Noise. Vibration. Cavitation. Prevention.

By Cla-Val Technical Products Department claval@cla-val.com 949.722.4987

The telltale signs of cavitation

In water distribution systems where high pressure differentials and high flow rates are present, valves, piping and equipment really take a beating. When automatic control valves are exposed to such conditions, they will often begin sounding off by exhibiting vibration and excessive noise, letting the operator know that the pressure differentials and high flow rates are taking their toll. When these symptoms appear, its a clear indication that cavitation is occurring, soon to be followed by diminished performance and failure. Cavitation in valves occurs when the velocity of the fluid at the seating area becomes excessive, creating a sudden, severe reduction in pressure below the vapor pressure level causing the formation of thousands of tiny bubbles. As fluid velocity subsequently decreases, the pressure level rises, causing the vapor bubbles to collapse, releasing a substantial amount of energy - literally eating away the metal surfaces of the valve interior. Over time, this can result in a spectrum of performance issues, including loss of flow capacity and erosion damage. The rule of thumb is: with relatively low downstream pressure conditions, the higher the pressure drop across the valve, the greater potential for damage. (See inset for a description of applications where cavitation commonly occurs)

What does cavitation damage look like?

It isnt pretty. In fact, its startling what the force of the vapor bubbles impinging on a valves metal surfaces can do. The collapse of vapor bubbles can cause local pressure waves of up to 1,000,000 psi, causing deterioration of any surface with which they come in contact. The noise and vibration that accompany the valve damage are also a concern, posing a potential safety hazard for personnel working in close proximity to the cavitating valve.

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Determining the potential for cavitation

The first step in avoiding this commonly occurring problem is to analyze the system to measure the potential for valve cavitation. Analysis should take into account parameters such as pipe and valve size, maximum and minimum flow rates, static/dynamic inlet and outlet pressure, water temperatures and elevation above sea level. This analysis can be performed using commercially available software or another approach such as the analytical method described in Hydraulics of Pipelines; Pumps, Valves, Cavitation, Transients by J. Paul Tullis of Utah State University (copyright 1989 by John Wiley & Sons, Inc.). Following Tullis methodology, flow tests are conducted to determine a Sigma curve for the valve. Sigma is defined as a cavitation index that identifies the level of cavitation that will occur with various flow and pressure conditions through a restriction device (such as a valve). Sigma is defined as (P2 - Pv) / (P1 - P2) Where: P1 = valve inlet pressure (psi) P2 = valve outlet pressure (psi) Pv = gage vapor pressure (psi) To further clarify, the conditions causing cavitation are directly proportional to the kinetic energy of fluid, which is related to delta P (see Figure 1 below).

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Preventing cavitation in valves

Once the potential for cavitation in a system is understood, the next step is determining the best method to prevent it from occurring. Some of the most common and effective measures are: 1. Installing two valves in series where extremely high pressure differentials exist 2. Using backpressure-producing devices such as one or more orifice plates downstream of a valve that is exposed to cavitation-causing conditions 3. Using valves equipped with anti-cavitation trim in systems where extreme pressure differentials and high velocity flow rates are present

Pros and cons of the most common cavitation prevention measures

1. Two Valves in Series: Installing two valves in series will effectively mitigate the incidence of cavitation. An added benefit is that the second valve acts as a backup in the event the first valve fails, ensuring that there will be at least some level of pressure reducing functionality in the application. The negative in this scenario is that space at valve installations is often limited and there simply isnt enough room to install two valves. In addition to these concerns, there is also the cost of the second valve to consider. 2. Orifice Plates: An obvious benefit of using orifice plates as backpressure devices to reduce the effect of cavitation is the relative low cost to purchase and install them in the pipeline. Unfortunately, when orifice plates are used in this way, they are only effective within a narrow flow range and will cause a reduction of flow capacity within the system. Yet another negative is that orifice plates can actually cause cavitation to occur, creating the potential for damage to downstream fittings and valves. 3. Anti-Cavitation Valves and Trim: Several automatic control valve manufacturers offer products that are designed to reduce or eliminate cavitation. By nature, any anticavitation device will result in reduced flow capacity. Fortunately, the negative effects can be minimized when the valve is properly sized for the application. This is achieved by performing comprehensive and thorough flow testing with a sizing program to ensure that the right size valve is chosen to provide cavitation protection. Despite this caveat, using an anti-cavitation valve is generally considered to be the most effective approach, especially if an existing, installed valve can be retrofitted with anticavitation trim. Whether an existing valve is enhanced with the cavitation-fighting components or a new valve equipped with such trim is used, this approach is highly desirable because the cavitation solution is self-contained and should be able to provide a wider range of flow rates and smooth operation with low levels of vibration and noise.

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Pros and cons of the most common cavitation prevention measures (continued)
It is important to note that there are occasionally applications where a systems pressure and flow rates are so extreme that the only effective measure against cavitation is a combination of a valve outfitted with anti-cavitation trim, installed in conjunction with orifice plates. Fortunately, this scenario is not the norm.

The best course of action: Designing a cavitationfree system

In the best-case scenario, distribution systems would be designed with cavitation prevention measures as an integral part of the system. Again it goes back to taking that all-important first step of performing a complete cavitation study before valves are selected, purchased and installed in a pipeline. Engineers and consultants can provide a significant value to their customers by taking cavitation into consideration when designing their systems. They can provide further value by consulting with valve manufacturers and specifying valves that are properly sized and equipped with anti-cavitation trim or other options as previously discussed. The long-term benefits are significant: lower maintenance costs; fewer equipment failures; less down time associated with valve replacements; and a system that performs with optimum efficiency. In the case of an existing pipeline, the most direct approach to minimizing or even eliminating cavitation is either replacing existing valves with cavitation-fighting valves or retrofitting them with anti-cavitation trim. Whichever avenue the water company chooses, operating a water distribution system with little or no cavitation is possible. Its just a matter of which approach will work best with the companys operational and financial parameters.

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Inset
Cavitation-Prone Applications in Water Distribution Systems

Pressure Reducing Valve Stations in vaults, high rise buildings or any application where high velocity flow rates and extreme pressure differentials exist

Installations where fluid is discharged to atmosphere

Tank/reservoir filling applications

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