Power Plant Handbook

MIL Controls Limited
A KSB Company
MAJOR SYSTEMS
VALVE SELECTION
MATERIAL SELECTION
INSTALLATION & MAINTENANCE
VALVES FOR POWER PLANTS
CONTROL VALVES FOR POWER PLANTS
MIL Controls Limited. The Machining Shop, a part of the world class manufacturing
facility at Meladoor near Cochin in Kerala.
MIL CONTROLS LIMITED, 2002. All rights reserved

ABOUT THIS HANDBOOK
Forthepast15years,MILControlsLimitedhasbeenoneofthepremiersuppliersofhighspeciality
ControlvalvesfortheIndianPowerPlantsector.Overtheseyearsourengineershavegained
enormousexperienceinallaspectsofvalvedesign,selectionandmaintenance.
The MIL Power Plant Application Handbook triestotranslatethisexperienceintoareadily
accessiblereferencetool,theneedforwhichhaslongbeenexpressedbymanyofourclientsand
associates.thehandbookthusencapsulatesMILscontinuingfocusonthepowersector.
Atasecondlevel,TheMILPowerPlantApplicationHandbook,alsoservesasaminicataloguefor
MILs wide range of products. It offers specific data on Valve Selection and Operational
Characteristics.
REFERENCE DOCUMENT: ISA HANDBOOK FOR CONTROL VALVES.

A KSB Company
RegisteredOffice&Works.Meladoor,Mala,PIN680741,ThrissurDistrict, Kerala,India
Tel: 91 (0)488 890272, 890772, 891773. Fax: 91 (0)488 890952. Email: milf@vsnl.com
MarketingHeadOffice.P.B.No.04,Aluva,PIN683101ErnakulamDist,Kerala,India
Tel: 91 (0)484-624955, 624876. Fax: 91 (0)484-623331. Email: ksbmil@sancharnet.in
APPLICATION HANDBOOK
Contents
Page
1.1 Company overview................................................. 8

2.0 Introduction ........................................................... 9
3.1 Major systems ...................................................... 13
3.2 Condensate system ............................................... 14
3.3 Feed Water system................................................ 17
3.4 Main Steam system ............................................... 22
3.5 Heater Drain system .............................................. 31
4.2 Typical applications. 116 MW ................................ 36
4.5 Typical applications.500 MW ................................. 42
5.1 Body material specs ............................................... 47
5.2 Allowableworkingpressure ................................... 48
5.3 Trimmaterialselection ........................................... 51
6.1 Handling&Installation .......................................... 55
7.1 PreventiveMaintenance ........................................ 61
7.2 Shop Overhaul ..................................................... 62
8.1 MIL 21000 Series .................................................. 67
8.2 MIL 41000 Series .................................................. 68
8.3 MIL 78000 Series .................................................. 69
8.4 MIL 91000 Series .................................................. 70
9.0 Index & List of Illustrations ..................................... 72
1.0 Contents
4.1 Typical applications. 67.5 MW ................................ 35
1.1 Company overview
MIL Controls Limited. The factory premises at Meladoor near Cochin in Kerala
ver since its inception in 1983, MIL has been unrivalled as a supplier of
high performance Control Valves to the Indian power sector.
The company, which stamped its class in its very first set of major project
supplies to the 210 MW Neyveli TPS (Unit III&IV), the 210 MW MSEB
Chandrapur TPS (Stage II), the 210 MW GEB Wanakbori TPS (Stage II)
and the 120 MW NALCO CPP (all 5 units) way back in 1984-85, has gone
on to excel in the design and manufacture of custom-built special
application Control Valves to meet the challenging process control
requirements in thermal power stations.
In May 2000, MIL achieved another milestone when it unveiled the

MATRIX Series extreme pressure, multi stage, multi path axial flow Control
Valves. A product of months of specialised R&D, the MATRIX Series valves
have been designed to kill upto 420 Kg/cm2 pressure in 40 stages. This
ingenious and unique design has a progressively declining resistance flow
path and is designed to eliminate Cavitation and limit Velocity in any
severe service condition.
In December 2001, MIL had its crown of glory when it became the first
Indian company to be accredited with the coveted CE marking (refer page
71) for Control Valves, mandatory for exports to the European Union
beyond May 2002. The first lot of MIL valves with CE marking is being
installed in high pressure steam / Feed Water service in a power plant at
Salvimona, Finland being built by M/s Foster Wheeler.
Today MIL is the preferred vendor in the country for the rugged, critical
application Control Valves for thermal power stations, be it a 33 MW
captive power plant or a 250/500 MW utility power plant.
With a comprehensive product range, world-class manufacturing and
testing facilities, and a highly skilled work force, we are today fully geared
to meet any critical process control requirements in the power plant sector.
POWER PLANT APPLICATIONS
Factorsdetermining
selectionofValves.
usedintheEnergySector.Theiroperational parameters
vary widely in terms of pressure, pressure drops, flow
rates and temperature.
In addition, other crucial factors like Noise, Cavitation,
Wire drawing, Leakage Class and Flashing also play an
important part in the selection of Control Valves for
power station applications.
1. HIGH TEMPERATURE
2. HIGH PRESSURE
3. HIGH PRESSURE DROP
4. COMBINED HIGH TEMPERATURE, PRESSURE & PRESSURE DROP
5. CONTINUOUS THROTTLING
6. TIGHT SHUT OFF CAPABILITIES
7. AERODYNAMIC NOISE
8. HIGH RANGEABILITY
9. CAVITATION AND FLASHING
2.0 Introduction
Extraordinary demands are placed on Control Valves
FIG. 1. GENERAL BOILER (DRUM STYLE) FLOW DIAGRAM
Powerplantapplications
4 major systems, their characteristics
and valves used in such applications.
1. CONDENSATE SYSTEM
Condensate Pump Minimum Recirculation Valve
Deaerator Level Control Valve
2. FEED WATER SYSTEM

Boiler Feed Pump Minimum Recirculation Valve.
Boiler Feed Water Startup Valve.
Boiler Main Feed Water Control Valve.
3. MAIN STEAM SYSTEM

SuperheaterAttemperatorSprayValve
ReheaterAttemperatorSprayValve.
Turbine Bypass Valves.
Deaerator Pegging Steam Valves.
Soot Blower Steam Pressure Reducing Valves.
PRDS System valves
4. HEATER DRAIN SYSTEM

High pressure heater drain valves.
Low pressure heater drain valves.
3.1 Major systems
The 4 major systems and critical valves .
3.2 Condensate system
Fig. 2. Condensate System.
Condensatesystem
The Condensate system consists
of the Feed Water Circuit starting
from the Condenser Hotwell to the
Deaerator. The Condenser is a
form of heat exchanger that
condenses the exhaust steam of
the Turbine.
The exhaust steam of the Turbine
which is very low in pressure and
temperature passes on its heat to
the cooling water, is condensed
and collects in the hotwell. The
low pressure steam which is very
high in volume creates a vacuum
when it is condensed into water.
The vacuum in the Condenser
increases the Thermodynamic
efficiency of the cycle. The most
critical valves which have a bearing
on the smooth operation of the
plant are Condensate Extraction
Pump Minimum Recirculation Valve
and Deaerator Level Control Valve.
Condensate RecirculationValve
The Condensate Pump extracts

theFeedWaterfromthe
CondensateHotwelland
dischargestotheDeaerator.
The Condensate Pump must

haveaminimmumRecirculation
orFlow toavoidoverheatingof
thepumpandprotectitfrom
Cavitation. The Condensate
RecirculationValve recirculates
waterfromthepumpbacktothe
Condenser toensureminimum
Recirculationofthepump.The
CondensateRecirculationValve
hastoabsorbthefullpressure
dropie.,frompumpdischarge
pressuretotheCondenser
pressure. Due to very near
saturatedconditionsexistingin
thedownstreamsideofthevalve
andrelativelyhigherpressure
drops, the valve is subject to
Cavitation andFlashing.
ControlValvesforthisapplication
shouldalsohavegoodshutoff
capabilitytoeliminateseat
damageduringshutoffconditions.
Anyleakageshouldbetakeninto
accountasaformoflostenergy.
ThefunctionofthisControlValve
istomaintain correctlevelsinthe
Deaerator.
Fig. 3. MIL 78000 Series. Condensate

Minimum Recirculation Valve.
TYPICAL
PARAMETERS
Inlet Pressure: 40- 45 bar( a)

Outlet Pressure: 0.1 bar(a)
Temperature: 40- 50o C
The typical valves for such

applicationshaveantiCavitation
featureswhicheliminateany
possibilityofCavitationby
droppingpressureoverstages.
Alsomaterialselectionshouldbe
verydiscreteinsuchapplications
takingintoaccountofhighly
ErosiveCavitatingconditions.
Use of 17-4PH and 440C
MartensiticSteelhaveyielded
excellentresults.
The typical valves for such
applications are 3 or 4 78000
Series Multi Step / Multi Stage
design or 41008 Series
MultiCage/Multi stage design.
DeaeratorLevelControlValve.
Theapparentlymildservice
conditionsmisleadmanyControl
Valvemanufacturersinthe
design of valves for this service.
TheFeedWaterlevelinthe
Deaeratoralsohelpsin
maintainingtheNetPositive
Suction Head (NPSH) of the
BoilerFeedWaterPump. The
DALCV has to cater to the widely
varyingflowdemandfrom
startupconditionsto
fullloadconditions.
Valveselectionanddesign should
bebasedonthefollowingfactors:
Duringthestartupthepump
dischargepressurewillbehigh
owingtolowflowrequirements.
Deaeratorpressureduringthe
startupoftheplantwillbelow.
These factors result in the valve
working at very low Cvs and the
associatedlowliftoperations.
Alsotherelativelyhigherpressure
dropsintheseconditonscanlead
tooccuranceofCavitation.
Whenthepumppicksupload,
theflowrateincreasesandthe
pumpdischargepressuregoes
down.Atthesametime,theback
pressureintheDeaerator
increases. This obviously
warrants ahigherflowcapacity.
TheDeaeratorisanopencontact
typeFeedWaterHeaterwhich
purgesanynoncondensableand
dissolved gases. Also the
Deaeratoractsas areservoirfor
FeedWatertosmoothentheFeed
Watersupplyatvaryingloads.
Fig. 4. MIL 41000. Deaerator level Control Valve.
Such extremeconditionscallfor
valveswithexceptionallyhigh
Rangeability,besidesCavitation
protectionatlowerflow
conditions.
Typicaldesignsforsuch
applications are the MIL 41921 or
the MIL 41621 Series which
incorporateanequalpercentage
characterizedTrimwhichtakes
careofthehighRangeability.
The basic design is a Cage Guided
PlugwiththeCagehaving
characterizedports.
TYPICAL
PARAMETERS
Inlet Pressure: 20- 42 bar (a)

Pressure drop: 7- 42 bar (a)
Temperature: 50 -100 o C
TheCagedesigncombinessmall
sized,drilled,antiCavitationholes
inthelowerportion,andlarger
holes athigherlifts.
This design gives the necessary
Cavitationprotectionatlowerlifts
andhigherflowcapacityathigher
liftsensuring verywide
Rangeability.
FeedWatersystem
The Feed Water system includes
those parts of the system from
Deaerator to the Boiler inlet.
The system consists of Feed Water
piping, Feed Water pumps, high
pressure heaters and the associated
accessories.
The Feed Water pressure is raised to
the Boiler pressure and the
temperature is also raised to near
saturation conditions by the high
pressure heaters and Economisers.
The critical Control Valve
applications in this system are Boiler
Feed Pump Minimum Recirculation
Valve, Boiler Feed Water Startup
Valve & Boiler Main Feed Water
Control Valve.
BoilerFeedPumpMinimum
Recirculation Valve.
Themostcriticalapplicationina
PowerStationistheBoilerFeed
PumpMinimumRecirculation
Service. A pump should have a
minimumFlowthroughittotake
careofthecoolingrequirements
ofthePump.
HenceeveniftheFeedWater
requirementsareverylow(dueto
lowloadconditions)thepump
shouldhandleaminimumflow.
Toensurethisminimumflow,a
certainamount ofFlowhastobe
recirculated backtothe
DeaeratorastheFlow
requirementsoftheBoilermay
notbesufficienttosatisfythe
minimumRecirculation
requirementsofthepump.
Theparametersareobviously
verydetrimental foranyvalveto
handle. The valve has to drop a
pressure of 220-250 bar to 10 bar
(Deaeratorpressure).Alsoitmay
benotedthat theoutlet
conditionsofthevalvearenear
saturation,andhencethevalveis
verysusceptibleto highenergy
CavitationandFlashing.
TYPICAL
PARAMETERS
Inlet Pressure: 220-250 bar (a)

Outlet Pressure: 10-12 bar (a)
Temperature: 200o C
3.3 Feed Water system
Fig. 5. Boiler Feed Pump Minimum Recirculation System.
3 methods of providing
Feed Pump
Recirculation.
1. The Modulating Type System
employsaModulatingValve
whichthrottlestheFlowtothe
minimumrequiredwhichisa
functionoftheFlowrequiredby
theBoiler.
Supposethe requiredminimum
Recirculation of the pump is 100
tons/hr,and theBoiler
requirement is 90 tons/hr, the
minimumRecirculationvalvewill
open so that it passes 10 tons/hr
andtheminimumRecirculation
condition is satisfied (90 tons/hr
throughthemainlineand10
tons/hr through the bypass line.
Totalflowthroughthepumpwill
be 100 tons/hr ie., 90 + 10).
2. The On/Off System employs
an On-Off valve which passes a
constantRecirculationFlow.
Supposethe requiredminimum
Recirculation of the pump is 100
tons/hr,and theBoiler
requirement is 90 tons/hr, the
MinimumRecirculationValvewill
fully open so that it passes 100
tons/hr so that the minimum
Recirculationconditionis
satisfied.OncetheBoiler
requirementgoesabove 100
tons/hr the Recirculation Valve
closesfullysincetheBoiler
requirementissufficienttosatisfy
theminimumRecirculation
requirementsofthepump.
3. A third method employed by

olderpowerplants, recirculatesa
constantflow,regardlessofthe
plantload. Thepressureiskilled
bySeriesof multiholeplates.
Oftheabovemethodstheideal
systemwouldbetheModulating
System, since it is the most energy
efficient . However it exerts
taxingdemandsonControlValve
functioning.
Valvearesubjectedto high
pressuredropthrottling ofvery
lowflowsto fullflowconditions.
Thehighpressuredropthrottling
atlowliftconditions adversely
affectTrimdurabilityduetowire
drawingeffectsandTrimErosion.
Fig. 6. MIL 78000. Boiler feed pump

minimum Recirculation valve.

Fig. 7. MIL 91000. Multi stage multi path, axial flow MATRIX Series valve for Boiler
feed pump minimum Recirculation service
In this context, the most cost

effectivesolutionisobviouslythe
On-Off system.
The typical valve for such
application is the MIL 78000
Serieswhichincorporatesa
uniqueMultiStep,MultiStage
designwhichkillspressureovera
numberofstages.
The 78000 Series ensures a metal
to metal Class V leakage.
Anothersalientfeatureisthe
uniqueSlidingCollarSeatRing
designforClassVIleakageshutoff.
MILscontinuousresearchand
innovationsinPowerPlant
applicationvalves hasbornefruit
inthesuccessfuldevelopmentof
theAxialFlow,MultiStage,
VariableResistancedesign,the
MATRIX Series Valve which is
suitableforaModulatingSystem.
Theprototypewasdevelopedfor
aPumpRecirculationapplication
withpressuredropsof420bar.
The salientfeatureofthisdesign
isthewidescopeforcustomizing
the valve to suit specific process
applications.
TheTrimcanbecustomizedto
varioushighpressuredrop
applicationsbyvaryingthe
numberofstages.
Thecharacteristiccanbe
customizedbyreallocatingthe
pressuredropratioindifferent
stages. Theexpandingflow
passagesalsoenhance the
Rangeabilityallowingsmooth
andpreciseFlowControlevenat
lowliftoperatingflowconditions.
FeedWaterRegulatorValve
Anothercritical applicationinthe
FeedWaterSystemistheBoiler
FeedWaterRegulatingValve
which controlsflowtotheBoiler
for varying loads of the system.
Thevalvetakesthe signalfrom
theFeedWaterControlwhich
employsathree-elementcontrol.
Thesignalisgeneratedasa
functionof Drumlevel,Steam
flowandFeedWaterflow.
Twokindsofvalvesareusedfor
FeedWaterregulation.
Onevalveisemployedduringthe
low loadconditionsorthestartup
conditionsoftheBoiler.
Fig. 8. Feed Water Regulating System.
Anothervalveisusedduringfull
loadconditions.Apparentlythe
applicationsmayseemsimilar.
Howevertheselection
philosophyanddesignare
entirelydifferentforthetwo
valves. This is because of the
differentpressuredropconditions
existingatthetimeofStartupand
Full Load.
ThetypicalparametersofLow
LoadFeedWaterControlValve
andFullLoadFeedWaterControl
Valvearegivenbelow.
LOW LOAD FEED WATER VALVE
TYPICAL
PARAMETERS
Inlet Pressure: 170-200 bar (a)

Temperature: 230o C
FULL LOAD FEED WATER VALVE
TYPICAL
PARAMETERS
Inlet Pressure : 220-250 bar (a)

Outlet Pressure: 210- 230 bar (a)
Temperature: 247o C
Fig. 9. MIL 41008. Multi stage, Low Load, Feed Water regulating valve.
Thetypicaldesignforlowloadandfullloadapplicationsisthe
MIL 41000 Series Valves which employ Heavy Duty Cage Guided
features.
TheCageGuideddesignensures goodThrottlingStabilityandgood
Rangeabilitytocatertowidelyvaryingflowconditions.
Wherethepressuredropduringstart-upconditionisveryhigh,which
can be detrimental in conventional valves, 41008 Series Multi Cage
designfindsitstypicalapplicationforthelowloadvalve.
ThisdesignwhichfeaturesaMultiStagePressureDropTrim,willtake
careoftheveryhighpressuredropsencounteredduringstart-up
conditionswherethedrumpressureisverylowandthepump
dischargepressureisveryhigh.
3.4 Main steam system
Fig. 10. Critical Control Valves in Main Steam Line
MainSteamSystem
The Main Steam System consists of
the steam circuit from the Boiler
outlet, Superheater System, Soot
Blowing system, Turbines, Reheater
System to Condenser. The steam
fully extracted of the energy is finally
dumped into the Condenser, which
is the heat sink.
The most critical application valves
in this system are: Superheater
Spray Control Valves, Superheater
Spray Block Valves, Reheater Spray
Control Valves, Reheater Spray
Block Valves, Soot Blower Pressure
Control Valves, PRDS System
Control Valves, Main Steam
Pressure Reducing Valves, PRDS
Spray Control Valves and Deaerator
Pegging Steam Valve.
SuperHeaterAttemperatorValve
Thetemperature ofthemain
steamcomingoutoftheBoileris
verycritical fromthepointof
Thermodynamic Efficiencyofthe
heatcycleandtheTurbineblade
protection.
Boilermanufacturersemploy
variousmethods likeburnertilt
mechanism, spray water systems
etc.tocontrolthetemperatureof
the Main Steam . A poor
temperaturecontrolsystemmay
resultindamagestoTurbine
blades,Superheatertubes,
Reheatertubesetc.
Hence Attemperator valves are
of critical relevance
The typicalproblemsfacedby
superheatersprayControlValves
arethrottlinginstability andwide
Rangeability.
The designparametersofthe
spray system include those
conditions whichaccountforthe
excessiveheatingoftheTurbine
atfull load,withtheFeedWater
atitsmaximumtemperature,
cleanBoilertubesandmost
favourableconditions.
Fig. 12. MIL 41200. Superheater Attemperator valve.
Fig. 11. MIL 41100. Superheater Attemperator valve.
Howevertheaboveconditions
seldomcomeintoplaydueto
deteriorationofBoilertubesdue
toScalebuildupandthe
consequentheattransferloss.
Alsothesituationisfurther
compoundedby withdrawalof
heat throughtheSootBlower.All
thesefactorsresultinadrastic
reductionofspraywater
requirements.
Hence in practice the Spray
WaterValvewillbeseldomtaken
intofullcapacity.Thevalvewillbe
workingatlowerliftconditions
duetoabovesaidreasons.
Anothercriticalfactorinfluencing
theselectionofControlValveis
the Leakage Class.
Anyexcessiveleakagewillresult
inthermalshocksin Secondary
SuperheaterTubesanderosionof
Turbineblades.
MIL offers special designs like the
41100 Series and the 41200
Seriesforsuchapplications.
The 41100 Series features an
unbalancedCageGuideddesign.
Thiscombinesthetwinbenefits
ofthegoodthrottling stability of
Cage Guided valves with the shut
offcapabilityofsingleseated
unbalanceddesigns.
TYPICAL
PARAMETERS
Inlet Pressure:181-200 bar (a)

Temperature: 247o C
Fig. 13. MIL 41400. Superheater

Attemperator block valve.
For higher sizes (2 and above)

theActuator thrustrequirements
willbeveryhighduetothe
unbalanced design of the 41100
Seriesdesign.
The 41200 features a balanced
design withanovelStaticSeal
concept. The 41200 design has
thesameadvantagesthatthe
41100 Series besides the added
featureofabalancedplug.
AnotherapplicationofSpray
System is the block valve.
The block valves assists the spray
ControlValves effectingatight
shutoff.Another requirementof
a block valve is faster response.
Hence the Spray System employs
apneumaticallyoperatedOnOff
ControlValveforthisapplication.
The typical MIL designs for block
valve applications are the 41400
Series and the 41200 Series. The
41400 design is a Cage Guided
designwherethemainplugis
assistedbyanauxiliarypilotplug
toeffecttightshutoff.
Fig. 15. MIL 41008. Reheater

Attemperator Control Valve.
ReheaterAttemperatorValves
ThesourceoftheSprayWater
caneitherbetheFeedWater
pumpoutletortheinterstage
tappingofthepump.
Incaseoftheformer,thepressure
drop can be as high as 100-120
bar, andlatter,itcanbeupto
60-70 bar.
The MIL solution to such
applications are the 78000 Series
or the 41128 Series for high
pressure drops (100-120 bar). In
thecaseofmoderatepressure
drops, it is the 41121 Series or the
41221 Series.
TheReheaterSprayBlockValve
applicationissimilarto
SuperheaterSprayBlock
applications,andtheselection
philosophyissimilartothatfor
SuperheaterSprayBlockservice.
Thisapplicationisalsosimilarto
theSuperheaterSprayControl
Valveapplication.
However fluctuationsin
temperatureis notvaryingasin
SuperheaterSprayControl.
The Leakage Class is very critical
since excessive leakage can lead
toErosionoflowpressureTurbine
blades.
Thevalveselectiondependson
thepressuredropacrossthe
valve.Itmaybenotedherethat
reheaterpressureistheoutlet
pressureofthehighpressure
Turbine. Thepressuredropacross
thevalvedependsonthesource
ofthespraywater.
Fig. 14. MIL 78000. Reheater

Attemperator Control Valve.
Fig. 16. Deaerator Pegging Steam System.
DeaeratorPeggingSteamValve
TheDeaerator isadirectcontact
typeheaterwhichremovesnon
condensable gases like Oxygen
andCarbondioxidefromthe
Feed Water. These gases, if not
expelled,willattackandcorrode
pipingandBoilertubes.Thehot
steamismixedwiththeFeed
WaterenteringtheDeaerator
bringingittosaturation
temperatureandthereby
liberatinganyundissolvedornon
condensablegases.
Steamissupplied tothe
Deaeratorfordeaeration ofFeed
Waterandalsotomaintaina
positivepressureinthe
Deaearator.Deaerator actsasa
FeedWaterstoragetanktothe
BoilerFeedPump.Maintaininga
higherpressureintheDeaerator
helpsinmaintainingtheNPSHof
thepump.
Normallythesteamistakenfrom
theAuxiliarySteamHeaderupto
15% MCR condition. Above this
and upto 40% MCR, the steam is
takenfromtheColdReheat
Header(Steamtappedafterthe
HighPressureTurbine).Infull
loadconditions,steamistaken
directlyfromtheTurbine
extractionline.
Typical valves in this system are:
1. DEAERATOR PEGGING FROM
AUXILLIARY STEAM HEADER
TYPICAL
PARAMETERS
Inlet Pressure: 16 bar (a)

Outlet Pressure: 3.5 bar (a)
Temperature: 220o C
2. DEAERATOR PEGGING FROM
COLD REHEAT STEAM HEADER
TYPICAL
PARAMETERS
Inlet Pressure: 21 bar (a)

Outlet Pressure: 3.6 bar (a)
Temperature: 330o C
SootBlowerValve
Theproblemsencounteredin
valve selection for such
applicationsare thehighnoise
levels associated with this valve.
MIL offers special low noise Trims
(Lo-dB Design) for such
applications. The 41000 Series
Cage Guided valves with special
LowNoiseTrimhavebeenfound
excellent for such services.
Additionalnoiseattenuationcan
beachievedwithdouble stage
pressuredropdesignssuchas
doubleCageordiffuseroptionsin
the 41000 Series.
Anotherproblemassociatedwith
this service is high exit velocities
duetovolumetricexpansionof
thesteamwhenthepressure
drops. MIL offers special low
noisecartridges whichdividethe
pressuredropbetweenthevalve
andthecartridges.
Theeffectivepressuredropratio
across the valve is reduced which
resultsinlowexitvelocitiesand
noiselevels.
Oneofthemajorchallengeshere
is to select and design a Control
ValvefortheSteamSootBlowers.
Theproblemsuniquetothis
serviceareHighpressuredrop,
HighnoiselevelsandThermal
cycling of the valve body and
valveinternals.
Sootblowingvalvesarenormally
isolatedbyanupstreamisolation
valve. Hence the valve is not
subjectedtohighpressureand
temperature whennotinservice.
HoweverwhentheSootBlowing
is being done, the valve is
subjected to very high pressures
andtemperatures.
TYPICAL
PARAMETERS
Inlet Pressure - 170 bar (a)

Outlet Pressure - 20 bar (a)
Temperature - 540o C
Fig. 17. MIL 41003. Deaerator pegging

steam Control Valve
Theeffectivenessoftheheat
transferthroughBoilertubesis
adverselyaffectedbythebuildup
ofsoot.Alsotherapidbuildupof
sootinthetubescanleadtothe
developmentofhotspotsinthe
Boilertubes.TheBoilertubes
shouldbefrequently cleaned to
remove thesoot.Thenormal
practice is to use high velocity
steamjetstoblowthesootfrom
the tubes. The soot removal is
effectedthroughSootBlowers.
SomeSootBlowersuseairalsofor
theremovalofsoot.
Fig. 18. MIL 71114. Soot blower pressure reducing Control Valve
Hence the valve is subjected to

thermal cycling which can cause
WarpageandCreepinthe
conventional castglobevalve
bodies.
Theobvioussolutionwouldbeto
useforgedanglebodiesorforged
inlinebodieswithspecialmulti
stagelownoiseTrims.
Here MIL offers its 41114 Series

(CageGuidedinlinebodywith
doublestagepressuredrop),or
its 71114 Series (Cage Guided
anglebodywithdoublestage
pressuredrop).Thebodyshallbe
forgeddesignandchrome
molybdenum steel (ASTM A 182
Gr. F22)
PRDSStationValves.
Apartfromsteambeingusedfor
powergenerationandsoot
blowing,steamisusedforother
auxiliaryserviceslikegland
sealingofTurbines,Steam
EjectorsinCondensersand
Deaerator pegging.
Themainsteamhastobe
Desuperheatedbyreducingits
pressureandtemperature to
utilisethesteamfortheabove
mentionedapplications.
MAIN STEAM PRESSURE
REDUCING VALVE
TYPICAL
PARAMETERS
ThesteamDesuperheating is
effectedthroughPRDSstations
PressureReducing
DesuperheatingSystem.
The PRDS system consists of a
Desuperheaterpressurereducing
valveandatemperatureControl
Valve. Thepressurereducing
valvereducesthepressureofthe
steambeforeentryintothe
Desuperheater.
ThetemperatureControlValve
regulatesthespraywater
quantityintotheDesuperheater.
TEMPERATURE CONTROL VALVE
(SPRAY WATER)
TYPICAL
PARAMETERS
Fig. 19. Typical Auxiliary PRDS System
Fig. 20. MIL 41914 Main Steam Pressure Reducing Valve.
The critical factors that govern

selection of Main Steam PRV are:
High pressure drop, High
temperature, High noise levels
and Material selection for high
temperature.
A seat ring - basket diffuser is

provided foreffectivenoise
attenuationathigherpressure
dropratios.
ThetemperatureControlValveis
anothercriticalvalvecomingin
MIL offers the 41912 Series or the the system. As in the case of
41914 Series for this application. ReheaterSprayControlValve,
ThisdesignfeaturesaCage
the selection of this valve is also
GuidedTrimwith specialLow
governedbythe sourceofthe
Noisemultipleholescontrolling
SprayWater.Thesourceofthe
theflow.Optionaldoublestage
SprayWatercaneitherbefrom
designisalsoavailablewhichis
FeedWaterPumpoutletorinter
veryeffectiveinnoiseattenuation stagetappingofthepump.
athigherpressuredropratios.
Inthecaseoftheformer,the
For Class V leakage, the 41413
pressuredropcanbeashighas
Series istheappropriate
100-120 bar, and in the latter
selection. The 41413 Series
case, it can be upto 60-70 bar.
design is a Cage Guided design
wherethemainplugisassistedby The MIL solution to such
applications are the 78000 Series
an auxiliarypilotplugtoeffect
or the 41128 Series for high
thetightshutoff.
pressure drops (100-120 bar).
The Cage design includes
Inthecaseofmoderatepressure
multipleholestoattenuatethe
dropsthe designshallbethe
noise.Theflowdirectionofthe
41121 Series or the 41221 Series.
valve is Over the Plug.
Thecriticalfactorsthat influence
theselectionofthevalvesare:
Body andTrimmaterial,Valve
sizeandValveflowcapacity
The liquid dropletsaccelerated

byrelativelyhighvelocityvapour
Fig. 21. MIL 21000. Heater Drain Valve
phase,impingesonthematerial
surface ofbodyand Trimcausing
TheHeaterDrainSystem
The heater drain system consists of heavywear.
the Feed Water heaters coming in
the Condensate system and Feed
Water system. The Feed Water
heaters coming in the Condensate
system are called low pressure
heaters which heats the Condensate
to saturation point before entry into
Deaerator.
The heaters coming in the Feed
Water system are the High pressure
heaters which heat the Feed Water
to near saturation point before the
entry into Boiler.
The HP heaters and LP heaters are
basically heat exchangers shell and
tubetype. The heating media for HP
heaters is the steam extracted from
the reheat cycle, whereas for LP
heaters the steam is extracted from
the low pressure Turbine.
GenerallyChromeMolybdenum
steelshaveexhibitedexcellent
resistancetoFlashingErosion.
Even though ASTM A 217 Gr C5
is recommended by some users, it
isbeing increasinglyreplacedby
ASTM A 217 Gr WC9 material as
C5 has some significant
manufacturingproblems,in
additiontopoorweldability,and
isthusdifficulttoweldrepair.
Anotherissueistheselectionof
valve body size. It is always
recommendedtoselecthigher
The heating media, i.e., the steam is bodysizeswithareduced
introduced into the heaters, cooled capacityTrim.
and ultimately condensed back to
liquid. The level in the heaters are to
be closely controlled to maintain the
Thermodynamic efficiency of the
system. The Condensate in the
heaters are at saturation condition,
and when the Condensate is drained
to either Deaerator or the
Condensate flash tank, the fluid
losses pressure and flashes.
Thebodysizeselectioncriteriais
theoutletFlashingvelocity.
MIL offers its 21000 Series and
the 4100 Series Valves for these
applications. Thebodymaterialis
either WC6 or WC9.
3.5 Heater drain system
Flashingproblemsencountered
intheseservicescausematerial
erosion.
3.5 Heater drain system
Fig. 22. LP Heaters System
Fig. 23. HP Heaters System
TypicalInstallations
Choosingtherightvalvemakesallthedifference
FW-2
FW-8
FULL LOAD FEED WATER FLOW CONTROL (BY-PASS)
FULL LOAD FEED WATER FLOW CONTROL
LOW LOAD FEED WATER FLOW CONTROL
Service
SD-5.SD-6
SD-23
SD-7
S57. S69
SB4
SD-8
Tag
AS-9
AS-3
BV-01
SW-10
SW-4
No.
PRDS VALVES
Tag
No.
LOW CAPACITY SPRAY WATER CONTROL VALVE
HIGH CAPACITY SPRAY WATER CONTROL VALVE
COMMON BLOCK VALVE FOR PRDS SPRAY
LOW CAPACITY STEAM PRESSURE REDUCING
HIGH CAPACITY STEAM PRESSURE REDUCING
Service
SOOT BLOWER STEAM PR.REDUCING VALVE
SH SPRAY BYPASS VALVES
INTERMITTENT BLOWDOWN VALVE
SH SPRAY BLOCK
SH SPRAY CONTROL
Service
SPRAY & SOOT BLOWER VALVES
Tag
FW-5
No.
FEEDWATER CONTROL VALVES

Size
3 in.
1500
1500
1500
Rating*
2 in.
2 in.
2 in.
Size
2 in.
2 in.
2500
2500
1500
1500
1500
1500
Rating*
Size
2 in.
2 in.
38-78101
1 in.
38-78101 1.5 in.
37-211X4
38-41412
38-41912 6x3 in.
Model
1500
1500
1500
1500
1500
Rating*
Project: TISCO 1X67.5MW
38-70571
38-70571
90-41024 2.5 in.
38-78001
38-414X1
38-41024
Model
90-41921 6x3 in.
38-41921 6x3 in.
38-78101
Model
A105
A105
WCC
WC9
WC9
Body
F22
F11
WCC
A105
WCC
WCC
Body
WC6
WC6
F11
Body
0.3
1.2
15
12
120
Cv
10
20
40
Cv
140
140
15
Cv
Temp.
Qty.
185 kg/cm 150 C

2
185 kg/cm 150 C

2
185 kg/cm 175 C

2
100 kg/cm 520 C

2
* ANSI
100 kg/cm 520 C

0
Qty.
2
Temp.
Pr.
Customer:BHEL Madras
110 kg/cm2 4200C
173 kg/cm2 4130C
186 kg/cm 242 C

2
110 kg/cm 350 C

2
185 kg/cm 250 C

0
4
2
185 kg/cm 250 C

0
Qty.
2
Temp.
Pr.
Customer: BHEL Trichy
170 kg/cm 235 C

2
170 kg/cm 235 C
170 kg/cm2 2350C
Pr.
Customer: BHEL Madras
4.1 Typical applications. 67.5 MW
Capacity 67.5 MW
CV-5.6
CV-7.8
CV-9.10
CV-11.12
CV-13.14
CV-15.16
CV-17.1
Tag
CV-23
CV-24
No.
PRDS VALVES
Tag
No.
SPRAY VALVES
Tag
No.
FEED CONTROL VALVES
Capacity 116 MW
PRDS SPRAY CONTROL VALVE
PRDS PR. REDUCING VALVE IN HP STEAM LINE TO AUX.HDR.
Service
LP BYPASS SPRAY VALVES
LP STEAM BYPASS VALVES
HP BYPASS SPRAY VALVES
HP STEAM BYPASS VALVES
Service
FEED REGULATING VALVE IN HP BFP DISCH.LINE (LOW LOAD)
FEED REGULATING VALVE IN HP BFP DISCH.LINE (FULL LOAD)
FEED REGULATING VALVE IN HP BFP DISCH.LINE
Service
2 in.
3 in.
2 in.
Size
900
900
300
Rating*
A105
WC6
WCC
Body
1 in.
8 in.
2 in.
6 in.
Size
600
150
600
1500
Rating*
WCC
WCC
WCC
WC6
Body
38-78003
38-41412
Model
1 in.
2 in.
Size
900
1500
Rating*
A105
WC6
Body
Project: Ahemedabad Electricity Company.
38-211X5
38-41421
37-211X5
38-41412
Model
38-78001
37-41612
38-41621
Model
0.3
30
Cv
3.8
640
46
145
Cv
95
26
Cv
2
2
2
115 kg/cm 121 C

115 kg/cm 120 C
o
Qty.
2
2
2
2
480 C
o
50 C
147 C
50 C
2
2
2
119 kg/cm 121 C

o
* ANSI
1
2
480 C
70 kg/cm
Qty.
2
Temp.
Pr.
Customer:BHEL Bangalore
13 kg/cm
7 kg/cm
13 kg/cm
Temp.
2
70 kg/cm
Pr.
121 C
15 kg/cm
Qty.
Temp.
Pr.
Customer: BHEL Bangalore
4.2 Typical applications. 116 MW
CV-25.26.27
CV-28.29.30
RECIRCULATION VALVE FOR LP BFP
RECIRCULATION VALVE FOR HP BFP
Service
Tag
CV-1
CV-2
CV-3
CV-4
CV-19
CV-20
CV-21.22
CV-31
CV-32
No.
DUMP MAKE-UP VALVE
NORMAL MAKE-UP VALVE
PREHEATER INLET CONTROL VALVE
PRESSURE REDUCING VALVE TO DEAERATOR
PRESSURE REDUCING VALVE TO DEAERATOR
DEAERATOR OVERFLOW TO DM STORAGE TANK
EXCESS RETURN CONTROL VALVE
MIN. FLOW RECIRCULATION CONTROL VALVE
MAIN CONDENSATE CONTROL VALVE
Service
HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES
Tag
No.
FEED PUMP RECIRCULATION VALVES

Size
1in.
600
900
Rating*
WCC
A105
Body
38-21125
37-21125
37-41621
38-41621
38-41621
38-414X1
37-41621
37-41612
38-41621
Model
2 in.
1 in.
4 in.
8 in.
3 in.
3 in.
2 in.
2 in.
6 in.
Size
600
600
300
150
150
150
300
300
300
Rating*
CF8M
CF8M
WCC
WCC
WCC
WCC
WCC
WCC
WCC
Body
37-211X5
37-78003 1.5 in.
Model
46
225
500
95
155
65
25
360
Cv
3.8
4.5
Cv
2
18 kg/cm
122 C
o
Qty.
48 C
o
48 C
120 C
147 C
147 C
118 C
2
2
2
2
2
10 kg/cm2
10 kg/cm2
13 kg/cm
7 kg/cm
7 kg/cm
7 kg/cm
13 kg/cm
40oC
40oC
13 kg/cm
48oC
2
Temp.
13 kg/cm2
Pr.
* ANSI
Qty.
Temp.
115 kg/cm 122 C
Pr.
Customer: BHEL Bangalore
Capacity 116 MW
FW-FCV-1
FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS)
Service
SD-4
SD-5.6.7.8
SD-9
SD-10.11.12.13
SD-14
SD-15.16.17.18
SD-19.20.21.22
PCV-8502A.B
Tag
MSPCV-1
MSPCV-2
SPTCV-1
SPTCV-2
V2505111
No.
PRDS VALVES
Tag
No.
BLOCK VALVE ON SPRAY WATER TO AUX. PRDS
AUX.PRDS 10%SPRAY FLOW CONTROL VALVE
AUX.PRDS 100%SPRAY FLOW CONTROL VALVE
AUX.PRDS 10%STEAM PR. CONTROL VALVE
AUX.PRDS 100%STEAM PR. CONTROL VALVE
Service
RH CONTROL
RH BLOCK BRANCH
RH BLOCK COMMON
SH STAGE II CONTROL
SH STAGE I I BLOCK
SH STAGE I CONTROL
SH STAGE I BLOCK
Service
2
FW-FCV-2
Tag
No.
FEED CONTROL VALVES
Capacity 210MW
Size
2500
Rating*
WC6
Body
Size
2 in.
2500
2500
2500
2500
2500
2500
2500
2500
Rating*
Size
2 in.
37-211X4
38-78101
2 in.
1 in.
38-78102 1.5 in.
38-41012
38-41412 6x3 in.
Model
2500
2500
2500
2500SPL
2500SPL
Rating*
Project : Raichur TPS. Unit IV
38-41012
38-78103 1.5 in.
38-410X4 1.5 in.
38-410X4 2.5 in.
38-41024 1.5 in.
38-410X4 2.5 in.
38-41024 2.5 in.
38-410X4 6x4 in.
Model
WCC
A105
A105
15
0.3
2.4
50
WC9
WC9
Cv
25
3.6
40
60
3.8
60
30
195
Cv
45
575
Cv
Body
F11
A105
WCC
WCC
WCC
WCC
WCC
WCC
Body
38-41412 6x4 in.

2500
WC6
Project : Unchahar TPS 2x210 MW
38-41921 12x8 in.
Model
Project : Raichur TPS Unit IV
Qty.
2
8
265 kg/cm 260 C
8
8
4
265 kg/cm 260 C

185 kg/cm 440 C
o
* ANSI
286 kg/cm 250 C

o
1
2
286 kg/cm2 250oC
1
286 kg/cm2 250oC
Qty.
165 kg/cm2 540oC
Temp.
165 kg/cm2 540oC
Pr.
Customer:BHEL Madras
265 kg/cm2 260oC

2
265 kg/cm2 260oC
265 kg/cm 260 C

2
Qty.
265 kg/cm 260 C
Temp.
2
2
265 kg/cm 260 C
Pr.
1
285 kg/cm 250 C
Customer:BHEL Trichy
Temp.
286 kg/cm 250 C
Pr.
Customer: BHEL Madras
Tag
FEED PUMP MINIMUM RECIRCULATION
Service
Tag
PAS-1
PCR-1
DR-2
DR-6
DR-9
DR-12
DR-15
DR-17
DR-20
DR-22
DR-25
DR-41
CD-14
CD-23
CD-19
CD-78
DM-1
DM-2
CD-47
No.
10
11
12
13
14
15
16
17
18
19
CONDENSATE FOR VALVE GLAND SEALING
DM MAKE-UP TO HOTWELL (HC)
DM MAKE-UP TO HOTWELL (LC)
HP DRAINS MANIFOLD SPRAY
CONDENSATE MINIMUM RECIRCULATION
CONDENSATE EXCESS RETURN
MAIN CONDENSATE
DEAERATOR OVERFLOW TO DRAIN TANK
LPH-2 DRAIN TO FLASH BOX-1
LPH-2 DRAIN TO LPH-1
LPH-5 NORMAL DRAIN TO FLASH BOX-1
LPH-3 NORMAL DRAIN TO LPH-2
HPH-5 NORMAL DRAIN TO FLASH BOX-2
HPH-5 NORMAL DRAIN TO DEAERATOR
HPH-6 NORMAL DRAIN TO FLASH BOX-2
HPH-6 NORMAL DRAIN TO HPH-5
PEGG. STEAM FROM CRH TO DEAERATOR
PEGG. STEAM FROM AUX. STEAM HEADER TO DEAERATOR
Service
HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES
No.

Size
2500
Rating*
A105
Body
10 in.
10 in.
8 in.
8 in.
4 in.
3 in.
4 in.
4 in.
3 in.
3 in.
3 in.
3 in.
2 in.
1 in.
6 in.
38-41621 1.5 in.
37-41611
37-41611
37-211X5
37-78003
300
300
300
300
300
300
300
300
300
300
300
300
300
300
600
600
600
600
300
6 in.
10 in.
Rating*
Size
38-41612 6x4 in.
38-41621
38-416X1
37-41621
38-41621
37-41621
38-41621
38-41321
38-41321
38-41321
38-41321
38-41321
38-41912
38-41912
Model
WCC
CF8M
CF8M
WCC
A105
WCC
WCC
WCC
WCC
WCC
WCC
WCC
WC6
WC6
WC6
WC6
WC6
WCC
WCC
Body
Cv
15
Cv
14
60
30
12
70
145
900
1000
575
575
225
140
90
90
56
56
56
430
300
Project : Vijayawada TPS Stage II Unit V&VI
37-78103 4x2 in.
Model
Project : Ropar TPS
Qty.
230 C
350 C
215 C
2
2
180 C
130 C
130 C
100oC
2
2
2
170 C
o
55 C
55 C
2
2
50 C
o
50 C
55 C
2
2
25 kg/cm
10 kg/cm
10 kg/cm
55oC
2
55oC
25 kg/cm2
25 kg/cm2
25 kg/cm
25 kg/cm
11 kg/cm
100oC
8 kg/cm2
8 kg/cm
8 kg/cm
8 kg/cm
20 kg/cm
180 C
2
20 kg/cm
48 kg/cm2 215oC
48 kg/cm2 215oC
Qty.
o
Temp.
2
48 kg/cm
48 kg/cm
20 kg/cm
Pr.
Customer:BHEL Delhi
Temp.
260 kg/cm 250 C
Pr.
Customer: BHEL Hyderabad
Capacity 210 MW
0728.1&2
728.3
FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS)
Service
SD-4
SD-5 TO SD-8
SD-9
SD-10 TO SD-13
SD-14
SD-15 TO SD-18
SD-19 TO SD-22
SD-23
AS-22
FD-22
FD-23
AS-32
FD-29
FD-30
Tag
No.
PRDS VALVES
Tag
No.
CRH PRDS SPRAY CONTROL
CRH PRDS SPRAY CONTROL
CRH STEAM PRDS
MS PRDS SPRAY CONTROL
MS PRDS SPRAY CONTROL
MS PRDS STEAM CONTROL
Service
RH SPRAY CONTROL
RH BRANCH BLOCK
RH SPRAY MAIN BLOCK
SH STAGE II SPRAY CONTROL
SH STAGE II SPRAY BLOCK
SH STAGE I SPRAY CONTROL
SH SPRAY STAGE I BLOCK
Service
Tag
No.
FEED CONTROL VALVES
Capacity 250 MW
Size
2500
2500
Rating*
WC6
WC6
Body
2in.
2in.
2in.
3in.
1.5in.
3in.
2.5in.
6in.
Size
2500
2500
2500
2500
2500
2500
2500
2500
Rating*
F22
F11
WC6
WC6
WC6
WC6
WC6
WC6
Body
Size
38-78001
38-78001
38-41012
38-41024
38-78002
1in.
1in.
2.5in.
1.5in.
1.5in.
38-41412 6x4in.
Model
2500
2500
600
2500
2500SPL
2500SPL
Rating*
A105
A105
WCC
WCC
A105
WC9
Body
Project : BSES DAHANU 2x250 MW
38-70571
38-78003
38-211X4
38-414X1
38-41024
38-414X1
38-41024
38-414X1
Model
Project : BSES DAHANU 2x250 MW
38-41921 6x4in.
38-41921 14x10in.
Model
0.3
0.3
20
2.4
110
Cv
13
3.5
15
30
75
30
240
Cv
225
900
Cv
Project : CESC Budge Budge TPS. 2*250 MW
8
2
8
182 kg/cm 350 C

282 kg/cm 350 C
282 kg/cm 350 C
o
2
2
267 kg/cm 170 C

2
267 kg/cm 170 C

2
Qty.
48 kg/cm2 360oC
267 kg/cm2 170oC
267 kg/cm2 170oC
Temp.
169 kg/cm 545 C
Pr.
182 kg/cm2 450oC
182 kg/cm2 350oC
2
2
262 kg/cm 350 C

2
Qty.
182 kg/cm 260 C
Temp.
2
2
262 kg/cm 260 C
Pr.
Qty.
330 kg/cm 248 C
Temp.
4
2
330 kg/cm 248 C
Pr.
Customer: BHEL Delhi
AS-2
CRH-2
DR-2
DR-6
DR-9
DR-13
DR-16
DR-19
DR-22
DR-25
DR-28
DR-38
CD-14&CD-17
CD-25
CD-21
CD-53
CD-58
DM-2 (LOW)
DM-5 (HIGH)
10
11
12
13
14
15
16
17
18
19
DM MAKE-UP TO HOTWELL (HC)
DM MAKE-UP TO HOTWELL (LC)
EMERGENCY MAKE-UP TO CONDENSATE HOTWELL
HP DRAINS FLASH TANK SPRAY
EXCESS CONDENSATE DUMP CONTROL
CONDENSATE EXCESS PUMP MIN. RECIRCULATION
MAIN CONDENSATE CONTROL
DEAERATOR OVERFLOW TO LP FLASH TANK
LPH-2 ALT. DRAIN TO LP FLASH TANK
LPH-3 ALT. DRAIN TO LP FLASH TANK
HPH-5 ALT. DRAIN TO HP FLASH TANK
HPH-6 ALT. DRAIN TO HP FLASH TANK
HPH-6 ALT. DRAIN TO DEAERATOR
HPH-6 NORMAL DRAIN TO HPH-5
PEGG. STEAM FROM CRH TO DEAERATOR
PEGG. STEAM FROM AUX. STEAM HEADER TO DEAERATOR
HEATER DRAIN & CONDENSATE SYSTEM VALVES
A105
3 in.
12 in.
3 in.
8 in.
8 in.
4 in.
4 in.
4 in.
4 in.
3 in.
3 in.
3 in.
10 in.
8 in.
37-41612
37-41512
37-41612
37-211X5
4 in.
3 in.
3 in.
1 in.
38-41612 6x3 in.
37-78003
38-41521
38-419X1
37-41621
38-41521
37-41621
38-41521
37-41921
38-41521
37-41921
38-41921
38-41521
38-41912
38-41912
150
300
150
300
300
600
300
300
150
150
150
150
300
300
600
600
600
600
300
CF8M
CF8M
WCC
WCC
WCC
A105
WCC
WCC
WCC
WCC
WCC
WCC
WC6
WC6
WC6
WC6
WC6
WCC
WCC
Project : Kothagudem TPS, 2*250 MW
2500
37-78103 4x2 in.
120
45
95
1,7
95
45
900
100
575
575
170
170
120
120
56
50
50
500
315
15
215 C
170 C
o
55 C
o
55 C
o
55 C
o
55 C
o
55 C
o
40 C
40 C
2
2
2
2
2
2
2
8 kg/cm
8 kg/cm
8 kg/cm
30 kg/cm
27 kg/cm
27 kg/cm
27 kg/cm
11 kg/cm
105oC
2
105oC
130oC
130oC
8 kg/cm2
8 kg/cm2
8 kg/cm2
8 kg/cm2
20 kg/cm2 175oC
20 kg/cm2 175oC
48 kg/cm2 215oC
48 kg/cm2 215oC
360 C
2
48 kg/cm
48 kg/cm
14 kg/cm2 220oC
Customer: BHEL Delhi
260 kg/cm2 250oC
Customer: BHEL Hyderabad
FEED PUMP MINIMUM RECIRCULATION
Project : Kothagudem TPS, 2*250 MW
Capacity 250 MW
FCV-0657
Service
SD-10
SD-11 TO SD-14
SD-15
SD-16 TO SD-19
SD-20 TO SD-23
SD-24
RH SPRAY CONTROL
RH BRANCH BLOCK VALVE
RH SPRAY BLOCK
SH SPRAY CONTROL
SH SPRAY BLOCK
Service
LCV-0507
LCV-0508
CONDENSATE NORMAL MAKE-UP
CONDENSATE SPILL TO CONDENSATE STORAGE TANK
CONDENSATE FLOW TO DEAERATOR
FCV-0559A/B
CRH FLOW TO DEAERATOR
PCV-0326B
AUX. STEAM TO DEAERATOR
CONDENSATE PUMPS A.B.C MINIMUM FLOW RECIRCULATION
PCV-0326A
Service
3 FCV-01514/0519/0524
Tag
No.
Tag
No.
Tag
No.
FEED CONTROL VALVES
Capacity 500 MW
Size
2500
Rating*
C5
Body
475
Cv
8 in.
Size
3 in.
2500
2500
2500
2500
2500
2500
Rating*
F11
WCC
WCC
WCC
WCC
WCC
Body
25
12
75
155
26
380
Cv
37-41621
38-41612
38-41521
37-78103
38-41512
37-41512
Model
4 in.
8 in.
10 in.
4 in.
300
300
300
600
600
300
12 in.
16 in.
Rating*
Size
CF8M
WC6
WCC
A105
WC6
WCC
Body
140
315
900
55
1200
725
Cv
Project : NTPC Talcher TPS 2x500 MW STPP
38-41012 4x2 in.
38-41024 2.5 in.
38-414X1
38-414X1 4x3 in.
38-41621 4x3 in.
38-414X1
Model
Project : NTPC Vindhyachal TPS 2x500 MW STPP
37-41512 12x8 in.
Model
Project :NTPC Talcher TPS 2x500 MW STPP
Qty.
Temp.
2
8
8
4
340 kg/cm 260 C

340 kg/cm 260 C
213 kg/cm 482 C
o
2
2
295 C
410 C
2
* ANSI
40 C
2
10 kg/cm
50oC
47 kg/cm2
47oC
47 kg/cm2
47oC
Qty.
o
Temp.
2
47 kg/cm2
57 kg/cm
20 kg/cm
Pr.
Customer:Keltron Controls
340 kg/cm 260 C

2
Qty.
340 kg/cm2 260oC
340 kg/cm2 260oC
Pr.
Temp.
360 kg/cm 200 C
Pr.
Customer: Keltron Controls
HP HEATER 5A & B EMERGENCY LEVEL
12
LP HEATER 3 EMERGENCY LEVEL
14
1-HDL-LCV-0757B
1-HDL-LCV-0722
1-HDL-LCV-0768
1-CO-PCV-0530
FCW-PCV-8701
LCV-8701
16
17
18
19
20
21
Tag
ASS-2 TO ASS-7
ASS-20 TO ASS-25
No.
PRIMARY SCAPH
SECONDARY SCAPH
Service
SCAPH CONTROL VALVES
DM WATER OVERHEAD LEVEL CONTROL
EQUIPMENT COOLING WATER DIFFERENTIAL PR. CONTROL
VALVE GLAND SEALING PRESSURE CONTROL
LP HEATER 1 NORMAL LEVEL
15 1-HDL-LCV-0757A
1-HDL-LCV-0746B
13 1-HDL-LCV-0746A
LCV-0714/0736
HP HEATER 5A & B NORMAL LEVEL
11 1-HDH-LCV-0712/34
LCV-0703/0722
HP HEATER 6A & B EMERGENCY LEVEL
GSC MAIN FLOW
10
LCV-0526
CONDENSATE EMERGENCY MAKE-UP
HP HEATER 6A & B NORMAL LEVEL
LCV-0509
Service
9 1-HDH-LCV-0701/23
Tag
No.
12 in.
2 in.
8 in.
8 in.
6 in.
6 in.
3 in.
3 in.
4 in.
3 in.
4 in.
3 in.
4 in.
8 in.
Size
300
150
300
300
300
300
300
300
300
600
300
600
600
600
150
Rating*
CF8M
CF8M
WC6
C5
WC6
C5
WC6
C5
WC6
C5
WC6
C5
WC6
WC6
CF8M
Body
35
1660
12
640
640
400
400
155
155
55
60
55
45
55
575
Cv
38-41321
38-41921
Model
4 in.
8 in.
Size
300
300
Rating*
WCC
WCC
Body
200
575
Cv
50 C
110 C
110 C
o
90 C
o
90 C
60 C
2
2
2
2
50 C
40 C
2
10 kg/cm
46oC
Qty.
20 kg/cm
20 kg/cm
Pr.
250 C
o
250 C
2
Temp.
* ANSI
Qty.
10 kg/cm2
47 kg/cm
60oC
3 kg/cm2
3 kg/cm
3 kg/cm
3 kg/cm
4 kg/cm
4 kg/cm
190 C
2
34 kg/cm
34 kg/cm2 190oC
57 kg/cm2 240oC
57 kg/cm2 230oC
47 kg/cm
40 C
2
Temp.
2
10 kg/cm
Pr.
Customer:Keltron Controls
Project : NTPC Vindhyachal TPS 2x500 MW STPP
37-41621 1.5 in.
37-41521
37-41612
37-41611
37-41511
37-41611
38-41511
37-41611
38-41511
38-78103
38-41512
37-78103
38-41512
37-78103
38-41621
Model
Project : NTPC Talcher TPS 2x500 MW STPP
Capacity 500 MW
MaterialselectionGuidelines
StandardisedMaterialsforhighperformance
MATERIAL SELECTION
Correctmaterialselectionisextremelyimportanttoensure
properfunctioningandlongevityofControlValvesinPower
pressureandtemperatures,designpressurecangoupashigh
as360kg/cm2 andtemperaturesupto566oC.TheBodyand
Trimmaterialselectionshouldalsotakeintoaccountthe
detrimentaleffectsofCavitation/Flashing/HighVelocity
whichareinherenttosuchsevereapplications.
CONTROL VALVE. PRESSURE CONTAINING MATERIAL
General Classification
Castings
Forgings
Max. Operating Temp.
Carbon Steel
ASTM A 216 Gr. WCB / WCC
ASTM A 105
427C
Alloy Steel, 1 Cr - Mo
ASTM A 217 Gr. WC6
ASTM A 182 Gr. F11
566C
Alloy Steel, 2 Cr - 1 Mo
ASTM A 217 Gr. WC9
ASTM A 182 Gr. F22
566C
Alloy Steel, 5 Cr - Mo
ASTM A 217 Gr. C5
ASTM A 182 Gr. F5a
566C
Stainless Steel, Ty. 316
ASTM A 351 Gr. CF8M
ASTM A 182 Gr. F316
566C
PRESSURE RATING. CEILING VALUES *

Temp.
150#ANSI
300#ANSI
600#ANSI
900#ANSI 1500#ANSI
2500#ANSI
< 93C
18.3
52.7
105.5
158.2
263.7
439.4
149C
16.2
51.3
102.3
153.6
255.9
426.8
204C
14.1
49.6
99.1
148.7
248.2
413.4
260C
12.0
46.8
93.5
140.3
233.8
389.5
316C
9.8
42.5
85.1
127.6
212.7
354.4
371C
7.7
40.1
79.8
119.9
199.7
332.6
427C
5.6
35.9
71.4
107.2
178.6
297.4
482C
3.5
31.6
63.3
94.9
157.8
263.3
538C
1.4
25.7
51.0
76.6
128.0
213.0
593C
0.0
22.9
45.3
67.8
113.2
188.8
* Max.. Working Pressure in Kg/cm for ANSI 150# to ANSI 2500#, Extracted from ANSI B16.34 - 1996. Varies
with material, See pages 48-50 for max. allowable working pressures for WCC, WC6 & WC9, the most
common body material used for Control Valves in power plant applications.
5.1 Body material specs
Plantapplications.Theserviceconditionsvarywidelyin
Allowable working pressure (Kg/cm2)
5.2 Allowable working pressure
Allowable working pressure for ASTM A 216 Gr. WCC
Operating temperature (oC)
Allowable working pressure for ASTM A 217 Gr. WC6
Allowable working pressure for ASTM A 217 Gr. WC9
Bar Stock: ASTM A 479 Ty. 410
Bar Stock: ASTM A 582 Ty. 416
NA
NA
NA
NA
Bar Stock: ASTM A 564 Gr. 630

Castings: ASTM A 747 CB7CU1
Casting: ASTM A743 Gr. CA6NM

(HeatTreated)
Bar Stock: ASTM A276 Ty.440C
Ty. 416 Stainless Steel

(Hardened&Tempered)
No.6 Stellite Hard Facing
No.6 Stellite Solid (< 2)
No.5 Colmonoy Hard Facing
No.6 Colmonoy Hard Facing
17.4 PH Stainless Steel
CA6NM Stainless Steel
Ty. 440C Stainless Steel
Bar Stock: ASTM A 479Ty. 316

Castings: ASTM A 351 Gr. CF8M
ASTM CODE
Ty. 410 Stainless Steel

(Hardened&Tempered)
TOUGH SERVICE
SS 316
GENERAL SERVICE
400C
650C
400C
650C
650C
650C
650C
400C
400C
593C
MAX. TEMP.
58 HRC min.
afterNitriding)
28 HRC min.
40 HRC min (H900)

32 HRC min (H1075)
56-62 HRC
45-50 HRC
38-47 HRC
38-47 HRC
31-38 HRC
35 HRC min.
14 HRC max.
HARDNESS
Very Erosive Service.
Erosive & Corrosive Service.

(700-1000 HV After case hardening, excellent for high
temperatureservice.
Erosive & Corrosive Service

Corrosion resistance similar to Inconel

Corrosion resistance similar to Inconel
Erosive & Corrosive Service
Slightly Erosive & Corrosive Service
Erosive & Non- Corrosive Service
Corrosive & Non- Corrosive Service
Non-Erosive, Corrosive,Mod. Press. Drop.

Most corrosion resistant of 300 Series
GENERAL APPLICATION
5.3 Trim material selection
GENERAL CLASSIFICATION.
HandlingandInstallation
A list of safe practices
6.1 Handling & Installation
Fig. 24. Clearance requirements for Globe Control Valves
1. Do not lift large size valves

by the Actuator. Lifting Lugs
providedontheActuatorsare
forliftingtheActuatoralone.
2. The Actuator Diaphragm
case, Eye Bolts etc. are not
designedtolifttheheavy
valve body assembly.
3. Do not turn the Actuator,
keepingthecouplingtight.
6. While choosing the

location to mount the valve,
provideadequatespacefor
future occasions when it may
become necessary to remove
theBodyandActuator
forrepairs.
7. Ensure that recommended
mountingorientationsare
alwaysfollowed.
8. Ensure that the Flange

4. In case of Bellow Sealed
Valves,neverrotatetheValve Bolts or Tie Rods can be
removedeasily.
stem.
5. Valves on smaller piping
andtubingmayneedtobe
mountedinBrackets.
9. Leave adequate space for

opening/adjusting
Positioners and Accessories.
6.1Handling & Installation
Fig. 25. Alternate orientations for Control Valves (position-1 is preferred)
10. Positioner Gauges and

13. Special attention must be
Travel Indicators must always given not to place an elbow
remainclearlyvisible.
or pipeT less than 5 pipe
diameters downstreamofa
11. Careful choice of
valvetoavoidinterference
locationhelpsprevent
withtheValvesFlow
Cavitation. When flow is
Capacity. In high pressure gas
upward,andifthefluid
partiallyvaporizesbecauseof orsteampressurereducing
applications, try to have only
lowerhydrostatichead,
straightpipesdownstreamof
locatingtheValvetowards
the valve, or alternatively use
thelowestpartofthepiping
alongsweepingelbowto
canpreventtwophaseflow
avoidaddedpipenoise.
throughtheValvethereby
minimizingCavitation.
14. In critical applications,
12. Valves in Flashing service
are to be located as close to
the receiving vessel as
possible. A very short length
of Discharge Pipe, and an
IsolationValvearepermitted.
provideamanuallyoperated
throttling valve in a bypass
around the valve. This allows
forreplacementorrepairof
theControlValvewithout
shutting down the process.
Fig. 27. Less satisfactory arrangement of upstream and downstream piping
15. Since Control Valves will require maintenance from time

to time, Block Valves at Upstream and Downstream are
essential. Bleed and drain valves may be necessary for safety.
16. On occassions when the Control Valve is out of service, if
a Bypass Valve is being provided along with isolation valves in
order to have flow, the style of the Bypass Valve should be
similar to that of the Control Valve. Or else an identical
Control Valve should be chosen as the Bypass Valve.
17. In cases of extreme ambient temperatures (over 80C)
where a valve is located, the valve and accessory
manufacturersshouldbeconsultedforproper,high
temperaturereplacementmaterial.
6.1 Handling & Installation
Fig. 26. Typical satisfactory arrangement of upstream and downstream piping
MaintenanceGuidelines
Howtoensurepeakperformance of
Control Valves in power plant applications
1. PREVENTIVE MAINTENANCE
BEFORE
START-UP
3. Ensure that the

recommendedmounting
orientationisfollowed.If a
valve is mounted with its
stemtravellinginthe
horizontalplane,itmustbe
properlysupported.
2.Ensure that misalignment

alongthepipelineisnot
corrected using the valve.
Pipeline stress on the valve
maycausemisalignmentof
the stem or plug/seat joint. It
can also cause flange leak or
packingleak.
5. Piping should be flushed

before installing the valve. If
additionalflushingisdone
afterinstallation,itmaybe
necessary to remove the
internals, Especially if antiCavitation or low noise Trim is
inplace.
AFTER
1.Periodicfieldinspections
shouldbemade.
2. Rememberthathighfrictionpackingneedstobe
compressedafterinsertion.
Packingwillcompressfurther
inservice,andthepacking
compressionmayhavetobe
readjusted.Tightenthe
packingnutswhenfound
necessary.
3. It dusty or dirty conditions
prevail,providearubberboot
aroundthestemtoprotectthe
packing.
4. Ensure that the mandatory

flowthroughdirection
indicatedontheControl
Valve (by an arrow mark) is
alwaysfollowed.
Continuedinnextpage
START-UP
4. Cover the valve suitably

whenprocessdrippingor
corrosiveatmospheric
conditionsprevail.Specialcare
tobegiventothevalve
accessories.
5. Airsetsusuallyhavefilters
thatcanclog;thedraincock
shouldbeopenedfromtimeto
timetobesuretrappedliquidis
drained.
6. Monitor the performance
of the valve accessories as it
hasa significanteffecton the
valveperformance.
7.1 Prevetive maintenance
1. It should be appreciated
thatduringplantstartups,
abnormaloperating
conditions can adversely
affecttheperformanceofthe
Control Valve and some times
severely damage the valve. It
is very important that these
abnormalconditionsbe
recognizedandtheControl
Valveisselectedtakinginto
account these conditions.
7.2 Shop overhaul
2. SHOP OVERHAUL
1. Valves and valve internal in
hazardousserviceshouldbe
cleanedthoroughlybefore
undertakinganyrepair.
Dependingoncontaminant,
waterwash,steamingor
specialheattreatmentmay
beresortedto.
2. Ensure that the person
whoisdisassemblingthe
ControlValveisthorough
withthereleventprocedure.
3. Before disassembly, mark
theActuatororientationwith
respect to the body flanges.
Maintenance.Beforestartup
6. If line trash like weld chips,

rust etc. are expected in the
pipeline,temporarystrainers
shouldbeinstalledupstream.
If the process stream
normally contains Scale, dirt
orotherforeignmaterial,itis
recommendedthat
permanentstrainersorfilters
beinstalled.Strainersshould
beinstalledfarenoughto
allownon-swirlflowatthe
valve inlet. Note that
strainersthatefficiently
protectthepumpmaynotbe
adequatewhenitcomesto
removingdebristhatcan
damagethevalveTrim.
4. Remove the bonnet from

thebody,andthenthegland
packingcomponents.
Further removetheTrimand
thebottomflange.
5. Disassemble the Actuator
andexaminecomponentsfor
damage.Afterwardsclean
thepartscarefully
6. Inspect the disassembled
componentsthoroughlyand
determinetheextentof
reconditioningandrepair
thatisrequired.
Continuedinfacingpage
CONTINUED FROM PREVIOUS PAGE
8. Air lines to be connected to

the Control Valves should be
blowncleanofoilanddebris
beforetheyareattached.
9. Avoid using Teflon tapes
ininstrumentairlines.While
Teflon tapeisanexcellent
threadlubricantandsealfor
screwed connections, it
neverthelesscanbreakoffin
small bits if not carefully
applied.Andthesebitsoften
migratetoorificesin
pneumatic accessories and
can clog them.
10. Do not start up a Control

7. Ensure that the air supply is Valvewithoutfirstchecking
thepackingtightness.
clean and devoid of oil.
ShopOverhaul
7. If the body is rusted,

descalethebody.While
handlingthebody, theflange
surfaces must be protected to
preventanygasketleakage.
12. Avoid use of non

standard Trims. These cannot
matchthemetallurgyand
workmanshipoffactory
finishedspares.
13. Reassemble the valve

bodyusingthereconditioned
/new parts. Ensure that gland
packingandgasketsare
changed every time the valve
isopenedandreassembled.
Use only OEM* gland
packing and gaskets. Low
quality gaskets can cause
9. The lapped contact should irreversibledamagetothe
not be too wide. If the contact valve by seat area Erosion,
bodybonnetErosionetc.
band is too wide, a machine
cuttorenewtheanglesofthe 14. While tightening the
mating pieces is necessary.
bonnetandbottomflanges,
Theanglesofthemating
itisimportanttotightenthe
piecesareslightlydifferentto diagonallyoppositeboltsto
allowanarrowseatingband. ensureevengasketloading.
10. For problems like marred Over tightening can cause
excessive elongation of the
stemsurface,replacement
with a factory finished stem is gasketstherebyresultingin
poorjoints.
theonlypracticalsolution.
The finish of the Control
15. Assemble parts of the
Valve stem is so fine that
Actuatorbarrel,installthe
highlypolishedsurfacesare
diaphragmcaseusingnew
requiredtogivethebest
cap screws and nuts, and
possible packing seal, and to
check for pneumatic leaks.
minimizethehysteresis.
16. Adjust the spring range
11. If the Trims are beyond
andstrokeoftheActuator.
repair,replacethemwith
17. Giving air supply to the
genuinespareparts.Valve
Trimsareamongstthemost
Actuator, keeptheActuator
precisionofinstrumentation
inmidstrokeandmountthe
components.
Actuatoronthevalvebody.
*Original Equipment Manufacturer
7.2 Shop overhaul
8. Assess the need for

remachiningofBodyand
Trims. First the plug and seat
shouldbeperfectlymatched,
by precise machining, then by
handgrindingorlapping.
Make sure that even fine
tracesoflappingcompound
is cleaned off.
ShopOverhaul
7.2 Shop overhaul
18. Tighten (finger tight) the

coupling.Applyairorremove
airtoensureproperseatingof
the valve. Then tighten the
couplingandadjustthetravel
indicator.
21. Carry out hydrotest, seat

leakagetestandcalibration
as per relevant standards.
22. When repair to an

existing valve is
uneconomical,replaceitwith
a new valve from a high19. Mount the accessories
back on to the Control Valve. quality OEM to avail of better
sizing,bettermaterials,
Several of the most common
betterdesign,andmostlikely,
accessories (Air Sets,
better service too. Process
Positioners, Transducers etc.)
conditionsshouldbe
haveRubberDiaphragms
stabilizedanddetermined
thatwillhardenandcrack.
accurately in case they were
Some have O Rings that
notcorrectlyanticipated
deteriorate.Itwouldbe
whentheoriginalvalve
economicaltoreplacethe
was specified.
whole accessory with spares
23. Do not buy valves or
(andrepairfaultymodels
replacementpartsfrom
duringslacktime)ratherthan
non OEMs. Overemphasis
repairing them On Site.
on short-term cost savings
20. Tubing connections for
cansometimesleadto
signalandoperatingair
hazardousworking
shouldbecheckedwith
environmentsforpersonnel,
processdowntimeand
soapywaterorotherleak
increased operating costs.
detectingfluids.
TheMILRange
HighperformanceControlValvesfor powerplants
MIL 21000
Rugged,heavytopGuided,single
seatedControlValves
For severe service, special double

stagevalveswithsimultaneous
throttlingintheplugandCage
alsoisavailable.
Quick Change Trim. Optional

clampedseatringfacilitateseasy
Trimremoval.
Angle Body (70000 Series).
Optionalanglebodydesignwith
Venturiseatisideallysuitedfor
specialapplicationslikeFlashing
liquidsandotherchokedflow
conditions.
Available Sizes & Rating

to 2
2: ANSI 150# to ANSI 2500#
3 to 1 0
0: ANSI 150# to ANSI 600#
SeatleakageclassasperANSI/FCI70.2
Standard:ClassIV.
Optional:ClassV&ClassVI
FEATURES
Heavy Top Guiding.The Valve

plugshankisGuidedwithinthe
lowerportionofthebonnet and
thisheavyandruggedguiding
ensuresplugstabilityand
eliminatesTrimvibration.
AntiCavitation/Low Noise Trims
replacingconventionalplug with
theLo-dBplugprovidesexcellent
noiseattenuationandCavitation
control.
8.1 MIL 21000 Series
Tight Shut-Off: Class IV leakage

isstandard.Optional
constructions meet Class V &
Class IV leakage.
MIL 41000
HeavyDutyCageGuided
ControlValves.
Standardisedhighperformance
material. Thisensurestrouble
freeoperationevenin
applicationswithinherenthigh
pressuredropsandextreme
temperatures.
Tight shut off valves. For lower

sizes,unbalanceddesignresults
in Class V leakage.
Forhighersizes,theexceptional
singleseatedleaktightnessof
Class V is achieved by the
followingspecialoptions:
1.Auxiliaryshut-offpilotplug
closesthebalancingholeslocated
inthemainpluginshut-off
conditions.

to 14: ANSI 1 50# to ANSI 2500#
20: ANSI 150# to ANSI 600#
16 to 20
SeatLeakageClassasperANSI/FCI70.2
Standard:ClassIII&ClassIV
Optional:ClassV
FEATURES
High allowable pressure drops.

Cage Guided valves provide
exceptionalperformanceovera
widerangeofpressuredropsin
severe services. They also handle
mostshutoffpressureswith
standardpneumaticspring
diaphragmActuators.
High capacity with low pressure
recovery.Flowcapacitiesremain
attoplevels,andareattained
withminimumpressurerecovery
reducingthepossibilityof
Cavitationinliquidservice.
2.Selfenergisedsealrings
pressingagainstwallsoftheCage
&Plugarrestsleakagepastthe
sealring.
Lo-dB/Anti-Cavitation Cages:
NoiseattenuationandCavitation
controlachievedbyreplacing
conventional Cages with Lo-dB
Cages.
SPECIAL
OPTIONS
Static Seal Ring, Double Cage design,

Two stage design with diffuser seat
ring, Multi-Stage Valves
MIL 41008 . These Multi-Stage valves
incorporateauniqueTrimdesignto
absorb high pressure drops that
prevent Cavitation and maintain
constantvelocitythroughoutthe
pressure dropping stages.
Concentric Cages incorporate a
tortuous flow path, which causes
numerous velocity head losses
withoutappreciablepressurerecovery.
High pressure recovery factors at lower
lifts eliminates Cavitation. High
impedance flow path reduces pressure
by friction and turbulence,
maintaining constant velocity
throughout.
MIL 78000
AntiCavitation&LowNoise
Multi-stepHighPressureDrop
ControlValves
High Noise Levels commonly

associatedwithconventionally
designedControlValves.
High allowable pressure drops.
Noindividualstageisexposedto
thefullpressuredrop,thus
extendingTrimlifesubstantially.
Low pressure recovery. This

minimisesCavitationpotential
andcontributestowards
reductionofNoiseforallfluids.
Pressure recovery factors as high
as 0.998.

to 6
6: ANSI 900# to ANSI 2500#
SeatleakageClassasperANSIIFCI70.2
Standard:ClassV
Optional:ClassVI
FEATURES
Multi Step Axial Flow High

Resistance Trim. Pressure
reductionoccursalongthelength
ofthepluginaseriesofthrottling
stages. The fluid also takes a
tortuousflowpath,whichadds
resistanceandthereforevelocity
headloss.
Thespecialdesignprovides
controlofhighpressurefluids
withouttheErosion,Vibrationor
Standardisedhighperformance
material:Toensurematerial
integrity, 78000 Series valves are
machinedfromsolidsteel
forging.HighperformanceTrim
materialensuresdurabilityinany
severeapplication.
Balanced Trims: Availablefor
sizes 2" and above, allow much
highershut-offpressureswith
conventionalActuators.
SPECIAL
OPTIONS.
Soft seat construction with

encapsulated inserts, Angle & Inline
bodyconfigurations.
Adiabatic Flow with Friction

Friction.
Reducespressuremuchinthe
same way as pressure loss
occurringinalongpipeline.
MIL 91000
MATRIX Series valves
ExtremePressureMulti-stage,Multi-path,AxialFlowAnti-Cavitation
HighPressureDropControlValves
FEATURES.
Varyingandexpandingflow
passage. This enables near Zero
Pressure Recovery thus ensuring
thatstagewisePressureDropsare
limitedbelowtheCriticalPressure
Drop.LikelihoodofCavitationis
ruledouteveninextreme
conditions.
Ingenious Flow Path. Reduces
downstreamVelocity.Exit
VelocityandKineticEnergykept
underlimits.Erosioneliminated.
Pressure recovery factor (Cf) as
high as 0.9999.
Flow to Open flow direction.

Eliminates DynamicInstability
inherent to Flow to Close valves.
TortuousflowpathwithHigh
Impedance forenergy
absorption limits Trim Velocity
Velocity.
Modified equal %
characteristics with 100 : 1
Rangeability. Characteristics can
be customised to suit specific
process applications.
Self energised body and seat
gaskets
gaskets. Ensures Zero Leak, and
optimisesbonnet/boltingdesign.
Ingenious design. Results in a

As many as 50 Pressure Dropping simplermanufacturingprocess.
stages.
Consequentlythismakes
MATRIXSeries Valvesbetter
Ruggedness of design. Ensures
pricedthanothervalvesinthis
longevityevenintheseverestof
league.
applications.
Axial Flow design. Eliminates
wiredrawingeffectsonthe
leadingedgesoftheplug.
SPECIAL
OPTIONS.
Available with Soft Seat with a special

sliding collar to protect the Soft Seat
from high pressure fluids.
MIListhefirstControlValvemanufacturerinIndiatohavebeenawardedtheprestigiousCEMarkingCertificatebyRWTUV,Germany.
INDEX
A
9.1 Index & List of Illustrations
Allowable working pressure 48
B
Block Valve 24
Body Material Specs 47
Boiler Feed Pump Min. Recirculation Valve 13, 17, 18
Boiler Feed Pump Minimum Recirculation System 17
Boiler Feed Water Startup Valve 13, 17
Boiler Main Feed Water Control Valve 13, 17
C
CE Marking 8, 71
Company overview 8
Condensate Recirculation Valve 13, 14
Condensate system 13, 14
Condenser 14
D
Deaerator 14, 15, 17
Deaerator Level Control Valve 13, 14, 15, 16
Deaerator Pegging Steam System 26
Deaerator Pegging Steam Valve 13, 22, 26, 27
E
Economisers 17
F
Feed Pump Recirculation 18
Feed Water Control 20
Feed Water Heaters 31
Feed Water Pumps 17
Feed Water Regulating System 20
Feed Water Regulator Valve 20
Feed Water System 13, 17
Foster Wheeler 8
Full Load Feed Water valve 20
G
General Boiler Flow Diagram 10
H
Handling and Installation 53
Heater Drain System 13, 31
Heater Drain Valve 31
High pressure heater drain valves. 13
HP Heaters 31
HP Heaters System 32, 55
L
Low Load Feed Water valve 20
Low pressure heater drain valves. 13
LP heaters 31
LP Heaters System 32
M
Main Steam Line 22
Main Steam Pressure Reducing Valve 22, 29, 30
Main Steam System 13, 22
Maintenance Guidelines 59
Martensitic Steel 15
Material Selection Guidelines 45, 47
MATRIX Series 8, 19, 70
MIL 21000 31, 67
MIL 41000 16, 21, 27, 31, 68
MIL 41003 27
MIL 41008 15, 21, 25
MIL 41100 23, 24
MIL 41114 28
MIL 41121 30
MIL 41128 25
MIL 41200 23, 24
MIL 41221 30
MIL 41400 24
MIL 41621 16
MIL 41912 30
MIL 41914 30
MIL 41921 16
MIL 70000 67
MIL 71114 28
MIL 78000 15, 18, 19, 25, 69
MIL 91000 19, 70
MIL Controls Limited 6, 8
Modulating Type System 18
O
On/Off System 18
Original Equipment Manufacturer 63
P
Positioner Gauges 56
PRDS Spray Control Valves 22
PRDS Station Valves 29
PRDS System Control Valves 22
PRDS System Valves 13
Pressure Reducing Desuperheating System 29
Preventive Maintenance 61
R
Reheater Attemperator Control Valve 25
Reheater Attemperator Spray Valve 13
Reheater Spray Block Valves 22
Reheater Spray Control Valves 22
Reheater System 22
Remachining 63
RWTUV 71
S
Shop Overhaul 62
Sliding Collar Seat Ring 19
Soot Blower 24, 27
Soot Blower Pressure Control Valves 22
Soot Blower Steam Pressure Reducing Valves. 13
Soot Blower Valve 27
Soot Blowing System 22
Soot Blowing Valves 27
Steam Ejectors 29
Steam Soot Blowers 27
Strainers 62
Super Heater Attemperator Valve 22, 23
Superheater Attemperator Block Valve 22, 24
Superheater Attemperator Spray Valve 13
Superheater Spray Control Valves 22
Superheater System 22
T
Teflon tapes 62
Temperature Control Valve(Spray water) 29
Trim material selection 51
Turbine Bypass Valves. 13
Typical Applications 116 MW 37
Typical Applications 210 MW 39
Typical Applications. 250 MW 41
Typical Applications. 500 MW 43
Typical Applications. 67.5 MW 35
U
Upstream Piping 57
ILLUSTRATIONS
Fig. 1. GeneralBoiler(Drumstyle)FlowDiagram 10
Fig. 2. CondensateSystem 14
Fig. 3. MIL 78000 15
Fig. 4. MIL 41000 16
Fig. 5. BoilerFeedPumpMin.RecirculationSystem 17
Fig. 6. MIL78000.FeedpumpMin.RecirculationValve 18
Fig. 7. MIL 91000 19
Fig. 8. FeedWaterRegulatingSystem. 20
Fig. 9. MIL 41008. Multi stage, Low Load Valve21
Fig. 10. CriticalControlValvesinMainSteamLine 22
Fig. 11. MIL41100.SuperheaterAttemperatorvalve 23
Fig. 12. MIL41200.SuperheaterAttemperatorvalve 23
Fig. 13. MIL41400.SuperheaterAttemperatorblock 24
Fig. 14. MIL78000.ReheaterAttemperatorControl 25
Fig. 15. MIL41008.ReheaterAttemperatorControl 25
Fig. 16. DeaeratorPeggingSteamSystem 26
Fig. 17. MIL 41003 27
Fig. 18. MIL 71114 28
Fig. 19. TypicalAuxiliaryPRDSSystem 29
Fig. 20. MIL 41914 30
Fig. 21. MIL 21000 31
Fig. 22. LP Heaters System 32
Fig. 23. HP Heaters System 32
Fig. 24. ClearancerequirementsforValves 55
Fig. 25. AlternateorientationsforControlValves 56
Fig. 26. Typicalsatisfactorypiping57
Fig. 27. Lesssatisfactoryarrangementofpiping57
Control Valves for Power Plants.

ApplicationHandbook
TheMILPowerPlantHandbookprovides
a broad overview of the various systems
in a Thermal Power Plant to help you
selecttherightvalveforeachapplication.
The handbook also offers expert tips for
proper Installation and Maintenance of
your Control valves.
Registered Office & Works.
Meladoor , Mala, PIN 680 741, Thrissur District, Kerala, India.
Tel: + 91 (0)488 890272, 890772, 891773. Fax: + 91 (0)488 890952.
Email: milf@vsnl.com
Marketing Head Office.
P. B. No. 04, Aluva, PIN 683 101, Ernakulam Dist, Kerala, India.
Tel: + 91 (0)484-624955, 624876, 628041. Fax: + 91 (0)484-623331.
Email: ksbmil@sancharnet.in
MIL CONTROLS LIMITED, 2002. All rights reserved
HB/Power/Rev-A/032002
A KSB Company

Power Plant Handbook

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Power Plant Handbook

Uploaded by

Copyright:

Available Formats

MIL Controls Limited

CONTROL VALVES FOR POWER PLANTS

MIL CONTROLS LIMITED, 2002. All rights reserved

MIL Controls Limited

1.1 Company overview................................................. 8

4.1 Typical applications. 67.5 MW ................................ 35

1.1 Company overview

CONTROL VALVES FOR POWER PLANTS

In May 2000, MIL achieved another milestone when it unveiled the

POWER PLANT APPLICATIONS

Extraordinary demands are placed on Control Valves

FIG. 1. GENERAL BOILER (DRUM STYLE) FLOW DIAGRAM

2. FEED WATER SYSTEM

3. MAIN STEAM SYSTEM

4. HEATER DRAIN SYSTEM

3.1 Major systems

The 4 major systems and critical valves .

3.2 Condensate system

3.2 Condensate system

CONTROL VALVES FOR POWER PLANTS

Fig. 2. Condensate System.

The Condensate Pump extracts

The Condensate Pump must

Fig. 3. MIL 78000 Series. Condensate

Inlet Pressure: 40- 45 bar( a)

The typical valves for such

3.2 Condensate system

3.2 Condensate system

CONTROL VALVES FOR POWER PLANTS

Fig. 4. MIL 41000. Deaerator level Control Valve.

Inlet Pressure: 20- 42 bar (a)

Inlet Pressure: 220-250 bar (a)

3.3 Feed Water system

Fig. 5. Boiler Feed Pump Minimum Recirculation System.

CONTROL VALVES FOR POWER PLANTS

3.3 Feed Water system

3. A third method employed by

Fig. 6. MIL 78000. Boiler feed pump

3.3 Feed Water system

In this context, the most cost

CONTROL VALVES FOR POWER PLANTS

3.3 Feed Water system

Fig. 8. Feed Water Regulating System.

Inlet Pressure: 170-200 bar (a)

Inlet Pressure : 220-250 bar (a)

3.3 Feed Water system

3.4 Main steam system

CONTROL VALVES FOR POWER PLANTS

Fig. 10. Critical Control Valves in Main Steam Line

Fig. 12. MIL 41200. Superheater Attemperator valve.

3.4 Main steam system

Fig. 11. MIL 41100. Superheater Attemperator valve.

CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system

Inlet Pressure:181-200 bar (a)

Fig. 13. MIL 41400. Superheater

For higher sizes (2 and above)

Fig. 15. MIL 41008. Reheater

3.4 Main steam system

Fig. 14. MIL 78000. Reheater

3.4 Main steam system

CONTROL VALVES FOR POWER PLANTS

Fig. 16. Deaerator Pegging Steam System.

Inlet Pressure: 16 bar (a)