the body of the cylinder 122. However, the present disclosure recognizes that the use of additive techniques may provide a better solution because they may avoid the need for stacking “plates” and therefore may be less costly, less complex, or offer other benefits than plate-stacked designs.

[0015] 5 and 6 show elevational views of a cross section of an exemplary structure of cage 120. Additional flow paths 138 may be located in lower section 134 of cylinder 122. In FIG. 5, flow paths 138 may embody through-holes 140 that direct flow essentially radially from the interior of the device. The through-holes may perforate lower section 134 in any number or configuration as desired. As best shown in FIG. 6, pathways 138 may embody large diameter through-holes 142.

[0016] FIG. 7 shows a side elevational view illustrating an exemplary structure of the trim 100. The cylinder 122 may reside within a casing 144 made of metal (or a material having suitable properties). The casing 144 may have a flow passage 146 terminating in a flanged opening 148. The flow passage 146 may receive material 104 from an adjacent conduit 106 attached to the casing at the flanged opening 148. The closure member 116 may embody a movable plug 150 residing within the bore 124 of the cylinder 122. The valve body 110 may include a bonnet 152 secured to the casing 144. A fastener F, such as a nut and bolt, may serve for this purpose. The valve stem 114 may extend through the bonnet 152. In one implementation, a packing 154 may fit over the valve stem 114. Packing 154 is useful for allowing movement of valve stem 114 but preventing flow control device 108 from venting fugitive emissions.

[0017] Considering the above, improvements can optimize the use of surface area for noise reduction in valves or flow controls in general. This design can maximize flow through the cage walls due to the additional flow channels available to direct flow from the inside to the outside of the cage. Additive manufacturing can offer some flexibility to achieve layout complexity.

[0018] The following examples include particular elements or clauses to describe embodiments contemplated within the scope of this specification. These elements may be combined with other elements and clauses to similarly describe embodiments. This specification may include and contemplate other examples that occur to those skilled in the art. These other examples fall within the scope of the claims, for example, if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that differ insignificantly from the literal language of the claims.

Claims

1. A valve, A closure member; a cage surrounding at least a portion of the closure member, the cage comprising a bore having an axis, the cage incorporating flow passages terminating in openings found respectively on an inner surface of the bore and an outer surface of the cage, the openings being offset along the axis such that the opening in the inner surface is in a first section of the cage within a maximum travel distance of the closure member and the opening in the outer surface is in a second section of the cage outside the maximum travel distance of the closure member.

2. The valve of claim 1 , wherein the openings are angularly offset from one another.

3. The valve of claim 1 , wherein the openings are vertically aligned with one another.

4. The valve of claim 1 , wherein the flow passages are configured such that the openings are angularly offset from one another.

5. The valve of claim 1 , wherein the flow passages are configured to direct flow through the cage axially and radially relative to the axis of the bore.

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

7. The valve of claim 1 , wherein the flow path has a serpentine shape.

8. 10. The valve of claim 1, further comprising a through hole in the cage having an axis perpendicular to the axis of the bore.

9. 2. The valve of claim 1, further comprising a throughbore in the cage having an axis perpendicular to the axis of the bore, the throughbore having a diameter greater than a diameter of the opening inside the bore.

10. 10. The valve of claim 1, further comprising a plurality of through holes in the cage, each having an axis perpendicular to the axis of the bore.

11. A valve, a cage having a bore; a closure member movable within said bore; a seat fixed relative to the cage; The cage includes a body that directs fluid inwardly along the bore from a first section below a highest position of the closure member to a second section above the highest position of the closure member.

12. 12. The valve of claim 11, wherein the body includes openings above and below the highest position of the closure member.

13. 12. The valve of claim 11, wherein the body includes an opening for fluid exit above the highest position of the closure member.

14. 12. The valve of claim 11, wherein the body includes an opening for fluid entry below the highest position of the closure member.

15. 12. The valve of claim 11, wherein the body is perforated with through holes perpendicular to the bore.

16. 12. The valve of claim 11, wherein the body is perforated with a through hole perpendicular to the bore below the highest position of the closure member.

17. A valve, a valve trim having a first section for radially receiving flow and a second section for radially discharging flow; a closure member present within the valve trim; The valve, wherein the first section is below a maximum travel distance of the closure member and the second section is above the maximum travel distance of the closure member.

18. 18. The valve of claim 17, wherein the first section and the second section are joined by a flow path.

19. 18. The valve of claim 17, wherein the first section and the second section are joined by a flow path having a serpentine shape.

20. 18. The valve of claim 17, wherein the first section and the second section are joined by a flow passage that directs fluid axially and radially within the valve trim.

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