Cage Trim Valves
Cage Trim Valves
Cage Trim Valves
Confidential Information
This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 2
Control valves are higher technology, higher specification and overall more
expensive than other types of valves, so why are they used and how are the
features selected.
Confidential Information
This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 4
A control valve is
simply a
restriction in a
pipe.
The restriction
causes a drop in
pressure.
Pressure
reduces to the
point of the vena
contract.
Beyond the vena
contracta the
pressure Minimum
Geometrical Vena Contracta
recovers Streamlines Contract as (Minimum Flow Area)
Flow Area
Flow Approaches Restriction
The Weir Group PLC 5
So if there is a high pressure drop, the potential for damage to the control valve
will increase.
Pressure drops are generally limited to a maximum of 50 bar (although there are
exceptions) for a single stage trim.
What do we do for higher pressure drops?
High pressure drops on liquid applications can cause erosion
High pressure drops on gas applications can cause high noise levels.
The Weir Group PLC 8
Multistage trims
Multistage trims are used to portion the drop in pressure across multiple stages of
pressure letdown (in the cases below 3 stages of pressure reduction)
Gas expands and compresses due to the flow through a multi stage orifice and
therefore the gas should be allowed to expand.
The Weir Group PLC 9
Reducing the P1
pressure in multiple
stages means there is
less energy generated
at the vena contracta. Pressure
Velocity ΔP
Variation
As a consequence of Variation
controlling the drop in
pressure, the velocity
across the trim is P2
reduced.
The potential for
erosion is reduced
due to the reduced
drop in pressure
across each stage of Valve Trim Valve
the trim and the Inlet Trim Exit Vena
reduced velocity Outlet
Inlet Contracta
The Weir Group PLC 10
Pressure Recovery
Valve Features
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This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 13
Confidential Information
This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 15
Contour Trims
Soft Faced
Trim
The Weir Group PLC 16
Spline Trims
Suitable for low flow applications. Spline Trim
The plug and seat are manufactured as a
matched pair to prevent leakage around the
circumference of the plug nose.
Where body impingement is a concern then a
seat diffuser can be provided.
Available Cv’s from 3.2 to 0.001
Flow characteristic is always modified =%
Available in metal to metal and soft faced
constructions.
Flow is from over the plug.
Spline With
Diffuser
The Weir Group PLC 17
3 Stage Spline
Trim
The Weir Group PLC
Confidential Information
This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 20
Cage
Seat Plug
The Weir Group PLC 21
Features
Valve
Globe or angle style body
High integrity cast body and bonnet
Low pressure recovery trim giving reduced down time.
Clamped seat ring for easy service
Stable cage guiding, anti vibration
Cavitation resistant trim
Flashing erosion control
Noise reduction trim
Multi stage trims available within the same body configuration
Top entry - valve can be serviced without removal from the line
Pressure balanced trim for stable pressure control.
Designed for use with standard, intermediate and severe service cages.
Small hole technology gives the most efficient pressure control of any type
of valve currently on the market
Actuator
Spring return diaphragm actuator with inherent fail safe operation
Actuator removal without disturbance to the valve packing
Actuator mounting for pneumatic diaphragm, piston, hydraulic or electic
actuator.
Single spring or multi spring actuators available depending on space
constraints
The Weir Group PLC 22
Cascade Trim
Characteristic
100
Quick Open
80
%
60
Design Cv
Cv
40
20
0
0 20 40 60 80 100
% Valve Travel
The Weir Group PLC 26
Bonnet Forms
Standard Packings
Supagraf Packings (Low Emissions)
PTFE Chevron
Up to 232 deg C
Graphite
Above 232 deg C
The Weir Group PLC
Liquid Sizing
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Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 31
Single
Stage Cage
Trim
Contoured
Trim Valve
The Weir Group PLC 33
P1
Pressure DP
Variation
P2
Velocity
Variation
Areas of re-circulating
flow in which solid
debris can become
trapped & the
premature onset of
cavitation
CFD Simulation of
X-StreamTM
CFD Simulation of Fluid Velocity Close proximity of cylinders minimise
areas of re-circulating flow & pressure
RED = High velocity
gradient across path
BLUE = Low velocity
eliminates premature onset of cavitation
due to areas of re-circulating flow
KarenAvg.
Vel Mag
25 0.841035
0.672828
0.504621
20
0.336414
Y mm
0.168207
15
0
10
10 20 30
X mm
Application Example
Pump Minimum Flow Duty on a Boiler
Feedwater Application.
Confidential Information
This document contains information which is confidential to companies forming the Weir Power & Industrial
Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir authorized personnel
The Weir Group PLC 43
3D Gas Sizing
3D Gas Sizing – the Approach taken
The basic problem with gas applications is the aerodynamic noise resulting from pressure fluctuations
induced by turbulence and unsteady flow.
Validate models
The Weir Group PLC 44
3D Gas Sizing
Size Matters!
Position affects performance!
In his PhD thesis “Wall Pressure Fluctuations
and Flow losses in Control Valve Models”
Jonathan Lodge concluded that the size of the
holes used in both single and multi-stage cage
arrangements had a significant effect on the
aerodynamic noise performance of the valve.
3D Gas Sizing
The holes in the final element of the trim have a profound effect on the aerodynamic noise
generated by the valve trim. If adjacent jets are allowed to coalesce they produced larger
noise generating shock cells.
shock cells
fluid jets
Outlet jets with holes in
Outlet jets with holes well close proximity to each
spaced. Result in lower other. Result in higher
noise levels noise levels
The Weir Group PLC 46
3D Gas Sizing
To prevent the jets from coalescing, he introduced a course “mesh” after the final stage of the valve
trim. His observations showed that the “mesh” disrupted jet formation, eliminated shock cell
formation, and reduced noise by approximately 15 dBA.
Standard
Sleeve =
+
Mesh
15 dBA
Noise reduction
The Weir Group PLC 47
3D Gas Sizing
•Four test samples were prepared.
•The first was a straight flow path with no cylinders designed to represent a single stage trim, and
act as a baseline for the test results.
•The second contained was an X-Stream flow path designed for liquid flow.
•Flow path three contained two rows of cylinders to define the flow rate with then an additional row
of smaller cylinders and to control the formation of the jets at the outlet of the flow path. This
sample represented the course mesh define by David Kirkwood
•The final sample comprised the X-stream flow path of test sample B with a final row of small
cylinders as sample C
•Each sample contained 4 plates stacked one on top of the other
3D Gas Sizing
The samples were laboratory tested at Manchester University’s Barton facility. The test rig was
designed to ensure that choked flow was achieved across each of the test samples with sonic velocity
at its outlet. The rig was designed to be used in two different configurations.
downstream upstream settling
working upstream
pipe upstream voltage chamber silencer control valve
section pipe measurement
transducer
amplifiers
data
collection
computer
manometer
oscilloscope
The Weir Group PLC 49
3D Gas Sizing
In the first, precise pressure fluctuations were recorded by measuring the wall pressure
fluctuations upstream and downstream of the pipe. A number of pressure sensors were used
to measure the static pressure vibrations produced by the acoustic field downstream of the
test piece. Noise readings were taken using a pre-calibrated noise meter.
Pressure Sensing Transducers
upstream settling
pipe chamber
P10 P9 P8 P7 P6 P5 P4 P3 P2 P1
downstream working
pipe section
manometer connection
The Weir Group PLC 50
3D Gas Sizing
3D Gas Sizing
After the completion of the first series of tests, the outlet section was removed
so that tests using the Scherlieren technique could be undertaken.
This process is used as a means of flow visualisation of compressible fluids.
Its primary use is to identify the formation of important flow features such as
vortices, jet formations and shock cells.
The Weir Group PLC 52
3D Gas Sizing
camera
The Weir Group PLC 53
3D Gas Sizing
As we look at the film of the blank flow path, you will note the growth and profile of the jet.
As the flow chokes, bright diamond shapes will appear. These are noise generating shock
cells.
The test piece also emits a high pitched squealing noise.
A
Blank Flow Path
3D Gas Sizing
The X-stream liquid path formed four independent parallel jets. These coalesce downstream
without producing large shock cells, although there are bright spots indicating much smaller shock
cells. You will alsoBnote the reduction in noise compared to the previous path.
X-StreamTM Liquid Path
3D Gas Sizing
Path C introduces the row of small columns representing the mesh suggested by David
Kirkwood’s work. As we play the film you will note the formation of a single jet at the outlet
of the section with no apparent shock cell formation. The noise generated is again much lower
than the initial sample.
C
2 Rows of Cylinders + “Mesh”
Vertical Plane
Flow
The Weir Group PLC 56
3D Gas Sizing
Finally, the X-Stream Liquid path plus a small row of columns. As with path B, four
independent and parallel jets are formed. This time they coalesce downstream without any
discernable shock cells being present. The reduction in noise was such that measurements could
be comfortably taken without using ear protection.
D
X-StreamTM Profile + “Mesh”