Butterfly Valve Flow Control Device with Downstream Diffuser
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Solution Overview
Problem
Butterfly valves experience significant pressure drop-related cavitation and noise issues, and existing flow control solutions either restrict flow capacity or complicate installation due to protruding cage walls, which limit their effectiveness and usability.
Innovation Solution
A control valve assembly featuring a cylindrical flow control device with a curved regress and sloping teeth that expose flow control channels as the valve opens, allowing for increased flow capacity and easy installation between pipes by providing a planar surface at both ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a diffuser is integrally incorporated into the valve element, then cavitation and noise problems are reduced, but the valve cannot be used in other configurations and flow control capability near fully opened position is limited
Solution Approach 1:
The diffuser is separated from the valve element and placed in the downstream pipe section. This segmentation allows the diffuser to function independently while maintaining its cavitation-reducing benefits, and enables the valve element to be used in different configurations without the diffuser being permanently attached to it.
Solution Approach 2:
The diffuser is extracted from the valve element and positioned separately in the downstream pipe. This extraction resolves the conflict by allowing the diffuser to provide cavitation protection while not constraining the valve's configurability or adaptability to different applications.
2Ease of operation
If cage walls protrude into the flow stream when valve is wide open, then flow control is improved, but maximum flow capacity is significantly reduced and installation between pipe sections is difficult
Solution Approach 1:
Instead of having cage walls protrude radially into the flow path (one-dimensional obstruction), the solution uses a downstream diffuser that acts in the axial dimension. The diffuser controls flow through its geometry and angle of attack, managing cavitation without blocking the radial flow path, thereby maintaining high flow capacity.
3Ease of operation
If cage walls protrude into the flow stream, then flow control is improved, but installation between pipe sections becomes difficult
Solution Approach 1:
The flow control and cavitation protection functions are segmented from the valve body and implemented as a separate downstream diffuser component. This segmentation creates a compact assembly that can be easily installed between pipe sections without protruding elements, while still providing the necessary flow control capabilities.
4Object-affected harmful factors
If flow control device restricts flow cross section, then cavitation is reduced, but flow capacity is reduced
Solution Approach 1:
Instead of restricting flow cross-section, the downstream diffuser changes flow parameters through its geometric design. The diffuser's angle of attack and surface geometry control the flow velocity and pressure distribution, reducing cavitation through parameter modification rather than physical restriction, thereby maintaining high flow capacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances flow characteristics, reduces cavitation, and decreases dynamic torque requirements, enabling more efficient fluid flow and easier installation while maintaining high flow capacity even at fully open positions.
Implementation Method 1
When fluid passes through a partially open butterfly valve, the fluid undergoes a significant pressure drop
Implementation Method 2
the pressure drop tends to cause cavitation and consequent cavitation-induced damage in liquid service and noise in gas service
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A control valve assembly that utilizes a butterfly valve having a valve (12) body and a valve disk (22) movable between a closed position and an open position, The control valve assembly includes a flow control device (36) positioned downstream from the butterfly valve. The flow control device (36) includes a series of teeth (66) spaced by a series of flow control channels (62) such that as the valve disk (22) moves from the seated position to the fully open position, the outer sealing edge (26) of the valve disk (22) passes over the series of teeth (66) to gradually expose the flow control channels (62). The control device aids in reducing cavitation, offers reduced dynamic torque and allows the control valve assembly to be inserted between an inflow pipe and an outflow pipe.