Training Module THINKTANKcontrol Valve PDF

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Control Valve

Comprehensive Training Module


This module is ideal for engineers, technicians, and professionals in process industries, aiming to
enhance their knowledge in control valve technology and applications. It combines theoretical
knowledge with practical skills, ensuring a comprehensive learning experience.

Will. Don | Marketing Director


marketing@cncontrolvalve.com
https://cncontrolvalve.com/
Category of
Industrial Valves
Automated Valves:
These valves are operated automatically.

Self-Operated Valves:
Self-operated valves operate receiving energy
from fluid pressure or fluid temperature. It has
high responsibility but generally is not good at
accuracy.

Control Valves:
Control valves operate receiving energy from
compressed air, electric power, etc.
used with controllers and sensors. Control
valves and related equipment realizes
most accurate control.
Introduction

What Is A Control
Valve?

The control valve functions to adjust the


flow of fluids like gas, steam, water, or
chemical compounds. Its role is to
counteract any disturbances in the load,
maintaining the process variable being
The control valve assembly typically consists of the:
regulated as close to the desired set point
• Valve body
as possible.
• Internal trim parts
• An actuator to provide the motive power to operate the valve.
• A variety of additional valve accessories, which can include positioners, transducers,
supply pressure regulators, manual operators, snubbers, or limitswitches.
Roles of Control Valves

Process Parameters Sensor Control Valve

Controller

Flow Sensor Orifice, Flow Meter

4-20mA

4-20mA
Pressure Sensor Pressure Transmitter D.P.
Transmitter

Level Sensor Level Transmitter

Orifice

Temperature Sensor Temperature Transmitterer

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Example of Process Control

FLOW CONTROL PRESSURE CONTROL LEVEL CONTROL TEMPERATURE CONTROL

Boiler feed pomp Turbine bypass valve Reactors Heat Exchanger


Minimum flow control valve

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Introduction
Typical Control Valve Assembly

Typical Control Valve Assembly Major Component of Typical Control Valve


Body

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Features of Each Actuator Types
Pneumatic type Hydraulic type Motorized type

Response time Dead time is rather long. Dead time is short. Action No dead time. Action speed is slow
Action speed is fast.
speed is fast

Maintaining safety position at supply Possible by using integrated spring Difficult to maintain Can stop and maintain only the
fail time or connecting volume tank easily and position at an emergency time.
certainly.

Output power Middle for spring diaphragm type. Small for oil integrated type. Bigger than pneumatic type and oil
Big for piston cylinder type Big for oil separated installation type pressure type

Structure Simple Complicated Complicated

Weatherproof and Exprosion proof Not necessary Should be considered Should be considered

Air piping or electric wiring Simple Simple for oil integrated type. Simple
Complicated for oil separated
installation

Maintenance work Easy Complicated Complicated

Cost Reasonable Expensive Expensive

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Combination of Body and Actuator

Actuator Body

Pneumatic Globe

Pneumatic Pneumatic

Motorized Hydraulic Angle Butterfly

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Cv Calculation

“ When you decide port size of control valve, you need to calculate required Cv value with fluid condition given on control
valve data sheet. Then, you can specify appropriate Rated Cv value and port size.
At this chapter, most popular Cv calculation formula that is established by FCI (Fluid Controls Institute, Inc.) is introduced.

What is Cv Value?
One of the popular coefficients that express flow capacity. Cv value us
defined as follows.
Flow rate of 60 degF ( 15.6 degC) clean water with the unit of US gal/min
at differential pressure of 1 psi and specific travel of valve.

Rated Cv value: Cv value at a valve is fully opened.


Required Cv value: Cv value calculated with fluid condition

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Flow Control Characteristics

“ As the actuator moves the valve plug through its travel range, the unobstructed flow area changes in size and shape
depending on the contour of the valve plug.

When a constant pressure differential is maintained across the valve, the changing relationship between percentage of
maximum flow capacity and percentage of total travel range can be portrayed, and is designated as the inherent flow
characteristic of the valve.

Commonly specified inherent flow characteristics include:

Linear Flow Characteristic

Equal-Percentage Flow Characteristics

Quick-Opening Flow Characteristic

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Flow Characteristic

Linear Flow Characteristic


Cv = K . L
(K: Constant, L: Valve plug travel)

Equal-Percentage Flow Characteristics

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Quick-Opening Flow Characteristic

Typical Construction to Provide Quick-Opening


Flow Characteristic

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Selection of Flow Characteristic

Control Valve Pressure Drop Best Inherent Characteristic

Constant ∆P Linear

Decreasing ∆P with Increasing Load , ∆P at Maximum


Linear
Load > 20% of Minimum Load ∆P

Decreasing ∆P with Increasing Load , ∆P at Maximum


Equal Percentage
Load < 20% of Minimum Load ∆P

Increasing ∆P with Increasing Load , ∆P at Maximum Load


Linear
< 200% of Minimum Load ∆P

Increasing ∆P with Increasing Load , ∆P at Maximum Load <


Quick Opening
200% of Minimum Load ∆P

Liquid Level Systems

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Control Valves


Valve and Actuator Types

The control valve regulates the rate of fluid flow as the position of the valve plug or disk is changed
by force from the actuator. To do this, the valve must:

Contain the fluid without external leakage;

Have adequate capacity for the intended service;

Be capable of withstanding the erosive, corrosive, and temperature influences of the process; and


Incorporate appropriate end connections to mate with adjacent pipelines and actuator attachment means
to permit transmission of actuator thrust to the valve plug stem or rotary shaft.

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Valve Bodies
Globe Valves
Single-Port Valve Bodies

Single-Ported Globe-Style
Valve Body

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Valve Bodies
Most Popular Type
Globe Valves
Single-Port Valve Bodies Valve plug has only one seat to shut-of fluid
Seat leakage is low even though it has metal seat
Unbalancing fluid force is higher than pressure
balancing type
When required valve size is lower than 2 inch,
This type is most advantageous because small sized
actuator can be mounted.
That means price is reasonable.
When required size is larger than 2 inch, generally,
price is not reasonable because the larger the valve
size is, the bigger the actuators size is comparing single
seated type to pressure balancing type.

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Valve Bodies
Globe Type Control Valves

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Top and Bottom Guided valve

The valve plug is guided at top and bottom

Pressure balanced type

This type is used mainly for oil refinery industry.

Generally, seat leakage is larger than single seated


valves.

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Cage Valve

• This type comes after single seated type in market.


• Valve plug is guided by cage (shaped like pipe and set in
valve body. It has window that consists of flow
characteristics.)
• Pressure balanced type is more popular than unbalanced type.
• For pressure balanced cage type, actuator size is smaller than
single seated type when body size is same.
• Therefore price is more competitive than single seated type
when valve size larger than 3 inch or used with high- pressure
rating.
• This type can reduce cavitation erosion and aerodynamic
noise that are typical control valve claim.
• Generally, seat leakage is larger than single seated valve.

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High Capacity,
Cage-Guided Valve Bodies

High Capacity Valve Body with


Cage-Style Noise Abatement Trim

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Angle Valve

Center of inlet and outlet of valves are right angle.

This type is advantageous for erosive or abrasive fluid.

Also used because of piping design advantage.

Wetted parts design is simpler than general 2 way valves. So this type
is also advantageous for viscous fluid.

Erosion: Destruction of valve bodies or trims due to high fluid velocity.

Abrasion: Erosion due to slurry that contains solids or particles.

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Three-Way Valve

Mixing Type Diverting Type

Three-Way Valve Bodies


Diverting type is used to separate flow to 2 way
Mixing type is used to mix 2 flow.
Mainly used for temperature control.

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Diaphragm Valve

• Elastic diaphragm made with rubber and PTFE modulate the flow
passage.

• Wetted parts can be lined with several materials (PTFE, Glass, and
rubbers). So this type is advantageous for slurry or corrosive fluid.

• This type is cost effective.

Full open Control Full close

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Rotary Valves
Butterfly Valve Bodies

• A disk that is almost same diameter as pipe size rotate so


as to modulates flow.
• Valve capacity is highest for all types of valves.
• Generally, this type is used at pressure rating 300# or
lower. For higher-pressure rating, this type cannot be
applied.

High-Performance
Butterfly Control Valve

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V-Notch Ball Control
Valve Bodies

Rotary-Shaft Control
Valve with V-Notch Ball

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Eccentric-Disk Control
Valve Bodies
Center of the plug rotating point is eccentric from the
center of valve body.

CV capacity is bigger than that of other globe valves.

Fluid can be passed easily because of straight trough


construction.

Eccentric-Disk
Rotary-Shaft Control Valve

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PTFE Valve

A branch of single seated control valve.

Especially used for corrosive fluid.

All wetted parts are made with PTFE, which resist


most of acids and alkalis.
Plug: PTFE with
304ss core
Body has rigid stainless casing to avoid warp with
Bellows: PTFE
piping stress.
Casing: SUS304

Applicable pressure and temperature is limited.


Body: PTFE

Max Operating Temperature: 140 deg C

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PVC / Polypropylene Valve

A branch of single seated control valve. Especially used


for corrosive fluid.

All wetted parts are made with PVC or Polypropylene,


which resist most of acids and alkalis.

Applicable pressure and temperature is limited.

Cheaper than PTFE valve

Max Operating Temperature:


PVC: 50 deg C.

Polypropylene: 80 deg C

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Ceramic Valve
Wetted part materials are all ceramics
All wetted parts are made with ceramics that resists most of
acids and alkalis.

Highest abrasion resistance.

There are application limitations for temperature, pressure and


seat leakage class.

Aluminum ceramic: 70 deg C


Model: HMC CV < 4.0
Model: HIC 13<CV<120

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Valve Plugs
Types of Valve Plugs
Cage

Plug for cage valve

Contoured plug

EQ% Linear

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Valve Plugs

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Cage-Guided
Characterization of Cage-Guided Valve Bodies

W0958/1L W0959/1L W0957/1L

QUICK OPENING LINEAR EQUAL PERCENTAGE

Characterized Cages for Globe-Style Valve Bodies

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End Connections
Control Valve End Connections

1 2 5 6
Thread type(S) Flat face type(FF) Groove type Fit- in type

Primarily for For cast iron valves for low To prevent leakage, For the same purpose as
connections of small pressure service for gas or vacuum those of the groove type
valves - 1 in. service.(Normally,the
(25mm) or less valve flange is female)

3 4 7 8
Raised face type(RF) Ring joint type(RJ) Socket welded type(SW) Butt welded type(BW)
For high-temperature high-
Most popular type for For high-temperature high- For the same purposes as
pressure service of ANSI
ANSI 600#,(JIS 40K) or pressure service those of the socket welded
900# or higher.For
lower type.Normally,for valves of
poisonous fluids,Normally,for
2½ in.(80mm)or larger
valves of 2 in.(50mm)or
smaller.

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Bonnets

Valve Body Bonnets

The bonnet of a control valve is that part of the


body assembly through which the valve plug
stem or rotary shaft moves.

Typical Bonnet, Flange, and Stud Bolts

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Bonnets
Extension Bonnets

Valve Body with


Extension Bonnet Fabricated Extension Bonnet

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Packing
Control Valve Packing

Single PTFE V-Ring Packing

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Packing

Comprehensive Packing Material Arrangements


for Globe-Style Valve Bodies

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Packing

Typical Valve
Stem Packing Assemblies

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Packing

PTFE V-Ring

Laminated and Filament Graphite

Single PTFE V-Ring Packing

ENVIRO-SEAL_ PTFE Packing

ENVIRO-SEAL PTFE Packing System

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Packing

V-PTFE V7132Y #4519 yarn

Graphite (T2200) SM636 TK2006

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Packing
Graphite Ribbon for Rotary Valves

Sliding-Stem Environmental Packing Selection

Maximum Pressure & Temperature Limits for 500 PPM


Service(1) Seal Performance
Packing System Service Life Index Packing Friction
Index
Customary US Metric

Single PTFE V-Ring 300 psi 0 to 200°F 20.7 bar -18 to 93°C Betten Long Very Low

See Fig. 3-25 -50 to See Fig. 3-25 -46 to


ENVIRO-SEAL PTFE Superior Very Long Low
450°F 232°C

ENVIRO-SEAL Duplex 750 psi -50 to 450°F 51.7 bar -46 to 232°C Superior Very Long Low

ENVIRO-SEAL Graphite ULF 1500 psi 20 to 600°F 103 bar -7 to 315°C Superior Very Long Moderate

(1)The valves shown are only guidelines.These guidelines can be exceeded, but shortened packing life or increased leakage might
result.The temperature ratings apply to the actual packing temperature, not to the process temperature.

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Gaskets
Operable temperature Operable maximum pressur
Type Type No. Of gasket Composition Use
range(℃) e
Flat type Copper
V562 -196 to +260 150 kgf/cm2 Oil-inhibited
Monel Aluminium
V564(Monel) -5 to +566 ANSI 2500
Service Oil-inhibited
V567 -196 to +400 150 kgf/cm2
coper inhibited service
Sawtooth Type Material of valve
V540 0 to +200 20 kgf/cm2 S15C
body:FC20
Oil-inhibited
150 kgf/cm2
V542 V543 (SUS316L) -196 to +260 -196 to +566 Copper SUS316 service General
ANSI 2500
Service
V544 -196 to 450 ANSI 2500 SUS316L
V544(Monel) -196 to +566 ANSI 2500 Monel
Oil-inhibited
V547 -196 to 400 150 kgf/cm2 Aluminium copper-inhibited
service
Spiral shaped external SUS316+ For seat of unit-
V590 -100 to +500 ANSI 1600
pressure type Asbestos structure cage

SUS316L+
V590(SUS316L) -100 to +450 ANSI 1600
Asbestos or teflon

V7590 -196 to +100 20 kgf/cm2 SUS316L+ teflon Oil inhibited service


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Gaskets
Operable temperature Operable maximum pressur
Type Type No. Of gasket Composition Use
range(℃) e

Others(special uses)
V1500 V1501 0 to 100 20 kgf/cm2 Asbestos For HLS,HTS(when
specified by
customer)
V1500AC V1501AC +100 to +260 10 kgf/cm2

V7010 -196 to +260 ANSI 300 Teflon


For HLS,HTS(when
specified by
Teflon + ceramics customer)
V7020 -196 to +260 ANSI 300
fillers

V563 Teflon coating -196 to +260 ANSI 300 SUS316+ teflon Oil-inhibited with
special material
spur-water service
V543 Teflon coating -196 to +260 ANSI 300 SUS316+ teflon

When heat cycles


are severe For
V6590 -196 to +566 ANSI 2500 SUS316L+ graphite
nuclear energy
service

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Gaskets
Examples on Uses of Gaskets

Serrated metal gasket


V543 V543 PTFE coated

Serrated metal gasket

Spiral gasket

Model HTS Model ACP

V8590

Spiral gasket

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Grease

Lubricator

PS6 #800 #400 #650

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Valve Plug Guiding

1. Cage Guiding 2. Top Guiding

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Valve Plug Guiding

3. Stem Guiding 4. Top-and-Bottom Guiding

Left view

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Valve Plug Guiding
5. Port Guiding

Right view

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Valve Plug Guiding

Restricted-Capacity
Control Valve Trim

Adapter Method for Providing Reduced


Flow Capacity

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Actuators

“ Actuators
Pneumatically operated control valve actuators are the most popular type in use,

but electric, hydraulic, and manual actuators are also widely used.

The spring-and-diaphragm pneumatic actuator is most commonly specified due to its

dependability and simplicity of design. Pneumatically operated piston actuators

provide high stem force output for demanding service conditions.

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Actuators
1. Diaphragm Actuators

3/1L W0364/1L

DIRECT- ACTING REVERSE-ACTING

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Actuators
1. Diaphragm Actuators

Diaphragm Actuator for


Field-Reversible Multi-Spring Actuator
Rotary Shaft Valves

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Actuators
2. Piston Actuators

Control Valve with


Double-Acting Piston Actuator

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Actuators
3. Electrohydraulic Actuators

Control Valve with Double-Acting


Electrohydraulic Actuator and Handwheel

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Actuators
4. Manual Actuators

W0595/1L W8176-1

FOR SLIDING-STEM VALVES FOR ROTARY-SHAFT VALVES

Typical Manual Actuators

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Actuators
5. Rack and Pinion Actuators

Typical Rack and Pinion Actuator

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Actuators
6. Electric Actuators

Traditional electric actuator designs use an electric motor and some


form of gear reduction to move the valve. Through adaptation, these
mechanisms have been used for continuous control with varying
degrees of success.

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Actuators
7. Types (Directions) of Valve and Actuator Actions

Types of valve and actuator actions should be correctly selected for fail-safe
plant operation when the driving power (air supply) has failed. The type (direct and
reverse) are defined as follows:

(a) Direct action: Valve opens when driving power has failed.
(b) Reverse action: Valve closes when driving power has failed.

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Actuators

1. When valve action cannot be reversed(Top-guided single-


seat valves, cage valves, angle valves,ceramics valves, and
Saunders valves)Valve:Direct action → Actuator:Direct
action Valve:Reverse action → Actuator:Reverse action

2. When valve action can be reversed(Top-and-bottom guided


single-seat or double-seat valves) Valve:Direct action →
Valve body:normal Actuator:Direct action Valve:Reverse
action → Valve body:Inverted Actuator:Direct action

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Actuators
3. When driving the valve via a lever mechanism(Butterfly
valves,FloWing valves)Valve:Direct action → Valve:Direct
action → Vane:Normal position Actuator:Direct
action Valve:Direct action → Vane:Reverse position
Actuator:Direct action

4. To change flow direction(3-way valves) (1)Converging 3-


way valves Valve:Bottom port open when air failure →
Actuator:Direct action Valve:Bottom port closed when air
failure → Actuator:Reverse action

(2)Diverting 3-way valves Valve:Bottom port open when air


failure → Actuator:Reverse action Valve:Bottom port
closed when air failure → Actuator:Direct action

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Positioners

“ Control Valve Accessories


Positioners
Pneumatically operated valves depend on a positioner to take an input signal from a
process controller and convert it to valve travel. These instruments are available in three
configurations:

1. Pneumatic Positioners

2.Analog I/PPositioner

3. Digital Controller

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Positioners
1. Pneumatic Positioners:
Apneumatic signal (usually 3-15 psig) is supplied to the
positioner.

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Positioners
2.Analog I/PPositioner

This positioner performs the same function as the one above, but uses electrical
current(usually 4-20 mA) instead of air as the input signal.

3. Digital Controller

Although this instrument functions very much as the Analog I/P described above,it differs
in that the electronic signal conversion is digital rather than analog. The digital products
cover three categories.

* Digital Non-Communicating

* HART

* Fieldbus

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Positioners

Modern Control Valves


Utilizing Digital Valve Controllers

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Positioners

Positioner Schematic for


Piston Actuator

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Volume Booster

Volume Booster

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Other Accessories
Other Control Valve Accessories

Top-Mounted Handwheel Top-Mounted Handwheel


for Direct-Acting Diaphragm Actuator for Reverse-Acting Diaphragm Actuator

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Other Accessories
Limit Switches

Cam-Operated Limit Switches

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Other Accessories
Solenoid Valve Manifold

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Other Accessories
Supply Pressure Regulator

Supply Pressure Regulator with Filter and Moisture Trap

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Other Accessories
Pneumatic Lock-Up Systems

Supply Pressure Regulator with Filter and Moisture Trap

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Other Accessories
Pneumatic Lock-Up Systems

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Other Accessories
Fail-Safe Systems for Piston Actuators

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Other Accessories
Electro-Pneumatic Transducers

Electro-Pneumatic Transducer Mounted on a


Diaphragm-Actuated Control Valve

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Other Accessories
Electro-Pneumatic Valve Positioners

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Other Accessories

“ Diagnostics
Digital valve controllers incorporate predefined instrument and valve diagnostics within
firmware to provide alerts if there are problems with instrument mounting, electronics,
hardware or valve performance.

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Seat Leakage Classifications
Standards and Approvals
Control Valve Seat Leakage Classifications
(In accordance with ANSI/FCI 70一2 and IEC 60534-4)

Maximum
Leakage class Designatio Test Testing Procedures Required for
Leakage Test Pressures Establishing Rating
n Medium
Allowable

No test required provided user and


Ⅰ ——- ——- ——-
supplier so agree.

Pressure applied to valve inlet, with outlet


Air or water 3-4bar(45-60psig) or
open to atmosphere or connected to a
0.5% of rated at 10- max. operating
Ⅱ low head loss measuring device, full
capacity 52℃ (50- differential, whichever is
125℉) lower. normal closing thrust provided by
actuator.

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Seat Leakage Classifications
0.1% of rated
Ⅲ As above As above As above.
capacity

0.01% of rated
Ⅳ As above As above As above.
capacity
0.0005ml per
minute of water Pressure applied to valve inlet
per Max.service pressure after filling entire body cavity and
inch of orifice drop across valve connected piping with water and
diameter per psi plug,
Water at 10-52℃(50- stroking valve plug closed.Use net
Ⅴ differential(5 X Not to exceed ANSI
125℉) specified max. Actuator thrust,
10-12m3 per body rating, or lesser
second of water pressure by but no more, even if available
per mm of orifice agreement. during test.allow time for leakage
diameter per bar flow to stabilize.
differential).

Pressure applied to valve inlet.


Not to exceed 3.5 bar (50 psig) or Actuator should be adjusted to
amounts shown in max. rated differential operating conditions specified with
Air or nitrogen at 10-
Ⅵ following table pressure across valve full normal closing thrust applied to
52℃(50-125℉)
based on port plug, whichever is valve plug seat. Allow time for
diameter. lower. leakage flow to stabilize and use
suitable measuring device.

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Cavitation and Flashing

“ Cavitation and Flashing


Choked Flow Causes Flashing and Cavitation
The IEC liquid sizing standard calculates an allowable sizing pressure drop, Δpmax. If the
actual pressure drop across the valve, as defined by the system conditions of P1 and P2, is
greater than Δpmax theneither flashing or cavitation may occur.

The change is from the liquid state to the vapor state and results from the increase
in fluid velocity at or just downstream of the greatest flow restriction,
normally the valve port.

Vena Contracta Illustration

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Cavitation and Flashing

Comparison of Pressure
Profiles for High and Low Recovery Valves

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Cavitation and Flashing

Typical Appearance of Typical Appearance of


Flashing Damage Cavitation Damage

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Noise Prediction

“ Noise Prediction
1. Aerodynamic

The method defines five basic steps to a noise prediction:

1. Calculate the total stream power in the process at the vena contracta.

2. Determine the fraction of total power that is acoustic power

3. Convert acoustic power to sound pressure.

4. Account for the transmission loss of the pipewall and restate the sound pressure at the outside

surface of the pipe

5. Account for distance and calculate the sound pressure level at the observer’s location

2. Hydrodynamic

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Noise Prediction
Noise Control

Valve Trim Design for Reducing Aerodynamic Noise

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Noise Prediction

Valve and Inline Diffuser Combination

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Noise Prediction

Valve and Vent


Diffuser Combination

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Noise Prediction

Special Valve
Design to Eliminate Cavitation

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Noise Prediction

Typical In-Line Silencer

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Noise Prediction
Noise Summary

Globe Style Valve


with Noise Abatement Cage for Aerodynamic Flow

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Noise Prediction

Ball Style Valve with Attenuator to Reduce


Hydrodynamic Noise

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THANK YOU

+86 199 2125 0077 marketing@cncontrolvalve.com

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