Sizing Valve Regulating Element

Abstract

The paper investigates the sizing methodology for control valve regulative element (per international standard ISA-75.01.01), produced by additive manufacturing. The overall objective is to develop a design of the valve controlling/ regulating element. This design should be the most suitable for the selective laser melting (SLM) 3D metal printing process – “design for manufacturing” ensuring the best techno-commercial balance for bringing the product successfully to the market. The 3D Metal Print technology, additive manufacturing in general, has reached the level of maturity which enables wide utilisation within different industries - processing industry/ control valve technology is the subject of the investigation. The complex shapes and geometries are the field where the additive manufacturing brings the real advantage, however not only in this segment. The physical properties of the obtained manufactured parts, combined with standard heat treatments, overcoming the values of forged parts. This fact enables much broader market space for product utilisation, especially within high pressure and erosion aggressive environment. The goals of the paper are to tackle the following:

 Developing the flow capacity and pressure reduction tool, i.e. calculator for the valve regulating element after the ISA-75.01.01 standard.  Design and production of the prototype. The finalized, piece is to be in the Nickel alloy steel, ∅25.4 x ∅67 x 38 mm. This prototype is already manufactured. It is of interest to study the turbulent flow parameters calculated in the ISA-75.01.01 standard. In addition to the presented research, it is planned to perform the evaluation of the used SLM technology capabilities, i.e. tolerances of channel dimensions and geometry, remaining of powder in channels and other traces of clogging. This will be based on the following:  Experimental evaluation of the prototype flow capacity. This test will be performed by the third-party certified laboratory. Negotiations are in progress.  Numerical simulation of the channel flow and calculation of the flow capacity (Cv) of regulative element. Obtained experimental results will be the boundary conditions for the planned numerical simulation. Preliminary numerical simulation results are presented in this paper.