Multistage Control Valve Trim for Erosion and Cavitation
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Solution Overview
Problem
In high-pressure and high-flow rate fluid systems, existing valves experience cavitation, flashing, noise, erosion, and reduced performance due to abrasive fluids, leading to potential failure.
Innovation Solution
A multistage, rising stem and expanding area control valve trim with a plug and liner configuration that employs horizontal and vertical fluid turns with increasing flow area, reducing erosion and inhibiting flashing, and includes a balance chamber to manage fluid pressure and reduce actuator size, while maintaining throughput and tolerance to debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional valve is used to control high-pressure and high-flow rate fluids, then the valve can direct and regulate fluid flow, but the valve experiences cavitation, flashing, erosion, and noise leading to reduced performance and potential failure
Solution Approach 1:
The valve body is divided into multiple stages (first stage, second stage, third stage) with progressively expanding flow areas. Each stage handles a portion of the pressure reduction and flow control, distributing the stress and reducing cavitation and erosion in any single stage. The multistage configuration allows gradual pressure equalization rather than abrupt changes.
Solution Approach 2:
The patent introduces vertical flow paths and elevation changes between stages, moving from horizontal to vertical orientation. This dimensional transition allows gravitational assistance in pressure management and creates expanding flow areas that reduce fluid velocity and minimize erosive impacts on valve components.
2Productivity
If the flow area is increased to maintain throughput, then fluid flow rate is maintained, but erosion and cavitation increase due to higher velocity and pressure differential
Solution Approach 1:
The flow path is segmented into multiple stages with progressively expanding areas. Each stage maintains adequate throughput while reducing the pressure differential across any single section. The segmented approach allows high overall throughput without subjecting any single component to excessive erosive forces.
Solution Approach 2:
The patent employs progressive parameter changes in flow area and pressure across multiple stages. The flow area increases from the first to the third stage while pressure decreases correspondingly. This controlled parameter transition maintains throughput while minimizing cavitation and erosion by avoiding abrupt changes.
3Stress or pressure
If a larger actuator is used to manage high fluid pressure, then pressure control is improved, but the device size and complexity increase
Solution Approach 1:
The pressure management function is segmented across multiple valve stages rather than requiring a single large actuator. Each stage handles a portion of the pressure differential, allowing the use of smaller, more manageable actuators while still achieving effective high-pressure control.
Solution Approach 2:
The patent utilizes vertical elevation changes and gravitational potential energy to assist in pressure management. By transitioning from horizontal to vertical flow paths between stages, the system reduces the mechanical burden on the actuator, allowing for more compact actuator design while maintaining effective pressure control.
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 effectively reduces erosion, noise, and the likelihood of clogging, while maintaining fluid throughput and pressure management, enhancing the reliability and performance of the valve system.
Implementation Method 1
A multistage, rising stem and expanding area control valve trim with a plug and liner configuration that employs horizontal and vertical fluid turns with increasing flow area
Implementation Method 2
includes a balance chamber to manage fluid pressure and reduce actuator size
Data Source
AI summary
Provided is a control valve trim, including a plug having a plurality of sections arranged in series along a longitudinal axis, wherein each of the plurality of sections has a diameter that is greater than the diameter of the preceding section, and a plurality of slots in the surface of each of the plurality of sections, and a liner, wherein the plug is disposed internal to the liner.