CFD Modeling of a Flow Control Valve

Overview

The Oil & Gas Industry requires the use of flow control valves operating under high-pressure conditions are exposed to intense hydraulic stresses. Localized pressure drops and the presence of suspended particles can lead to damaging phenomena such as cavitation and surface erosion, threatening both performance and durability.

The Challenge

Repeated damage had been observed in certain valves, suggesting a combined effect of cavitation and particle erosion. However, the precise mechanisms responsible for the wear were not fully understood. A detailed investigation was required to identify the underlying causes and guide improvements in design and operation.

Our Contribution

HCS conducted a series of CFD simulations using OpenFOAM to analyze fluid flow through the valve at different operating gaps. The models captured velocity fields, pressure distributions, and cavitation risk zones, as well as particle trajectories and impact locations on internal surfaces. Results confirmed that both cavitation and particle erosion contributed to the observed damage, with clear correspondence between predicted and real wear zones. The study provided key technical input for developing design improvements and mitigation strategies to extend valve lifespan and reliability.