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.thehandbookthusencapsulatesMIL’scontinuingfocusonthepowersector. Atasecondlevel,TheMILPowerPlantApplicationHandbook,alsoservesasaminicataloguefor MIL’s wide range of products. It offers specific data on Valve Selection and Operational Characteristics.
REFERENCE DOCUMENT: ISA HANDBOOK FOR CONTROL VALVES.

MIL Controls Limited 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 4.1 Typical applications. 67.5 MW ................................ 35 4.2 Typical applications. 116 MW ................................ 36 4.3 Typical applications. 210 MW ................................ 38 4.4 Typical applications. 250 MW ................................ 40 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

CONTROL VALVES FOR POWER PLANTS

1.1 Company overview

MIL Controls Limited. The factory premises at Meladoor near Cochin in Kerala

E

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 it’s 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 it’s 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.

APPLICATION HANDBOOK

POWER PLANT APPLICATIONS

Factorsdetermining selectionofValves.
Extraordinary demands are placed on Control Valves 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

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

Powerplantapplications
4 major systems, their characteristics and valves used in such applications.

APPLICATION HANDBOOK

3.1 Major systems

The 4 major systems and critical valves .
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.

CONTROL VALVES FOR POWER PLANTS

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.

3.2 Condensate system

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.

Condensate RecirculationValve

The Condensate Pump extracts theFeedWaterfromthe CondensateHotwelland dischargestotheDeaerator.

APPLICATION HANDBOOK

ThefunctionofthisControlValve istomaintain correctlevelsinthe Deaerator. TheDeaeratorisanopencontact typeFeedWaterHeaterwhich purgesanynoncondensableand dissolved gases. Also the Deaeratoractsas areservoirfor FeedWatertosmoothentheFeed Watersupplyatvaryingloads.
Fig. 3. MIL 78000 Series. Condensate Minimum Recirculation Valve. TYPICAL PARAMETERS

3.2 Condensate system

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.

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.

Theapparentlymildservice conditionsmisleadmanyControl Valvemanufacturersinthe design of valves for this service.

CONTROL VALVES FOR POWER PLANTS

3.2 Condensate system
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.

APPLICATION HANDBOOK

Fig. 5. Boiler Feed Pump Minimum Recirculation System.

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

CONTROL VALVES FOR POWER PLANTS

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.

3.3 Feed Water system

Fig. 6. MIL 78000. Boiler feed pump minimum Recirculation valve.

APPLICATION HANDBOOK

3.3 Feed Water system
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.

MIL’scontinuousresearchand 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.

CONTROL VALVES FOR POWER PLANTS

TheTrimcanbecustomizedto varioushighpressuredrop applicationsbyvaryingthe numberofstages. Thecharacteristiccanbe customizedbyreallocatingthe pressuredropratioindifferent stages. Theexpandingflow passagesalsoenhance the Rangeabilityallowingsmooth andpreciseFlowControlevenat lowliftoperatingflowconditions.
FeedWaterRegulatorValve

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

3.3 Feed Water system

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.

Inlet Pressure: 170-200 bar (a) Outlet Pressure: 30-110 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. 8. Feed Water Regulating System.

APPLICATION HANDBOOK

3.3 Feed Water system

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.

CONTROL VALVES FOR POWER PLANTS

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.

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.

SuperHeaterAttemperatorValve

Thetemperature ofthemain steamcomingoutoftheBoileris verycritical fromthepointof Thermodynamic Efficiencyofthe heatcycleandtheTurbineblade protection.

APPLICATION HANDBOOK

3.4 Main steam system

Fig. 11. MIL 41100. Superheater Attemperator valve.

Fig. 12. MIL 41200. Superheater Attemperator valve.

CONTROL VALVES FOR POWER PLANTS

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 Fig. 13. MIL 41400. Superheater Attemperator block valve.

3.4 Main steam system

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.

Inlet Pressure:181-200 bar (a) Outlet Pressure: 161-180 bar (a) Temperature: 247o C

APPLICATION HANDBOOK

3.4 Main steam system

Fig. 14. MIL 78000. Reheater Attemperator Control Valve.

Fig. 15. MIL 41008. Reheater Attemperator Control Valve.

ReheaterAttemperatorValves

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.

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.

CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system

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

APPLICATION HANDBOOK

SootBlowerValve

Fig. 17. MIL 41003. Deaerator pegging steam Control Valve

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.

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. 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

3.4 Main steam system

Inlet Pressure - 170 bar (a) Outlet Pressure - 20 bar (a) Temperature - 540o C

CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system
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 it’s 41114 Series (CageGuidedinlinebodywith doublestagepressuredrop),or it’s 71114 Series (Cage Guided anglebodywithdoublestage pressuredrop).Thebodyshallbe forgeddesignandchrome molybdenum steel (ASTM A 182 Gr. F22)

APPLICATION HANDBOOK

3.4 Main steam system

Fig. 19. Typical Auxiliary PRDS System

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

Inlet Pressure - 170 bar (a) Outlet Pressure - 16 bar (a) Temperature - 540o C

Inlet Pressure - 185 bar (a) Outlet Pressure - 16 bar (a) Temperature - 170o C

CONTROL VALVES FOR POWER PLANTS

3.4 Main steam 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.

APPLICATION HANDBOOK

Thecriticalfactorsthat influence theselectionofthevalvesare: Body andTrimmaterial,Valve sizeandValveflowcapacity Flashingproblemsencountered intheseservicescausematerial erosion. 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.

3.5 Heater drain system

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 it’s 21000 Series and the 4100 Series Valves for these applications. Thebodymaterialis either WC6 or WC9.

CONTROL VALVES FOR POWER PLANTS

3.5 Heater drain system

Fig. 22. LP Heaters System

Fig. 23. HP Heaters System

TypicalInstallations
Choosingtherightvalvemakesallthedifference

Capacity 67.5 MW
Project: TISCO 1X67.5MW Model 38-78101 38-41921 6x3 in. 90-41921 6x3 in. Project: TISCO 1X67.5MW Model 38-41024 38-414X1 38-78001 90-41024 2.5 in. 38-70571 38-70571 2 in. 2 in. 2 in. 1500 1500 2500 2500 2 in. 1500 2 in. 1500 WCC WCC A105 WCC F11 F22 Size Rating* Body Cv 8 40 4 20 6 10 1500 WC6 140 1500 WC6 140 3 in. 1500 F11 15 Size Rating* Body Cv Pr.
2

FEEDWATER CONTROL VALVES

Customer: BHEL Madras Temp.
0

No.

Tag

Service

Qty. 1 1
2 0

1

FW-5

LOW LOAD FEED WATER FLOW CONTROL

170 kg/cm2 2350C 170 kg/cm 235 C 170 kg/cm 235 C

2

FW-2

FULL LOAD FEED WATER FLOW CONTROL

3

FW-8

FULL LOAD FEED WATER FLOW CONTROL (BY-PASS)

1 Customer: BHEL Trichy Pr.
2

SPRAY & SOOT BLOWER VALVES

No.

Tag

Service

Temp. 185 kg/cm 250 C
0

Qty. 4 185 kg/cm 250 C
2 0

1

SD-5.SD-6

SH SPRAY CONTROL

2

SD-23

SH SPRAY BLOCK

2 110 kg/cm 350 C
2 0

3

SD-7

INTERMITTENT BLOWDOWN VALVE

2 186 kg/cm 242 C
2 0

4

S57. S69

SH SPRAY BYPASS VALVES

4 173 kg/cm2 4130C 110 kg/cm2 4200C 2 4 Customer:BHEL Madras

5

SB4

SOOT BLOWER STEAM PR.REDUCING VALVE

6

SD-8

SOOT BLOWER STEAM PR.REDUCING VALVE

APPLICATION HANDBOOK

PRDS VALVES Model

Project: TISCO 1X67.5MW Size Rating* 1500 38-41412 37-211X4 2 in. 2 in. 38-78101 1.5 in. 38-78101 1 in. 1500 1500 1500 1500 Body WC9 WC9 WCC A105 A105 Cv 120 12 15 1.2 0.3

No.

Tag

Service

Pr.
2

Temp. 100 kg/cm 520 C
0

Qty. 1 100 kg/cm 520 C
2 0

1

AS-9

HIGH CAPACITY STEAM PRESSURE REDUCING

38-41912 6x3 in.

2

AS-3

LOW CAPACITY STEAM PRESSURE REDUCING

1 185 kg/cm 175 C
2 0

3

BV-01

COMMON BLOCK VALVE FOR PRDS SPRAY

1 185 kg/cm 150 C
2 0

4

SW-10

HIGH CAPACITY SPRAY WATER CONTROL VALVE

1 185 kg/cm 150 C
2 0

5

SW-4

LOW CAPACITY SPRAY WATER CONTROL VALVE

1
* ANSI

4.1 Typical applications. 67.5 MW

4.2 Typical applications. 116 MW
Project: Ahemedabad Electricity Company. Model 38-41621 37-41612 38-78001 Project: Ahemedabad Electricity Company. Model 38-41412 37-211X5 38-41421 38-211X5 1 in. 600 8 in. 150 2 in. 600 WCC WCC WCC 6 in. 1500 WC6 Size Rating* Body Cv 145 46 640 3.8 2 in. 900 A105 4 3 in. 900 WC6 95 2 in. 300 WCC 26 15 kg/cm
2 2

Capacity 116 MW
Customer: BHEL Bangalore Cv Pr. Temp. 121 C
0 o

FEED CONTROL VALVES Size Rating* Body

No.

Tag

Service

Qty. 2 2

1

CV-5.6

FEED REGULATING VALVE IN HP BFP DISCH.LINE

2

CV-7.8

FEED REGULATING VALVE IN HP BFP DISCH.LINE (FULL LOAD)

115 kg/cm 121 C 115 kg/cm 120 C
2 o

3

CV-9.10

FEED REGULATING VALVE IN HP BFP DISCH.LINE (LOW LOAD)

2 Customer:BHEL Bangalore Pr. 70 kg/cm
2

SPRAY VALVES

No.

Tag

Service

Temp. 480 C
o

Qty. 2 13 kg/cm 7 kg/cm
2 2

1

CV-11.12

HP STEAM BYPASS VALVES

2

CV-13.14

HP BYPASS SPRAY VALVES

50 C
o

2 147 C
o

3

CV-15.16

LP STEAM BYPASS VALVES

2 13 kg/cm
2

4

CV-17.1

LP BYPASS SPRAY VALVES

50 C
o

2 Customer:BHEL Bangalore

PRDS VALVES Model 38-41412 38-78003 Size 2 in. 1 in.

Project: Ahemedabad Electricity Company. Rating* 1500 900 Body WC6 A105 Cv 30 0.3

No.

Tag

Service

Pr. 70 kg/cm
2 2

Temp. 480 C
o

Qty. 1 119 kg/cm 121 C
o

1

CV-23

PRDS PR. REDUCING VALVE IN HP STEAM LINE TO AUX.HDR.

CONTROL VALVES FOR POWER PLANTS

2

CV-24

PRDS SPRAY CONTROL VALVE

1

* ANSI

Capacity 116 MW
Project: Ahemedabad Electricity Company. Model 37-78003 1.5 in. 37-211X5 Project: Ahemedabad Electricity Company. Model 38-41621 37-41612 37-41621 38-414X1 38-41621 38-41621 37-41621 37-21125 38-21125 4 in. 1 in. 2 in. 8 in. 3 in. 3 in. 150 150 150 300 600 600 2 in. 300 2 in. 300 WCC WCC WCC WCC WCC WCC CF8M CF8M 6 in. 300 WCC Size Rating* Body Cv 360 25 65 155 95 500 225 6 46 1in. 600 WCC 3.8 900 A105 4.5
2

FEED PUMP RECIRCULATION VALVES Size Rating* Body Cv Pr.

Customer: BHEL Bangalore Temp.
o

No.

Tag

Service

Qty. 3
2

1

CV-25.26.27

RECIRCULATION VALVE FOR HP BFP

115 kg/cm 122 C 18 kg/cm Pr. 13 kg/cm2 13 kg/cm
2

2

CV-28.29.30

RECIRCULATION VALVE FOR LP BFP

122 C
o

3 Customer:BHEL Bangalore Temp. 48oC 48 C
o

HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES

No.

Tag

Service

Qty. 1 1 13 kg/cm 7 kg/cm
2 2

1

CV-1

MAIN CONDENSATE CONTROL VALVE

2

CV-2

MIN. FLOW RECIRCULATION CONTROL VALVE

3

CV-3

EXCESS RETURN CONTROL VALVE

48 C
o

1 120 C
o

4

CV-4

DEAERATOR OVERFLOW TO DM STORAGE TANK

1 7 kg/cm
2

5

CV-19

PRESSURE REDUCING VALVE TO DEAERATOR

147 C
o

1 7 kg/cm
2

6

CV-20

PRESSURE REDUCING VALVE TO DEAERATOR

147 C
o

1 13 kg/cm
2

7

CV-21.22

PREHEATER INLET CONTROL VALVE

118 C
o

2 10 kg/cm2 10 kg/cm2 40oC 40oC 1 1

APPLICATION HANDBOOK

8

CV-31

NORMAL MAKE-UP VALVE

9

CV-32

DUMP MAKE-UP VALVE

* ANSI

4.2 Typical applications. 116 MW

4.3 Typical applications. 210 MW
Project : Raichur TPS Unit IV Model 38-41921 12x8 in. 38-41412 6x4 in. 2500 WC6 Project : Unchahar TPS 2x210 MW Model 38-410X4 6x4 in. 38-41024 2.5 in. 38-410X4 2.5 in. 38-41024 1.5 in. 38-410X4 2.5 in. 38-410X4 1.5 in. 38-78103 1.5 in. 38-41012 Model 2 in. Size 2500 2500 2500 2500 Rating* 2500SPL 38-41012 2 in. 38-78102 1.5 in. 38-78101 37-211X4 1 in. 2 in. 2500SPL 2500 2500 2500 2500 2500 WCC WCC WCC WCC A105 F11 Body WC9 WC9 A105 A105 WCC 2500 WCC 2500 WCC 195 30 60 3.8 60 40 3.6 25 Cv 50 6 2.4 0.3 15 Size Rating* Body Cv 45 2500 WC6 575
2

Capacity 210MW
Customer: BHEL Madras Body Cv Pr. Temp.
o

FEED CONTROL VALVES Size Rating*

No.

Tag

Service

Qty. 2

1

FW-FCV-1

FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS)

286 kg/cm 250 C
2 o

2 FW-FCV-2 LOW LOAD FEED WATER FLOW CONTROL SPRAY & SOOT BLOWER VALVES

1 285 kg/cm 250 C Customer:BHEL Trichy Pr.
2

No.

Tag

Service

Temp. 265 kg/cm 260 C
o

Qty. 2 265 kg/cm 260 C
2 o

1

SD-4

SH STAGE I BLOCK

2

SD-5.6.7.8

SH STAGE I CONTROL

8 265 kg/cm 260 C
2 o

3

SD-9

SH STAGE I I BLOCK

2 265 kg/cm 260 C
2 o

4

SD-10.11.12.13

SH STAGE II CONTROL

8 265 kg/cm2 260oC 265 kg/cm2 260oC 265 kg/cm 260 C
2 o

5

SD-14

RH BLOCK COMMON

2 8 8 185 kg/cm 440 C
2 o

6

SD-15.16.17.18

RH BLOCK BRANCH

7

SD-19.20.21.22

RH CONTROL

8

PCV-8502A.B

SOOT BLOWER STEAM PR.REDUCING VALVE

4 Customer:BHEL Madras Pr. Temp. 165 kg/cm2 540oC 165 kg/cm2 540oC 286 kg/cm2 250oC 286 kg/cm2 250oC 286 kg/cm 250 C
2 o

PRDS VALVES

Project : Raichur TPS. Unit IV

CONTROL VALVES FOR POWER PLANTS

No.

Tag

Service

Qty. 1 1 1 1 1
* ANSI

1

MSPCV-1

AUX.PRDS 100%STEAM PR. CONTROL VALVE

38-41412 6x3 in.

2

MSPCV-2

AUX.PRDS 10%STEAM PR. CONTROL VALVE

3

SPTCV-1

AUX.PRDS 100%SPRAY FLOW CONTROL VALVE

4

SPTCV-2

AUX.PRDS 10%SPRAY FLOW CONTROL VALVE

5

V2505111

BLOCK VALVE ON SPRAY WATER TO AUX. PRDS

Capacity 210 MW
Project : Ropar TPS Model 37-78103 4x2 in.
2

FEED PUMP RECIRCULATION VALVES Size 2500 Rating* 300 600 600 600 600 300 300 300 300 300 8 in. 10 in. 10 in. 38-41612 6x4 in. 37-78003 37-211X5 37-41611 37-41611 6 in. 1 in. 2 in. 3 in. 38-41621 1.5 in. 300 300 300 300 300 300 300 300 300 WC6 WC6 WC6 WCC WCC WCC WCC WCC WCC WCC A105 WCC CF8M CF8M WCC WC6 WC6 WCC 430 56 56 56 90 90 140 225 575 575 1000 900 145 70 12 30 60 14 WCC 300 Body Cv Pr. 20 kg/cm
2

Customer: BHEL Hyderabad Rating* A105 15
o

No. Project : Vijayawada TPS Stage II Unit V&VI Model 38-41912 38-41912 38-41321 38-41321 38-41321 38-41321 38-41321 38-41621 37-41621 38-41621 37-41621 38-416X1 38-41621 4 in. 8 in. 3 in. 4 in. 4 in. 3 in. 3 in. 3 in. 10 in. 6 in. Size

Tag

Service

Body

Cv

Pr.

Temp.

Qty. 2

1

FEED PUMP MINIMUM RECIRCULATION

260 kg/cm 250 C Temp. 230 C
o

HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES

Customer:BHEL Delhi Qty. 2 48 kg/cm
2

No.

Tag

Service

1

PAS-1

PEGG. STEAM FROM AUX. STEAM HEADER TO DEAERATOR

2

PCR-1

PEGG. STEAM FROM CRH TO DEAERATOR

350 C
o

2 48 kg/cm
2

3

DR-2

HPH-6 NORMAL DRAIN TO HPH-5

215 C
o

2 48 kg/cm2 215oC 48 kg/cm2 215oC 20 kg/cm
2

4

DR-6

HPH-6 NORMAL DRAIN TO DEAERATOR

2 2 180 C
o

5

DR-9

HPH-6 NORMAL DRAIN TO FLASH BOX-2

6

DR-12

HPH-5 NORMAL DRAIN TO DEAERATOR

2 20 kg/cm 8 kg/cm
2 2

7

DR-15

HPH-5 NORMAL DRAIN TO FLASH BOX-2

180 C
o

2 130 C
o

8

DR-17

LPH-3 NORMAL DRAIN TO LPH-2

2 8 kg/cm
2

9

DR-20

LPH-5 NORMAL DRAIN TO FLASH BOX-1

130 C
o

APPLICATION HANDBOOK

10

DR-22

LPH-2 DRAIN TO LPH-1

8 kg/cm

2

100oC 8 kg/cm2 11 kg/cm
2

2 100oC 170 C
o

11

DR-25

LPH-2 DRAIN TO FLASH BOX-1

2 2 25 kg/cm
2

12

DR-41

DEAERATOR OVERFLOW TO DRAIN TANK

13

CD-14

MAIN CONDENSATE

55 C
o

2 25 kg/cm
2

14

CD-23

CONDENSATE EXCESS RETURN

55 C
o

2 25 kg/cm2 25 kg/cm2 10 kg/cm
2

15

CD-19

CONDENSATE MINIMUM RECIRCULATION

55oC 55oC 50 C
o

2 2 2 10 kg/cm
2

16

CD-78

HP DRAINS MANIFOLD SPRAY

17

DM-1

DM MAKE-UP TO HOTWELL (LC)

18

DM-2

DM MAKE-UP TO HOTWELL (HC)

50 C
o

2 25 kg/cm
2

19

CD-47

CONDENSATE FOR VALVE GLAND SEALING

55 C
o

2

4.3 Typical applications. 210 MW

4.4 Typical applications. 250 MW
Project : CESC Budge Budge TPS. 2*250 MW Model 38-41921 14x10in. 38-41921 6x4in. Project : BSES DAHANU 2x250 MW Model 38-414X1 38-41024 38-414X1 38-41024 38-414X1 38-211X4 38-78003 38-70571 Model 38-78002 38-41024 38-41012 38-78001 38-78001 2in. Size 1.5in. 1.5in. 2.5in. 1in. 1in. 2in. 2in. 3in. 2500 2500 2500 2500 Rating* 2500SPL 2500SPL 2500 600 2500 2500 1.5in. 2500 3in. 2500 WC6 WC6 WC6 WC6 F11 F22 Body WC9 A105 WCC WCC A105 A105 2.5in. 2500 WC6 6in. 2500 WC6 240 30 75 8 30 15 3.5 13 Cv 110 2.4 6 20 0.3 0.3 Size Rating* Body Cv 2500 WC6 225 2500 WC6 900
2

Capacity 250 MW
Customer: BHEL Delhi Pr. Temp.
o

FEED CONTROL VALVES Size Rating* Body Cv

No.

Tag

Service

Qty. 4

1

0728.1&2

FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS)

330 kg/cm 248 C 330 kg/cm 248 C
2 o

2

728.3

LOW LOAD FEED WATER FLOW CONTROL

2 Customer:BHEL Trichy Pr.
2

SPRAY & SOOT BLOWER VALVES

No.

Tag

Service

Temp. 262 kg/cm 260 C
o

Qty. 2 182 kg/cm 260 C
2 o

1

SD-4

SH SPRAY STAGE I BLOCK

2

SD-5 TO SD-8

SH STAGE I SPRAY CONTROL

8 262 kg/cm 350 C
2 o

3

SD-9

SH STAGE II SPRAY BLOCK

2 182 kg/cm 350 C
2 o

4

SD-10 TO SD-13

SH STAGE II SPRAY CONTROL

8 282 kg/cm 350 C
2 o

5

SD-14

RH SPRAY MAIN BLOCK

2 282 kg/cm 350 C
2 o

6

SD-15 TO SD-18

RH BRANCH BLOCK

8 182 kg/cm2 350oC 182 kg/cm2 450oC Pr.
2

7

SD-19 TO SD-22

RH SPRAY CONTROL

8 2 Customer:BHEL Bangalore Temp. 169 kg/cm 545 C
o

8

SD-23

SOOT BLOWER STEAM PR.REDUCING VALVE

PRDS VALVES

Project : BSES DAHANU 2x250 MW 38-41412 6x4in.

CONTROL VALVES FOR POWER PLANTS

No.

Tag

Service

Qty. 2 267 kg/cm2 170oC 267 kg/cm2 170oC 48 kg/cm2 360oC 267 kg/cm 170 C
2 o

1

AS-22

MS PRDS STEAM CONTROL

2

FD-22

MS PRDS SPRAY CONTROL

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

3

FD-23

MS PRDS SPRAY CONTROL

4

AS-32

CRH STEAM PRDS

5

FD-29

CRH PRDS SPRAY CONTROL

6

FD-30

CRH PRDS SPRAY CONTROL

2

Capacity 250 MW
Project : Kothagudem TPS, 2*250 MW 37-78103 4x2 in. Project : Kothagudem TPS, 2*250 MW 38-41912 38-41912 38-41521 38-41921 37-41921 38-41521 37-41921 38-41521 37-41621 38-41521 37-41621 38-419X1 38-41521 37-78003 8 in. 8 in. 3 in. 12 in. 3 in. 38-41612 6x3 in. 37-211X5 37-41612 37-41512 37-41612 1 in. 3 in. 3 in. 4 in. 4 in. 4 in. 150 150 150 150 300 300 600 300 300 150 300 150 4 in. 300 4 in. 300 3 in. 600 WC6 WC6 WC6 WCC WCC WCC WCC WCC WCC A105 WCC WCC WCC CF8M CF8M 3 in. 600 WC6 3 in. 600 WC6 50 50 56 120 120 170 170 575 575 100 900 45 95 1,7 95 45 120 10 in. 600 WCC 500 8 in. 300 WCC 315 2500 A105 15 Customer: BHEL Hyderabad 260 kg/cm2 250oC Customer: BHEL Delhi 14 kg/cm2 220oC 48 kg/cm
2

FEED PUMP RECIRCULATION VALVES

1

FEED PUMP MINIMUM RECIRCULATION

2

HEATER DRAIN & CONDENSATE SYSTEM VALVES

1

AS-2

PEGG. STEAM FROM AUX. STEAM HEADER TO DEAERATOR

2 360 C
o

2

CRH-2

PEGG. STEAM FROM CRH TO DEAERATOR

2 48 kg/cm
2

3

DR-2

HPH-6 NORMAL DRAIN TO HPH-5

215 C
o

2 48 kg/cm2 215oC 48 kg/cm2 215oC 20 kg/cm2 175oC 20 kg/cm2 175oC 8 kg/cm2 8 kg/cm2 8 kg/cm2 8 kg/cm2 11 kg/cm
2

4

DR-6

HPH-6 ALT. DRAIN TO DEAERATOR

2 2 2 2 130oC 130oC 105oC 105oC 170 C
o

5

DR-9

HPH-6 ALT. DRAIN TO HP FLASH TANK

6

DR-13

HPH-5 NORMAL DRAIN TO DEAERATOR

7

DR-16

HPH-5 ALT. DRAIN TO HP FLASH TANK

8

DR-19

LPH-3 NORMAL DRAIN TO LPH-2

2 2 2 2 2 27 kg/cm
2

9

DR-22

LPH-3 ALT. DRAIN TO LP FLASH TANK

10

DR-25

LPH-2 NORMAL DRAIN TO LPH-1

APPLICATION HANDBOOK

11

DR-28

LPH-2 ALT. DRAIN TO LP FLASH TANK

12

DR-38

DEAERATOR OVERFLOW TO LP FLASH TANK

13

CD-14&CD-17

MAIN CONDENSATE CONTROL

55 C
o

4 27 kg/cm
2

14

CD-25

CONDENSATE EXCESS PUMP MIN. RECIRCULATION

55 C
o

2 27 kg/cm
2

15

CD-21

EXCESS CONDENSATE DUMP CONTROL

55 C
o

2 30 kg/cm 8 kg/cm
2 2

16

CD-53

HP DRAINS FLASH TANK SPRAY

55 C
o

2 55 C
o

17

CD-58

EMERGENCY MAKE-UP TO CONDENSATE HOTWELL

2 8 kg/cm
2

18

DM-2 (LOW)

DM MAKE-UP TO HOTWELL (LC)

40 C
o

2 8 kg/cm
2

19

DM-5 (HIGH)

DM MAKE-UP TO HOTWELL (HC)

40 C
o

2

4.4 Typical applications. 250 MW

4.5 Typical applications. 500 MW
Project :NTPC Talcher TPS 2x500 MW STPP Model 37-41512 12x8 in. Project : NTPC Vindhyachal TPS 2x500 MW STPP Model 38-414X1 38-41621 4x3 in. 38-414X1 4x3 in. 38-414X1 38-41024 2.5 in. 38-41012 4x2 in. 2500 2500 3 in. 2500 WCC WCC F11 2500 WCC 2500 WCC 26 155 75 12 25 8 in. 2500 WCC 380 Size Rating* Body Cv Pr. 2500 C5 475
2

Capacity 500 MW
Customer: Keltron Controls Cv Pr. Temp.
o

FEED CONTROL VALVES Size Rating* Body

No.

Tag

Service

Qty. 2 Temp. Qty.

1

FCV-0657

LOW LOAD FEED WATER FLOW CONTROL

360 kg/cm 200 C

SPRAY & SOOT BLOWER VALVES

Customer:BHEL Trichy

No.

Tag

Service

1

SD-10

SH SPRAY BLOCK

340 kg/cm2 260oC 340 kg/cm2 260oC 340 kg/cm 260 C
2 o

2 8 2 340 kg/cm 260 C
2 o

2

SD-11 TO SD-14

SH SPRAY CONTROL

3

SD-15

RH SPRAY BLOCK

4

SD-16 TO SD-19

RH BRANCH BLOCK VALVE

8 340 kg/cm 260 C
2 o

5

SD-20 TO SD-23

RH SPRAY CONTROL

8 213 kg/cm 482 C
2 o

6

SD-24

SOOT BLOWER STEAM PR.REDUCING VALVE

4 Customer:Keltron Controls

HEATER DRAIN & CONDENSATE SYSTEM VALVES Model 37-41512 38-41512 37-78103 38-41521 38-41612 37-41621 Size 12 in. 16 in. 4 in. 10 in. 8 in. 4 in.

Project : NTPC Talcher TPS 2x500 MW STPP Rating* 300 600 600 300 300 300 Body WCC WC6 A105 WCC WC6 CF8M Cv 725 1200 55 900 315 140

No.

Tag

Service

Pr. 20 kg/cm
2

Temp. 295 C
o

Qty. 2 57 kg/cm
2

1

PCV-0326A

AUX. STEAM TO DEAERATOR

2

PCV-0326B

CRH FLOW TO DEAERATOR

410 C
o

2 47 kg/cm2 47 kg/cm2 47 kg/cm2 10 kg/cm
2

CONTROL VALVES FOR POWER PLANTS

3 FCV-01514/0519/0524

CONDENSATE PUMPS A.B.C MINIMUM FLOW RECIRCULATION

47oC 47oC 50oC 40 C
o

6 4 2 2

4

FCV-0559A/B

CONDENSATE FLOW TO DEAERATOR

5

LCV-0507

CONDENSATE SPILL TO CONDENSATE STORAGE TANK

6

LCV-0508

CONDENSATE NORMAL MAKE-UP

* ANSI

Capacity 500 MW
Project : NTPC Talcher TPS 2x500 MW STPP Model 38-41621 37-78103 38-41512 37-78103 38-41512 38-78103 38-41511 37-41611 38-41511 37-41611 37-41511 37-41611 37-41612 37-41521 8 in. 8 in. 2 in. 12 in. 37-41621 1.5 in. 6 in. 6 in. 3 in. 300 300 300 300 300 300 150 300 3 in. 300 4 in. 600 C5 WC6 C5 WC6 C5 WC6 C5 WC6 CF8M CF8M 3 in. 300 WC6 4 in. 600 C5 55 60 55 155 155 400 400 640 640 12 1660 35 Project : NTPC Vindhyachal TPS 2x500 MW STPP Model 38-41921 38-41321 Size 8 in. 4 in. Rating* 300 300 Body WCC WCC Cv 575 200 3 in. 600 WC6 45 4 in. 600 WC6 55 8 in. 150 CF8M 575 10 kg/cm
2 2

HEATER DRAIN & CONDENSATE SYSTEM VALVES Size Rating* Body Cv Pr.

Customer:Keltron Controls Temp. 40 C
o

No.

Tag

Service

Qty. 2 50 C
o

7

LCV-0509

CONDENSATE EMERGENCY MAKE-UP

8

LCV-0526

GSC MAIN FLOW

47 kg/cm

2 57 kg/cm2 230oC 57 kg/cm2 240oC 34 kg/cm2 190oC 34 kg/cm 4 kg/cm
2 2

9 1-HDH-LCV-0701/23

HP HEATER 6A & B NORMAL LEVEL

4 4 4 190 C
o

10

LCV-0703/0722

HP HEATER 6A & B EMERGENCY LEVEL

11 1-HDH-LCV-0712/34

HP HEATER 5A & B NORMAL LEVEL

12

LCV-0714/0736

HP HEATER 5A & B EMERGENCY LEVEL

4 110 C
o

13 1-HDL-LCV-0746A

LP HEATER 3 NORMAL LEVEL

2 4 kg/cm
2

14

1-HDL-LCV-0746B

LP HEATER 3 EMERGENCY LEVEL

110 C
o

2 3 kg/cm
2

15 1-HDL-LCV-0757A

LP HEATER 2 NORMAL LEVEL

90 C
o

2 3 kg/cm
2

16

1-HDL-LCV-0757B

LP HEATER 2 EMERGENCY LEVEL

90 C
o

2 3 kg/cm
2

17

1-HDL-LCV-0722

LP HEATER 1 NORMAL LEVEL

60 C
o

2 3 kg/cm2 47 kg/cm
2

APPLICATION HANDBOOK

18

1-HDL-LCV-0768

LP HEATER 1 EMERGENCY LEVEL

60oC 50 C
o

2 2 10 kg/cm
2

19

1-CO-PCV-0530

VALVE GLAND SEALING PRESSURE CONTROL

20

FCW-PCV-8701

EQUIPMENT COOLING WATER DIFFERENTIAL PR. CONTROL

40 C
o

2 10 kg/cm2 46oC 2 Customer:BHEL Trichy Pr. 20 kg/cm
2

21

LCV-8701

DM WATER OVERHEAD LEVEL CONTROL

SCAPH CONTROL VALVES

No.

Tag

Service

Temp. 250 C
o

Qty. 4 20 kg/cm
2

1

ASS-2 TO ASS-7

SECONDARY SCAPH

2

ASS-20 TO ASS-25

PRIMARY SCAPH

250 C
o

4
* ANSI

4.5 Typical applications. 500 MW

MaterialselectionGuidelines
StandardisedMaterialsforhighperformance

APPLICATION HANDBOOK

MATERIAL SELECTION

Correctmaterialselectionisextremelyimportanttoensure properfunctioningandlongevityofControlValvesinPower Plantapplications.Theserviceconditionsvarywidelyin pressureandtemperatures,designpressurecangoupashigh as360kg/cm2 andtemperaturesupto566oC.TheBodyand Trimmaterialselectionshouldalsotakeintoaccountthe detrimentaleffectsofCavitation/Flashing/HighVelocity whichareinherenttosuchsevereapplications.
CONTROL VALVE. PRESSURE CONTAINING MATERIAL
General Classification Carbon Steel Alloy Steel, 1 ¼ Cr - ½ Mo Alloy Steel, 2 ¼ Cr - 1 Mo Alloy Steel, 5 Cr - ½ Mo Stainless Steel, Ty. 316 Castings ASTM A 216 Gr. WCB / WCC ASTM A 217 Gr. WC6 ASTM A 217 Gr. WC9 ASTM A 217 Gr. C5 ASTM A 351 Gr. CF8M Forgings ASTM A 105 ASTM A 182 Gr. F11 ASTM A 182 Gr. F22 ASTM A 182 Gr. F5a ASTM A 182 Gr. F316 Max. Operating Temp. 427ºC 566ºC 566ºC 566ºC 566ºC

5.1 Body material specs

PRESSURE RATING. CEILING VALUES *
Temp. 150#ANSI 300#ANSI 600#ANSI 900#ANSI 1500#ANSI 2500#ANSI

< 93ºC 149ºC 204ºC 260ºC 316ºC 371ºC 427ºC 482ºC 538ºC 593ºC

18.3 16.2 14.1 12.0 9.8 7.7 5.6 3.5 1.4 0.0

52.7 51.3 49.6 46.8 42.5 40.1 35.9 31.6 25.7 22.9
2

105.5 102.3 99.1 93.5 85.1 79.8 71.4 63.3 51.0 45.3

158.2 153.6 148.7 140.3 127.6 119.9 107.2 94.9 76.6 67.8

263.7 255.9 248.2 233.8 212.7 199.7 178.6 157.8 128.0 113.2

439.4 426.8 413.4 389.5 354.4 332.6 297.4 263.3 213.0 188.8

* 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.

CONTROL VALVES FOR POWER PLANTS

Allowable working pressure for ASTM A 216 Gr. WCC

5.2 Allowable working pressure

Allowable working pressure (Kg/cm2)

Operating temperature (oC)

APPLICATION HANDBOOK

Allowable working pressure for ASTM A 217 Gr. WC6

5.2 Allowable working pressure

Allowable working pressure (Kg/cm2)

Operating temperature (oC)

CONTROL VALVES FOR POWER PLANTS

Allowable working pressure for ASTM A 217 Gr. WC9

5.2 Allowable working pressure

Allowable working pressure (Kg/cm2)

Operating temperature (oC)

GENERAL CLASSIFICATION. 593ºC 14 HRC max. Non-Erosive, Corrosive,Mod. Press. Drop. Most corrosion resistant of 300 Series Corrosive & Non- Corrosive Service Erosive & Non- Corrosive Service Slightly Erosive & Corrosive Service Erosive & Corrosive Service Erosive & Corrosive Service. Corrosion resistance similar to Inconel Erosive & Corrosive Service. Corrosion resistance similar to Inconel Erosive & Corrosive Service

ASTM CODE

MAX. TEMP.

HARDNESS

GENERAL APPLICATION

GENERAL SERVICE

SS 316

Bar Stock: ASTM A 479Ty. 316 Castings: ASTM A 351 Gr. CF8M 400ºC 400ºC 650ºC 650ºC 650ºC 650ºC 400ºC 650ºC 28 HRC min. afterNitriding) 400ºC 58 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.

TOUGH SERVICE

Ty. 410 Stainless Steel (Hardened&Tempered)

Bar Stock: ASTM A 479 Ty. 410

Ty. 416 Stainless Steel (Hardened&Tempered)

Bar Stock: ASTM A 582 Ty. 416

No.6 Stellite Hard Facing

NA

No.6 Stellite Solid (< 2”)

NA

No.5 Colmonoy Hard Facing

NA

No.6 Colmonoy Hard Facing

NA

17.4 PH Stainless Steel

Bar Stock: ASTM A 564 Gr. 630 Castings: ASTM A 747 CB7CU1

APPLICATION HANDBOOK

CA6NM Stainless Steel

Casting: ASTM A743 Gr. CA6NM (HeatTreated)

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

Ty. 440C Stainless Steel

Bar Stock: ASTM A276 Ty.440C

5.3 Trim material selection

HandlingandInstallation
A list of safe practices

APPLICATION HANDBOOK

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.

CONTROL VALVES FOR POWER PLANTS

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 withtheValve’sFlow 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.

APPLICATION HANDBOOK

6.1 Handling & Installation

Fig. 26. Typical satisfactory arrangement of upstream and downstream piping

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 80ºC) where a valve is located, the valve and accessory manufacturersshouldbeconsultedforproper,high temperaturereplacementmaterial.

MaintenanceGuidelines
Howtoensurepeakperformance of Control Valves in power plant applications

APPLICATION HANDBOOK

1. PREVENTIVE MAINTENANCE
BEFORE START-UP

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. 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.
AFTER

3. Ensure that the recommendedmounting orientationisfollowed.If a valve is mounted with it’s stemtravellinginthe horizontalplane,itmustbe properlysupported. 4. Ensure that the mandatory ‘flowthrough’direction indicatedontheControl Valve (by an arrow mark) is alwaysfollowed. 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.
Continuedinnextpage
START-UP

7.1 Prevetive maintenance

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. 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.

CONTROL VALVES FOR POWER PLANTS

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

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

7.2 Shop overhaul

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.

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.

APPLICATION HANDBOOK

ShopOverhaul

CONTINUED FROM PREVIOUS PAGE

7. If the body is rusted, descalethebody.While handlingthebody, theflange surfaces must be protected to preventanygasketleakage. 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.

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

CONTROL VALVES FOR POWER PLANTS

ShopOverhaul

CONTINUED FROM PREVIOUS PAGE

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 Several of the most common sizing,bettermaterials, 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.

7.2 Shop overhaul

TheMILRange
HighperformanceControlValvesfor powerplants

APPLICATION HANDBOOK

MIL 21000
Rugged,heavytopGuided,single seatedControlValves

For severe service, special double stagevalveswithsimultaneous throttlingintheplugandCage alsoisavailable. Tight Shut-Off: Class IV leakage isstandard.Optional constructions meet Class V & Class IV leakage. Quick Change Trim. Optional clampedseatringfacilitateseasy Trimremoval. Angle Body (70000 Series). Optionalanglebodydesignwith Venturiseatisideallysuitedfor specialapplicationslikeFlashing liquidsandotherchokedflow conditions.

8.1 MIL 21000 Series

Available Sizes & Rating 2”: ½” to 2” ANSI 150# to ANSI 2500# 0”: 3” to 1 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.

CONTROL VALVES FOR POWER PLANTS

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. 2.Selfenergisedsealrings pressingagainstwallsoftheCage &Plugarrestsleakagepastthe sealring. Lo-dB/Anti-Cavitation Cages: NoiseattenuationandCavitation controlachievedbyreplacing conventional Cages with Lo-dB Cages.
SPECIAL OPTIONS

8.2 MIL 41000 Series
Available Sizes & Rating ¾” to 14”: ANSI 1 50# to ANSI 2500# 20”: 16” to 20” ANSI 150# to ANSI 600# 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.

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.

APPLICATION HANDBOOK

MIL 78000
AntiCavitation&LowNoise Multi-stepHighPressureDrop ControlValves

High Noise Levels commonly associatedwithconventionally designedControlValves. High allowable pressure drops. Noindividualstageisexposedto thefullpressuredrop,thus extendingTrimlifesubstantially. Friction. Adiabatic Flow with Friction Reducespressuremuchinthe same way as pressure loss occurringinalongpipeline. Low pressure recovery. This minimisesCavitationpotential andcontributestowards reductionofNoiseforallfluids. Pressure recovery factors as high as 0.998. 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.

8.3 MIL 78000 Series

Available Sizes & Rating 6”: ½” to 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

Soft seat construction with encapsulated inserts, Angle & Inline bodyconfigurations.

CONTROL VALVES FOR POWER PLANTS

MIL 91000

MATRIX Series valves

ExtremePressureMulti-stage,Multi-path,AxialFlowAnti-Cavitation HighPressureDropControlValves

8.4 MIL 91000 Series

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 Velocity. absorption limits Trim 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.
SPECIAL OPTIONS.

Axial Flow design. Eliminates wiredrawingeffectsonthe leadingedgesoftheplug.

Available with Soft Seat with a special sliding collar to protect the Soft Seat from high pressure fluids.

MIListhefirstControlValvemanufacturerinIndiatohavebeenawardedtheprestigiousCEMarkingCertificate byRWTUV,Germany.

CONTROL VALVES FOR POWER PLANTS

INDEX
A
Allowable working pressure 48

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

9.1 Index & List of Illustrations

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

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

C
CE Marking 8, 71 Company overview 8 Condensate Recirculation Valve 13, 14 Condensate system 13, 14 Condenser 14

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

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

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

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

U
Upstream Piping 57

L
Low Load Feed Water valve 20 Low pressure heater drain valves. 13 LP heaters 31 LP Heaters System 32

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

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

MIL Controls Limited
A KSB Company

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/03·2002

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