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  • Scholars' Mine

    Masters Theses Student Research & Creative Works

    1966

    A study of modified plug designs for a globe valveRobert W. Wagner

    Follow this and additional works at: http://scholarsmine.mst.edu/masters_thesesDepartment: Mechanical and Aerospace Engineering

    This Thesis - Open Access is brought to you for free and open access by the Student Research & Creative Works at Scholars' Mine. It has been acceptedfor inclusion in Masters Theses by an authorized administrator of Scholars' Mine. For more information, please contact [email protected].

    Recommended CitationWagner, Robert W., "A study of modified plug designs for a globe valve" (1966). Masters Theses. Paper 5724.

  • A STUDY OF MODIFIED

    PLUG DESIGNS

    FOR

    A GLOBE VALVE

    BY

    ROBERT W. WAGNER

    A

    THESIS

    submitted to the faculty of the

    UNIVERSITY OF MISSOURI AT ROLLA

    in partial fulfillment of the vork required tor the

    Degree ot

    MASTER OF SCIENCE IN MECHANICAL ENGINEERING

    Rolla Misaouri

    1966

    Approved by

  • ii

    ABSTRACT

    This thesis presents an empirical study of the charac-

    teristics of a cylindrical skirted disk valve used as a

    flow regulating device. Holes were drilled in two separate

    removable cylinders, which, when respectively attached to

    the valve plug adapter, provided control of the flow rate.

    These cylinders could be moved to permit exposure of more

    or less flow area by means of the valve stem and crank

    mechanism. At the closed position of the valve no holes

    were available for flow within the differential pressure

    zone of the valve, while at the full-open position all the

    drilled holes were within the flow zone of the valve, per-

    mitting maximum water flow rate.

    The method used in adding the holes to the cylinders

    was "cut and try" because the desired flow rate was already

    determined before any holes were drilled. In other words,

    holes were drilled until the desired flow rate was achieved.

    The flow rate through each cylinder was established

    at several cylinder positions by means of the weir trough

    measuring device. This relationship was used to determine

    the valve characteristic. The valve characteristic is

    merely a graphical comparison of the flow rate through the

    valve versus the percent valve opening.

    A second set of curves was plotted to find the rela-

    tionship between the flow rate and the exposed flow area

  • iii

    for each cylinder to establish a possible design criterion.

    The cylindrical skirted disk plug exhibits a new and

    accurate approach to fluid flow control. The results of

    this study indicate that the experimental procedure pur-

    sued can be used to obtain desired valve characteristics.

  • iv

    ACKNOWLEDGEMENT

    The author wishes to express his appreciation to Pro-

    fessor Archie Culp, Associate Professor of Mechanical Engi-

    neering, University of Missouri at Rolla, whose suggestions

    and guidance made this thesis possible.

    Thanks are also extended to the engineering staff of

    the Crane Company of Chicago, Illinois, especially Mr. T.

    A. Rodda, Engineering Project Supervisor, for sup,gestions and correspondence throughout this investigation.

    Finally, appreciation is due my fellow graduate assis-

    tants, Mr. Donald Land 1 Mr. Michael Reyburn, Mr. Stephen

    Thompson, and Mr. Gary Hinz for their assistance and en-

    couragement during the course of this investigation.

  • v

    TABLE OF CONTENTS

    Page

    ABSTRACT ii

    ACKNOWLEDGEMENT iv

    LIST OF TABLES vi

    LIST OF FIGURES vii

    I. INTRODUCTION. 1

    II. REVIEW OF LITERATURE. 3

    III. DISCUSSION. 5

    DESCRIPTION OF APPARATUS. 6

    Equipment De sign. 6 Water Supply System 11 Measuring Devices 11

    DESIGN ANALYSIS AND PROCEDURE 14

    EXPERIMENTAL PROCEDURE. 16

    First Test Set-up .. 16 Second Test Set-up. 17 Test Procedure. 17

    WEIR AND ORIFICE THEORY . 19

    RESULTS 23

    IV. CONCLUSIONS 28

    v. RECOMMENDATIONS 29

    VI. BIBLIOGRAPHY. 31

    VII. VITA. 32

    VIII. APPENDIX. 33

  • LIST OF TABLES

    Table Page

    l

    2

    3

    (Note: these tables are in Appendix)

    WEIR CALIBRATION

    DATA COLLECTED ON THE LINEAR FLOW PLUG TEST

    DATA COLLECTED ON THE LINEAR HEAD PLUG TEST

    34

    34

    35

    vi

  • LIST OF FIGURES

    Figure

    1

    2

    3

    4

    5

    6

    7

    ASSEMBLED VALVE . . . . . . . . . . VALVE TEST SECTION

    CYLINDER AND STUD MOUNTED ON THE VALVE CRANK MECHANISM

    VALVE SEAL COMPONENTS . .

    OVERALL VIEW OF TEST EQUIPMENT.

    V-NOTCH WEIR

    e

    ORIFICE . .

    (Note: The remaining figures are in Appendix)

    8 VALVE CHARACTERISTIC FOR THE LINEAR FLOW VALVE

    vii

    Page

    5

    6

    8

    10

    12

    19

    22

    PLUG. 36

    9 HEAD VERSUS PERCENT VALVE OPENING FOR THE LINEAR HEAD VALVE PLUG 37

    10 RELATIONSHIP BETWEEN AREA CHANGE AND VALVE PLUG POSITION CHANGE FOR THE LINEAR FLOW PLUG. 38

    11 RELATIONSHIP BETWEEN AREA CHANGE AND VALVE PLUG POSITION CHANGE FOR THE LINEAR HEAD PLUG. 39

    12 RELATIONSHIP BETWEEN AREA CHANGE AND FLOW RATE

    13

    14

    CHANGE FOR THE LINEAR FLOW VALVE PLUG . . 40

    RELATIONSHIP BETWEEN AREA CHANGE AND FLOW RATE CHANGE FOR THE LINEAR HEAD VALVE PLUG

    COMPARISON OF YARNALL'S FLOW EQUATION AND THE ORIFICE EQUATION FOR THE LINEAR FLOW PLUG

    41

    42

    15 COMPARISON OF YARNALL'S FLOW EQUATION AND THE

    16

    ORIFICE EQUATION FOR THB LINEAR HEAD PLUG 42 WEIR FLOW EQUATION FLOw RATE VERSUS ACTUAL FLOW RATE (WEIGHED) 43

  • 1

    I. INTRODUCTION

    There are two basic functions of a valve in a fluid flow

    system. These are; regulation of flow rate or regulation

    of pressure. The type of regulation studied in this inves-

    tigation was the flow rate through a modified globe valve.

    Specifically, the flow rate of water was evaluated both

    experimentally and analytically.

    There are countless uses of flow control or throttling

    valves. Hydraulic systems, oil transmission lines, and city

    water supply systems represent a partial list of applications.

    The use of throttling valves is as common as regulating

    your shower or controlling the sprinkler for your lawn.

    A continuing study of plug designs for globe valves

    has been made in order to produce desired valve character-

    istics. Again, the characteristic of a valve is a plot of

    the flow rate versus percent opening of the valve. A basic

    problem encountered in designs using cylindrical plugs is

    that of sealing the area between the cylinder and the seat

    in order to constrain the flow to the configurations machined

    in the wall of the cylinder.

    The primary objective of this investigation, therefore, was to design a cylindrical skirt plug for a globe valve

    with a positive seal at the valve seat. Two valve plug

    configurations were tested in an attempt to achieve the pre-

    determined valve characteristics. A secondary objective

  • of this investigation was to try to establish a more deli-

    berate design procedure for programming the valve charac-

    teristic.

    2

  • II. REVIEW OF LITERATURE

    The study of control valves dates back over one hun-

    dred years. Since then butterfly valves, plug valves, gate

    valves, globe valves, and others too. numerous to mention

    have been investigated and modified to fit almost every

    flow requirement. Therefore, to maintain conciseness, this

    3

    review will be limited to the globe valve and its derivatives.

    Before 1900, piston type globe valves were already in

    use in the steam engines of railroads and ships. Seely

    and Talbot (1) conducted experiments with globe valves in

    1918, for the purpose of correlating the head loss within

    small globe valves with various valve openings. The prin-

    ciple contribution of Seely and Talbot's study was the fact

    that the head loss depended primarily upon the shape of

    the exit passage of the valve. Their conclusion that head

    loss in a valve varied directly with the square of the flow

    velocity has proved to be a very useful tool in hydraulic

    studies. Lansford (2), in a later study of globe valves, verified these results.

    In his treatise on hydraulics, Addison (3) disclosed

    that although losses within globe valves ware rather large,

    such valves made excellent flow regulators. Rhodes (4), in 19~1, suggested several types of ported plug designs to

    achieve desired valve characteristics. One was solid disk

    with a symmetrical parabolic cross section designed to

    produce a parabolic flow relationship with percent of valve

  • lift. He also mentioned the V-ported plug valve which pro-

    duced a similar parabolic flow characteristic because of

    the mathematical relationship between the area and the al-

    titude of a triangle. However, Rhodes' most significant

    statement in relation to this study was: "Where greater

    accuracy is required than will result from the use of the

    simple triangular shaped orifice, the plug is made with a

    series of small orifices of different shapes so designed

    as to give a total flow at any time exactly equivalent to

    that needed for perfect control."

    Beard (5) completed a thorough investigation of V-port and parabolic plug designs in 1957. His emphasis of valve

    rangeability, "the ratio of maximum to minimum flow over

    which the usable flow characteristic exists," is something

    every valve designer must bear in mind.

    4

  • III. DISCUSSION

    The discussion is divided into two primary sections:

    the first subdivision is concerned with the equipment re-

    quirements and experimental procedure, and the second eub-

    division is concerned with analysis of the experimental re-

    sults. In addition, a section on experimental apparatus

    discusses the purpose and capability of each piece of

    equipment.

    A section covering design analysis and experimental

    procedure dwells on the methods used in designing the flow

    PLUG ATTACHMENT

    C.RANK AND STEM MECHANISM

    DETACHABLE CYLINDER

    FIGURE l ASSEMBLED VALVE

    5

  • 6

    c~ntrolling device. and the procedure used in conducting

    the- tests on the complete valve. The remainder of the dis-

    cussion tabulates and evaluates the experimental results

    w~th known weir and orifice theory in order to establish

    a mathematical r .elationship that .can . be used in future de-

    sign procedueea~ .

    DESCRIPTION OF APPARATUS

    EQuipment Design - A-major portion of this research was con-cerned with the diign of a valve with a cylindrical skirt

    plug. For convenience. it was decided that the valve plug

    J'IGU~l; 2 ~~VE ~E~T ~ECTiON

  • would be fabricated to fit in an existing 3-inch diameter

    Crane globe valve, since this commercial valve was already

    installed in a pump test loop in the Mechanical Engineering

    Laboratory. The Crane valve stem, plug assembly, and seat

    were removed from the body and the plug was modified. The

    cylindrical skirt plug illustrated in Figures 1 and 3 was

    then installed in place of the plug and seat of the former

    valve. The seat of the new valve was machined to the same

    thread pitch and pitch diameter of the original Crane seat

    since it had to fit the threaded holder within the valve

    body.

    7

    The modified valve seal contained three component parts;

    the seat, the plug adapter, and the cylindrical skirt plug.

    All three were machined from aluminum round stock. The

    purpose of the seat was to provide a machined surface upon

    which the valve would seal in the closed position. In or-

    der to prevent water flow by the housing, a rubber seal,

    which will be described later in the discussion, was in-

    stalled. The plug adapter serves as a connection between

    the cranking mechanism, the stem, and the actual flow con-

    trolling device- the cylindrical skirt plug. The purpose

    of using detachable cylinders was to reduce the machining

    time in case a cylinder had to be scrapped during the

    test period.

    The main difficulty associated with modification of

    the valve was concerned with finding a method to seal the

  • 8

    valve from leaks while under fluid pressure. Close atten-

    tion was given to the means of sealing the gap between the

    outside diameter of the cylindrical skirt plug and the

    inside diameter of the seat. This task was accomplished

    by the use of a butyl ORing which was flexible enough to allow relati~e mo~ion between the cylinder and the seat.

    In order to keep the diameter of the valve as close to 3 .., : ,. ,, I

    inches as possible the outside diameter of the cylinder was ... !

    set at 3.000 + .005 inches and a suitable 0-Ring was chosen ..... ... . . ( ~

    ..

    to dynamically seal the cylinder. A # 337 Precision 0-Ring . '

    was used. To insure a positive seal on the inside diameter

    FlGURE 3 C LillD1!~ AND STUD MOUNTEb ON

    THE VALVE CRANK MECHANISM

  • of the 0-Rinr,, a .025 inch diametral squeeze was recommend-

    ed by the manufacturer. Since the inside diameter of the

    0-Ring was 2.975 inches, an adequate seal was obtained for

    pressure differentials up to 500 psi accordin~ to the

    manufacturer's specifications.

    q

    After the outside diameter of the cylinder was deter-

    mined, the inside diameter of the seat was bored to allow

    the cylinder to pass through with no interference or scar-

    ring. At that time the slot tor containing the O-Rin~ was

    bored as close to the leading edge of the seat as possible

    to prevent appreciable flow interference by the seat it-

    self upon opening the valve. A 45 chamfer was then turned

    on the leading edge of the seat to mate with the ~5 bevel

    on the plug adapter at the full-closed position of the

    valve.

    One of the principal machining problems was that of

    maintaining the concentricity of the moving parts to in-

    sure that the cylinder would not bind or cock as the valve

    was opened or reclosed. To prevent this from occurring,

    the cylinders were all initially bored to 2.750 inches,

    faced and threaded at one end to fit the plug assembly.

    The cylinders were then screwed on the plug and turned

    down to the specified 3.000 inch outside diameter. This

    operation kept the cylinder concentric with the drive

    stem. As a final means to prevent binding and cocking,

    the drive stem was connected to the plug in such a way as

  • 10

    to a.a..low only a "push" or '.'pulil" force to be transferred

    to the plug. Hence, the cylinder and plug assembly was

    eonfJtrained to move only in,, horizontal translation removing

    the possibility that the cylinder would unserew from the

    p.).l,ig duri~g st,~ - movement . Figure 3 shows the component par~ of th~ -V8lX' c seal; the _s,a1f, the detachable cylinders,

    and the plug . a.dapter.

    The .. ctuJ. mechanicf. of the valve is simple. The con-

    t ~oll~d va.;c :J:able, v e.ter., _passes t hrough tbe inside of the

    cylinder :rrom the hi gh p ressur e side of the valve to the

    FIGURE ~ VALVE SEAL COMPONENTS

  • 11

    low pressure si de-throus;rh whatever openinr: it "sees" in the

    cylinder wall. For water to flow, however, the openinps

    must appear beyond the 0-Ring on the low pressure side o~

    the seat. It is apparent here that the 0-Ring divides the

    high and low pressure sides of the valve. The openin~s

    mentioned above are discussed later in this thesis.

    Water Supply System - The test set-up shown in Figure 5 was

    used in all the tests performed on the valve. The pumn used

    was an Aurora centrifugal pump mechanically driven by a

    General Electric d-e motor. The pump capacity was 200 ~al

    lons per minute and it was already connected in the test

    set-up.

    The suction side of the pump is connected to a sump

    below the lab floor, and the discharge side is connected

    to the valve where it empties into the weir trou gh. Upon

    leaving the tank, the water flows back into the sump to

    complete the circulation process. The piping from the

    pump to the valve has a nominal 3-inch inside diameter

    which is the same diameter as the pipe at the valve outlet.

    The pipe and valve extending above the test valve seen in

    the over-all test set-up figure is used for another labora-

    tory experiment and was shut off during these tests.

    Measuring Devices - Only two pressure gau~es were used in

    the experiment and both were used in conjunction with the pump to indicate the pump suction and discharge pressures.

    The gauge on the suction side vas a u.s. Gauge with a range

  • 13

    weir was actually calibrated for several flow rates by col-

    lecting the water for a period of one to two minutes, de-

    pending upon the ma~nitude of the head, and weighin~ the

    amount collected. A comparison of the calculated flow r~te

    obtained from the weir equation and the actual weighed flow

    per second is illustrated in Figure 16. The curve indicates

    that the weir equation flow rate was nearly equal to the

    actual flow rate- the maxirr.um error being about 5%.

    The hook gauge mentioned in the previous paragraph was

    calibrated in inches. The vernier fixed to the frame of

    the gauge allowed the head to be measured to 0.01 inch with

    good accuracy. To enhance the accuracy of reading the

    head, flow straighteners were placed ahead of the hook

    gauge in the flow stream, thereby reducing oscillations

    within the measuring tube. Also, to remove the effects of

    approach from the head measurement, the ~auge was nlaced

    several feet ahead of the weir. The phenomenon of adhesion

    of the water to the side of the glass measuring tube was

    compensated for by placing the point of the hook one-half

    the distance from the center of the cross section to the

    wall; i.e., an average reading was taken. During the act-

    ual test of the valves, the hook gauge was found to pro-

    duce inconsistent results because of a vacuum above the

    water level in the hook gauge. The inconsistency was re-

    moved by drilling a hole through the top of the instrument

    to provide venting.

  • The actual procedure for locatin~ the water level in

    the hook gauge was sicple. The viewer had to merely watch

    the mirror image of the hook, while stationed below the

    water level, until the actual hook and the mirror image

    touched each other. All head readings on the weir had to

    be corrected to zero because the actual zero head readin r

    was 8.57 inches on the hook gauge. This zero reading was

    determined by means of a hydraulic level.

    DESIGN ANALYSIS AND PROCEDURE

    Valve design is generally concerned with achieving a

    desired valve characteristic which is important from the

    standpoint of control of fluid flow. This characteristic

    is the variation of flow with the change of valve opening.

    The valves designed for this study were developed using

    two predetermined characteristics, which will be referred

    to as control graphs. They were: A linear relationship

    between the flow through the valve and the valve opening,

    and a linear relationship between head on the weir (flow

    measuring means) and the valve opening.

    Before the first configuration was machined, the de-

    sired graph of flow versus percent valve opening was made

    and a straight line relationship was chosen. The chosen

    characteristic passed through the origin of the plot to

    the known flow at the full flow condition for the previous

    3-inch Crane ~lobe valve at maximum opening. This vas done

    to obtain maximum flow at the full-open position of the

  • 15

    valve. The method emnloyed in achievin~ a desired flow

    was to drill holes in the detachable cylinder which allowed

    the water to flow from the high pressure inside to the at-

    mospheric pressure downstream from the vnlve. The actual

    pressure drop across the valve will be discussed in a later

    discussion.

    A special procedure was used to drill the holes in the

    cylinder in order to expedite the experimental procedure.

    A random pattern of holes would involve too much experi-

    menting time. Therefore. a more expedient way was developed.

    Since the thread pitch of the drive screw was found

    to be 4 threads per inch. each one-half revolution resulted

    in a 1/8 inch cylinder movement. Therefore, the cylinder

    was divided in 1/8 inch circular bands. each of which must

    contain enough holes to meet the flow requirement for the

    corresponding valve position. In this way each successive

    one-half revolution would add a new band of holes- no sin-

    gle hole of which would be divided by the sealing mechanism

    (the 0-Ring). To keep the holes within the respective bands,

    a 3/32 inch diameter drill was used together with a ri~id

    clamping arrangement that insured that the hole centers

    were in the same plane even though the cylinder had to be

    removed and rotated each time a hole was drilled.

    To determine the number of holes within each band,

    reference was made to the two control graphs depicting the

    desired flow characteristics. Both cylinders were designed

  • 16

    with this procedure. For each 1/8 inch advance of the cy-

    linder from the full-closed position to the full-open posi-

    tion a corresponding flow rate existed on the respective

    control graph. This was the criterion for the design pro-

    cedure. Hence, the method was "cut and try" in that a

    series of holes was drilled to prevent overrunning the

    specified flow rate for the position. When the flow rate

    was accomplished, the cylinder was advanced to the next

    position and the procedure was repeated.

    EXPERIMENTAL PROCEDURE

    First Test Set-up - The initial set-up was made to test the

    feasibility of the valve itself, since the experimental set-

    up including the pump, piping, and the flow measuring device

    had been tested repeatedly by a Mechanical Engineering Sy-

    stems Laboratory class. The first configuration machined

    in the cylindrical shell was a triangular shaped hole. The

    opening was symmetrical on opposite sides of the cylinder.

    The sum of the areas of the two configurations was equated

    to the area of the entrance pipe in order to obtain the

    maximum flow rate at the full-open position of the valve.

    The triangle was isosceles and was positioned so that the

    side opposite the apex was parallel and directly under the

    periphery of the 0-Ring at the full-open position of the

    valve.

    Upon testing this cylinder, difficulties were encoun-

    tered with severing of the 0-Ring during the valve advance-

  • ment period. This was caused by the expansion of the r-

    Ring in triangular non-seal areas of the cylinder, result-

    ing in a pinching action on the 0-Ring by the ed~es sur-

    rounding the triangle at the outside surface of the cylin-

    17

    der. Hence, a different configuration had to be used which

    would be compatible with the sealing device or a new seal-

    ing device would be required.

    Second Test Set-up - With the small 3/32 inch diameter holes

    as the new configuration, a new cylinder was tested and

    found to perform very smoothly with only a slight vibration

    at the initial position of the valve after it was unseated.

    A preliminary test indicated that the head level in

    the hook gauge was too oscillatory to be measured accurate-

    ly, so a short flexible hose was connected to the hook gauge

    inlet and extended to the center of the tank- keeping the

    opening perpendicular to the flow so as not to add the velo-

    city head of the flowing water. This remedied the oscilla-

    tion problem in the hook gauge, thus permitting experimen-

    tal evaluation of the valve characteristic.

    Test Procedure - The actual test procedure was simple and

    could be performed by one man. After the holes had been

    drilled in the wall of the cylindrical skirt in accordance

    with the design procedure, the cylinder was mounted on the

    plug adapter and the complete valve was installed in the

    housing. The crank mechanism was advanced one-half revolu-

    tion from the seated or full-closed position to allow the

  • 18

    first l/8 inch band to appear between the high and low pres-

    sure zone of the valve. It is in this first band that the

    holes were placed to allow just enough flow rate for the initial valve position to correspond to the desired flow

    rate from the control curves.

    The d-e motor driving the pump was started and the

    water in the weir trough was allowed to come to steady-

    state for the specific valve position. Since the capaci-

    tance of the weir trough was large, time was required to

    reach steady-state conditions. For small flow rates the

    steady-state condition required approximately one-half

    hour.

    For each test position (one-half revolution of the crank) the design procedure of "cut and try" was carried out until the desired flow rate corresponding to the re-

    spective control curve was realized. The procedure was

    repeated until the full-open position was reached. At

    this time the overall test of the newly designed cylindri-

    cal skirt plug was completed. The procedure for the final

    test closely paralleled the previous procedure except that

    readings of the pump suction pressure, pump discharge pres-

    sure, and the hook gauge were recorded for each valve posi-

    tion. This operating procedure was repeated for the second

    cylinder and the same readings were recorded for the valve

    positions studied.

  • WEIR AND ORIFICE THEORY

    Since the flow rate could not be measured directly

    during the ex~ertmental procedure, it had to be calculated

    using Yarnall's equation. The following is the derivation

    of the weir equation for a 90 V-notch weir. Figure 6 ap-

    plies to this derivation, where:

    Q =total weir discharge in ft. 3 /sec. H = static head on weir in ft.

    h =

    e =

    cd =

    vm =

    dh =

    static head at any distance below

    surface in ft.

    included angle of V-notch, 90

    coefficient of discharge for the

    velocity of approach of upstream

    ft./sec.

    differential element of head.

    FIGURE 6 V-NOTCH WEIR

    the water

    weir

    channe 1 in

    19

  • 20

    Assumptions:

    (1) Torricelli's equation for discharge prevails for

    weir discharge or V c (2gh)l.l2. avg

    (2) The velocity of approach is negligible, hence the

    velocity head at the plate location is negligible.

    Therefore,

    and,

    dQ = C VdA d = Cd[2(H- h)tan l/2e](2gh) 1 /2dh,

    where,

    dA = 2(H - h)tan l/2edh

    V = (2gh)ll2. (Torricelli's equation)

    Hence,

    II Q = cd(/ [2H tan l/2e(2gh) 1/2- 2h tan l/2e(2gh)l/2]dh),

    0

    which reduces to

    Q = Cd8/15(2g) 1 / 2tan ~ 5 1 2 2

    Since for V-notch weirs Cd has been experimentally found

    to be 0.58, and e is 90 1 the above equation reduces to

    Yarnall's equation which will be referred to as Equation

    1 in the following discussion of experimental results,

    (1)

  • 21

    In the following section. the discussion of experiment-

    al results. an analogy using orifice theory will be used

    in an attempt to correlate the test results. A brief deri-

    vation will be given at this time concerning water flow

    through orifices and will serve as a reference for that

    article. Figure 7 shows the location of the reference points

    1 and 2 with the corresponding nomenclature:

    v1 = upstream velocity in ft./sec.

    v2 = velocity at the vena-contract a in ft./sec.

    pl = pressure at the upstream position in lb!/ft~ P2 = pressure at the downstream position in lb!/ft~ y = specific weight in lb!/ft~ g = acceleration due to gravity in ft./sec~. z 1 = elevation of flow at upstream position in ft.

    z2 = elevation of flow at downstream position in ft.

    Q = volume flow rate through the orifice in ft~/sec.

    Al = area of inlet pipe in ft~

    A2 = area of cross section of flow at vena-contracta

    in ft~

    A = area of orifice in ft~ Cv = discharge coefficient of the orifice

    Cc = contraction coefficient of the orifice

    Bernoulli's equation for steady flow is:

  • a z t I

    t I

    CD Al .... !. ? 2

    pl vl

    .... r -----.--

    I

    0 _A_~ I 2 I I

    P2 v2

    FIGURE 7 ORIFICE

    I *

    r

    but because the elevation change for a very small orifice

    even for vertical flow is negligible,

    According to the continuity equation,

    hence,

    which, when combined with Bernoulli's equation along with

    the discharge and contraction coefficients of the orifice

    yields Equation 2,

    ( 2 )

    22

  • and Equation 3,

    C = CvCc//1- C~(A/A 1 )2 RESULTS

    ( 3)

    The resulting curves for the two cylinders tested

    proves rather conclusively that nearly any desired valve

    characteristic may be produced with the experimental pro-

    23

    cedure used in this investigation. Figures 8 and 9 are the

    basic experimental relationships that were produced from

    the two cylinders tested. Figure 8 shows that a linear

    relationship between flow rate and percent valve opening

    was accomplished. Figure 9 reveals that the second re-

    quirement of the investigation - a linear relationship

    between weir head and percent valve opening - was also

    realized. Although both curves were tested with the same

    procedure at one-eighth inch advancements a check was made

    at smaller intervals to see if the flow rates at the un-

    tabulated positions justified the plotted straight line between the tabulated positions. This investigation re-

    vealed that the error in assuming the straight line rela-

    tionship between tabulated positions was negligible.

    Another important aspect of this investigation was

    the relationship between area change and cylinder advance,

    depicted by Figures 10 and 11. For the linear head cylin-

    drical skirt plug the curve was parabolic in nature, while

    the linear flow plug had a very distinct linear curve

  • 24

    especially at smaller flow rates. A further and more signi-

    ficant analysis produced from these curves is shown, how-

    ever, in the flow rate versus percent available area curves,

    Figures 12 and 13. These graphs indicate that for both

    cylinders the curves did not differ appreciably from a

    straight line; hence, the configuration area (the holes) appeared to be directly proportional to , the flow rate. In

    orifice theory the flow rate was also found to vary direct-

    ly with the area permitting flow, namely,

    Q = CA{2g6p/y;

    hence, the analogy between the configuration flow through

    the cylinders and simple orifice flow may now be support-

    ed. First, however, in order to validate the use of this

    orifice equation, the following three assumptions were

    made:

    1. The cylindrical plug is an orifice plate and the

    holes in the cylinder wall are considered as in-

    dividual orifices.

    2. The roundness of the orifice plate is negli g ible

    for each orifice because the 3/32 inch diameter

    is small compared to the 3-inch diameter of the

    cylinder.

    3. The high pressure side of the valve will be con-

    sidered to be an infinite reservoir with a con~

    stant pressure of 20 psig.

  • 25

    The first two assumptions are self-explanatory due to

    the geometry of the cylinder and the flow configurations.

    The third, however, needs some explanation. The pump dis-

    charge pressure, recorded for each test position, indicat-

    ed a variable pressure, first increasing, then decreasing

    with increasing flow rates for both cylinders. Since the

    pressure did not change appreciably throughout the tests

    and the head losses within the piping system amounted to

    approximately 5 psi, the average pump discharge pressure

    minus the head losses within the piping system resulted in

    the 2 0 psi g pressure at the valve in let. It must be kept

    in mind here that a 3 psi pressure drop from the pump to

    the valve is immediately accounted for because of the ele-

    vation change of the water.

    With the assumptions stated, the coefficient C, of

    the orifice flow equation may be evaluated. Since by the

    second assumpti~, the area of the individual orifices is

    small in comparison with the reservoir area, the pipe

    cross section, the A/A 1 term of Equation 3 is approximately

    zero, hence,

    Vennard (6) states that the product of Cc and Cv is 0.61

    for a sharp edged orifice and 0.98 for a rounded edge ori-

    f i c e An ave rage of t he s e two c o e f f i c i en t s y i e 1 de d 0 8 0

    for the discharge coefficient since the sharpness or

    roundness of the inside edge of the holes could not be

  • determined.

    tion 4,

    Therefore, Equation 2 can be reduced to Equa-

    Q = o.8oA/2g6p/y. ( 4 )

    This equation evaluates the flow through a single hole

    26

    in the cylinder, where again, A, is the area of the hole

    and p is the pressure drop across the orifice - 20 psi -

    since the gauge pressure of the low pressure side of the

    valve was atmospheric pressure. To find the total flow

    rate for each valve position, Equation 4 was multiplied by

    the total number of holes permitting flow. The theoreti-

    cal flow rate at each valve position, Equation 4, was then

    plotted versus the actual flow rate found Dy the weir equa-

    tion. Figures 14 and 15 indicate an equality between the

    actual weir flow rate and orifice flow rate for the low

    flow rate positions of the valve. The deviation of the

    curves from the linear relationship at high flow rates was

    expected, however, since the assumption of a constant pres-

    sure reservoir was no longer valid due to a finite upstream

    velocity in the pipe at the highest flow positions of the

    valve. The fact that close spacing of orifices on a plate

    reduces the flow capability of each orifice should not con-

    tribute a significant error since only the inlet flow stream

    is affected by the close spacing of holes. This type of

    error would combine directly with the coefficient of dis-

    charge, a term that was already approximated. As stated

    above, the orifice flow equation was indeed a good

  • approximation of the flow rate and offers a mathematical

    approach to the problem of flow control.

    27

  • 28

    IV. CONCLUSIONS

    The results of this investigation have led to the fol-

    lowing conclusions:

    l. Almost any flow characteristic can be achieved by

    use of the cylindrical skirt plug - depending on-

    ly on the cylinder size and stroke length.

    2. There exists a linear relationship between configu-

    ration area change and percent opening for the

    valve plug with a linear characteristic.

    3. For small flow rates the orifice flow equation

    offers a reliable mathematical approximation of

    the flow rate, thus providing a means of predict-~

    ing the number of holes required to achieve a giv-"

    en flow rate.

    4. The flow rate at all but the full-open position

    of the valve varied direct+y with the percent

    available flow area.

    5. The head loss of the cylindrical skirt plug is

    greater than the head loss of the ori g inal poppet

    plug in the Crane valve.

    6. The type of plug designed offers an accurate flow

    control capability from the O% to 60% open positions.

  • V. RECOMMENDATIONS

    In order to benefit from what has already been done,

    the author suggests that the following minor changes be

    made to improve the valve design, as well as system per-

    formance. The primary suggestion is that more instrumen-

    tation, particularly within the valve test section, be

    added because the pressure drop across the cylinder por-

    tion of the valve is a critical factor in the valve's de-

    29

    sign. A pressure tap above the valve, as well as below the

    valve is suggested, since at low flow rates a small but

    definite suction condition existed due to the vertical

    drop in the pipe at the valve exit. This condition could

    be heard by obstructing the air flow into the flange with

    the hands.

    A second centrifugal pump, which is shown in the over-

    all test set-up, might be coupled to stabilize and increase

    the flow capability of the water supply system. This would

    also increase the stability of the upstream pressure in

    the valve test section, a very desirable condition.

    There are two basic changes within the valve itself

    that would improve flow stability through the configuration.

    One change would be to increase the lift of the valve by

    redesigning the stem connection to allow more room for the

    stroke. Another possibility would be to remove the volume

    on the stud beyond the outside dia~eter of the cylinder since

    the valve actually doesn't have to seat at the "off" position.

  • Thus, the cylinder length could be increased to the con-

    strained distance from the 0-Ring to the rear body of the

    valve. Both of these suggestions would increase the con-

    trol stroke of the valve, the axial distance of the cylin-

    der within which all the holes must be located.

    30

    Aside from the design changes, there are several areas

    within the scope of this thesis that merit further investi-

    gation. A study of higher flow phenomenon should be under-

    taken to see if the control aspects of the valves studied

    in this thesis are valid for higher flow rates. A similar

    study could be made of the pressure regulation capabilities

    of the cylindrical skirt plug at small and large flow rates.

    The effect of reducing the hole size should be investigated

    to improve control of both pressure and flow rate. An area

    that also suggests turther investigation is that of a solid

    plug using the percent area available for flow versus flow rate curvea of this thesis as a design criterion.

    One of the primary disadvantages of the cylindrical

    skirt plug designed in this thesis is the large head loss

    incurred by the directional change of the flow stream.

    The head loss of the modified plug was larger than the

    original poppet plug for all valve openings. A second

    disadvantage of the modified plug is concerned with con-

    tamination due to solid matter existing in the flow medium.

    Because of the size of the holes clogging could become an

    acute problem.

  • 31

    VI. BIBLIOGRAPHY

    l. Seely, F.B. and Talbot, A.N. (1918), University of Illi-nois Experimental Station, Bulletin Number 105.

    2. Lansford, W.M. , (1943), University of Illinois Experi-mental Station, Bulletin Number 340.

    3. Addison, H. (1934), Applied Hydraulics, John Wiley and Sons, Inc., New York.

    4. Rhodes, T.J. (1941), Industrial Instruments for Mea-surement and Control, McGraw-Hill Book Company, Inc., New York and London.

    5. Beard, c.s . (1960) 1 Control Valves, Instruments Publish-ing Company, Pittsburgh, Pennsylvania.

    6. Vennard, J.K. (1961), Elementary Fluid Mechanics, John Wiley and Sons, Inc., New York and London.

    1. Eckman, D.P. (1958), Automatic Process Control, John Wiley and Sons, Inc., New York and London.

    8. Caddell, J.R. (1956), Fluid Flow in Practice, Reinhold Publishing Company, Inc.

    9. Prandtl, L., and T~etjens, O.G. (1934), Applied Hydro-and Aeromechanics, McGraw-Hill Book Company, Inc., New York and London.

    10. Dalby, W.E. (1906), Valves and Valve Gear Mechanisms, Edward Arnold Publishing Co., London.

    11. Linford, A. (1949), Flow Measurement and Meters, E. and F.N. Span Limited, London.

    12. Schmeer, L. (1909), The Flow of Water, D. Van Nostrand and Company, New York.

    13. Rouse, H. (1938), Fluid Mechanics for Hydraulic Engi-neers, McGraw-Hill Book Company, Inc., New York and London.

  • VII. VITA

    The author was born January 20, 1943, in St. Louis,

    Missouri. He received his primary and secondary education

    in Webster Groves, Missouri, a suburb of St. Louis- In

    September, 1960, he entered Colorado University, Boulder,

    Colorado, then transferred to the University of Missouri

    School of Mines and Metallurgy in February, 1961, where

    he received his Bachelor of Science degree in Mechanical

    Engineering in May, 1964.

    He has been enrolled in the Graduate School of the

    University of Missouri at Rolla since September, 1964, and

    has held a Graduate Assistantship in Mechanical Engineer-

    ing during his enrollment in the Graduate School.

    The author is a student member of the American Socie-

    ty of Mechanical Engineers and the American Institute of

    Aeronautics and Astronautics. He is also a member of Tau

    Beta Pi and Pi Tau Sigma engineering honor societies.

    32

  • 33

    VIII. APPENDIX

    The following appendix contains Tables 1 to 3, tabu-

    lated data taken during the test period. Table 1 is the

    weir calibration curve, while Tables 2 and 3 represent re-

    corded and calculated data pertinent to the test of each

    cylinder. Figures 8 through 16 are a series of plotted

    curves representing the tabulated data in Tables l, 2, and

    3.

  • 34

    TABLE 1

    WEIR CALIBRATION

    RUN NUMBER 1 2 3 4

    HEAD (in.) .1.360 2. 360 3.080 3. 910 TIME (sec.) 60 120 60 60 WEIGHT ( 1bs. ) 45 330 285 604 DENSITY ( 1 bs. I ft.) 62.4 62.4 62.4 62.4 Qa(ft./sec.) 0.012 o.o44 0.076 0.161 Qth(rt./sec.) 0.011 0.045 0.077 0.151

    TABLE 2

    DATA COLLECTED ON THE LINEAR FLOW PLUG TEST

    % VALVE OPENING PUMP DISCHARGE PRESSURE FLOW RATE (psig) (cfs)

    0 0 0

    14.3 27 0.035

    28.6 30 0.104

    42.9 30 0.156

    57.2 28 0.196

    71.5 27 0.241

    85.8 24 0.298

    100.0 23 0.348

  • 35

    TABLE 3

    DATA COLLECTED ON THE LINEAR HEAD PLUG TEST

    % VALVE OPENING PUMP DISCHARGE PRESSURE FLOW RATE (psig) (cfs)

    0 0 0

    16.6 27 0.055

    33.2 29 0.027

    49.8 30 0.083

    66.4 28 0.163

    83.3 24 0.280

    100.0 23 0.375

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    75

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    FIGURE 8 -

    VALVE CHAR-ACTERISTIC FOR THE LINEAR FlOW VALVE PLUG

    --

    87.5 100

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    PERCENT VALVE OPENING

    FIGURE 9 - HEAD VERSUS PERCENT VALVE OPENING FOR THE . LINEAR HEAD VALVE PLUG

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    FIGURE 11- RELATIONSHIP BETWEEN AREA CHANGE AND VALVE PLUG R>SITION CHANGE FOR THE LINEAR HEAD PLUG

    f37.5 100 w \0

  • -~-

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    17

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    FLOW RATE (cubic feet per second)

    FIGURE 12 - RELATIONSHIP BETWEEN AREA. CHANGE AND FIDW RATE CHANGE FOR THE LINEAR FlOW VALVE PLUG

    0.35 0.4 ... .

    .... ..

    ~ 0

  • .. ~

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    1- 7. 2 ~~1!-1-t ~-: AND THE ORIFICE EQUATION

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    - . .. ....... I 10 1-t---+---l C\l -0

    +------1---++-~+H-H-H I I I I H+-1------f-----1- H --+--+---+ ---+------!-----1-. +++-+---

    -1------1--- ---l------1 I I I I I I ! I I I I I I I I I I I I I I

    1-------1-++1 I I I I I I l l I I Ill I I II I I I I I I I I I I I I I I I

    -.. ":EE 1------l-----4 I I I I I I I I I I I I I I I I' I 1+1 I I I I FIGURE 16 - WEIR FIDW: EQUATION FIDW RATE VERSUS

    ACTUAL FIDW RATE (WEIGHED ) riffll l !j i . .. - ~ . . 0 0.025 0.05

    ~~.w:-:~~~~~LLIIIIIIII:J:l::!:t!llli::!:J.._-------- ._. ~--0.0'75 0.1 0.125 0.15 0.1?5 0.2 -~ .

    -.

    ACTUAL FLOW RATE (cubic feet per second)

    .r:-w

    -.

    Scholars' Mine1966

    A study of modified plug designs for a globe valveRobert W. WagnerRecommended Citation

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