CFD led design improvement in valves

Background

The basic problem with the existing valve design was cavitation. First and foremost our goal was to identify the regions of cavitation.

Then based on the simulations, we would have to propose design changes to increase efficiency by minimizing the pressure losses in the valve.

Technical approach

To achieve the goals, we did a computational study of the following design parameters:

  • Calculation of Flow coefficient (cv)
  • Calculate Forces & Torques required to move valve bodies against fluid pressure
  • Calculate temperatures and heat transfer rate during different operating conditions

Results of CFD Analysis

Based on the CFD simulations:

  • Pressure drop for different valves & opening was determined before prototyping.
  • Flow of fluid across flow passages were studied and areas of improvement were identified.
  • Regions of cavitation were identified.

Recommendations made for improved design

The mandate of the project was to minimize flow losses.

With performance prediction we recommended the following design improvements:

  1. Improvement in dimensions of the flow passage to minimize losses.
  2. Design changes in the dimensions of the flow regions to help minimize the effects of cavitation.

Conclusions

  • The CFD-led design process helped achieve the design goals of minimizing the pressure losses across different types of valves. Furthermore the numerical simulation process predicted cavitation prone zones that lead to harmful effects like loud noise, strong vibrations, choked flow erosion etc.
  • Additionally, the use of CFD simulations reduced design costs by reducing the number of prototypes needed for physical testing.