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

In December 2001. mandatory for exports to the European Union beyond May 2002. we are today fully geared to meet any critical process control requirements in the power plant sector.CONTROL VALVES FOR POWER PLANTS 1. and a highly skilled work force. In May 2000. The company. Today MIL is the preferred vendor in the country for the rugged. A product of months of specialised R&D. . The factory premises at Meladoor near Cochin in Kerala E ver since its inception in 1983. 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. 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. the 210 MW GEB Wanakbori TPS (Stage II) and the 120 MW NALCO CPP (all 5 units) way back in 1984-85. critical application Control Valves for thermal power stations. With a comprehensive product range. the 210 MW MSEB Chandrapur TPS (Stage II). multi stage. the MATRIX Series valves have been designed to kill upto 420 Kg/cm2 pressure in 40 stages. be it a 33 MW captive power plant or a 250/500 MW utility power plant. world-class manufacturing and testing facilities. MIL has been unrivalled as a supplier of high performance Control Valves to the Indian power sector. which stamped its class in it’s very first set of major project supplies to the 210 MW Neyveli TPS (Unit III&IV). MIL achieved another milestone when it unveiled the MATRIX Series extreme pressure. 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.1 Company overview MIL Controls Limited. multi path axial flow Control Valves. 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.

HIGH PRESSURE DROP 4. other crucial factors like Noise. pressure drops. 1. HIGH RANGEABILITY 9. Leakage Class and Flashing also play an important part in the selection of Control Valves for power station applications. In addition. HIGH TEMPERATURE 2. TIGHT SHUT OFF CAPABILITIES 7. Cavitation. Extraordinary demands are placed on Control Valves usedintheEnergySector. Wire drawing. HIGH PRESSURE 3.0 Introduction . COMBINED HIGH TEMPERATURE.APPLICATION HANDBOOK POWER PLANT APPLICATIONS Factorsdetermining selectionofValves. CAVITATION AND FLASHING 2. PRESSURE & PRESSURE DROP 5. AERODYNAMIC NOISE 8. CONTINUOUS THROTTLING 6.Theiroperational parameters vary widely in terms of pressure. flow rates and temperature.

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

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

Low pressure heater drain valves. Soot Blower Steam Pressure Reducing Valves.APPLICATION HANDBOOK 3. FEED WATER SYSTEM Boiler Feed Pump Minimum Recirculation Valve. Boiler Feed Water Startup Valve.1 Major systems The 4 major systems and critical valves . Turbine Bypass Valves. 3. CONDENSATE SYSTEM Condensate Pump Minimum Recirculation Valve Deaerator Level Control Valve 2. Deaerator Pegging Steam Valves. HEATER DRAIN SYSTEM High pressure heater drain valves. 1. PRDS System valves 4. . MAIN STEAM SYSTEM SuperheaterAttemperatorSprayValve ReheaterAttemperatorSprayValve. Boiler Main Feed Water Control Valve.

The Condenser is a form of heat exchanger that condenses the exhaust steam of the Turbine. The low pressure steam which is very high in volume creates a vacuum when it is condensed into water.frompumpdischarge pressuretotheCondenser pressure. Due to very near saturatedconditionsexistingin thedownstreamsideofthevalve andrelativelyhigherpressure drops. The Condensate RecirculationValve recirculates waterfromthepumpbacktothe Condenser toensureminimum Recirculationofthepump. . 3. The vacuum in the Condenser increases the Thermodynamic efficiency of the cycle. The exhaust steam of the Turbine which is very low in pressure and temperature passes on its heat to the cooling water. Condensatesystem The Condensate system consists of the Feed Water Circuit starting from the Condenser Hotwell to the Deaerator. the valve is subject to Cavitation andFlashing. 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. is condensed and collects in the hotwell. 2..2 Condensate system The Condensate Pump must haveaminimmumRecirculation orFlow toavoidoverheatingof thepumpandprotectitfrom Cavitation.CONTROL VALVES FOR POWER PLANTS 3. Condensate RecirculationValve The Condensate Pump extracts theFeedWaterfromthe CondensateHotwelland dischargestotheDeaerator.The CondensateRecirculationValve hastoabsorbthefullpressure dropie. ControlValvesforthisapplication shouldalsohavegoodshutoff capabilitytoeliminateseat damageduringshutoffconditions.2 Condensate system Fig. Condensate System. Anyleakageshouldbetakeninto accountasaformoflostenergy.

theback pressureintheDeaerator increases. This obviously warrants ahigherflowcapacity. TheFeedWaterlevelinthe Deaeratoralsohelpsin maintainingtheNetPositive Suction Head (NPSH) of the BoilerFeedWaterPump.Atthesametime. Use of 17-4PH and 440C MartensiticSteelhaveyielded excellentresults. Condensate Minimum Recirculation Valve. Alsomaterialselectionshouldbe verydiscreteinsuchapplications takingintoaccountofhighly ErosiveCavitatingconditions. Fig. These factors result in the valve working at very low Cvs and the associatedlowliftoperations.45 bar( a) Outlet Pressure: 0. TYPICAL PARAMETERS 3. The DALCV has to cater to the widely varyingflowdemandfrom startupconditionsto fullloadconditions. The typical valves for such applications are 3” or 4” 78000 Series Multi Step / Multi Stage design or 41008 Series MultiCage/Multi stage design. . Valveselectionanddesign should bebasedonthefollowingfactors: Duringthestartupthepump dischargepressurewillbehigh owingtolowflowrequirements. DeaeratorLevelControlValve. Alsotherelativelyhigherpressure dropsintheseconditonscanlead tooccuranceofCavitation. Deaeratorpressureduringthe startupoftheplantwillbelow. Also the Deaeratoractsas areservoirfor FeedWatertosmoothentheFeed Watersupplyatvaryingloads.2 Condensate system Inlet Pressure: 40.APPLICATION HANDBOOK ThefunctionofthisControlValve istomaintain correctlevelsinthe Deaerator. Whenthepumppicksupload. Theapparentlymildservice conditionsmisleadmanyControl Valvemanufacturersinthe design of valves for this service. MIL 78000 Series.1 bar(a) Temperature: 40. theflowrateincreasesandthe pumpdischargepressuregoes down.50o C The typical valves for such applicationshaveantiCavitation featureswhicheliminateany possibilityofCavitationby droppingpressureoverstages. 3. TheDeaeratorisanopencontact typeFeedWaterHeaterwhich purgesanynoncondensableand dissolved gases.

4. This design gives the necessary Cavitationprotectionatlowerlifts andhigherflowcapacityathigher liftsensuring verywide Rangeability. .2 Condensate system Fig.42 bar (a) Pressure drop: 7. Deaerator level Control Valve.besidesCavitation protectionatlowerflow conditions. TYPICAL PARAMETERS Inlet Pressure: 20. MIL 41000. Such extremeconditionscallfor valveswithexceptionallyhigh Rangeability.CONTROL VALVES FOR POWER PLANTS 3.antiCavitationholes inthelowerportion.drilled.andlarger holes athigherlifts. Typicaldesignsforsuch applications are the MIL 41921 or the MIL 41621 Series which incorporateanequalpercentage characterizedTrimwhichtakes careofthehighRangeability. The basic design is a Cage Guided PlugwiththeCagehaving characterizedports.42 bar (a) Temperature: 50 -100 o C TheCagedesigncombinessmall sized.

Feed Water pumps. 5. BoilerFeedPumpMinimum Recirculation Valve. TYPICAL PARAMETERS Inlet Pressure: 220-250 bar (a) Outlet Pressure: 10-12 bar (a) Temperature: 200o C ~ 3. Boiler Feed Water Startup Valve & Boiler Main Feed Water Control Valve. A pump should have a minimumFlowthroughittotake careofthecoolingrequirements ofthePump.APPLICATION HANDBOOK Fig. FeedWatersystem The Feed Water system includes those parts of the system from Deaerator to the Boiler inlet. Toensurethisminimumflow. Theparametersareobviously verydetrimental foranyvalveto handle.3 Feed Water system .andhencethevalveis verysusceptibleto highenergy CavitationandFlashing. 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. Themostcriticalapplicationina PowerStationistheBoilerFeed PumpMinimumRecirculation Service. The valve has to drop a pressure of 220-250 bar to 10 bar (Deaeratorpressure).Alsoitmay benotedthat theoutlet conditionsofthevalvearenear saturation. Boiler Feed Pump Minimum Recirculation System. HenceeveniftheFeedWater requirementsareverylow(dueto lowloadconditions)thepump shouldhandleaminimumflow.a certainamount ofFlowhastobe recirculated backtothe DeaeratorastheFlow requirementsoftheBoilermay notbesufficienttosatisfythe minimumRecirculation requirementsofthepump. high pressure heaters and the associated accessories. The system consists of Feed Water piping. The critical Control Valve applications in this system are Boiler Feed Pump Minimum Recirculation Valve.

CONTROL VALVES FOR POWER PLANTS 3 methods of providing Feed Pump Recirculation. the MinimumRecirculationValvewill fully open so that it passes 100 tons/hr so that the minimum Recirculationconditionis satisfied. Supposethe requiredminimum Recirculation of the pump is 100 tons/hr. A third method employed by olderpowerplants. .and theBoiler requirement is 90 tons/hr. 6. the minimumRecirculationvalvewill open so that it passes 10 tons/hr andtheminimumRecirculation condition is satisfied (90 tons/hr throughthemainlineand10 tons/hr through the bypass line.. Supposethe requiredminimum Recirculation of the pump is 100 tons/hr. The Modulating Type System employsaModulatingValve whichthrottlestheFlowtothe minimumrequiredwhichisa functionoftheFlowrequiredby theBoiler. 3. The On/Off System employs an On-Off valve which passes a constantRecirculationFlow. Boiler feed pump minimum Recirculation valve. since it is the most energy efficient .and theBoiler requirement is 90 tons/hr. However it exerts taxingdemandsonControlValve functioning. Thepressureiskilled bySeriesof multiholeplates. Oftheabovemethodstheideal systemwouldbetheModulating System. Totalflowthroughthepumpwill be 100 tons/hr ie.OncetheBoiler requirementgoesabove 100 tons/hr the Recirculation Valve closesfullysincetheBoiler requirementissufficienttosatisfy theminimumRecirculation requirementsofthepump. 90 + 10).regardlessofthe plantload. Thehighpressuredropthrottling atlowliftconditions adversely affectTrimdurabilityduetowire drawingeffectsandTrimErosion.3 Feed Water system Fig. Valvearesubjectedto high pressuredropthrottling ofvery lowflowsto fullflowconditions. 3. 1. 2. MIL 78000. recirculatesa constantflow.

7. VariableResistancedesign.the MATRIX Series Valve which is suitableforaModulatingSystem. the most cost effectivesolutionisobviouslythe On-Off system. MIL’scontinuousresearchand innovationsinPowerPlant applicationvalves hasbornefruit inthesuccessfuldevelopmentof theAxialFlow.MultiStage designwhichkillspressureovera numberofstages.MultiStage.3 Feed Water system Fig. Theprototypewasdevelopedfor aPumpRecirculationapplication withpressuredropsof420bar.APPLICATION HANDBOOK 3. The 78000 Series ensures a metal to metal Class V leakage. Multi stage multi path. The typical valve for such application is the MIL 78000 Serieswhichincorporatesa uniqueMultiStep. Anothersalientfeatureisthe uniqueSlidingCollarSeatRing designforClassVIleakageshutoff. MIL 91000. The salientfeatureofthisdesign isthewidescopeforcustomizing the valve to suit specific process applications. axial flow MATRIX Series valve for Boiler feed pump minimum Recirculation service In this context. .

. Howevertheselection philosophyanddesignare entirelydifferentforthetwo valves. Thevalvetakesthe signalfrom theFeedWaterControlwhich employsathree-elementcontrol.Apparentlythe applicationsmayseemsimilar.CONTROL VALVES FOR POWER PLANTS TheTrimcanbecustomizedto varioushighpressuredrop applicationsbyvaryingthe numberofstages. Thesignalisgeneratedasa functionof Drumlevel. 8. Onevalveisemployedduringthe low loadconditionsorthestartup conditionsoftheBoiler. Feed Water Regulating System. This is because of the differentpressuredropconditions existingatthetimeofStartupand Full Load.3 Feed Water system Anothercritical applicationinthe FeedWaterSystemistheBoiler FeedWaterRegulatingValve which controlsflowtotheBoiler for varying loads of the system. ThetypicalparametersofLow LoadFeedWaterControlValve andFullLoadFeedWaterControl Valvearegivenbelow. 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. FeedWaterRegulatorValve Anothervalveisusedduringfull loadconditions. Theexpandingflow passagesalsoenhance the Rangeabilityallowingsmooth andpreciseFlowControlevenat lowliftoperatingflowconditions.230 bar (a) Temperature: 247o C Fig. Thecharacteristiccanbe customizedbyreallocatingthe pressuredropratioindifferent stages.Steam flowandFeedWaterflow. LOW LOAD FEED WATER VALVE TYPICAL PARAMETERS 3. Twokindsofvalvesareusedfor FeedWaterregulation.

Multi stage.willtake careoftheveryhighpressuredropsencounteredduringstart-up conditionswherethedrumpressureisverylowandthepump dischargepressureisveryhigh. Low Load. 9. Thetypicaldesignforlowloadandfullloadapplicationsisthe MIL 41000 Series Valves which employ Heavy Duty Cage Guided features. . TheCageGuideddesignensures goodThrottlingStabilityandgood Rangeabilitytocatertowidelyvaryingflowconditions. Feed Water regulating valve. ThisdesignwhichfeaturesaMultiStagePressureDropTrim. 41008 Series Multi Cage designfindsitstypicalapplicationforthelowloadvalve.APPLICATION HANDBOOK 3.3 Feed Water system Fig. MIL 41008. Wherethepressuredropduringstart-upconditionisveryhigh.which can be detrimental in conventional valves.

Superheater Spray Block Valves. Reheater System to Condenser.tocontrolthetemperatureof the Main Steam . 10. Reheater Spray Control Valves.4 Main steam system Fig. PRDS Spray Control Valves and Deaerator Pegging Steam Valve. which is the heat sink. spray water systems etc. The designparametersofthe spray system include those conditions whichaccountforthe excessiveheatingoftheTurbine atfull load. Turbines.withtheFeedWater atitsmaximumtemperature. Soot Blowing system. SuperHeaterAttemperatorValve Thetemperature ofthemain steamcomingoutoftheBoileris verycritical fromthepointof Thermodynamic Efficiencyofthe heatcycleandtheTurbineblade protection. Reheater Spray Block Valves. . Critical Control Valves in Main Steam Line MainSteamSystem The Main Steam System consists of the steam circuit from the Boiler outlet. Hence Attemperator valves are of critical relevance The typicalproblemsfacedby superheatersprayControlValves arethrottlinginstability andwide Rangeability. PRDS System Control Valves. Main Steam Pressure Reducing Valves. Superheater System.CONTROL VALVES FOR POWER PLANTS 3. A poor temperaturecontrolsystemmay resultindamagestoTurbine blades. Soot Blower Pressure Control Valves. Boilermanufacturersemploy variousmethods likeburnertilt mechanism. The steam fully extracted of the energy is finally dumped into the Condenser.Superheatertubes. cleanBoilertubesandmost favourableconditions. The most critical application valves in this system are: Superheater Spray Control Valves. Reheatertubesetc.

Superheater Attemperator valve. 12. . 11. MIL 41100. MIL 41200. Fig.APPLICATION HANDBOOK 3. Superheater Attemperator valve.4 Main steam system Fig.

The 41200 design has thesameadvantagesthatthe 41100 Series besides the added featureofabalancedplug. The 41100 Series features an unbalancedCageGuideddesign.4 Main steam system For higher sizes (2” and above) theActuator thrustrequirements willbeveryhighduetothe unbalanced design of the 41100 Seriesdesign. The 41400 design is a Cage Guided designwherethemainplugis assistedbyanauxiliarypilotplug toeffecttightshutoff. The typical MIL designs for block valve applications are the 41400 Series and the 41200 Series. 13.Another requirementof a block valve is faster response. Hence the Spray System employs apneumaticallyoperatedOnOff ControlValveforthisapplication. Alsothesituationisfurther compoundedby withdrawalof heat throughtheSootBlower. AnotherapplicationofSpray System is the block valve. Anothercriticalfactorinfluencing theselectionofControlValveis the Leakage Class. Inlet Pressure:181-200 bar (a) Outlet Pressure: 161-180 bar (a) Temperature: 247o C . The block valves assists the spray ControlValves effectingatight shutoff.Thevalvewillbe workingatlowerliftconditions duetoabovesaidreasons. Anyexcessiveleakagewillresult inthermalshocksin Secondary SuperheaterTubesanderosionof Turbineblades. MIL offers special designs like the 41100 Series and the 41200 Seriesforsuchapplications. MIL 41400.All thesefactorsresultinadrastic reductionofspraywater requirements. The 41200 features a balanced design withanovelStaticSeal concept. Thiscombinesthetwinbenefits ofthegoodthrottling stability of Cage Guided valves with the shut offcapabilityofsingleseated unbalanceddesigns.CONTROL VALVES FOR POWER PLANTS Howevertheaboveconditions seldomcomeintoplaydueto deteriorationofBoilertubesdue toScalebuildupandthe consequentheattransferloss. Superheater Attemperator block valve. TYPICAL PARAMETERS Fig. 3. Hence in practice the Spray WaterValvewillbeseldomtaken intofullcapacity.

Itmaybenotedherethat reheaterpressureistheoutlet pressureofthehighpressure Turbine. Thevalveselectiondependson thepressuredropacrossthe valve.4 Main steam system Fig.andtheselection philosophyissimilartothatfor SuperheaterSprayBlockservice.thepressure drop can be as high as 100-120 bar.itcanbeupto 60-70 bar. TheReheaterSprayBlockValve applicationissimilarto SuperheaterSprayBlock applications. The MIL solution to such applications are the 78000 Series or the 41128 Series for high pressure drops (100-120 bar). Incaseoftheformer. 14. Fig. The Leakage Class is very critical since excessive leakage can lead toErosionoflowpressureTurbine blades. Thepressuredropacross thevalvedependsonthesource ofthespraywater. . it is the 41121 Series or the 41221 Series. ThesourceoftheSprayWater caneitherbetheFeedWater pumpoutletortheinterstage tappingofthepump. MIL 41008. However fluctuationsin temperatureis notvaryingasin SuperheaterSprayControl.APPLICATION HANDBOOK 3. In thecaseofmoderatepressure drops. Reheater Attemperator Control Valve. MIL 78000. 15. andlatter. Reheater Attemperator Control Valve. ReheaterAttemperatorValves Thisapplicationisalsosimilarto theSuperheaterSprayControl Valveapplication.

16.Thehot steamismixedwiththeFeed WaterenteringtheDeaerator bringingittosaturation temperatureandthereby liberatinganyundissolvedornon condensablegases.willattackandcorrode pipingandBoilertubes. Above this and upto 40% MCR.Maintaininga higherpressureintheDeaerator helpsinmaintainingtheNPSHof thepump.5 bar (a) Temperature: 220o C 2. These gases.6 bar (a) Temperature: 330o C . Deaerator Pegging Steam System.CONTROL VALVES FOR POWER PLANTS 3. Typical valves in this system are: 1.Infull loadconditions. if not expelled. DEAERATOR PEGGING FROM AUXILLIARY STEAM HEADER TYPICAL PARAMETERS Inlet Pressure: 16 bar (a) Outlet Pressure: 3. the steam is takenfromtheColdReheat Header(Steamtappedafterthe HighPressureTurbine). Normallythesteamistakenfrom theAuxiliarySteamHeaderupto 15% MCR condition.Deaerator actsasa FeedWaterstoragetanktothe BoilerFeedPump. Steamissupplied tothe Deaeratorfordeaeration ofFeed Waterandalsotomaintaina positivepressureinthe Deaearator.4 Main steam system Fig. DeaeratorPeggingSteamValve TheDeaerator isadirectcontact typeheaterwhichremovesnon condensable gases like Oxygen andCarbondioxidefromthe Feed Water. DEAERATOR PEGGING FROM COLD REHEAT STEAM HEADER TYPICAL PARAMETERS Inlet Pressure: 21 bar (a) Outlet Pressure: 3.steamistaken directlyfromtheTurbine extractionline.

540o C .Alsotherapidbuildupof sootinthetubescanleadtothe developmentofhotspotsinthe Boilertubes.4 Main steam system Inlet Pressure . MIL 41003. Sootblowingvalvesarenormally isolatedbyanupstreamisolation valve.20 bar (a) Temperature . Oneofthemajorchallengeshere is to select and design a Control ValvefortheSteamSootBlowers. Deaerator pegging steam Control Valve Theproblemsencounteredin valve selection for such applicationsare thehighnoise levels associated with this valve.TheBoilertubes shouldbefrequently cleaned to remove thesoot. Additionalnoiseattenuationcan beachievedwithdouble stage pressuredropdesignssuchas doubleCageordiffuseroptionsin the 41000 Series. 17.APPLICATION HANDBOOK SootBlowerValve Fig. Hence the valve is not subjectedtohighpressureand temperature whennotinservice. The soot removal is effectedthroughSootBlowers. the valve is subjected to very high pressures andtemperatures. Theproblemsuniquetothis serviceareHighpressuredrop.Thenormal practice is to use high velocity steamjetstoblowthesootfrom the tubes. TYPICAL PARAMETERS 3. MIL offers special low noise Trims (Lo-dB Design) for such applications. Theeffectivepressuredropratio across the valve is reduced which resultsinlowexitvelocitiesand noiselevels.170 bar (a) Outlet Pressure . MIL offers special low noisecartridges whichdividethe pressuredropbetweenthevalve andthecartridges. Anotherproblemassociatedwith this service is high exit velocities duetovolumetricexpansionof thesteamwhenthepressure drops. HoweverwhentheSootBlowing is being done. HighnoiselevelsandThermal cycling of the valve body and valveinternals. SomeSootBlowersuseairalsofor theremovalofsoot. Theeffectivenessoftheheat transferthroughBoilertubesis adverselyaffectedbythebuildup ofsoot. The 41000 Series Cage Guided valves with special LowNoiseTrimhavebeenfound excellent for such services.

Theobvioussolutionwouldbeto useforgedanglebodiesorforged inlinebodieswithspecialmulti stagelownoiseTrims.CONTROL VALVES FOR POWER PLANTS 3. MIL 71114. Soot blower pressure reducing Control Valve Hence the valve is subjected to thermal cycling which can cause WarpageandCreepinthe conventional castglobevalve bodies.or it’s 71114 Series (Cage Guided anglebodywithdoublestage pressuredrop). Here MIL offers it’s 41114 Series (CageGuidedinlinebodywith doublestagepressuredrop).4 Main steam system Fig.Thebodyshallbe forgeddesignandchrome molybdenum steel (ASTM A 182 Gr. F22) . 18.

MAIN STEAM PRESSURE REDUCING VALVE TYPICAL PARAMETERS ThesteamDesuperheating is effectedthroughPRDSstations– PressureReducing DesuperheatingSystem. The PRDS system consists of a Desuperheaterpressurereducing valveandatemperatureControl Valve.170o C . Thepressurereducing valvereducesthepressureofthe steambeforeentryintothe Desuperheater.185 bar (a) Outlet Pressure .16 bar (a) Temperature . Apartfromsteambeingusedfor powergenerationandsoot blowing.16 bar (a) Temperature .steamisusedforother auxiliaryserviceslikegland sealingofTurbines.4 Main steam system Fig.APPLICATION HANDBOOK 3. ThetemperatureControlValve regulatesthespraywater quantityintotheDesuperheater.170 bar (a) Outlet Pressure . 19. TEMPERATURE CONTROL VALVE (SPRAY WATER) TYPICAL PARAMETERS Inlet Pressure .Steam EjectorsinCondensersand Deaerator pegging. Typical Auxiliary PRDS System PRDSStationValves.540o C Inlet Pressure . Themainsteamhastobe Desuperheatedbyreducingits pressureandtemperature to utilisethesteamfortheabove mentionedapplications.

High temperature.Optionaldoublestage SprayWatercaneitherbefrom designisalsoavailablewhichis FeedWaterPumpoutletorinter veryeffectiveinnoiseattenuation stagetappingofthepump. athigherpressuredropratios. Inthecaseoftheformer. The Cage design includes Inthecaseofmoderatepressure multipleholestoattenuatethe dropsthe designshallbethe noise. The 41413 Series case. The critical factors that govern selection of Main Steam PRV are: High pressure drop. valve is Over the Plug. A seat ring . ThetemperatureControlValveis anothercriticalvalvecomingin MIL offers the 41912 Series or the the system. . ThisdesignfeaturesaCage the selection of this valve is also GuidedTrimwith specialLow governedbythe sourceofthe Noisemultipleholescontrolling SprayWater.CONTROL VALVES FOR POWER PLANTS 3. pressure drops (100-120 bar). it can be upto 60-70 bar. MIL 41914 Main Steam Pressure Reducing Valve. High noise levels and Material selection for high temperature.basket diffuser is provided foreffectivenoise attenuationathigherpressure dropratios.Theflowdirectionofthe 41121 Series or the 41221 Series. ReheaterSprayControlValve. 20.4 Main steam system Fig. the 41413 pressuredropcanbeashighas Series istheappropriate 100-120 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.the For Class V leakage. As in the case of 41914 Series for this application.Thesourceofthe theflow. and in the latter selection.

and isthusdifficulttoweldrepair. the steam is bodysizeswithareduced introduced into the heaters. The heating media for HP heaters is the steam extracted from the reheat cycle. the fluid losses pressure and flashes.impingesonthematerial surface ofbodyand Trimcausing TheHeaterDrainSystem The heater drain system consists of heavywear.5 Heater drain system GenerallyChromeMolybdenum steelshaveexhibitedexcellent resistancetoFlashingErosion. 21.e. 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. Even though ASTM A 217 Gr C5 is recommended by some users.APPLICATION HANDBOOK Thecriticalfactorsthat influence theselectionofthevalvesare: Body andTrimmaterial. i.. it isbeing increasinglyreplacedby ASTM A 217 Gr WC9 material as C5 has some significant manufacturingproblems. 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 HP heaters and LP heaters are basically heat exchangers – shell and tubetype. whereas for LP heaters the steam is extracted from the low pressure Turbine. 3. Anotherissueistheselectionof valve body size. MIL offers it’s 21000 Series and the 4100 Series Valves for these applications. The liquid dropletsaccelerated byrelativelyhighvelocityvapour Fig. Thebodysizeselectioncriteriais theoutletFlashingvelocity.Valve sizeandValveflowcapacity Flashingproblemsencountered intheseservicescausematerial erosion. cooled capacityTrim. It is always recommendedtoselecthigher The heating media. The level in the heaters are to be closely controlled to maintain the Thermodynamic efficiency of the system. Thebodymaterialis either WC6 or WC9. and when the Condensate is drained to either Deaerator or the Condensate flash tank. The Condensate in the heaters are at saturation condition. MIL 21000. and ultimately condensed back to liquid.in additiontopoorweldability. Heater Drain Valve phase.

22.CONTROL VALVES FOR POWER PLANTS 3. LP Heaters System Fig.5 Heater drain system Fig. HP Heaters System . 23.

TypicalInstallations Choosingtherightvalvemakesallthedifference .

1 100 kg/cm 520 C 2 0 1 AS-9 HIGH CAPACITY STEAM PRESSURE REDUCING 38-41912 6x3 in. Tag Service Pr.5MW Model 38-41024 38-414X1 38-78001 90-41024 2. 38-78101 1 in.Capacity 67.5 in.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. 1500 F11 15 Size Rating* Body Cv Pr.5MW Size Rating* 1500 38-41412 37-211X4 2 in. 100 kg/cm 520 C 0 Qty. 0 No. 2 in. Tag Service Qty. 2 in. 2 in. 1500 2 in. 38-78101 1.5 MW Project: TISCO 1X67.3 No.REDUCING VALVE APPLICATION HANDBOOK PRDS VALVES Model Project: TISCO 1X67.5 MW . 185 kg/cm 250 C 0 Qty. Project: TISCO 1X67. Tag Service Temp. 90-41921 6x3 in. 2 Temp. 2 SPRAY & SOOT BLOWER VALVES No. 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. 67.5MW Model 38-78101 38-41921 6x3 in. 4 185 kg/cm 250 C 2 0 1 SD-5.5 in.1 Typical applications. 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 1500 1500 1500 Body WC9 WC9 WCC A105 A105 Cv 120 12 15 1. 38-70571 38-70571 2 in. 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 0.REDUCING VALVE 6 SD-8 SOOT BLOWER STEAM PR. 2 FEEDWATER CONTROL VALVES Customer: BHEL Madras Temp. 1500 1500 2500 2500 2 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.

Tag Service Pr. 600 8 in. 300 WCC 26 15 kg/cm 2 2 Capacity 116 MW Customer: BHEL Bangalore Cv Pr. Project: Ahemedabad Electricity Company.6 FEED REGULATING VALVE IN HP BFP DISCH. Model 38-41412 37-211X5 38-41421 38-211X5 1 in. 900 A105 4 3 in. 600 WCC WCC WCC 6 in.LINE (LOW LOAD) 2 Customer:BHEL Bangalore Pr. 2 2 1 CV-5. 900 WC6 95 2 in.2 Typical applications. Model 38-41621 37-41612 38-78001 Project: Ahemedabad Electricity Company. 70 kg/cm 2 SPRAY VALVES No.8 FEED REGULATING VALVE IN HP BFP DISCH.LINE 2 CV-7. 121 C 0 o FEED CONTROL VALVES Size Rating* Body No.4. Temp.16 LP STEAM BYPASS VALVES 2 13 kg/cm 2 4 CV-17. 480 C o Qty.10 FEED REGULATING VALVE IN HP BFP DISCH. Rating* 1500 900 Body WC6 A105 Cv 30 0. CONTROL VALVES FOR POWER PLANTS 2 CV-24 PRDS SPRAY CONTROL VALVE 1 * ANSI .8 2 in.14 HP BYPASS SPRAY VALVES 50 C o 2 147 C o 3 CV-15.3 No. 70 kg/cm 2 2 Temp.1 LP BYPASS SPRAY VALVES 50 C o 2 Customer:BHEL Bangalore PRDS VALVES Model 38-41412 38-78003 Size 2 in. 116 MW Project: Ahemedabad Electricity Company. 1 119 kg/cm 121 C o 1 CV-23 PRDS PR.LINE (FULL LOAD) 115 kg/cm 121 C 115 kg/cm 120 C 2 o 3 CV-9.HDR. 2 13 kg/cm 7 kg/cm 2 2 1 CV-11. Tag Service Temp.12 HP STEAM BYPASS VALVES 2 CV-13. 150 2 in. Tag Service Qty. 1 in. 480 C o Qty. REDUCING VALVE IN HP STEAM LINE TO AUX. 1500 WC6 Size Rating* Body Cv 145 46 640 3.

8 900 A105 4.Capacity 116 MW Project: Ahemedabad Electricity Company.29. 300 WCC WCC WCC WCC WCC WCC CF8M CF8M 6 in. 3 in. 48oC 48 C o HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES No. 8 in. 37-211X5 Project: Ahemedabad Electricity Company. 150 150 150 300 600 600 2 in. 300 WCC Size Rating* Body Cv 360 25 65 155 95 500 225 6 46 1in. Tag Service Qty. 116 MW .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 4.27 RECIRCULATION VALVE FOR HP BFP 115 kg/cm 122 C 18 kg/cm Pr. Model 38-41621 37-41612 37-41621 38-414X1 38-41621 38-41621 37-41621 37-21125 38-21125 4 in.5 2 FEED PUMP RECIRCULATION VALVES Size Rating* Body Cv Pr.2 Typical applications. 3 2 1 CV-25. Tag Service Qty. Model 37-78003 1. 3 in. 13 kg/cm2 13 kg/cm 2 2 CV-28. 600 WCC 3. Customer: BHEL Bangalore Temp. 300 2 in. 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. 1 1 13 kg/cm 7 kg/cm 2 2 1 CV-1 MAIN CONDENSATE CONTROL VALVE 2 CV-2 MIN. 2 in.30 RECIRCULATION VALVE FOR LP BFP 122 C o 3 Customer:BHEL Bangalore Temp. o No. 1 in.5 in.26.

16.5 in. 2 No.22 RH CONTROL 8 PCV-8502A. 265 kg/cm 260 C o Qty.3 Typical applications.PRDS 100%STEAM PR.21.5 in. Tag Service Temp.18 RH BLOCK BRANCH 7 SD-19. 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. 38-410X4 1.PRDS 10%STEAM PR. 38-410X4 2. 2 MSPCV-2 AUX. 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. 210 MW Project : Raichur TPS Unit IV Model 38-41921 12x8 in.5 in. o FEED CONTROL VALVES Size Rating* No. Size 2500 2500 2500 2500 Rating* 2500SPL 38-41012 2 in.4. 38-41012 Model 2 in. 1 1 1 1 1 * ANSI 1 MSPCV-1 AUX.12. 2 in. 2 265 kg/cm 260 C 2 o 1 SD-4 SH STAGE I BLOCK 2 SD-5. 38-78103 1.B SOOT BLOWER STEAM PR.5 in.17.5 in.7. Temp.REDUCING VALVE 4 Customer:BHEL Madras Pr.5 in. Tag Service Qty. CONTROL VALVE 38-41412 6x3 in. 38-78101 37-211X4 1 in.5 in. 38-41024 1. 38-410X4 2.8 60 40 3.4 0.PRDS 100%SPRAY FLOW CONTROL VALVE 4 SPTCV-2 AUX.6.6 25 Cv 50 6 2.8 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. 2500 WC6 Project : Unchahar TPS 2x210 MW Model 38-410X4 6x4 in. Unit IV CONTROL VALVES FOR POWER PLANTS No.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-15.11.20.PRDS 10%SPRAY FLOW CONTROL VALVE 5 V2505111 BLOCK VALVE ON SPRAY WATER TO AUX. CONTROL VALVE 3 SPTCV-1 AUX. 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. Tag Service Qty. PRDS . Temp. 38-41024 2.3 15 Size Rating* Body Cv 45 2500 WC6 575 2 Capacity 210MW Customer: BHEL Madras Body Cv Pr. 38-78102 1. 38-41412 6x4 in.

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. Qty. 1 in. 20 kg/cm 2 Customer: BHEL Hyderabad Rating* A105 15 o No. 4 in. 3 in.5 in. 10 in. 6 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. 2 FEED PUMP RECIRCULATION VALVES Size 2500 Rating* 300 600 600 600 600 300 300 300 300 300 8 in. 37-78003 37-211X5 37-41611 37-41611 6 in. 2 48 kg/cm 2 No. 210 MW . 3 in.Capacity 210 MW Project : Ropar TPS Model 37-78103 4x2 in. 10 in. 2 1 FEED PUMP MINIMUM RECIRCULATION 260 kg/cm 250 C Temp. Temp. 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.3 Typical applications. 3 in. 8 in. 3 in. 4 in. STEAM FROM AUX. 2 in. 230 C o HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES Customer:BHEL Delhi Qty. 38-41612 6x4 in. 10 in. Tag Service 1 PAS-1 PEGG. 3 in. 38-41621 1. STEAM HEADER TO DEAERATOR 2 PCR-1 PEGG. Size Tag Service Body Cv Pr.

Temp.5in.5in. 2. 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.3 LOW LOAD FEED WATER FLOW CONTROL 2 Customer:BHEL Trichy Pr. 3in. o FEED CONTROL VALVES Size Rating* Body Cv No.4. 2500 WC6 240 30 75 8 30 15 3. Size 1. 2500 3in. 2in. 2 7 SD-19 TO SD-22 RH SPRAY CONTROL 8 2 Customer:BHEL Bangalore Temp. 38-41921 6x4in.3 0. 2 SPRAY & SOOT BLOWER VALVES No. 2500 WC6 6in. 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. Tag Service Temp.5 13 Cv 110 2. Tag Service Qty. CONTROL VALVES FOR POWER PLANTS No.1&2 FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS) 330 kg/cm 248 C 330 kg/cm 248 C 2 o 2 728. 262 kg/cm 260 C o 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 .5in. 4 1 0728.3 Size Rating* Body Cv 2500 WC6 225 2500 WC6 900 2 Capacity 250 MW Customer: BHEL Delhi Pr. 2500 WC6 WC6 WC6 WC6 F11 F22 Body WC9 A105 WCC WCC A105 A105 2.4 Typical applications. 2*250 MW Model 38-41921 14x10in. 250 MW Project : CESC Budge Budge TPS. Tag Service Qty. 1. 1in. 2in. 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.5in. 2500 2500 2500 2500 Rating* 2500SPL 2500SPL 2500 600 2500 2500 1. 1in.4 6 20 0.5in.

4 Typical applications. DRAIN TO LP FLASH TANK 10 DR-25 LPH-2 NORMAL DRAIN TO LPH-1 APPLICATION HANDBOOK 11 DR-28 LPH-2 ALT. 300 4 in. 3 in. 2*250 MW 37-78103 4x2 in. 150 150 150 150 300 300 600 300 300 150 300 150 4 in. DRAIN TO HP FLASH TANK 6 DR-13 HPH-5 NORMAL DRAIN TO DEAERATOR 7 DR-16 HPH-5 ALT. Project : Kothagudem TPS. 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. 600 WCC 500 8 in. 3 in. 250 MW . 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. 12 in. 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. 600 WC6 50 50 56 120 120 170 170 575 575 100 900 45 95 1. 4 in.Capacity 250 MW Project : Kothagudem TPS. STEAM HEADER TO DEAERATOR 2 360 C o 2 CRH-2 PEGG. 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. 600 WC6 WC6 WC6 WCC WCC WCC WCC WCC WCC A105 WCC WCC WCC CF8M CF8M 3 in. 300 3 in. STEAM FROM AUX. 600 WC6 3 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. 38-41612 6x3 in. 37-211X5 37-41612 37-41512 37-41612 1 in. 3 in. 8 in. 4 in. 4 in.7 95 45 120 10 in. DRAIN TO DEAERATOR 2 2 2 2 130oC 130oC 105oC 105oC 170 C o 5 DR-9 HPH-6 ALT. 3 in. 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.

20 kg/cm 2 Temp. 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. 4 in. 2500 C5 475 2 Capacity 500 MW Customer: Keltron Controls Cv Pr. 38-41012 4x2 in. 4 in. Temp.5 Typical applications.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 .4. 10 in. o FEED CONTROL VALVES Size Rating* Body No.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. 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. 2500 WCC WCC F11 2500 WCC 2500 WCC 26 155 75 12 25 8 in. 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. 2 Temp. 16 in. 295 C o Qty. 2500 2500 3 in. 2 57 kg/cm 2 1 PCV-0326A AUX. 1 FCV-0657 LOW LOAD FEED WATER FLOW CONTROL 360 kg/cm 200 C SPRAY & SOOT BLOWER VALVES Customer:BHEL Trichy No. Project : NTPC Vindhyachal TPS 2x500 MW STPP Model 38-414X1 38-41621 4x3 in. Tag Service Pr. 8 in. Qty. 38-414X1 4x3 in. 38-414X1 38-41024 2.B. Tag Service Qty. 2500 WCC 380 Size Rating* Body Cv Pr.5 in. 500 MW Project :NTPC Talcher TPS 2x500 MW STPP Model 37-41512 12x8 in.

12 in. 8 in.5 Typical applications. 300 4 in. 40 C o No. 6 in. 600 WC6 55 8 in. 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. 150 CF8M 575 10 kg/cm 2 2 HEATER DRAIN & CONDENSATE SYSTEM VALVES Size Rating* Body Cv Pr. 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. 4 in. Rating* 300 300 Body WCC WCC Cv 575 200 3 in. Tag Service Qty. 6 in. 300 300 300 300 300 300 150 300 3 in. 300 WC6 4 in. 250 C o Qty. 37-41621 1. Customer:Keltron Controls Temp. Tag Service Temp.5 in. 20 kg/cm 2 21 LCV-8701 DM WATER OVERHEAD LEVEL CONTROL SCAPH CONTROL VALVES No. 500 MW . 3 in.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. 2 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. 600 C5 WC6 C5 WC6 C5 WC6 C5 WC6 CF8M CF8M 3 in. 600 WC6 45 4 in.

.

MaterialselectionGuidelines StandardisedMaterialsforhighperformance .

WC9 ASTM A 217 Gr.9 31. Extracted from ANSI B16.9 2 105.9 107.7 178.0 45.4 332.0 9.6 297. 2 ¼ Cr . allowable working pressures for WCC.7 22.1 35.1 Body material specs PRESSURE RATING.6 148.8 7.7 255.3 127. CEILING VALUES * Temp.4 263. 1 ¼ Cr .1 79.8 71. CF8M Forgings ASTM A 105 ASTM A 182 Gr.8 413.5 1.3 51.2 439.8 128. Ty. 427ºC 566ºC 566ºC 566ºC 566ºC 5.2 153. 5 Cr .Theserviceconditionsvarywidelyin pressureandtemperatures.7 199.3 99.APPLICATION HANDBOOK MATERIAL SELECTION Correctmaterialselectionisextremelyimportanttoensure properfunctioningandlongevityofControlValvesinPower Plantapplications.5 85.9 248.3 49.2 14. F5a ASTM A 182 Gr.5 102. 150#ANSI 300#ANSI 600#ANSI 900#ANSI 1500#ANSI 2500#ANSI < 93ºC 149ºC 204ºC 260ºC 316ºC 371ºC 427ºC 482ºC 538ºC 593ºC 18.4 0.4 426.8 42.5 354. PRESSURE CONTAINING MATERIAL General Classification Carbon Steel Alloy Steel.6 3. F22 ASTM A 182 Gr.6 119. the most common body material used for Control Valves in power plant applications. CONTROL VALVE.6 157. F316 Max.4 389.4 63. WC6 ASTM A 217 Gr.2 94.7 51.1 Mo Alloy Steel.5 40. See pages 48-50 for max.6 67.6 25. WCB / WCC ASTM A 217 Gr. Varies with material.1 12. WC6 & WC9.0 188.34 .0 113. C5 ASTM A 351 Gr.8 212.8 * Max.0 52..3 213.3 158.½ Mo Alloy Steel.9 76. F11 ASTM A 182 Gr.TheBodyand Trimmaterialselectionshouldalsotakeintoaccountthe detrimentaleffectsofCavitation/Flashing/HighVelocity whichareinherenttosuchsevereapplications.3 16. . Working Pressure in Kg/cm for ANSI 150# to ANSI 2500#.1996.1 93.6 46. Operating Temp.7 140.designpressurecangoupashigh as360kg/cm2 andtemperaturesupto566oC.½ Mo Stainless Steel.7 5. 316 Castings ASTM A 216 Gr.2 233.8 263.

WCC 5.CONTROL VALVES FOR POWER PLANTS Allowable working pressure for ASTM A 216 Gr.2 Allowable working pressure Allowable working pressure (Kg/cm2) Operating temperature (oC) .

2 Allowable working pressure Allowable working pressure (Kg/cm2) Operating temperature (oC) .APPLICATION HANDBOOK Allowable working pressure for ASTM A 217 Gr. WC6 5.

CONTROL VALVES FOR POWER PLANTS Allowable working pressure for ASTM A 217 Gr.2 Allowable working pressure Allowable working pressure (Kg/cm2) Operating temperature (oC) . WC9 5.

6 Stellite Solid (< 2”) NA No. (700-1000 HV After case hardening. Drop. 410 Ty. 440C Stainless Steel Bar Stock: ASTM A276 Ty.Mod. afterNitriding) 400ºC 58 HRC min. CF8M 400ºC 400ºC 650ºC 650ºC 650ºC 650ºC 400ºC 650ºC 28 HRC min. excellent for high temperatureservice. Non-Erosive. Corrosion resistance similar to Inconel Erosive & Corrosive Service. Press. 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.3 Trim material selection .Corrosive Service Erosive & Non. TEMP. TOUGH SERVICE Ty. Ty.440C 5.GENERAL CLASSIFICATION. 630 Castings: ASTM A 747 CB7CU1 APPLICATION HANDBOOK CA6NM Stainless Steel Casting: ASTM A743 Gr. 416 Stainless Steel (Hardened&Tempered) Bar Stock: ASTM A 582 Ty. 416 No. 593ºC 14 HRC max.6 Stellite Hard Facing NA No.5 Colmonoy Hard Facing NA No.Corrosive Service Slightly Erosive & Corrosive Service Erosive & Corrosive Service Erosive & Corrosive Service. 410 Stainless Steel (Hardened&Tempered) Bar Stock: ASTM A 479 Ty. Very Erosive Service. 316 Castings: ASTM A 351 Gr. Most corrosion resistant of 300 Series Corrosive & Non. HARDNESS GENERAL APPLICATION GENERAL SERVICE SS 316 Bar Stock: ASTM A 479Ty. CA6NM (HeatTreated) Erosive & Corrosive Service. Corrosion resistance similar to Inconel Erosive & Corrosive Service ASTM CODE MAX.6 Colmonoy Hard Facing NA 17.4 PH Stainless Steel Bar Stock: ASTM A 564 Gr. Corrosive.

.

HandlingandInstallation A list of safe practices .

In case of Bellow Sealed Valves. stem. 6. . are not designedtolifttheheavy valve body assembly. 24.neverrotatetheValve Bolts or Tie Rods can be removedeasily. 9. The Actuator Diaphragm case.APPLICATION HANDBOOK 6. Clearance requirements for Globe Control Valves 1. Do not lift large size valves by the Actuator. Eye Bolts etc. Lifting Lugs providedontheActuatorsare forliftingtheActuatoralone. Do not turn the Actuator. 7. 2. 3. Ensure that recommended mountingorientationsare alwaysfollowed. 8.1 Handling & Installation Fig. keepingthecouplingtight. Ensure that the Flange 4. Valves on smaller piping andtubingmayneedtobe mountedinBrackets. provideadequatespacefor future occasions when it may become necessary to remove theBodyandActuator forrepairs. Leave adequate space for opening/adjusting Positioners and Accessories. 5. While choosing the location to mount the valve.

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 .

It can also cause flange leak or packingleak. Ensure that the recommendedmounting orientationisfollowed.andthepacking compressionmayhavetobe readjusted.itmaybe necessary to remove the internals.thedraincock shouldbeopenedfromtimeto timetobesuretrappedliquidis drained. It dusty or dirty conditions prevail. 3. 2. 5. Especially if antiCavitation or low noise Trim is inplace. Packingwillcompressfurther inservice.APPLICATION HANDBOOK 1. It is very important that these abnormalconditionsbe recognizedandtheControl Valveisselectedtakinginto account these conditions.Ensure that misalignment alongthepipelineisnot corrected using the valve.itmustbe properlysupported. 4.Periodicfieldinspections shouldbemade. It should be appreciated thatduringplantstartups. If additionalflushingisdone afterinstallation.Tightenthe packingnutswhenfound necessary. 4.1 Prevetive maintenance 1. Continuedinnextpage START-UP 7. Monitor the performance of the valve accessories as it hasa significanteffecton the valveperformance. Pipeline stress on the valve maycausemisalignmentof the stem or plug/seat joint. 6.Specialcare tobegiventothevalve accessories.providearubberboot aroundthestemtoprotectthe packing. 5. abnormaloperating conditions can adversely affecttheperformanceofthe Control Valve and some times severely damage the valve. Rememberthathighfrictionpackingneedstobe compressedafterinsertion. AFTER 3. 2. Piping should be flushed before installing the valve. Ensure that the mandatory ‘flowthrough’direction indicatedontheControl Valve (by an arrow mark) is alwaysfollowed. .If a valve is mounted with it’s stemtravellinginthe horizontalplane. Airsetsusuallyhavefilters thatcanclog. Cover the valve suitably whenprocessdrippingor corrosiveatmospheric conditionsprevail. PREVENTIVE MAINTENANCE BEFORE START-UP 1.

. SHOP OVERHAUL 1. Inspect the disassembled componentsthoroughlyand determinetheextentof reconditioningandrepair thatisrequired.Strainersshould beinstalledfarenoughto allownon-swirlflowatthe valve inlet.Afterwardsclean thepartscarefully 6.While Teflon® tapeisanexcellent threadlubricantandsealfor screwed connections. mark theActuatororientationwith respect to the body flanges. Avoid using Teflon® tapes ininstrumentairlines. rust etc.Andthesebitsoften migratetoorificesin pneumatic accessories and can clog them. Do not start up a Control 7. Air lines to be connected to the Control Valves should be blowncleanofoilanddebris beforetheyareattached. Disassemble the Actuator andexaminecomponentsfor damage. 9. 10.itis recommendedthat permanentstrainersorfilters beinstalled. Ensure that the person whoisdisassemblingthe ControlValveisthorough withthereleventprocedure. it neverthelesscanbreakoffin small bits if not carefully applied. Ensure that the air supply is Valvewithoutfirstchecking thepackingtightness.steamingor specialheattreatmentmay beresortedto. 2. Further removetheTrimand thebottomflange. 5. are expected in the pipeline.andthenthegland packingcomponents. 8.CONTROL VALVES FOR POWER PLANTS 2. clean and devoid of oil.Beforestartup 4. If line trash like weld chips. 3. Before disassembly. If the process stream normally contains Scale. Dependingoncontaminant. Maintenance. Note that strainersthatefficiently protectthepumpmaynotbe adequatewhenitcomesto removingdebristhatcan damagethevalveTrim.2 Shop overhaul 6.temporarystrainers shouldbeinstalledupstream. Remove the bonnet from thebody. Continuedinfacingpage CONTINUED FROM PREVIOUS PAGE 7. Valves and valve internal in hazardousserviceshouldbe cleanedthoroughlybefore undertakinganyrepair. dirt orotherforeignmaterial. waterwash.

12. Reassemble the valve bodyusingthereconditioned /new parts. Use only OEM* gland packing and gaskets. *Original Equipment Manufacturer 7. Giving air supply to the genuinespareparts.2 Shop overhaul . ensureevengasketloading.replacethemwith 17. Theanglesofthemating itisimportanttotightenthe piecesareslightlydifferentto diagonallyoppositeboltsto allowanarrowseatingband. First the plug and seat shouldbeperfectlymatched. and possible packing seal. theonlypracticalsolution. Adjust the spring range 11.APPLICATION HANDBOOK ShopOverhaul CONTINUED FROM PREVIOUS PAGE 7. These cannot matchthemetallurgyand workmanshipoffactory finishedspares. If the body is rusted. While tightening the mating pieces is necessary. band is too wide. repair. Avoid use of non standard Trims.Valve Trimsareamongstthemost Actuator. theflange surfaces must be protected to preventanygasketleakage. Actuatoronthevalvebody. descalethebody. and to check for pneumatic leaks. 16. Low quality gaskets can cause 9. If the Trims are beyond andstrokeoftheActuator. 10. bonnetandbottomflanges. by precise machining. keeptheActuator precisionofinstrumentation inmidstrokeandmountthe components. Make sure that even fine tracesoflappingcompound is cleaned off. then by handgrindingorlapping. The lapped contact should irreversibledamagetothe not be too wide.installthe highlypolishedsurfacesare diaphragmcaseusingnew requiredtogivethebest cap screws and nuts. minimizethehysteresis.replacement with a factory finished stem is gasketstherebyresultingin poorjoints. If the contact valve by seat area Erosion. For problems like marred Over tightening can cause excessive elongation of the stemsurface. Assemble parts of the Valve stem is so fine that Actuatorbarrel. a machine cuttorenewtheanglesofthe 14. 8. Ensure that gland packingandgasketsare changed every time the valve isopenedandreassembled.While handlingthebody. The finish of the Control 15. Assess the need for remachiningofBodyand Trims. bodybonnetErosionetc. 13.

whole accessory with spares 23. Process Positioners. better service too. accurately in case they were Some have O Rings that notcorrectlyanticipated deteriorate. 22.Itwouldbe whentheoriginalvalve economicaltoreplacethe was specified. When repair to an existing valve is uneconomical.) conditionsshouldbe haveRubberDiaphragms stabilizedanddetermined thatwillhardenandcrack. accessories (Air Sets. seat leakagetestandcalibration as per relevant standards. Do not buy valves or (andrepairfaultymodels replacementpartsfrom duringslacktime)ratherthan non OEMs.Applyairorremove airtoensureproperseatingof the valve.2 Shop overhaul . quality OEM to avail of better Several of the most common sizing.CONTROL VALVES FOR POWER PLANTS ShopOverhaul CONTINUED FROM PREVIOUS PAGE 18.bettermaterials.replaceitwith a new valve from a high19. 7. Transducers etc. 21. Overemphasis repairing them On Site.andmostlikely. processdowntimeand soapywaterorotherleak increased operating costs. Then tighten the couplingandadjustthetravel indicator. betterdesign. Carry out hydrotest. detectingfluids. Tighten (finger tight) the coupling. Tubing connections for cansometimesleadto signalandoperatingair hazardousworking shouldbecheckedwith environmentsforpersonnel. on short-term cost savings 20. Mount the accessories back on to the Control Valve.

TheMILRange HighperformanceControlValvesfor powerplants .

8. Tight Shut-Off: Class IV leakage isstandard. special double stagevalveswithsimultaneous throttlingintheplugandCage alsoisavailable. Optional:ClassV&ClassVI FEATURES Heavy Top Guiding.single seatedControlValves For severe service.heavytopGuided.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.APPLICATION HANDBOOK MIL 21000 Rugged.The Valve plugshankisGuidedwithinthe lowerportionofthebonnet and thisheavyandruggedguiding ensuresplugstabilityand eliminatesTrimvibration. . Optionalanglebodydesignwith Venturiseatisideallysuitedfor specialapplicationslikeFlashing liquidsandotherchokedflow conditions.2 Standard:ClassIV.Optional constructions meet Class V & Class IV leakage. Quick Change Trim. Angle Body (70000 Series). Optional clampedseatringfacilitateseasy Trimremoval. AntiCavitation/Low Noise Trims replacingconventionalplug with theLo-dBplugprovidesexcellent noiseattenuationandCavitation control.

maintaining constant velocity throughout.Flowcapacitiesremain attoplevels. . High pressure recovery factors at lower lifts eliminates Cavitation.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. Multi-Stage Valves MIL 41008 . High capacity with low pressure recovery. Double Cage design. Forhighersizes. Cage Guided valves provide exceptionalperformanceovera widerangeofpressuredropsin severe services. Concentric Cages incorporate a tortuous flow path.Selfenergisedsealrings pressingagainstwallsoftheCage &Plugarrestsleakagepastthe sealring. They also handle mostshutoffpressureswith standardpneumaticspring diaphragmActuators. Two stage design with diffuser seat ring.unbalanceddesignresults in Class V leakage. which causes numerous velocity head losses withoutappreciablepressurerecovery.2 Standard:ClassIII&ClassIV Optional:ClassV FEATURES High allowable pressure drops. 2. Lo-dB/Anti-Cavitation Cages: NoiseattenuationandCavitation controlachievedbyreplacing conventional Cages with Lo-dB Cages. Standardisedhighperformance material.theexceptional singleseatedleaktightnessof Class V is achieved by the followingspecialoptions: 1. Static Seal Ring. SPECIAL OPTIONS 8. These Multi-Stage valves incorporateauniqueTrimdesignto absorb high pressure drops that prevent Cavitation and maintain constantvelocitythroughoutthe pressure dropping stages.andareattained withminimumpressurerecovery reducingthepossibilityof Cavitationinliquidservice. High impedance flow path reduces pressure by friction and turbulence. For lower sizes.CONTROL VALVES FOR POWER PLANTS MIL 41000 HeavyDutyCageGuided ControlValves.Auxiliaryshut-offpilotplug closesthebalancingholeslocated inthemainpluginshut-off conditions. Tight shut off valves. Thisensurestrouble freeoperationevenin applicationswithinherenthigh pressuredropsandextreme temperatures.

Standardisedhighperformance material:Toensurematerial integrity.2 Standard:ClassV Optional:ClassVI FEATURES Multi Step Axial Flow High Resistance Trim. 8. Pressure recovery factors as high as 0. Noindividualstageisexposedto thefullpressuredrop.APPLICATION HANDBOOK MIL 78000 AntiCavitation&LowNoise Multi-stepHighPressureDrop ControlValves High Noise Levels commonly associatedwithconventionally designedControlValves. SPECIAL OPTIONS. Pressure reductionoccursalongthelength ofthepluginaseriesofthrottling stages. allow much highershut-offpressureswith conventionalActuators. Angle & Inline bodyconfigurations.3 MIL 78000 Series Available Sizes & Rating 6”: ½” to 6” ANSI 900# to ANSI 2500# SeatleakageClassasperANSIIFCI70.Vibrationor Soft seat construction with encapsulated inserts.998. Friction. The fluid also takes a tortuousflowpath. Adiabatic Flow with Friction Reducespressuremuchinthe same way as pressure loss occurringinalongpipeline.HighperformanceTrim materialensuresdurabilityinany severeapplication. . Thespecialdesignprovides controlofhighpressurefluids withouttheErosion. Balanced Trims: Availablefor sizes 2" and above. 78000 Series valves are machinedfromsolidsteel forging. This minimisesCavitationpotential andcontributestowards reductionofNoiseforallfluids. High allowable pressure drops. Low pressure recovery.whichadds resistanceandthereforevelocity headloss.thus extendingTrimlifesubstantially.

and optimisesbonnet/boltingdesign.Multi-path. Self energised body and seat gaskets. TortuousflowpathwithHigh Impedance forenergy Velocity. Axial Flow design. This enables near Zero Pressure Recovery thus ensuring thatstagewisePressureDropsare limitedbelowtheCriticalPressure Drop. . Available with Soft Seat with a special sliding collar to protect the Soft Seat from high pressure fluids. Reduces downstreamVelocity.AxialFlowAnti-Cavitation HighPressureDropControlValves 8. Ensures pricedthanothervalvesinthis longevityevenintheseverestof league. gaskets Ensures Zero Leak. Ingenious Flow Path. Eliminates wiredrawingeffectsonthe leadingedgesoftheplug.Erosioneliminated. Eliminates DynamicInstability inherent to Flow to Close valves. Varyingandexpandingflow passage.Exit VelocityandKineticEnergykept underlimits. Consequentlythismakes MATRIXSeries Valvesbetter Ruggedness of design. Ingenious design. Pressure recovery factor (Cf) as high as 0.LikelihoodofCavitationis ruledouteveninextreme conditions. Results in a As many as 50 Pressure Dropping simplermanufacturingprocess.4 MIL 91000 Series FEATURES. Flow to Open flow direction.9999. Characteristics can be customised to suit specific process applications.CONTROL VALVES FOR POWER PLANTS MIL 91000 MATRIX Series valves ExtremePressureMulti-stage. absorption limits Trim Velocity Modified equal % characteristics with 100 : 1 Rangeability. applications. SPECIAL OPTIONS. stages.

MIListhefirstControlValvemanufacturerinIndiatohavebeenawardedtheprestigiousCEMarkingCertificate byRWTUV.Germany. .

1. MIL41100.RecirculationValve 18 Fig. 17 Boiler Main Feed Water Control Valve 13. 55 U Upstream Piping 57 L Low Load Feed Water valve 20 Low pressure heater drain valves. MIL41008. 23. 13 Typical Applications 116 MW 37 Typical Applications 210 MW 39 Typical Applications. 19. FeedWaterRegulatingSystem. 21. 29. GeneralBoiler(Drumstyle)FlowDiagram 10 Fig. 26.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. 22. 21. 24 Superheater Attemperator Spray Valve 13 Superheater Spray Control Valves 22 Superheater System 22 D Deaerator 14. 27. 18. 30 Main Steam System 13.FeedpumpMin. TypicalAuxiliaryPRDSSystem 29 Fig. Recirculation Valve 13. 15. MIL41400. 17. 10. 7. LP Heaters System 32 Fig. Lesssatisfactoryarrangementofpiping57 M Main Steam Line 22 Main Steam Pressure Reducing Valve 22. 14. 22 Maintenance Guidelines 59 Martensitic Steel 15 Material Selection Guidelines 45. CriticalControlValvesinMainSteamLine 22 Fig. 21. 6. 70 MIL 21000 31.RecirculationSystem 17 Fig. MIL 78000 15 Fig.1 Index & List of Illustrations B Block Valve 24 Body Material Specs 47 Boiler Feed Pump Min. 25. 3. 71 Company overview 8 Condensate Recirculation Valve 13. 500 MW 43 Typical Applications. 20 Fig. 12. AlternateorientationsforControlValves 56 Fig. BoilerFeedPumpMin. 16 Deaerator Pegging Steam System 26 Deaerator Pegging Steam Valve 13. MIL 41000 16 Fig. 14 Condenser 14 S Shop Overhaul 62 Sliding Collar Seat Ring 19 Soot Blower 24. 2. 8. 20. HP Heaters System 32 Fig. 13 LP heaters 31 LP Heaters System 32 ILLUSTRATIONS Fig. 13 HP Heaters 31 HP Heaters System 32. 19. 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. 13. 250 MW 41 Typical Applications. CondensateSystem 14 Fig. 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. Typicalsatisfactorypiping57 Fig. 23 Superheater Attemperator Block Valve 22.SuperheaterAttemperatorvalve 23 Fig. 27 Soot Blower Pressure Control Valves 22 Soot Blower Steam Pressure Reducing Valves. 11. MIL78000. 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 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.SuperheaterAttemperatorblock 24 Fig. MIL 71114 28 Fig. 14 Condensate system 13. 47 MATRIX Series 8. MIL 41008. ClearancerequirementsforValves 55 Fig. 8 Modulating Type System 18 O On/Off System 18 Original Equipment Manufacturer 63 . 17 Deaerator Level Control Valve 13. 22. MIL41200. 25 MIL 41100 23. 5. 4.ReheaterAttemperatorControl 25 Fig. DeaeratorPeggingSteamSystem 26 Fig. 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 15.5 MW 35 G General Boiler Flow Diagram 10 H Handling and Installation 53 Heater Drain System 13. 18 Boiler Feed Pump Minimum Recirculation System 17 Boiler Feed Water Startup Valve 13.ReheaterAttemperatorControl 25 Fig. 14. MIL 21000 31 Fig. MIL 41914 30 Fig. 19. 18. 67 MIL 41000 16. Low Load Valve21 Fig. 17. MIL 41003 27 Fig. 68 MIL 41003 27 MIL 41008 15. 27. 16.SuperheaterAttemperatorvalve 23 Fig. Multi stage. 26. 24 MIL 41114 28 MIL 41121 30 MIL 41128 25 MIL 41200 23. 67. 31 Heater Drain Valve 31 High pressure heater drain valves. 24. 25. MIL78000. MIL 91000 19 Fig. 9. 15. 69 MIL 91000 19. 70 MIL Controls Limited 6. 15. 31.

Mala. Registered Office & Works. Thrissur District. All rights reserved HB/Power/Rev-A/03·2002 .in © MIL CONTROLS LIMITED. Kerala. Fax: + 91 (0)484-623331. 624876. 891773. Tel: + 91 (0)488 890272. 628041. B. P. Tel: + 91 (0)484-624955.com Marketing Head Office. 890772. Kerala. India. Ernakulam Dist. Meladoor . PIN 680 741. India. PIN 683 101. Fax: + 91 (0)488 890952. The handbook also offers expert tips for proper Installation and Maintenance of your Control valves. 04. No. Email: milf@vsnl. Email: ksbmil@sancharnet. Aluva. 2002. ApplicationHandbook TheMILPowerPlantHandbookprovides a broad overview of the various systems in a Thermal Power Plant to help you selecttherightvalveforeachapplication.MIL Controls Limited A KSB Company Control Valves for Power Plants.

Sign up to vote on this title
UsefulNot useful