Control valve noise can be a significant issue caused by high-pressure drops and turbulent flow. Traditional low noise trim designs have limitations in terms of cost and flow capacity. However, the emergence of 3D printing technology has revolutionized the control valve industry, offering innovative solutions to reduce noise while maintaining high flow rates.
Control valve noise arises from factors such as mechanical vibration, turbulent gas flow, and cavitation. Excessive noise levels not only pose a threat to hearing but can also damage valve components and adjacent piping connections. To combat this issue, sound path solutions involving thick pipes, heavy insulation, and acoustic blankets have been used. However, these solutions have limitations in terms of effectiveness and cost.
By utilizing metal 3D printing, manufacturers can overcome the limitations of traditional low noise trim designs. These 3D printed parts enable the breakup of flow into multiple paths or the reduction of pressure drops across multiple stages, resulting in decreased flow velocity and attenuated sound. Unlike standard valve trims, 3D printed parts maintain high flow capacity while offering cost savings. They also provide a solution for reducing noise in rotary valves, which typically produce higher noise levels.
Next-generation rotary valve trim configurations produced through 3D printing can significantly reduce sound levels, up to 20 dBa. These additive manufactured rotary valve trims maintain high flow capacity while offering up to an 80% reduction in noise compared to traditional designs.
Similarly, globe valves can benefit from 3D printed parts that achieve high noise reduction levels without sacrificing flow capacity. Modal attenuators, which utilize resonant cavities to cancel noise, are another effective solution enabled by 3D printing technology.
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