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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No.

- SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

Technical Description Spherical Valve as MIV

143525303.doc

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

Table of contents
1 Introduction.......................................................................................................................................... 3 2 Design Data.......................................................................................................................................... 4 2.1 Main Dimensions................................................................................................................................. 4 2.2 Operation Conditions........................................................................................................................... 4 2.3 Allowable stresses............................................................................................................................... 5 3 Design Features................................................................................................................................... 7 3.1 Valve Body (Housing).......................................................................................................................... 7 3.2 Rotor with Trunnions........................................................................................................................... 8 3.3 Valve Seals......................................................................................................................................... 9 3.3.1 Service Seal..................................................................................................................................... 9 3.3.2 Maintenance Seal............................................................................................................................. 9 3.4 Bearings............................................................................................................................................ 10 3.5 Valve Servomotor.............................................................................................................................. 10 3.6 By-Pass............................................................................................................................................. 10 3.7 Control and Monitoring...................................................................................................................... 10 3.8 Downstream Pipe with Dismantling Joint .......................................................................................... 11 3.9 Upstream Pipe................................................................................................................................... 11 3.10 Accessories..................................................................................................................................... 11 4 Shop Assembly and Tests................................................................................................................. 11 5 Field Tests........................................................................................................................................... 12 6 Operation and Maintenance.............................................................................................................. 12

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

1 Introduction
The Main Inlet Valve (spherical valve) will be installed upstream of the turbine inlet pipe in the power house. The valve body will be bolted to the upstream pipe which will be welded at lower end of the penstock. Downstream side will be connected to the turbine inlet pipe by a dismantling joint. The valve body will be settled over embedded base plates and can slide freely in axial direction to compensate pipe deflections due to the axial force when valve is closed. The spherical valve is a protection element of the Hydropower Plant and acts as an emergency closing device in case guide apparatus fails to close the guide vanes and also in case of any damage to the inlet pipe, Spiral case or any other element downstream of the valve. The valve serves also as an isolating element, to drain the spiral case for inspection and maintenance of turbine component(s) without the necessity of emptying the penstock. Typical views / arrangements are provided in this document. However, exact details / arrangements will be provided specific to the project during detailed engineering.

1 2 3 4 5

Valve Body Counterweight Upstream pipe Dismantling pipe Valve Servomotor

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

Typical Spherical Valve Arrangement

2 Design Data
2.1 Main Dimensions
Nominal diameter Design pressure Test Pressure Oil pressure rating Maximum Discharge DN PN Ptest p Qmax 2200 250.3 375.5 80 to 120 40 mm mwc mwc bar m3/s

2.2 Operation Conditions

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV
Normal closing: Normal opening: Emergency Closing: By counter weights

Revision -

By servomotor(s) oil pressure under no-flow & balanced condition (closed wicket gates). By counterweights under full flow condition. Also closing under 200% of max discharge(As an extreme load case)

2.3 Allowable stresses


The following sections present some principal criteria for determining the dimensions of load carrying valve components, based on stress levels and loading. It is divided in two paragraphs, describing in paragraph a) the allowable stresses and in paragraph b) the definition of loading cases for different valve components. a) Allowable stresses Adequate factors of safety will be used throughout the design. Under the most severe conditions of loading expected in the various load cases, stresses in the material will not exceed the values listed below. The values for uniform stresses apply for conventional calculation methods, the values for peak stresses can be considered by means of finite element calculations. The allowable stresses are determined to the minimum yield point and consider local peak stresses. The actual combined stresses have to be calculated according to the von Mises Theory:
V = 2 + 3 2

and must not exceed the allowable stresses shown in the diagram below.

V allow = K Yield

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

b) Definition of load cases Spherical Valve Components Normal Operation Operating Loading Cases
Max. static Head + Water Hammer

Severe Operation Exceptional Extreme Loading Loading Cases Cases


Maintenance Seal engaged (effective Penstock Pressure with Valve closed and other Units facing Full Load Rejection) Maintenance Seal engaged (Penstock Pressure with Valve closed and other Units facing Full Load Rejection)

Valve Body

Pressure Test

Valve Rotor and Trunnion

Effective Pressure during closing at Max. static Head at normal Flow Penstock Pressure with Valve closed and other Units facing Full Load Rejection Closing under full Flow

Closing under rupture of Pipe (200% of max discharge) Pressure Test with Rotor closed (if no downstream Test Head foreseen) Pressure Test Closing under Rupture of Pipe (200% of max

Servomotor and Drive

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision discharge) Rotor blocked

3 Design Features
3.1 Valve Body (Housing)
The valve body will be in two parts and will be a integrally cast or cast welded or welded design. The connection between the upstream and downstream parts of the valve body shall be made with bolts of high strength steel utilizing rubber O-rings as sealing elements. The body will have a tap on the highest point for aeration and an adequate flange connection at the bottom for draining the valve for maintenance. The body will have integral feets to support it on embedded base plate. To allow axial movements of the housing, the feet will be equipped with an arrangement suitable for the intended service.

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

Typical Spherical Valve Design

3.2 Rotor with Trunnions


The valve rotor will be designed from cast steel and/or fabricated steel plate. It will withstand the forces due to water pressure keeping the deflections to an absolute minimum. The attached trunnions will be made of cast stainless steel. They will be attached to the rotor by high strength steel bolts. Alternatively trunnion will be made with forged carbon steel with stainless steel sleeve.

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

Typical Rotor Design

3.3 Valve Seals


The spherical valve shall be equipped with two main seals, a service seal and a maintenance seal. To attain sealing, the movable part of seals will be pressed to the stationary seat ring by using penstock water through seal water control system. The movable parts are located in body and stationary seat rings are on the rotor.

3.3.1

Service Seal

The service seal is arranged at the downstream end of the spherical valve. In the open position of the rotor and during the closing motion the seal remains retracted by pressurized water taken from the penstock through seal water control system. It will be ensured by governing system that seal gets applied only when rotor is in closed position.

3.3.2

Maintenance Seal

The maintenance seal is arranged at the upstream end of the spherical valve. It permits maintenance work on the service seal at the downstream end of the valve. It will be applied by

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

a manually operated hydraulic valve utilizing pressurized water from the penstock. It will be ensured by governing system that seal gets applied only when rotor is in closed position.

3.4 Bearings
The proposed bearings are maintenance free, with stainless steel mating surfaces on the trunnions and bronze carrying bushings that can be exchanged with a minimum of disassembly effort. The radial bearings and trunnion seals will be fitted inside carrier bushings. The trunnion seals are arranged to prevent water from entering the bearing.

3.5 Valve Servomotor


Opening of the valve is performed by two single acting hydraulic servomotors, which are operated by pressurized oil from a hydraulic oil supply system. Closing weights are provided for the closing of inlet valve. The valve servomotor will be designed to withstand the maximum forces during emergency closure.

3.6 By-Pass
A by-pass pipe will be included from the upstream connecting pipe to the downstream pipe extension of the valve. The bypass line shall also have one full flow guard valve for the bypass valve. The bypass valve shall be slide valve with valve seat. It shall be operated hydraulically (by servomotor) and be equipped with proximity switches indicating the open and closed positions of the bypass.

3.7 Control and Monitoring


For control and monitoring purposes, the valve will be equipped with the following instrumentation: Penstock pressure gauge Pressure gauge for pressure measurement on downstream side on valve Valve rotor position indication (with scale, limit switches) Pressure differential switches

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

3.8 Downstream Pipe with Dismantling Joint


The downstream pipe is equipped with boss for bypass line connection. On upstream side, it has welded flange for connection with valve body. On downstream side, it comprises of dismantling joint with loose flange(s) which will be connected to spiral case inlet flange.

3.9 Upstream Pipe


The upstream pipe is equipped with boss for bypass line connection. Its downstream end has welded flanges for connection with valve body and upstream side will be prepared to weld with Penstock. It will be designed to transmit axial load to concreted thrust block when the valve is in closed position.

3.10 Accessories
The following accessories will be supplied: Pipe for drainage, including shut-off valve. Air Release valve to release/ supply air. Access platforms complete with stairs and guard-rails for access to operate/maintain arrangements on the top of the valve, e.g. bypass arrangement, etc.

4 Shop Assembly and Tests


The spherical valve will be assembled in the workshop without servomotor and counter weights. The assembly will be filled with water, leakage tested at the maximum operating pressure and pressure tested for integrity at 1.5 times the design pressure. Function Tests: The complete valve with testing levers excluding servomotors and counter weights shall be assembled and tested in the workshop. Operating test of the complete inlet valve. Operating test of the servomotor separately for free movement for closing and opening. Operating test of bypass arrangement separately.

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Nafra Hydro Electric Project (2 x 60 MW) Techno-Commercial Bid Document ICB No. - SEW/NAFRA/E &M- Package - 2/09/2010

2 x 60 MW NAFRA HE Project

Technical Description
Spherical Valve as MIV

Revision -

5 Field Tests
Valve seals leakage test. Operational tests to check sequence of operation of by-pass valve, valve seals, etc as per approved logic diagram. Closing under full flow condition. Opening under pressure balanced condition. Determination of valve opening / closing time.

6 Operation and Maintenance


Operation manuals and maintenance manuals will be provided before commissioning phase.

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