Cavitation and Flashing

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Vaporization Effects in Fluid Flow

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Pressure

Fusion Fusion Line Line Liquid Phase

Critical Point Vapor Phase

Solid Phase

Triple Point

Temperature
3

Triple Point Diagram

Triple Point
oF

psia 0.0886 75.09

Water CO2
4

32 - 69.88

Pressure

Fusion Fusion Line Line Liquid Phase

Critical Point Vapor Phase

Water (Solid, Liquid, Vapor)

Solid Phase

Triple Point
CO2 (Solid, Vapor, NO Liquid)

Temperature
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Triple Point Diagram

What is Cavitation?
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What is Cavitation?
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Varying Area Flow Channel

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Flow with Pressure Recovery

Basic Equations:

Bernoullis Energy Equation

V12 + P1 V22 + P2

+ gz 1 =

+ gz 2

Continuity
1V1A1 = 2V2A2
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11 11

Flow Channel with sharp edge orifice

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Flow Channel with out Pressure Recovery

(Inlet Pressure)

Cavitation
P
Line ( Pressure) Drop

P1
Valve Pressure Drop
PV

P2
(Outlet Pressure)
o ooo o o o o o o o o o o o o o o o o (Pressure at Vena Contracta)

P vc

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Single Seated Valve Pressure Recovery Diagram

Bubble formation and collapse mechanism

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Implosions with bubble next to wall

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Bubble Implosion 1 diameter from wall

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Bubble Implosion 1 diameter from wall

Within a relatively short time the total damage can become very significant.

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CavControl trim
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CavControl trim
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316 Stainless Steel with Tungsten Carbide Insert

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316 Stainless Steel with Tungsten Carbide Insert

With higher magnification

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Results of Cavitation

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Pitting and erosion Noise and vibration Corrosion Combination

Basic Equations:

Bernoullis Energy Equation

V12 + P1 V22 + gz 1 = P2 +

1 V12

2 V22
= 2 +

2 P2
2

+ gz 2

P1
+ 1

2
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V1
+ 2

P1
=
1

V2
+ 2
=

P2
2

V1 A1
therefore
CV Term Capacity

V2 A2

P/Gf

V1 =
25

[ ( )]
1+ A1

A2

1/2

2 P Gf W

Reduces to ISA Sizing Equation

P
Q = V2 A2 = CV

Gf
where: CV is defined for units/area used

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Ideal Fluid q
Slope = CV

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Actual Liquid

A
P

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(Significant) (Significant) (Sometimes called incipient)

Point A Cavitation 2 Pic = Fi (P1 - PV)

Fi = .85FL
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Actual Liquid

Theoretical choking point

Actual choking point

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Point B Choked
Pc =
32

2 FL ( P1

- FF PV )

Cavitation Regimes

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No Cavitation:

Pressure drop produces noise and vibration from vapor free flow turbulence. Simply Flow Noise

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Incipient Cavitation:
Intermittent Noise and cavity formation.

Constant Cavitation
(or Critical)

Steady constant Noise and constant cavity formation.

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Full Cavitation:
Increases in vibration and Noise intensity to the level of "maximum vibration" vibration" "maximum

Significant Damage" often

occurs somewhere in this regime.
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Super Cavitation:
A decrease in noise and vibration. Choking often occurs in this area. `
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Erosion damage from o high velocity o o o o can occur giving a o damage o o o appearance. o o o o
o o
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Vibration Curve Cavitation Index,

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P1 - based index: 1 =
Sigma 1
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P1 - Pv P1 - P2

P2 - based index: 2 =
Sigma 2
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P2 - Pv P1 - P2

1 = 2 + 1 =

2 1/Fi

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Testing for Cavitation in "Low Pressure Recovery" Control Valves

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Sound Meter

Ways of Measuring Intensity of Cavitation

1 m. down Soft Aluminum Plate

and

1 m. out Accelerometer

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Testing 1. Noise / Acceleration 2. Damage 3. Visual

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45

Acceleration

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= (P1- PV) / P

 mv c

Acceleration

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= (P1- PV) / P

 mv c

Acceleration

SuperCavitation

Full Cavitation

Incipient Cavitation

No Cavitation

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= (P1- PV) / P

Testing 1. Noise / Acceleration 2. Damage 3. Visual

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50

Cavitation

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Velocity Erosion

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Corrosion

Testing 1. Noise / Acceleration 2. Damage 3. Visual

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Visual Cavitation

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Transparent pipe

Strobe Light

Visual Cavitation

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Transparent pipe

Strobe Light

Control of Cavitation Damage

1. Remove all nuclei

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Control of Cavitation Damage

1. Remove all nuclei 2. Inject air or gas

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Control of Cavitation Damage

1. Remove all nuclei 2. Inject air or gas 3. Increase the FL value

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FL = .92
Flow Under

Valve Recovery Factors

1.00 F LL Flow-to-Open 1.00 0.90 0.80 F Fii Flow-to-Open 1.00 0.90 0.80 Valdisk

0.90
0.80

FL 0.70
0.60 0.50 0.40 0 0 20 20 40 40 60 60 80 80 100 100 % % of of Rated Rated Capacity Capacity F L Flow-to-Close FL Flow-to-Close

Fi 0.70
0.60 0.50 F Fii Flow-to-Close 0.40 0 20 40 60 80 100 % of Rated Capacity

FL 0.70
0.60 0.50 0.40 0 30 60 Degrees Open 90 ShearStream

Globe Valve FL Values

Globe Valve Fi Values

Rotary Valve FL Values

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FL = .70
Flow Over

FL = .92?

Control of Cavitation Damage

1. Remove all nuclei 2. Inject air or gas 3. Increase the FL value 4. Hardened materials (brute force)
Estimated force = approx. 250,000# per in2

No materials available that have such strength

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Flowserve prefers: 316 ss / #6 Stellite

Note: For 2 valves and smaller, the entire plug head and seat ring are solid Stellite.

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Hardened Trim

Control of Cavitation Damage

1. Remove all nuclei 2. Inject air or gas 3. Increase the FL value 4. Hardened materials (brute force) 5. Remove metal boundary

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CavControl

FLOW

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CavControl

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Counterbored holes from outside in.

CavControl

Flow
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67 65

CAVITATION CONTROL

A. Single Orifice
This looses less energy

B. Multiple Orifice B. Multiple Orifice

A.A. Single Orifice Single Orifice

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Control of Cavitation Damage

1. Remove all nuclei 2. Inject air or gas 3. Increase the FL value 4. Hardened materials (brute force) 5. Remove metal boundary

6. Multi-stage trim design

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P1 1

Liquid

P2 2
PV o ooo o o o o o o o o o o o o o o vc o o

Liquid and Vapor

The Problem
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The Solution P1 1

Liquid

P2 2
PV

Liquid and Vapor

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The Solution P1 1
(Multi-Stage trim)

Liquid

P2 2
PV

Liquid and Vapor

Since, Pressure does not go below PV ,

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The Solution P1 1
(Multi-Stage trim)

Liquid

P2 2
PV

Since, Pressure does not go below PV ,

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Cavitation does NOT occur!

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76

Channel widths increase outside to Inside.

NO CAVITATION

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CHANNELSTREAM

Visual Comparison

SINGLE STAGE

MULTI-STAGE

CAVITATION CONTROL
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CHANNELSTREAM
DOES NOT CAVITATE

CAVITATES

Tiger-Tooth

Flow
Tiger-Tooth Trim also eliminates cavitation.

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Flashing
P1 PV
Liquid

(Valve Pressure Drop)

P2
(Outlet Pressure)

Liquid / Gas combination

PVC
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(Pressure at Vena Contracta)

Pressure Profile Single Seated Valve

Problems
a. High Velocities b. Choking

c. Erosion
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Since the Enthalpy of a control valve is considered constant between P1 & P2 :

h1 = hf (1-x) + hg(x)
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x = % of liquid mass flashed to vapor

Constant Enthalpy, h

Liquid

Gas

P1

2 Vapor
Liquid

P2

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S
Typical T S Diagram

Example
Water @ 250o F P1 = 200 psia P2 = 15 psia
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Percent Flash

x = [ (hf1 - hf2) / hfg2 ] 100

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Enthalpies from Steam Tables

hf1 = 218.59 B/lb m hf2 = 181.19 B/lb m

hfg2 = 967.70 B/lb m

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Percent Flash
Enthalpy of Sat. Liquid at Inlet Temp Enthalpy of Sat. Liquid at Outlet Press

(218.59 - 181.19) = 3.86% flash 967.70

Enthalpy of Evaporation at Outlet Press
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Sp. Vol. = (1 - x)vf + xvg

vfm = .017(96.1%) + 26.29(3.09%)
Liquid Vapor

vfm = 1.04 ft3 / lb m

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61+ times as much volume as the original liquid.

( )= ( ) (

V2 V1

v2 v1

1.04 2 = = 61.18 .017

) (

KEratio = 3743:1
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To minimize Flashing Damage

1. Harden the trim 2. Control velocities 3. Select Proper materials
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Vaporization Requires ` Careful Engineering

Return to Performance!

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