Turbine Bypass Valve

WEIR CONTROL & CHOKE VALVES
Weir Turbine Bypass Valves & Desuperheaters
Excellent solutions
providing optimum
performance for
all Turbine Bypass
applications
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Power & Industrial
Engineering
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Weir Control & Choke Valves
Weir Turbine Bypass Valve
Weir Control & Choke Valves provides a

wide range of control valves for the process
industry. These include severe service,
choke, desuperheating and turbine bypass
applications.
Weir UK purpose built factory at Elland
Our world-wide reputation is based

on engineering excellence applied to a
comprehensive range of specialist products
and effective customer support.
Weir International, South Korea
A proven track record
Quality assurance
We have extensive references and a proven track

record in the supply of valves across a number of
key industries.
Weir is qualified to industry standards and

working practices including:
Our valves are industry renowned brands,

each with an established reputation for quality
engineering and reliability.
Valve testing
All pressure containing items are hydrostatically
tested, seat leakage tested and functionally tested.
We can also perform gas, packing emission,
cryogenic and advanced functional testing, as
well as seismic testing for nuclear applications.
Material testing
Non-destructive examination by radiography,
ultrasonics, magnetic particle and liquid
penetrant.
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direct reading emission spectrometer.
Mechanical testing for tensile properties at
ambient and elevated temperatures, bend and
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elevated and sub-zero temperatures.
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Our valve aftermarket solutions are based on
our engineering heritage, applying our OEM
knowledge and expertise to maintenance
strategies, life extension and upgrade projects.
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Contents
Member of
Weir Control & Choke valves Engineered valves for protection & process control
Turbine bypass valve description

Reasons for Turbine bypass valve
Trim types
Plug seals
Outlet diffuser
Bonnet types
Water injection nozzles
Design options
Sizing and configuration
3
4
5
6
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9
www.weirpowerindustrial.com
The Turbine Bypass Valve

The turbine bypass valve is designed to bypass the steam cycle from the boiler
to the turbine and dump the steam directly into the condenser. The valve is
used on start-up and turbine trips.
BV995
Angle Turbine Bypass Valve
The BV994 (Globe) and BV995 (Angle) range of turbine bypass valves
have been developed to handle the most severe process conditions
while maintaining valve stability, tight shut off, noise reduction and fast
operating speeds. The valves have a combined pressure letdown and steam
temperature reduction system. Water is injected through a series of nozzles
located towards the valve outlet.
Conditions usually associated with turbine bypass systems are high pressure
drop in the critical flow regime leading to sonic conditions across the valve
trim. Weir can offer a wide range of trims to eliminate the detrimental effects
of dropping the pressure. Available trims are:
Multi flow (single stage of pressure letdown)
Cascade (up to 5 stages of pressure letdown)
X-Stream (multi-stage pressure letdown)
These trims are selected based on the valve sizing conditions but are selected
to handle the pressure drop without generating the detrimental by products
of dropping pressure such as vibration, erosion and high noise levels.
To maintain the station efficiency turbine bypass valves are usually specified
with a tight shut off (normally Class V). Depending on the valve size and the
actuation mechanism then the valves are designed with either a balanced or
unbalanced trim.
On balanced valves Weirs unique sealing mechanism ensures that Class V
closure can be maintained while ensuring actuation forces are minimised. The
valve is positionally controlled by either a pneumatic or hydraulic actuator
which ensures repeatable positional control.
Depending on the amount of water to be injected into the steam then a
selection of spray nozzle options can be offered. These nozzles ensure that the
water is effectively atomised to minimise the absorption time into the steam.
High pressure Turbine Bypass valve
The turbine bypass valves are supplied with an associated spraywater valve
that is used to reduce the spray water pressure before injection into the
steam.
Standard Design Options

Pressure Ratings
ASME Class 150 to ASME Class 4500
Sizes
Inlet 40mm to 500mm (1 to 20)
Outlet 40mm to 1000mm (1 to 40)
Trim Options
Multiflow
Cascade
X-Stream
Actuation
Pneumatic
double acting
piston
Electro hydraulic
Reasons for Turbine Bypass Valves
Valve Body design
Turbine bypass valves are used to reduce the

temperature of steam by injection of water into the
steam flow. Where steam supply exists at a relatively
high temperature for driving the turbine, it needs
to contain a large amount of superheat to ensure
that dry steam is used. Any entrained water would
damage the turbine blades. Steam is used for heat
transfer which is a function that requires the steam
to be cooled close to its saturation point. When the
turbine bypass valve is used it must dump steam
into the condenser or cold re-heat system. Therefore
all superheat must be removed from the steam.
The valve body design must take into

consideration the thermal cycling that will occur
during its lifetime. The flow path must be as
smooth as possible to ensure that noise and
vibration levels caused by turbulent flow are
minimised.
The object of a desuperheater is therefore to remove

some or nearly all of the superheat. The process of
adding water to steam to lower its temperature is
quite a complex process due to the two stage flow
that is generated at the point of water injection.
Desuperheaters are therefore selected to:
As with most types of high pressure valve used

in the power industry, a pressure seal bonnet is
preferred at least for the HP Bypass Valves.
Materials are selected to ensure the valve body has
a minimum wall thickness. This minimises the risk
of a large temperature gradient across the valve.
Temperature gradients can cause thermal stress
in the body and result in cracking due to the rapid
changes in temperature.
Actuation
To improve the thermal efficiency of the heat

transfer process by reducing the overall steam
temperature close to the saturation point.
One of the major differences between the US

market and Europe is that in Europe Turbine
Bypass Systems are predominantly actuated by
Hydraulic Power Units and cylinders. In the US
Combined Cycle market Pneumatic systems are
preferred for cost reasons, although in the US Fossil
fired stations, hydraulic units are required due to
the higher actuation forces required.
In order for the temperature to be reduced and

controlled effectively several conditions must be
met. These include:
In addition to the main bypass and spraywater

valves there are a number of other significant
elements that make up a Bypass system.
Efficient atomization of the cooling medium
Hydraulic Power Units including PLC systems
A vapour velocity that promotes mixing
Pressure Safety Device
The correct cooling medium temperature
Steam Blowthrough Trim
Pressure Reducing Trim
Acid Cleaning Trim
Reduce the steam temperature to protect

downstream equipment from excess
temperature.
To prevent superheat steam from reducing the
pressure of the steam.
The ratio between inlet and outlet pressure for both

high and low pressure turbine bypass applications
can be significant. The steam mass flow range can
also be significant, and these two factors suggest
that the steam pressure reduction must be done in a
number of stages. These stages must be active over
the complete flow range, unlike fixed baffle plates
which are optimised for one flow rate only.
Condenser Dump Tubes
Special Features
Warming Line
In order to prevent thermal stress on startup,
turbine bypass warming lines can be
incorporated to pass a small steam volume into
the downstream pipe.
Spraywater Injection Nozzles
Orientation
It is usually important for the spraywater to be

evaporated within a very short distance from its
injection point. It is also critical to ensure that water
does not impinge on the valve body or pipe wall. It
is normal practice to locate the spraywater injection
nozzles downstream of all the valve pressure
reducing trim, and the use of atomising steam spray
nozzles is used for efficient water absobtion.
Turbine bypass valves are often required to lay

horizontal due. Stable seat guiding ensures
this can be achieved without special design
modifications.
Fully Accessible Trip and Diffuser
The valve incorporated a fully serviceable trim
and diffuser.
Seat Tightness
When Turbine Bypass Valves are discharging into
the condenser it is imperative that they have a tight
shutoff to ensure that the partial vacuum existing
in the condenser is maintained. The tight shut off is
achieved with a Class V sealing system.
Trim Design
Control valve trims for turbine bypass valves are selected
according to the valve process conditions. Cage designs are
described below.
Multiflow and Single Stage Multiflow
The Multiflow and Single Stage Multiflow trim gives a single
stage of pressure letdown. In this design the flow is broken up
into multiple jets by a number of radial holes in the valve cage.
On turbine bypass valves the flow is usually from outside to in so
that jet impingement and high turbulence levels are controlled
with the confines of the trim. Impingement of the jets within the
centre of the trim gives a more stable downstream flow, reduces
the effect of large scale separation and produces a smaller scale
turbulence structure in the valve outlet. This in turn leads to a
reduction in acoustic efficiency and changes the power spectrum
of the generated noise both of which contribute to an overall noise
reduction of 15 to 20dBA compared to contoured trim valves.
Further noise reductions in this style of valve can be achieved by
drilling smaller holes in the valve cage. This design is referred to as
Single Stage Multiflow.
Cascade
The cascade trim is used in applications which require up to 5
stages of pressure letdown. The cascade trim has been designed to
eliminate problems such as noise, vibration and erosion by staging
the pressure drop through a series of discrete pressure drop
stages. The cascade trim is manufactured to a close tolerances
and consists of a series of drilled sleeves. The number of sleeves
(pressure drop stages) required depends on the amount of
treatment required for a particular application. Each successive
sleeve has a number of radial holes and a carefully calculated
increase in flow area to ensure correct apportionment of the
pressure drop. The small radial jets pass through a tortuous path
resulting in high frictional and impingement losses. At the same
time the impingement of the jets onto the outer radial sleeves
control the shock wave formation which has a major influence on
the overall noise reduction.
X-Stream
The X-Stream trim is specifically designed for severe service
applications where detrimental valve factors such as noise, erosion
and vibration need to be eliminated. Using a series of stacked discs,
multiple stages of pressure letdown are provided using a series of
complex flow paths. The flow path of the X-Stream is designed
with a series of columns which ensure a smooth flow pattern.
This ensures that if dirt/debris should enter the trim then it will be
washed through to the valve outlet.
On steam applications the X-Stream trim has a special jet control
row. This eliminates shock cells at the outlet of the trim. These
shock cells are responsible for high noise and vibration at the valve
outlet.
Further details of the X-Stream can be found in the X-Stream
trim brochure.
Class V Sealing
In order to maintain a condenser vacuum and ensure
maximum power station efficiency turbine bypass
valves often require a tight shut off which is referred
to as Class V. Due to the high temperatures associated
with a turbine bypass valve conventional resilient
seals cannot be used, therefore many valve suppliers
use pilot balanced trim designs. Depending on the
stability of the process flow, pilot balanced trims can
often generate trim instability and poor control.
Weirs solution is to use a conventional balanced
valve trim and install a metallic seal to prevent leakage
between the valve plug and cage. The seal is pressure
energised so that higher pressures across the valve
trim result in increased sealing load and therefore
tighter shut-offs.
Controlling the Outlet Steam Conditions

Due to the pressure drops associated with turbine
bypass valves then additional noise and velocity
control is often required in the outlet of the valve.
Existing turbine bypass valve suppliers often weld
diffusers into the valve outlet. This can result in
thermal cracking and when these diffusers require to
be serviced then the complete valve outlet section
must be completely removed.
In the Weir system trim components have been
designed for ease of service. All trim components are
clamped into the valve body. The seat ring extends
into the valve outlet section which contains the trim
outlet diffusers. These can incorporate a number of
basket style diffusers. Diffusers are designed so that
steam expansion due to pressure drop is achieved in
the expanded outlet section resulting in lower steam
velocities. The location of the holes in the diffuser
results in minimum jetting against the walls of the
outlet section.
Stable Plug Guiding

Outlet diffuser
To ensure the most stable trim the valve plug is

guided in the seat rather than in the valve cage. An
additional stage of pressure letdown is incorporated
on an articulated section of the plug nose which
ensures stable pressure letdown and therefore
elimination of pressure induced vibration.
Bonnet Designs
Bonnet designs are selected according to the pressure
rating, size and operating temperature of the valve.
On high temperature steam applications then a
normalizing bonnet is used to lift the valve packings
away from the main temperature gradient. In high
pressure and temperature applications a pressure
seal bonnet is used to simplify the bonnet assembly,
remove weight from the bonnet neck and to eliminate
the requirement for special torque equipment.
Normalising bonnet
Pressure seal bonnet
Water Injection Options

BV984 Spring Loaded Nozzle
The BV984 nozzle gives high capacity water injection while
offering protection of the water system in case of loss of
water supply. The superior pressure of the water system
lifts the spring loaded nozzle away from its seat which
results in a cone shape jet of water being injected into the
steam. The system requires a separate spray water control
valve to control the amount of water injection. This system
ensures a high rangeability while ensuring the water
droplet size is kept to a minimum. On loss of water pressure
the water system is protected against high temperatures
due to spring loading of the nozzle.
BV984 Spring Loaded Nozzle
BV985 Variable Area Nozzle

The BV985 spray nozzle is used on applications where high
rangeability is required with direct control across the spray
nozzle. The BV985 is designed so that steam is injected into
the centre of the pipe resulting in minimum droplet contact
against the pipe walls. Water is injected across a series of 12
variable area nozzles which atomises the water into micro
fine droplets resulting in faster absorption rates and shorter
outlet steam pipe lengths. The amount of water injected
into the pipe is directly controlled by the valve plug which
is in turn controlled by the actuator. Where the pressure
differential between the cooling medium and the vapour
exceeds 60 bar, a two stage nozzle is available that extends
the available pressure drop range to 100 bar. The two stage
nozzle ensures erosion across the valve plug is maximised.
The BV985 unit is fitted into steam pipes greater than
150mm (6).
BV986 Mini Desuperheater
BV985 Variable Area Nozzle
BV986 Mini Desuperheater
The BV986 unit is a simplified spray nozzle where the spray

water is circulated around an internal gallery and then
injected into the steam through a series of radial holes.
The BV986 unit fits between conventional flanges and
is therefore easy to remove for service and maintenance
purposes. The unit is connected to a stand alone
spraywater valve which controls the amount of water being
injected into the vapour. The BV986 can also be directly
mounted onto the outlet of a pressure control valve so that
water is injected into the turbulent vapor flow at the outlet
of the valve. The BV986 is used on pipe sizes from 25mm
(1) and above.
BV988 Fixed Area Sparay Nozzle
BV988 Fixed Area Spray Nozzle

The BV988 unit offers good spraywater atomisation but
with separate spray water control. The valve is similar to
the BV985 unit but with all spraywater control removed
from the unit. A flanged or butt weld connection is used
to connect the spraywater which in turn is controlled via
a separate control valve. This allows for high technology
control valve trims to be used to eliminate the detrimental
effects of erosion sometimes created by high pressure
drops. The unit is also used in situations where space
around the desuperheating system is limited.
Special Applications
Pressure reducing and desuperheating units are often
specified and selected according to the application.
Customer requirements often require special designs
to accommodate unusual requirements. Selected
special designs are shown below.
Condenser Steam Dump
End User S2 Ruwais Power Company
Customer Samsung C & T
Project Shuweihat S2 IWPP U.A.E.
Product 4 off 1400mm Inlet x 1000mm Body x
2700mm Outlet ANSI 150
Angles Control Valves c/w Electro-Hydraulic
Actuators and Control Panels
Condenser Steam Dump valve
Application LP Process Steam Dump to

Condensator
Condenser Steam
Dump valve section
Materials ASTM A216 WCB with 410 SS Trim

Total Weight 15 metric tonnes each
Delivery completed in 28 weeks
Special Shape
Turbine bypass valves are often required to lie
horizontally due to the nature of steam systems in
a power station. This can cause premature wear on
seals and cause increased friction through the valve
trim. Producing a special body design with the flow
turned through 90 degrees in the horizontal plane
allows for the trim and actuator to be mounted
vertically in the pipe. This in turn ensures more stable
control through the full valve stroke range.
90 degree mounted
valve with vertical
actuator
Actuation
There are two main types of actuators used on
turbine bypass valves, either pneumatic actuators or
hydraulic actuators. In both cases to ensure stable
control and protection of the turbine the actuators
are selected for fast stroke speeds often below 3
seconds for full stroke.
Hydraulic actuators have the advantage of delivering
a high thrust capability while maintaining stable
valve control.
Pneumatic systems are used where hydraulic
supplies are limited but where plant air is readily
available. Pneumatic systems are specified with
a high thrust piston actuator which is
controlled via a series of high capacity
instruments. Stable control is
achieved due to the responsiveness
of the instruments through the full
stroke of the valve.
Hydraulic actuation
Fast operating pneumatic system
Initial Sizing of Desuperheaters

Location in pipework
Information required at enquiry stage

P1
Inlet Pressure
Bara
(Psia)
T1
Inlet temperature
(F)
P2
Required outlet pressure
Bara
(Psia)
T2
Required outlet temperature
(F)
PW
Available spraywater pressure
Bara
(Psia)
TW
Spraywater temperature
(F)
WS
Maximum inlet steam flow
kg/hr
(lb/hr)
Initial calculations
Calculate the required flow of water WW, kg/hr (lb/hr), needed to
control the steam temperature at the outlet, by the heat balance
method.
WW =
WS (h1 - h2)
(h2 - hF)

where:

h1 = enthalpy of superheated steam at inlet
h2 = enthalpy of steam mixture at outlet
hF = enthalpy of spraywater at inlet
values in kJ/kg (Btu/lb)
Total outlet steam flowrate WM = WS + 2W kg/hr (lb/hr)
Sizing of low pressure pipeline

This is the recommended pipe size for BV985, BV986 and BV988
pipeline types, or the outlet size for the BV995 design for efficient
desuperheating.
The pipe is sized so that the steam velocity does not exceed 90m/s
(300ft/s) or, for BV984, BV985, BV986, BV988 types, fall below 4.5m/s
(14ft/s). The preferred velocity is 75m/s (250ft/s).
The minimum pipe diameter is calculated using the following formulae.
D = 18.8
where:
WM x VS
Velocity
mm or D = 0.225
WM x VS
Velocity
WM = outlet steam flowrate kg/hr
(lb/hr)
VS = outlet specific volume m3/kg
(ft3/lb)
Velocity m/sec
(ft/sec)
in.
For BV984, BV985, BV986 and BV988 desuperheaters there is a selection

of standard trim sizes available
BV994 and BV995 units are often associated with outlet silencer
sections depending upon the ratio of inlet and outlet pressures and
the maximum permissible sound pressure. For these reasons each unit
receives individual considerations based upon customer requirements.
The desuperheater should be installed so that the

spray nozzle is located at the steam inlet of the tube (if
supplied). A filter should be fitted in the spray water inlet
line to prevent ingress of dirt.
Pipe Joints
Owing to the severe expansion strains which may be
imposed on the joints when starting up it is essential that
all flange joint bolts are manufactured from high tensile
alloy steel irrespective of the steam pressure. These
remarks also apply to the water joint flanges which are
also subject to sudden temperature changes.
Drainage and drainage systems
Efficient drainage of the pipework following the
desuperheater is essential. To ensure that water cannot
accumulate at any point the pipe should be arranged
to fall in the direction of flow approximately 20mm per
metre (14 per foot) under actual working conditions
and be provided with an efficient large capacity trap
(10% of maximum flow to facilitate start-up and shut
down of plant) at the lowest point. To prevent the trap
becoming airbound the drain pipe should have ample
capacity to deal with the drainage and be fixed as near
to vertical as possible. There must be sufficient space
in the drain pipe for water to flow down and air to pass
up the pipe.
When starting up the plant it is advisable to open the
trap by-pass valve to deal with any excess water. If a
by-pass valve is not fitted the trap should be inspected
to ensure that it is passing water and has not become
airbound. When the pipework has warmed through to
working temperature and a reasonable amount of steam
is flowing the drainage of water should practically cease
and the trap by-pass valve can then be closed.
Successful operation of a desuperheater depends to
a large extent on the injection of water being hot,
preferably near to the saturation temperature of the
steam to be cooled so that it is mainly the latent heat
which is extracted from the steam to evaporate the
injected water. This minimises the time of the suspension
of the water particles in the steam so that all the water
is evaporated and none falls to the inside walls of the
pipework. As mentioned below the pipes connecting the
water supply to the injection nozzle should be efficiently
lagged to minimise the loss of heat.
The water pressure and temperature should be no less
than the values originally specified at the enquiry/order
stage since these figures are used for design purposes
in sizing the injection nozzle. The pipes connecting
the water supply to the injection nozzle should be no
less in diameter than the water isolating valve flange
connections indicate.
Condensate supply should be free from debris and
effectively filtered to less than 0.25mm.
10
Notes
Notes
11
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Turbine Bypass Valve

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WEIR CONTROL & CHOKE VALVES

Weir Turbine Bypass Valves & Desuperheaters

Weir Control & Choke Valves

Weir Turbine Bypass Valve

Weir Control & Choke Valves provides a

Weir UK purpose built factory at Elland

Our world-wide reputation is based

Weir International, South Korea

A proven track record

We have extensive references and a proven track

Weir is qualified to industry standards and

Our valves are industry renowned brands,

ASME BPVC Section III (N and NPT Stamp)