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16th Australasian Fluid Mechanics Conference

Crown Plaza, Gold Coast, Australia
2-7 December 2007

CFD Modeling of Globe Valves for Oxygen Application

* 1 2 1
Aditi Oza , Sudipto Ghosh and Kanchan Chowdhury
1
Cryogenic Engineering Centre, Indian Institute of Technology, Kharagpur 721 302, India
2
Department of Metallurgical & Materials Engineering, Indian Institute of Technology, Kharagpur 721 302,
India
*
( Corresponding author: [email protected])

Abstract the stiction, erosion, vibration, cavitation etc. were also

modeled for effective performance of the valve using CFD
Components used in high-pressure, high-temperature, flowing methods (Choudhury et al. [8, 9]; FLUENT User’s Guide [12];
oxygen are susceptible to ignition and combustion in presence Forder et al. [13]; Kalsi et al. [17]; Newton et al. [23]). Many
of restriction or when particles impact these restriction. The analyses have specifically provided the flow patterns for
valves in any systems are the common flow restrictors, hence, different ports and opening gaps in the valves, which
the design and analyses of valves are most critical tasks. The eventually determined the design and operation of the
flow of oxygen through valves distinguishes itself by hardware (Oza et al. [25]; Parslow et al. [26]; Stevenson et al.
accentuating auto-ignition and consequent flame propagation [31]; Slockers et al. [32]). Experimentation and CFD analyses
in metals and non-metals, apart from other usual were also performed to investigate the cause of vibrations that
characteristics present with gases/liquids. The combination of cause valve instability (Morita et al. [22]). The turbulence
ignition resistance, proper and reliable performance and modeling around the valve opening for both steady and
fabrication economy marks the specification of material and unsteady flow were carried out in both compressible and
design of valves in oxygen-enriched environment. The incompressible ranges, as a part of determination of flow and
analyses have been performed by applying the commercial viscous forces on valves (Ahuja et al. [1]; Davis et al. [10];
computational fluid dynamics (CFD) code, FLUENT, to Forsyth et al. [15]; Mazur et al. [20]).
obtain the solution of the two-dimensional turbulent flow field
through a globe valve for its different openings in the GOX Selection of Valve for High Pressure and High Flow
environment. The flow control valves in high velocity oxygen Rate Gaseous Stream
systems for different openings are simulated for turbulence
and eddy dissipation. The influence of pressure, flow rate and There are different kinds of valves available and each one is
opening of the valve on the rise in temperature and eddy used for a specific purpose (Vu et al. [33]). Gate valves are
dissipation rate is also obtained for compressible flow range. generally used in systems where low flow resistance for a
The simulation for turbulence is done by k- and k- fully open valve and no throttling are desired. Globe valves
turbulence models and the results have been compared. are used in systems where good throttling characteristics and
low seat leakage are desired with relatively high head loss
Introduction allowable in an open valve. Ball valves allow quick, quarter
turn on-off operation and have poor throttling characteristics.
Valves control the fluid flow and pressure in a system or a Plug valves are used for changing flow direction between
process. The selection of their types, design and material plays different ports via a single valve. Diaphragm valves and pinch
a vital role in the performance and reliability of any system. A valves are used in systems wherein the system is required to
number of researchers have experimented and analyzed valves be completely isolated from the fluid. Butterfly valves provide
for all its parts, fluid types, operating parameters, discharge significant advantages over other valves in weight, space, and
coefficient, stiction and eroding characteristics and have cost for large valve applications. Check valves are used in
improved the valve technology. Now, with the emergence of applications where open flow in one direction and prevention
robust computational fluid dynamics (CFD) tools and of flow in the reverse direction are desirable. A combination
powerful computers, the analysis of valve performance, and of characteristics of lift check valve and a globe valve gives a
thus the job of designing valves to suit a particular application stop check valve. Safety relief valves are used to provide
can be done much faster. Apart from this, CFD analysis can automatic protection for over-pressurization in a system.
reveal the complex flow structure and the sonic characteristics Researchers have extensively experimented with all the above
around the valve, which the experiments hardly provide. Even categories of the valves in order to identify the valves for
otherwise, experimentation needs to be supplemented with specific applications (Zappe et al. [36]). The computational
CFD analysis because of the complex geometry as well as analyses have not been performed that extensively as the
complexities like turbulence during the sonic flow through a experimental study. The application of valves in high pressure
valve. The experimental results were validated by CFD and high flow rate gaseous streams calls for thorough research
analysis or vice versa. In the present study, CFD analysis of a and analysis. The methodology adopted in these systems focus
specific globe valve design has been carried out to understand on the analyses, design and then experimental validation of the
its performance and reliability during the high pressure flow of analyzed results.
gaseous oxygen.
Valves, when used in high pressure systems, often get
The analyses of the flow behavior inside a valve using CFD damaged by the frequent and severe movement of the metal
method have provided the relation between flow, geometry pieces, back and forth, against each other over an extended
and pressure loses (Amirante et al. [2, 4]; Beeson et al. [5]; period of time and by shock waves during the closing of the
Chern et al. [7]; Vu et al. [33]). Valve-related problems like valves. Leakage is another problem in the valves used in high

1356
pressure systems. The repair or replacement requires Oxygen System Hazard and its Analysis using CFD
demounting of the valve from an existing piping structure. The
inconvenience and attendant damage to the surrounding piping Oxygen is reactive at ambient conditions, and its reactivity
structure poses major impediment to the valve replacement. increases with increasing pressure, temperature, and
Another shortcoming in the valves employed in high pressure concentration. Most materials, both metals and non-metals, are
applications is the requirement of considerable pressure for flammable in high-pressure oxygen, therefore, systems must
actuating the valve. This is because the high seal pressure and be designed to reduce or eliminate ignition hazards. With
related high friction forces are necessary to insure sealing. oxygen systems, unlike other systems, the design and material
Further, the contaminants affect the seal life so severely that selection is very critical to avoid ignition hazards. This risk is
the life of the valves reduces to nearly half of its prescribed caused since oxygen is a strong oxidizer that causes ignition
life time. In addition to all these, the geometry of the valve and vigorously supports combustion. The use of oxygen,
and the drop in velocity around the downstream region therefore, always involves risk. Normal engineering materials,
involves the risk of particle accumulation. like the carbon steel, stainless steel, polymers etc. utilized in
oxygen systems without precautions, often cause incidents and
Globe valve is commonly used as the control valve for high accidents when ignition mechanisms are not appropriately
pressure system due to lesser leakage and higher erosion mitigated. Examples of such events are numerous in all areas
resistance compared to other valves. Gate valves are good for of engineering that utilize oxygen. It includes combustion of
low pressure systems and can perform efficiently without steel pipelines along a considerable length because of high gas
leakage only for low pressure systems. For high pressure velocity and low levels of cleanliness, burning of aluminum
systems, the vibration and shock waves due to the turbulence alloy pumps because of metal impacts and fires in oxygen
causes rapid erosion of the gate of the gate valve. This makes cylinder (and other gas) regulators in industrial, commercial
gate valve vulnerable to failure in high pressure gaseous and medical applications. Fires in pumps, compressors, valves,
systems. regulators, life support systems and aerospace/space system
units containing oxygen-enriched atmospheres often result in
The high pressure oxygen system is more prone to incidents losses of lives and properties. In the oxygen systems, the
and accidents as compared to other fluid owing to its oxidizing igniting fuel is often non-metals, while it causes propagation
property. For any system to be in flames the presence of fuel, in the metal or alloy structure itself.
the igniter and oxidizer is required. In oxygen systems, valve
materials act as fuel and once the ignition occurs, the oxygen
Sr. Components Possible Ignition Source
itself acts as oxidizer. Ignition sources are the only ones which
No.
need to be avoided. Thus, the material compatibility along
1 Ball Valve Particle impact, adiabatic
with the configuration plays a vital role for the safe
compression, promoted
performance of the Globe valves used in high pressure and
ignition
high flow rate gaseous oxygen systems (GOX).
2 Relief Valve Mechanical impact or
frictional heating, promoted
ignition
3 Globe Valve Particle impact, promoted
ignition
4 Butterfly Valve Particle impact, promoted
ignition
5 Check valve Mechanical impact or
frictional heating, promoted
ignition
6 Fittings Particle impact, promoted
ignition
7 Flex Hose Adiabatic compression
8 Soft goods Pneumatic impact,
mechanical impact, and
particle impact
9 Compressor & Friction, fresh metal
Pump exposure
10 Cylinders Adiabatic compression,
over pressurization
11 Filters Particle impact, static
electricity
12 Measuring Particle impact, pneumatic
Fig. 1 Schematic of Globe Valve [37] Equipment impact, resonance

The computational modeling along with the turbulent and Table 1: Oxygen System Components with Possible Ignition Source
unstable flow condition (flow eddies) for GOX in higher (Stevenson, et. al. [31])
pressure and temperature ranges has not yet been done by any
researcher. In this paper, the turbulent modeling of a globe Ignition of the metal or alloy can occur directly through
valve, shown in Fig. 1, for pressures near and above 250 bara impact of particles entrained in the gas flow, due to friction
and mass flow rate of 7 kg/s has been performed in order to between surfaces within the unit, or due to the kindling chain,
understand its performance and estimate its reliability with or burning of a more flammable material. While some of the
respect to oxygen hazard. ignition potential can be eliminated through a sound system

1357
design, the use of appropriate procedural controls to limit the testing as well as actual firing of rocket engines. Therefore,
contamination and ensuring appropriate operating limits, the any failures of such systems or sub-systems need to be
practical solution is to select the proper metallic materials, prevented through reliable design of these components with
such as the burn resistant alloys like copper alloys, Inconel, appropriate operation and selection of materials.
Monel etc. and/or the mitigation of the important ignition
mechanisms (Jackson et al. [16]; Ramanath et al. [28]). The
commonly recognized ignition sources (or their combination)
that can raise the thermal energy within the system above its GV 14
ignition threshold include the following: GV 11
GV 12 PR 1
Fl 4
1) Friction 7) Resonance SV 2
2) Particle impact 8) External heat sources PR 3 GV 13 Fl 3
3) Mass impact 9) Internal Flexing SV 3 GV 10
4) Promoted ignition 10) Flow friction Fl 5 PR 2
5) Static electric discharge 11) Fresh metal exposure
GV 8 Fl 2
6) Electric arc and spark GV 7 GV 9

Table 1 shows the probable cause of ignition source in some PT 1

components used in the oxygen environment. Reduction of GV 5
PT 3
ignition and fire risk requires consideration of following
GV 2
factors: PT 2 SV 1
• Equipment design GV 4 GV 3
• Selection of materials GO2 250 bar
• Design, configuration and construction of Fl 1 GV 1
devices/systems GV 6
• Operating parameters (including flow GOX
characteristics) Fig. 2 A 2-D Piping and Instrumentation Diagram for
Computational analyses for systems ranging from cryogenic the system considered
control valves and pressure regulator systems to cavitating
venturis used to support rocket engine and component testing
have been made (Choudhury et al. [8]). A CFD model was
developed to investigate the combustion and gas dynamics in a
high velocity oxygen–fuel (HVOF) thermal spray gun using
the liquid fuel propane (Newton et al. [23]). Studies on the
complex three-dimensional flow field of oxygen safety Exit
124 mm

25 mm
51 mm

pressure relieve valve, check valves and ball valves have been 3-D Region
performed. The pressure, temperature and velocity profiles
have been obtained for various opening gaps for the valves.
Inlet
The particle impact testing in the valves along with the erosion
characteristics were studied experimentally in many 3-D Region
organizations (Parslow et. al. [26]) Although, computational
analysis have been performed in valve performance in liquids
and other gases, such analysis in oxygen or oxygen enriched Plug & Seat
systems have not yet been done exhaustively. 2-D Region
203 mm

The k - and k - turbulence model for compressible flow Fig. 3 Different Regions of Globe Valve [37]
range has been compared. The performance and comparison of
both the models have been done for orifice flow in a pipeline, Fig. 3 shows the cross section of a single seat globe valve. The
irregular geometries and nozzles. However, the comparison plug and the seat region, unlike the inlet and the exit region
for valves has not been yet performed by any investigator. could be considered as axisymmetric. Thus the inlet and exit
Hence, the present analyses involve the comparison of the geometry have been simplified as shown in Fog. 4. This
above models for globe valve. assumumption is justified as within the plug and seat region
the flow complexities due to the inlet/outlet 3-D flow will not
System Considered be significant.

Fig. 2 shows a segment of 2-D piping and instrumentation

(P&I) diagram of a process using high pressure gaseous Seat
oxygen. The manually controlled globe valve (GV 1) is the Outlet
subject of consideration for the analyses here. The filter (FL 1)
is placed just after the T-section, joining GV 1, GV 2 and FL Inlet
1. The body of the valve is made of cast carbon steel, while Plug
the valve seat and the stem are made of Monel and the sealing
Centerline
elements like the gland packing, disc seal, back seal, body seal
etc are of PTFE (polytetrafluroethylene) material. The P & I
diagram indicates that the globe valves are used in numerous
places along other components such as sensors, like pressure Fig. 4 Axisymmetric view of grid for the plug and seat region
transducer (PT), safety valves (SV), pressure regulators (PR) (rotated 90º)
etc. Such a system may be a part of a larger system used for

1358
The ground level testing of components to be used in rockets spanning large domains with complicated geometries are
calls for testing with the parameters with appropriate range required, only two-equation models are currently practical.
within which it shall actually be subjected to in reality. Hence, The k - model relates the turbulence viscosity, µt (Pa-s), the
the present study involves the analyses of the globe valve turbulence kinetic energy, k (m2s-2), and the turbulence
subjected to high pressure and high temperature gaseous dissipation rate, (m2 s-3). The k - turbulence model is
oxygen (GOX). similar to the low Reynolds number k - model, with
replacing , which represents the specific dissipation rate (s-1).
CFD and Selection of Turbulent Model The development and improvisation of the models (Amirante
et al. [3]; Chern et al. [6]) and their comparison led to the
Ball valve and butterfly valves have been analyzed using general inference that the near-wall simulation results for
CFD. The CFD analyses with ball and butterfly valves in turbulent flow with k model were more accurate than the
oxygen systems provided key insights into the ignition k model. The k model is known to behaves well for
mechanism through visualization of the flow through the wall-bounded problems and is simpler and faster in
valves and identification of the most probable impact targets convergence than the k model. On the contrary, k
of the carried over particulate matters (Newton et al. [23]). It model gives better results in the free stream region. The k -
also provides the probable gas pressure and velocity inside the model captures the features of the flow more accurately when
valve which aides in evaluating the ignition and possible compared with the one-equation and mixing length model.
propagation phenomenon. However, the experimental or
computational evaluation of the reliability of globe valve vis- The grid used in the study is a structured grid. The grid
à-vis the ball or butterfly valves has not yet been done. Thus independence investigation leads to the optimum grid with
the CFD based analysis of flow of GOX at high pressure 744 cells and 1565 faces. Fig.5 shows the grid independence
through a globe valve was taken up, with the focus on safety test results. The increase in cells beyond 744 had no
from fire hazard under oxygen-enriched atmosphere. significant variation in the parameter values. Symmetry
boundary conditions have been used in the centerline. All
Though the CFD results in the present study have not been solid boundaries have been represented using the no slip
experimentally validated, they provide useful information on velocity conditions. The governing equations are discretized in
the flow dynamics across the globe valve seat during the FLUENT using finite volume formulations with the second
initial opening sequences, the temperature rise in the valve, the order spatial accuracy. The continuity is satisfied by SIMPLE
velocity profile, the turbulent kinetic energy rise and eddy (semi-implicit pressure linked equations) algorithm. The
dissipation around the plug region. The CFD analyses are used residuals used for the convergence criteria have been
as an intermediate step towards the determination of the safety normalized with three orders of magnitude.
of the system.
.
Turbulent flows are characterized by fluctuating velocity
fields. Turbulence brings fluids of differing momentum 744 cells
content into contact. Turbulence is characterized by eddies or 644 cells
instabilities. During turbulence, large eddies extract energy
from the flow and the smaller eddies extract energy from the
544 cells
larger eddies. The energy continues to flow to still smaller
eddies until the eddies are too small to be sustained and in that
case the energy is dissipated by turbulent viscous forces. The
reduction of the velocity gradients, in the presence of
restrictions, due to the action of viscosity reduces the kinetic
energy of the flow and this mixing is dissipative. Hence the
energy “cascades” down through smaller length scales.
Fig. 5 Grid Independence Test
The choice of turbulence model depends on consideration
such as the physics encompassed in the flow, the established
practice for a specific class of problem, the level of accuracy Results and Discussion
required, the available computational resources, and the
amount of time available for the simulation. The selection of The results for both the turbulence models for 20% and 50%
particular model for specific application from the general openings are shown in Fig. 6 through 26
guidelines (Kamnis et al. [18]; Leutwyler et al. [19]; Min et al. In each case, the flow initially accelerates through the plug
[21]) is not easy. In general terms, a good turbulence model and seat region, and then flows downstream in the form of a
requires minimum complexity (i.e. contain a minimum wall jet while remaining attached to the plug. In addition, a
number of differential equations, empirical constants and recirculation region develops on the downstream side of the
functions, but still provide sufficiently accurate and physically seat. As the valve percent opening increases, the plug begins
realistic results), robustness (i.e. promote stable convergence to retract beyond the plane of the seat as shown in Fig. 6.
and not have difficulty resolving the steep gradients in near-
wall regions), possess extensive universality (i.e. can be
applied to a wide variety of flows without adjusting the
empirical constants). For engineering calculations, two-
equation turbulence models have become the most popular, Particulate Accumulation Region
since they are relatively simple to program and place much on the Polymeric Back Seal
lower requirements on computer resources than other more
complex models (e.g. algebraic and Reynolds stress models).
Consequently, when cost effective, timely solutions of flows Fig. 6 Velocity Profile 20 % opening (k - model)

1359
 Fig. 7 Turbulent Kinetic Energy 20 % opening (k - model)
Fig. 13 Velocity Profile 20 % opening (k - model)

Fig. 8 Turbulent Eddy Dissipation Rate 20 % opening

(k – model)

Fig. 14 Contour for Turbulent Kinetic Energy for

20% opening (k - model)

Fig.9 Contour for Mach number for 20% opening (k - model)

Fig. 15 Contour for Turbulent Eddy Dissipation

Rate for 20% opening (k - model)
1200
Turbulent Kinetic energy (m2/s2)

1000

800

600
Fig. 10 Contour for Turbulent Kinetic Energy for 20%
400
opening (k - model)
200

0
0 0.02 0.04 0.06 0.08 0.1

Position (m)

Fig. 16 Turbulent Kinetic Energy value Comparison for

20% opening k – model k - model

7000

6000
Turbelent Kinetic Energy (m2/s2)

Fig.11 Contour for Turbulent Eddy Dissipation

Rate for 20% opening (k – model) 5000

4000

3000

2000

1000

0
0 0.02 0.04 0.06 0.08 0.1
Position (m)

Fig. 17 Turbulent Kinetic Energy value Comparison for

50% opening k – model k - model

Fig. 12 Contour for Total temperature for 20%

opening (k – model)

1360
 being complex, the pressure gradient is observed to be more
than that of ball or butterfly valve.

The turbulent kinetic energy values are higher in the plug

region for the fifty percent opening than the twenty percent
opening. The restriction is more towards the downstream,
hence, explaining more energy dissipation and turbulence. The
drop in the velocity (Fig. 6) at the back seal position in all the
opening contours enhances the particulate accumulation. The
seal, being made of flammable material, along with the
particulate accumulation might cause the initiation of ignition
in presence of source of heating or a electrostatic charge
(Amirante et al. [3]).
Fig. 18 Velocity Vector for 50% opening

Fig. 22 Total Temperature profile for 50% opening

Fig. 19 Turbulent Kinetic Energy profile for 50% opening

Fig. 20 Velocity profile for 50% opening

Fig. 23 Velocity profile for 50% opening (k- model)

Fig. 21 Turbulent Eddy Dissipation Rate profile for 50% Fig. 24 Total Temperature profile for 50% (k- model)
Flow separation from the plug with the formation of a second
recirculation zone occurs around the region between the jet
and the plug. This may result in either flow reattachment to
the plug at a point downstream or it is flowing as a free jet
until the impingement on the surface of the valve body. In
each case the pressure decreases in the downstream direction
with more pressure gradients occurring around the plug and
seat region. No significant pressure changes are observed
upstream of the seat and only minor changes are observed
downstream of the seat. Minor pressure changes downstream
of the seat imply little or no pressure recovery. This is
desirable in a control valve. But in globe valves the flow path Fig. 25 Turbulent Kinetic Energy for 50% opening
(k- model)

1361
 are probabilities of particulate accumulation around the back
seal region of the plug due to the velocity drop by nearly 90%
towards the wall region and the recirculation of the flow. The
material considered in the simulation was taken to be the same
as existing in reality. The temperature rise in the simulation
was less than 10K, hence, the selection of Monel in the
sensitive areas would resist the ignition initiation, since it is
used only in those regions prone to get ignited.
Fig. 26 Specific Dissipation Rate Profile for 50% opening
(K- model)

The simulations of the valve have been done with both k - Reference
method and k - model of turbulence. The k - model
converges slower as compared to k- model. But k- model [1] Ahuja, V., Hosangadi, A., Shipman, J., Daines, R. and
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