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February 2012
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
TABLE OF CONTENTS
Abstract ............................................................................................. 3
Abbreviations .................................................................................... 4
Market Trends/Challenges ................................................................ 5
Challenges for valves in HVAC applications: .................................... 8
Solution ............................................................................................. 9
Best Practices ................................................................................. 12
Common Issues .............................................................................. 14
Conclusion....................................................................................... 15
Reference ........................................................................................ 16
Author Info ....................................................................................... 16
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Abstract
A control valve is often required to be designed for different
kinds of flow characteristics, depending on the process to be
controlled. The flow characteristics refer to the sensitivity of
the valve spindle movement or opening to the increase in the
flow.
In this paper, a new hybrid flow characteristic is explained.
Generally, flow characteristics are achieved by various valve
trims or shapes of the plugs to be designed. The challenge lies
in the design of the shape of the valve trim to achieve the
required flow characteristic. Often, many iterations of design,
manufacture and testing are done, and this cycle is repeated to
achieve the flow characteristic. In this paper, a novel iterative
method is demonstrated to achieve not only the above flow
characteristics, but also their new S-shaped flow characteristic
derived by the author. A new empirical relation for the flow
coefficient K is derived, which is verified by CFD analysis.
Further, after the design, the valve can also be virtually
verified by CFD analysis.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Abbreviations
Sl. No.
Acronyms
Full form
CV
Control Valve
EEV
Pressure
Velocity
VRF
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Market Trends/Challenges
Valves are used for controlling the flow in engineering
production processes, for environment control in closed
chambers, and in many other applications. The processes
range from chemical processes, steam generation,
pharmaceutical, food industry, textile industry, etc. The
expectations from valve design are as follows.
Accurate flow control by suitable valve design for
better end product quality: In many cases, the
quantity of the flow affects the quality of the end
product. This is particularly seen in the chemical,
pharma, food and textile industries.
Reduce the power consumption: In many cases, such
as HVAC applications, pumping applications, etc., the
mass flow through the valve causes higher pressure
loss and thus energy consumption.
Control the cost of the end product: To control the
cost of the end product, it is necessary to reduce energy
consumption, and in the case of process, precisely
control the quantity of costly reactants, the quantity of
heating steam for heating, or the quantity of refrigerant
for cooling and maintaining the temperature in a
chamber.
Valves are used in HVAC to achieve the required
pressure, and thus the temperature drop for the
refrigerant. The earlier trend was to use a capillary
tube because the mass flow of the refrigerant was
fixed.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Solution
A new mathematical solution for the design of a Proportional
Flow Control Valve:
Cooling capacity KW = M (Kg/sec) * (H evap. out H evap.
in)/1,000
M (Kg/sec) is the mass flow rate of refrigerant
H evap out: (KJ/Kg) Enthalpy at the exit of the evaporator
H evap in: (KJ/Kg) Enthalpy at the inlet to the evaporator
Pressure difference available for the flow, dP = Pin Pout
Density of the fluid at the EEV inlet for Pinlet and Tinlet
Maximum theoretical velocity m/s = SQRT(2* dP/Density)
V actual
(velocity) =
Where K
empirical=
N =
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Exit to EEV
Temperature,
C
32
Super
heat K
P Inlet
bar
Abs
Pr
outlet
abs
bar
Pr Drop
Require
bar
19.676
9.32
13.5
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
10
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
The valve trim shape at near zero flow has a hump to achieve
the above flow characteristic.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
11
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Best Practices
The best practices for flow characteristics design are
suggested below for the respective conditions.
1. Collect the operating conditions for which the valve
has to function
2. This includes the ranges of the refrigerants, ambient
temperatures at various geographic
3. From HVAC calculation, estimate the mass flow of
fluid required to achieve the required cooling or
heating
4. Conduct hand calculations for the valve port dia or
the orifice dia
5. Conduct hand calculations for the design of the
valve trim dia for a particular valve opening say 5%
to meet the required flow (say 5% flow) at this
position. For linear flow characteristic the flow at
5% valve opening will be 5% of the maximum
flow.
6. Repeat the above calculations for other % valve
openings and % flow
7. Prepare a CAD model of the valve trim with the
valve seat
8. Conduct CFD analysis with the operating condition
and the input operating condition at minimum
flow, median flow and maximum flow
9. Specify the only the pressures and temperatures at
the inlet and outlet for the CFD analysis. The mass
flow is to be estimated by the CFD analysis
10. Check whether the mass flow obtained from CFD
analysis matches with that estimated from the hand
calculation.
11. If the resulting mass flow rates match, conduct
CFD analysis for other valve openings
12. If the resulting mass flow rates do not match, repeat
the design process from step 4
13. After successfully attaining the required flow from
the CFD analysis within the accepted tolerance, the
entire valve manufacturing drawings may be
completed
14. The valve may be manufactured
15. Test the valve for its flow characteristic
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
12
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
13
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Common Issues
The Electronic Expansion valve (EEV) in HVAC has to
provide the right pressure drop, and thus the temperature
drop, at all mass flow rates.
The same EEV of a certain capacity has to meet:
1. The ranges of Mass flow rates from nearly 0.5 % of design
flow to 130% of the design flow
2. Able to handle various refrigerants/fluids as per customer
choice
3. Various operating conditions of temperatures depending
on the country where it is sold for various operating
conditions of pressure depending on refrigerants and
country where it is sold
4. Flow varies depending on the application, whether for air
conditioning or refrigeration or display cases
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
14
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Conclusion
The design calculations for the flow characteristic of a
proportional flow control valve may go through a few
iterations to match the flow obtained from the CFD at the
respective valve position. It is observed by the author that the
single phase liquid flow CFD analysis is good enough for the
expansion valve flow verification. The single phase liquid
flow matches fairly well with the known performance of a
typical EEV valve, as was verified by the authors for a base
case, though in the actual performance in an expansion valve,
the fluid changes phase from liquid at the entry to a liquid-gas
mixture at the exit.
The single phase flow analysis will reduce the computational
time and still be close to the actual performance of the valve.
The flow characteristics of valves play a major role in energy
saving. Hence, it is necessary to attain the required flow
characteristic to match the overall operation of the compressor
with the valve.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
15
A New Approach in Control Valve Design With a New Hybrid Flow Characteristic | February 2012
Reference
General information on types of valves from the internet
Author Info
Dr. Madhusudan, R.S. (popularly known as
Doc), SME, Fluid Power, ERS, Mechanical, HCL
Tech, Bangalore
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
16
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