How to determine vena contracta pressure for a control valve?
I am working on a failure investigation of a control valve in my
plant. The valve type is a Fisher 461 Sweep Flow Valve. The valve has
been cavitating badly and has caused damage to the valve and downstream
piping.
What I want to do is to determine at what feed conditions
(rate, upstream pressure, downstream pressure, etc) flashing starts, ie
when the initial pressure drop to the vena contracta drops below the
vapour pressure before recovering to the downstream pressure.
The
reading I have done allows you to calculate choke flow conditions etc,
but this is based on upstream and downstream pressure, not really
looking at the vena contracta.
The valve/(gate valve) you mention is specifically designed with low Fl factor to flash/cavitate/mix more than a typical angle valve. It is used for dirty flashing liquids.
It is used as a visbreaker valve and is useful for medium pressure drop applications.
If your pressure drop is beyond the 461 capabilities then consider a Fisher DST-G or Masoneilan 77000 series which will reduce vibration and cavitation while handling the flashing.
You need to size upstream piping large to keep the liquid above bubble-point with a long reducer just upstream of the valve and 5 pipe diameter straight run upstream of the valve then swage up immediately downstream of the valve.
You did not state the Viscosity or flowrate, but I guessed at some
reasonable values for those parameters and when I ran the numbers
through the Flowserve sizing program I get severe cavitation. Yes
cavitation CAN cause vibration.
The math in any sizing program
assumes pure chemicals with well-defined properties. With Bitumen or
most distillates you have sixteen dozen specific chemicals and they all
have slightly different vapor pressures. When you get a little pocket
of flash it forms a bubble and launches a blob of tar downstream. This
would be sluggy flow and that causes real shock to the piping.
I
wouldn't use an anticavitation valve with the tarry product. I don't
think you are seeing cavitation damage inside the valve. You seem just
to be describing inertial effects from the sluggy flow.
If you
can put the valve directly on the nozzle for the vessel into which it
discharges you may find that the vibration is attenuated. I think a lot
of what you are experiencing is because of the way the stuff flows in
the downstream piping. If you get rid of the downstream pipe you get
rid of the impulse mechanism.
Moving the valve seat closer to
the nozzle would also help but it would mean you need to replace the
valve. I'm thinking an eccentric rotary valve such as the Valtek
Maxflo3, Masoneilan Camflex, with the seat at the outlet end. Hardfaced
trim, probably reduced capacity. Go for the cylinder actuator option as
it is stiffer and would be more stable with this stuff that's flowing
nonuniformly through the valve.
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