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Simulation of the flow inside the control valve using CFD software

Number of pages: 134 File Format: word File Code: 32616
Year: 2013 University Degree: Master's degree Category: Facilities - Mechanics
Tags/Keywords: CFD software - Control valves - flow - Flow in the control valve - Flow simulation - fluid - Fluid transfer - Flushing - Optimization - Simulation - tension
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  • Summary of Simulation of the flow inside the control valve using CFD software

    Master's Thesis in Mechanics

    Trend:

    Mechanical Engineering - Energy Conversion

    Abstract:

         One of the most important components of fluid transmission systems are control valves that are in different pipelines. oil and gas transfer and It is visible. In control valves, the most important issue is the property of the flow in order to achieve the proper behavior of the valve, in order to control the flow rate or the pressure of the passing flow. In this thesis, a control valve with proper flow properties to reduce vibration and extreme noise is designed and modeled and then simulated. For this purpose, by using the fluid modeling of the control valve, the flow behavior inside the valve is simulated by numerical solution in CFX software, so that with the help of analytical results, in addition to a suitable internal profile for the control valve, it can be designed in such a way that it meets the desired requirements in terms of the flow rate and the property applied to the valve. And as much as possible, avoid creating too much noise and vibration. In this thesis, the internal profile of a valve sample with certain control properties is designed in Catia software and then analyzed by CFX software. In order to control the accuracy of the modeling results, the obtained results are compared and checked with the information provided at the place of its installation on one of the gas pipelines in Aghar area. that the results obtained from the simulation of the flow in several different modes were checked and it was found that the results of the software in Cage differ by maximum 2% and for the internal profile of the valve body by maximum 5% with the original sample. which has the ability to control the flow according to the specified pattern. Also, in order to reduce the noise, it was determined after the investigations that the sound produced in the control valves is caused by the passage of the fluid through the throat, cavitation, flushing and vibrations of the pipeline. Hydrodynamic noise is intensified by phenomena such as cavitation and flashing. that the sound pressure level increases or decreases due to environmental factors. The most important factor in increasing the sound level in the environment is the presence of hard sound-reflecting surfaces, which usually increases the sound pressure level by about 3 decibels.

    Introduction

    Control valves are widely used in various industrial fields, including oil and gas industries, power plants, petrochemicals, and water transmission systems. These valves have different types, including globe, ball, butterfly and plug valves. The purpose of fluid modeling of the control valve is to simulate the flow behavior inside the valve using CFX software, so that with the help of its results, a suitable internal profile can be designed for the control valve in a way that prevents vibration and excessive noise in the valve. In addition, by using modeling, it is possible to prevent excessive pressure drop in the valve and actually prevent the possible damage of the control valve, including wear and corrosion. In other words, the use of fluid modeling helps to predict the behavior of the fluid inside the valve and to optimize the design parameters instead of spending a lot of time and money to conduct experimental tests. , the control valve consists of a valve and is connected to a drive mechanism, which has the ability to change the fluid control element. This change is based on the signal it receives from the control system. Therefore, due to the high noise and severe vibration in one of the gas flow control valves (FCV) in the Parsian region, it prompted us to model the flow inside the valve by CFX software and simulate the flow inside it so that we can have a more accurate analysis of the forces and stresses applied to the different parts of the valve, so that in addition to optimizing the working conditions, we can also investigate the noise problem and reduce it if possible. which is the first step of designing and modeling the control valve and then simulating the behavior of the flow inside the control valve and finally optimizing and providing a solution. Therefore, according to the availability of the information of a 3-inch control valve of spherical type (Globe) with pneumatic actuator and linear property according to the ANSI 2500 standard.. Therefore, according to the availability of information on a 3-inch globe type control valve with a pneumatic actuator and linear properties according to the ANSI 2500 standard, in order to control the gas flow rate of the 10 Agar well by designing and modeling it and then simulating the flow inside it, we investigated the desired parameters. Noise in control valves and noise control can be changed on the source or on the route or on both of them. Controlling noise at the source is the best way to control it, provided that it is physically and economically possible. One of the common ways to control noise at the source of noise is to use special trims. This type of trim reduces flow disturbance as much as possible by having narrow and numerous grooves and provides optimal speed distribution. In order to achieve these results and obtain the speed distribution, the flow inside the control valve should be simulated with the help of one of the softwares, so that we can have a more accurate analysis of the forces and stresses applied to different parts of the valve, and then check the noise problem and reduce it if possible. In order to do the work, the first step is to design and model the control valve, then simulate the flow behavior inside the control valve, and finally optimize and provide a solution. 1-4-Study model: The control valve intended to simulate the flow inside it is a 3-inch globe type control valve with a pneumatic actuator and linear properties according to the ANSI standard. 2500 in order to control the gas flow rate of 10 wells, which at a certain time is under the inlet pressure of 187/5 Bar and the outlet pressure of 155 Bar, the inlet temperature is 61/07, the opening percentage of the control valve is 29%, the outlet flow rate from the valve is 20/847, and the working fluid is methane gas with 18/45.

    1-5- Working method

    The method implemented in the thesis includes two main parts of designing and modeling the control valve and simulating the flow behavior inside the control valve using Catia and Ansys CFX. In this project, due to the availability of the control valve sample, the design of the cage was used using the reverse engineering process and the design of the flow path inside the body was used using the direct design method. According to the documents and standards related to control valves, its cage was compared and designed directly with Catia software, and the flow path inside the valve was designed after several stages of trial and error. And then it was transferred to the Design Modler environment of the Ansys CFX software, among which the results of some more important models are detailed in chapters 4 and 5.

    1-5-2- Fluid modeling of the control valve

    For the fluid analysis of the control valve, the Ansys CFX software was used, and the general shape of the valve designed with the Catia software after transferring to the Ansys environment CFX and separation of the fluid path in the Desigen Modler environment, and also in some cases, due to the symmetry with respect to the YZ axis, the Symmetry mode is used, and after performing the equalization operation, we enter the Meshing environment. And considering that the Ansys CFX software includes several environments and in each environment, the work related to the same environment must be done, so the method of doing the work in different environments is as follows. It enters the meshing environment. In this environment, the initial size of the volume elements of the object and also an operation such as reducing the elements of a specific area are performed. In addition, a more regular element is created in the walls near the boundary surfaces (considering that the speed of changes in the areas near the boundary surfaces is high). And in several different states, we check the flow passing through the cage and the path of the flow through the body.

    1-5-2-2- Boundary conditions

    According to the physics of the problem, the appropriate boundary condition is one of the three conditions, applying pressure at the inlet and flow at the outlet, pressure at the outlet and inlet (difference between inlet and outlet pressure), and applying flow at the inlet and pressure at the outlet.

  • Contents & References of Simulation of the flow inside the control valve using CFD software

    List:

    Abstract: 1

    Chapter One (Introduction) 2

    1-1- Introduction 2

    1-2- Statement of the problem 2

    1-3- Objectives: 3

    1-4- Study model: 3

    1-5- Work method 3

    1-5-1- Design and modeling of control valve 4

    1-5-2- Fluid modeling of control valve 4

    1-6- General conclusion 6

    1-7- Thesis structure: 7

    Chapter two (research background) 8

    2-1- Introduction 8

    2-2- Research background: 10

    3-2- Types of industrial valves and their applications 12

    3-2-1- Gate valve 12

    3-2-2- Ball valve) 13

    2-2-3- Cock valve 14

    2-2-4- Globe valve) 15

    2-2-5- Check Valve 16

    2-2-6- Butter fly Valve) 17

    2-2-7- Safety Valve 18

    2-2-8- Control Valve: 19

    2-2-9- Flow Limiting Valve (Chock Valve) 20

    2-2-10- Needle valve 20

    2-2-11- Angle valve (Angle Valve) 20

    2-3- How to choose valves 21

    2-4- The most important use of valves: 21

    2-4-1- Stopping and connecting the flow 21

    2-4-2- Adjustment or control Flow 21

    2-4-3- Preventing flow back 22

    2-4-4- Reducing the pressure of a system 22

    2-5- Flow through valves 23

    2-5-1- ? resistance coefficient 23

    2-5-2- Valve coefficient and flow rate 28

    2-5-3- Mutual relationship between resistance coefficients and flow 31

    2-6- Cavitation phenomenon in valves 31

    Chapter three (control valves) 33

    3-1- Introduction 33

    3-1-1- Definition of control valve: 33

    3-2- History of control valve: 34

    3-3- Selection of control valves: 35

    3-4- How control valve works 35

    3-5- Technical terms (Terminology) of control valve 36

    3-6- Types of control valves 38

    3-6-1- In terms of flow control type: 38

    3-6-2- In terms of path 38

    3-6-3- In terms of performance 40

    3-7-Rotary Shaft valves 42

    3-8- Fail Safe 43

    3-9- Flow specifications for control valves 44

    3-10- Control valve accessories 46

    3-10-1- Actuators: 46

    3-10-2-Positioner in the control valve (Positioner): 47

    3-10-3-Limit Switches: 49

    3-10-4- Solenoid Valves: 49

    3-10-5- Air Lock Reverse Relays (Lock up Relay): 49

    3-10-6- Transducers 49

    3-10-7- Lock up Valves 50

    3-10-8- Booster Relays and Amplifier: 50

    3-10-9- Capacity Tanks (Capacity Tanks) 50

    3-10-10-Hand Wheel Actuators: 50

    3-10-11- Pressure regulators with filters and moisture traps: 50

    3-11- Sizing of control valves 51

    3-12- Cavitation in control valves: 52

    3-13- Flashing: 53

    Fourth chapter (acquaintance with the process of modeling and simulation of flow with CFD) 55

    4-1- Introduction: 55

    4-1-1- CFD history: 55

    4-1-2- CFD mathematics: 56

    4-1-3- CFD applications: 58

    4-1-4- CFD methodology 59

    4-2- Introduction to ANSYS software: 61

    4-3- Structure of ANSYS CFX software 62

    4-3-1- Geometry environment or Design Modeler: 62

    4-3-2- Meshing environment: 63

    4-3-3- Setup or CFX-Pre environment: 63

    4-3-4- Solution or CFX-Solver environment: 64

    4-3-5- Results or CFD-Post environment: 64

    4-4- How to discretize and solve flow equations: 64

    4-4-1- Numerical discretization: 66

    4-4-2- Solving strategy: 69

    4-4-3- Solving linear equation 70

    4-5- Introduction to CATIA software 71

    4-6- Control valve flow property 73

    4-6-1- Choosing the correct flow property 74

    4-6-2- Control valve design method 74

    4-7- Control valve design with CAD software 75

    4-7-1- Control valve "8" available in Agar area as an example: 75

    4-7-2-Control "8 as a model with a scale of 1 to 10: 77

    4-7-3- Design and modeling of the control valve "3: 78

    4-8- Familiarity with natural gas: 86

    4-8-1- Characteristics of natural gas: 86

    4-8-2- Types of natural gas 86

    Chapter five (simulation steps) The flow inside the control valve with CFX software) 87

    5-1- Introduction 87

    5-1-1- Finite element model: 87

    5-1-2- Boundary conditions 87

    5-1-3- Solution methods 88

    5-2- Simulation steps: 89

    5-2-1- Simulation Flow inside the cage: 89

    5-2-2-Simulation of the flow inside the body of the control valve: 109

    Sixth chapter (summary and comparison of analysis results and presentation of solution) 122

    6-1- Introduction 122

    6-2- Summary and comparison of analysis results from the software 122

    6-2-1- Validation of results: 122 6-3-Checking noise in control valves and practical methods to reduce it 124 6-3-1 Noise standards in control valves 124 6-3-2 Introducing the method of expressing the intensity of the sound produced 125 6-3-3 Noise prediction steps 126 6-3-4 Noise reduction methods Produced in milk 127

    6-4- Conclusion 132

    6-5- Proposals for the continuation of the project 133

    Resources 134

    Source:

    EMERSON Company, 1387, control valves, Akbar Shirkhorshidian, Tehran, designer publishing house

    Kazemi Lari and colleagues, 1391 computational fluid dynamics modeling and analysis using Ansys CFX software, Tehran, Abid Publishing

    Amir Hossein Hamedanian et al. "Investigation of noise in control valves and practical methods to reduce it" First National Conference on Acoustics, Tehran, Malik Ashtar University, 2009

    Amir Hossein Hamedanian et al. 23rd International Electricity Conference, Tehran, November 1387

    Sina Salemi et al., "Design and optimization of the internal profile of a control valve sample using computational fluid dynamics methods", 23rd International Electricity Conference, Tehran, November 1387

    Ali Siyami et al., "Design and modeling of a control valve with the feature of designing and optimizing the internal profile of a control valve sample using From the computational fluid dynamics methods of specific flow for use in the feed water path of the boiler of the combined cycle power plant" 22nd International Electricity Conference, Tehran, November 1386

    Farhad Khosravi et al. "Comparison of the performance of a control valve sample with the knowledge of designing and manufacturing in the country with foreign samples available in a power plant" Proceedings of the second thermal power plant industry conference at Sharif University of Technology, November 1389

    Mohsen Bakhtiari Fard et al. "How to use relations Geometry to obtain the flow through the control section in a specific liquid fuel engine control valve" 8th conference of Iran Aerospace Society, Tehran, 1388

    Mohsen Bakhtiari Fard et al. "Optimization of a control valve by creating an internal bypass in a liquid fuel engine" 8th conference of Iran Aerospace Society, Tehran, 1388

    Davis, J. A. "Predicting Globe Control Valve Performanc-Part I: CFD Modeling". Journal of Fluids Engineering, September 2002, Volume 124, Issue 3, pp. 772-777.

    Salvador, G. P., Valverde, J. A. and Frankel, S. "Three-Dimensional Control Valve with Complex Geometry: CFD Modeling and Experimental Validation", 34th AIAA Fluid Dynamics Conference and Exhibit, 28 June-1 July 2004, Portland, Oregon, AIAA 2004-2422.

    Stares, J., Glaun, A. "Simulation Helps Design More Efficient Control Valve", Journal Articles by Fluent Software Users, JA 188,2003, .

    Skousen, P. L., Valve Handbook, Second Edition, United States, McGraw-Hill, 2004.

Simulation of the flow inside the control valve using CFD software
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