CONTROL VALVE ANTI CAVITATION & FLASHING TRIMS

Abstract:

The document describes many aspects of the control valve anti cavitation trims and different designs available in the
market and necessary look into Anti Cavitation aspects. The document is prepared for the technical knowledge sharing
among the valve experts.

Introduction:

In almost every industry, there are several applications in which Instrument & Process Engineers come across the
Cavitation. Addressing the cavitation by selecting the proper valve is one of the most important task for the Instrument
Engineers.

How:

Cavitation or Flashing happens in control valves when there’s variation in the flow velocity, in particular, when the fluid
in the valve accelerates rapidly. It occurs when the pressure drop in the valve exceeds a critical point or when
downstream pressure exceeds the fluid vapor pressure.
Valve characteristics can also contribute to cavitation. The more streamlined a valve is, the more pressure recovery is
experienced. This increases the possibility of cavitation or flashing.

Consequences:

Since cavitation is common, many control valves are built to withstand it for limited amounts of time. However,
extended exposure to cavitation can seriously damage the control valves.
When the vapor bubbles collapse, they create an implosion that causes pitting in the metal of the valve. Over the time
this wear and tear results in severe erosion, which can cause the valve to fail.
Cavitation also creates high levels of noise and vibration, which can damage not only the valve, but also the piping,
instruments, and other equipment.
Physical damage to a control valve due to uncontrolled cavitation is a concern because of the high maintenance cost,
inconvenience, unpredictability, and unplanned downtime. Damage can consist of a mechanical and selective chemical
attack on the material surface. Typically, cavitation damage is characterized by a very irregular, pitted, rough
appearance. Valve parts with extensive damage may have large amounts of material missing.
Whereas, when the flow due to flashing impinges on valve components, it can cause erosive damage. This erosion can
be severe and may occur even when no abrasive solids are present in the liquid. With increased flashing, the vapour
carries the liquid. As the velocity of the flowstream is increased, the liquid acts like solid particles as it strikes the
internal parts of the valve. This causes erosion in the internal parts of the valve.
Another problem is noise. One of the most easily recognizable problems in the valve is the noise. Noise other than a
disruption to the comfort of work can also cause injury/damage to the hearing system. Noise is caused by turbulence
after flowing through the valve. Turbulence causes pressure fluctuations and this will cause vibration. The vibration that
is at the threshold frequency of human hearing will cause noise.
 Overcoming the problem:

There are several ways to avoid excessive cavitation. Some of them are listed here:
• Selecting the right valve for the application. If the selected valves are the wrong size or the wrong style, their likelihood
of cavitation increases. In water and liquid systems with high pressure drop, use an anti-cavitation valve.
• Use multiple control valves or multistage control valves so that the pressure drop happens gradually rather than all at
once. This is called pressure drop staging.
• Place the control valve at a lower elevation in the system or in an area where the fluid temperature is reduced.
• The velocity of the outlet flow can be reduced by increasing the size of the valve outlet that would reduce the damage.
Options of using hardened materials are another solution.

Here, we’ll discuss on first point i.e. Using Right Valve or Choosing Anti Cavitation valve and that is nothing but choosing
the Valve with Anti Cavitation Trim.

Let’s see what are the designs available in market for Anti Cavitation.

The Anti Cavitating Trims:-

1. Fisher Control Valves:

a.
b. Whisper Trim I:

c. Whisper Trim III:

d. WhisperFlo:
e. Aerodome:

f. Cavitrol Hex

g. Cavitrol III
h. Micro-Flat
2. DRAG
a. 900D
b. 800D
3. FLOWSERVE
a. CavControl
Works best in low-to mild-cavitation applications. Characterization available to cover a wide range of
applications.

b. TigerTooth
Reduces process velocities (which generate noise) at every point across the discs. As the fluid progresses
through the stack, the expanding tooth pattern allows the pressure to be reduced in a series of successively
smaller pressure drops without excursions below the vapor pressure – avoiding the formation of cavitation
altogether.

c. ChannelStream
With the ChannelStream trim, staged pressure drops eliminate cavitation in difficult applications. It is well
suited for moderate to severe cavitation applications.
d. DiamondBack
With the DiamondBack trim, staged pressure drops eliminate cavitation in difficult applications. It is suited for
moderate to severe cavitation applications. The product can pass slurries and particulates of small to moderate
size.

e. SilentPac
Reduces noise for gas, steam, and liquid services. A cost effective solution for moderate noise reduction.

f. MultiStream
Reduces noise for gas, steam, and liquid services. Eliminates noise in moderate to high-pressure drops.
g. MegaStream
Effectively lowers sound pressure levels associated with turbulence generated within the valve, helping to avoid
downstream turbulence that can vibrate relatively thin pipe walls and impact surrounding environs.

h. Stealth
Angled paths direct the flow to the valve exit to reduce exit turbulence, thereby lowering noise and increasing
the flow capacity of the valve. Combines pressure reduction and velocity control features with noise elimination
features to create the most advanced noise elimination technology available.
i. Type I, II and III Trims
Type I – SoundControl:
For noise reduction only. Combines a standard parabolic plug with a 1- to 3-stage silencer as a non-guided cage
around the plug. Retrofitable for applicable valve series.
Type II – StreamControl:
Similar to Type I – SoundControl but with a multihole plug, which can be used for medium noise reduction for
gases and as cavitation reduction for liquids. StreamControl with silencer cages are for gases with improved
noise attenuation only.
Type III – CageControl:
Heavy-duty noise and cavitation reduction. The solid cage guides the plug, which can be parabolic or multihole
based on the application. Suitable for use in any version for gases and liquids.

j. Z-Trim

Can be used in Setball, Duball and Trunnball valve types for cavitation control or noise applications. A cost
effective solution for eliminating common cavitation and noise problems in many applications. Retrofits into
existing valves.
k. C1 Trim
Economical trim based on the CavControl design that minimizes cavitation damage. Controls the location and
concentration of the cavitation vapor bubble implosion in an area away from the metal bubble. Features •
Diametrically-opposed flow suppresses the effect of cavitation through collapsing vapor bubbles away from the
metal parts • Reduces hydrodynamic noise up to 20 dBA Solutions Works best in low to mild cavitation
applications. Characterization available to cover a wide range of applications.

l. Z2 Trim
Z2 Trim, based on Flowserve Z-trim technology, is designed to minimize noise and cavitation in rotary control
valve application. Features • Omni-directional trim for smooth transition without stair stepping in the
characteristic curve • Self-cleaning design with noise reductions up to 26 dBA Solutions A cost effective solution
for eliminating common cavitation and noise problems in many applications.

m. N2 Trim
Multistage trim based on field proven MegaStream designs to minimize noise. Features • Staged pressure drop
through curved plates with optimized holes for smooth flow characteristics • Small pressure drop with each
stage keeps velocity low, reduces cavitation and noise • Self-cleaning design with noise reductions up to 30 dBA
Solutions A cost effective method to eliminate control valve noise by dealing with gaseous pressure reduction
across multiple stages.
The above list is just the short go through over the many designs available from various vendors across the globe.

Despite addition of the several thousands of designs, the list will be incomplete and one need to look the fact that the
design target is same. i.e. Anti Cavitation. Thus, to achieve a similar target i.e. anti cavitation, there are varieties of the
designs available in the market. Different vendors have different designs. The basic is same, distraction of the flow.
Multiple flow paths, multiple flow stages and designing the flow conditioning in their own way to get the cavitation as
low as possible. However, there is not a single solution to all the problems facing cavitation. Depending upon the
differential pressure, flow, temperature, service conditions, fluid properties (i.e Fluid Viscosity, Density, etc.), line size,
etc. the selection is to be done. i.e. Application requirements shall decide which is the best solution for the particular
application. Application experience, knowledge of cavitation science, and the effect of valve size, type, trim style,
geometry, and materials are all critical to select the exact solution.

Conclusion:

Generally, the vendors suggest their own designs depending on the application requirements. Our role is to ensure that
the process requirements and the design basis fulfillments i.e. noise and valve controllability. When we meet these two,
designs suggested by vendors are normally acceptable. Many times, we need to cross verify the designs offered by
vendors for particular application and then need to ensure that the offered design is necessary for that application.
ASSUMPTION:

Minimum knowledge about the Cavitation & Flashing is assumed to be known to everybody.

REFERENCES:

https://alliedvalveinc.com/the-valve-expert/cavitation-control-valves-need-know/

http://www.ccivalve.com/~/media/files/c/cci/pdf/956%20900d%20brochure%20screen.pdf

http://www.ccivalve.com/products/~/media/Files/C/CCI/pdf/326-drag-800d-control-valves-for-severe-service-
applications.pdf

https://www.flowserve.com/sites/default/files/2017-02/fcenbr00002-e.pdf

https://www.emerson.com/documents/automation/brochure-noise-attenuation-technologies-for-control-valves-en-
127214.pdf

https://www.spartancontrols.com/~/media/resources/fisher/ca/477_fisher_catalog.pdf

https://www.theprocesspiping.com/flashing-cavitation-piping-valves/

https://instrumentationtools.com/control-valve-cavitation-and-flashing/

https://automationforum.co/different-problems-in-control-valve-cavitation-flashing/

Edited by:
Anupam A. Gandhewar

https://www.linkedin.com/in/anupam-gandhewar-3b571358/