1. A Study of the Effects of Design Features on the Flow Forces of Pressure Regulating Spool Valves Progress Report #1 Frank Henderson 11/5/09

2. Tasks Revise Project Scope –Action from Proposal Presentation Build 3D models in UG Mesh and set up boundary surfaces Run CFD in Fluent using same inputs Results Report Writing

3. Original Project Plan Sensitivity Study of Seven (7) Design Features Each Feature Varied Multiple Time Over Multiple Valve Positions –For example, a dimension varied three (3) times both positive and negative and at five (5) different valve positions for a total of 30 models for each of seven (7) features for a total of …way too much work Each Fluent Case Iterated to Obtain a Valve In Force Balance –Iterate in the inlet conditions on a set stroke of the valve until the Pressure’s on each end and the spring rate equal out to zero –This would aligned the model with real condition, but is not necessary for the purpose of this project. Design features can still be investigated by comparison using one set of input conditions for each model. Action from Proposal Presentation to decrease the number of models. –A total of ten (10) 3D model’s for CFD was suggested to start.

4. Project Scope Revised New Selection of Design Features to Investigate: Housing Exit Annulus Diameter (see A below) –Vary by + and - 10% from baseline Sleeve Exit Annulus Diameter (see B below) –Vary by + and - 10% from baseline Revising method: Set one inlet flow and run baseline model Revise only one feature in one direction (one model) and rerun with same conditions Compare results This revised method eliminates timely iteration originally planned to put the valve in force balance This is a total of five (5) models which should allow time for further study as process developed. A B

5. Status Build models in UG –Completed (screen captures to follow) Mesh Models and Set Up Surface Boundaries (Gambit) –Completed (screen captures to follow) Run 3D Fluent CFD Analysis on 5 model –4 of 5 completed –Results indicate little affect on flow forces –Adding two more features (3 models) to investigate features that may more drastically affect flow forces

6. 3D Models Exit Housing Annulus Change Baseline model

7. 3D Models Exit Sleeve Annulus Change

8. Meshing 700,000 to 800,000 Tetrahedral Cells

9. Spool Surfaces Surfaces of interest (those representing the spool surfaces) are set apart as their own group. This way in Fluent the forces can easily be read.

10. CFD Filled Contours Colored By Velocity

11. CFD Filled Contours Colored By Pressure 6970 pph inlet 114.6 psid (inlet – outlet)

12. CFD Filled Contours Colored By Velocity

13. CFD Filled Contours Colored By Velocity

14. CFD Filled Contours Colored By Velocity Spool faces only X direction

15. CFD DescriptionX-direction Force Total (lbf)% change from Baselinew/2nd order upwind % change Baseline Model1.73710251.8589111 Housing Annulus Increased 10%1.74352960.37%1.8394763-1.05% Housing Annulus Decreased 10%1.76778221.77%1.7985951-3.24% Sleeve Annulus Increased 10%1.79305773.22%1.88361931.33% Sleeve Annulus Decreased 10%-100.00% Small change in x-direction forces as a result of varying the sleeve or housing annulus distances up and down 10%.

16. Additional Features Additional Features to Investigate –Distance from spool exit edge to sleeve exit annulus edge (see A below) –Rotation of spool inlet bucket from in-line with windows A