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Crane Energy Flow Solutions - Americas

CenterLine RS Butterfly Valves in POWER / FGD
Werner Kremer Product Manager RS/MS BU Energy / Power

The Power Station CRANE ENERGY POWER

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What Is Flue Gas Desulphurization? •Process used to remove Sulfur Dioxide (SO2) gas prior to release of furnace emissions to the atmosphere •The process is accomplished by using wet limestone FGD Scrubber technology gy
• FGD systems are commonly installed on coal fired power plants • Wet FGD Scrubber technology can also be applied to Refineries, Pulp Mills, and various other industries

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The coal fired Power Station A – E: Steam and boiler houses F: G: H: I: K: L: M: N: Machine house Coal belt Coal breaker Coal belt to vessel bunker Stack Cooling towers Transformer Raw gas channels to FGD 4 .

A further 25% is the result of oil refinery. oil power generation ti and d other th oil il consumption.Flue Gas Cleaning Basic Diagram of FGD FGD-System Flue Gas Fl G Desulphurization D l h i ti i the is th removal l of f the th oxides id of f sulphur l h and d nitrogen it produced d d during the burning of fossil fuels from emissions to the atmosphere. A major source of pollution is coal fired power generation which together with other coal consumption operations. accounts for 60% of all emissions. ti Clean Gas Water air i Additive Raw Gas FGD– S System Gypsum Waste Water 5 .

Wet Limestone Scrubber System for SO2 Removal  Think of SO2 as excess stomach acid We take anti-acids to neutralize the acid A scrubber uses limestone as the neutralizer!   6 .

Gas flow 7 .

A flow diagram of a FGD (Source: Penwell) Flow diagram of a typical wet FGD plant 8 .

g.Where to install Crane Energy Valves e. RS Butterfly Valves in the FGD Process 9 .

Where to install (Process systems. no gas systems) Fl Flow diagram di of f a typical t i l wet t FGD plant l t CenterLine RS Saunders KB XOMOX 108G HP butterfly valve MS And ball valves Total circa 300 – 650 different kind of valves 10 .

R 201 RS. R 201 IDV. IDV RS IDV RS. KV 108G = Xomox Lined Butterfly Valve R201 = Xomox Lined Ball Valve KV = Xomox Ball Valve 11 .CRANE Butterfly Valves and Diaphragm Valves in FGD Black Box Washer/ Scrubber " " Gypsum treatment Water treatment Air systems y Heating system Medium Wash suspension Process water Oxidation Gypsum (fluid) Waste water Air Water. 108G RS IDV RS. MS. KV RS. IDV. air Type of valve RS. . IDV. RS. MS. 108G.

Corrosion C i & Abrasion Ab i - 12 .Requirements of valves for operation in Flue Gas Desulphurization plants .

They meet requirements regarding: Corrosion Abrasion Velocity Temperature 13 .Requirements for Butterfly Valves in FGD Service Material guidelines for wetted parts of the CenterLine RS Series Butterfly Valve are based on fi ld experience field i since i 1980 1980. Crane C E Energy is i able bl to give for every existing service / operating condition a material recommendation.

14 .Requirements high reliability protection against corrosion protection against p g abrasion absolute and permanent tight shut-off Why risk Wh i k of f corrosion? i ? high chloride contents. fluorides and operating temperatures of more than 40°C (104°F) Why risk of abrasion? high contents of solid particles in form of calcium hydroxide or limestone in the media. a low ph-value.

.... < 72° 72 C (>113° F ….000 ppm 1 ..<162° F) 15 . 6 0 .. 500 ppm > 45° 45 C .Requirements Why y risk of corrosion? Corrosion originates from FGD process conditions: Chloride concentration ph values ph-values Fluorides Temperatures up to 100.

.3 m/s .5 m/s (7 5 f/s…11.5 (7. 3.Requirements Why risk of abrasion? Abrasion originates from FGD process conditions: Solid particles (Calcium Hydroxyd) Operating pressures Velocities up to 50 % 2 ...5 f/ 11 5 f/ f/s) ) 16 .. 8 bar (29 …116 psi) 2.

contact corrosion and stress corrosion 17 .Requirements How to construct a butterfly valve in order to guarantee best protection against corrosion? a) ) the th best b t possible ibl use of f materials t i l b) minimizing number of wetted parts c) avoidance of pitting corrosion.

Hostalen GUR Lining material: EPDM (CSM) 18 . Superduplex.Requirements Are these conditions fulfilled by CRANE CenterLine RS ? a) best possible use of materials Disc material: Hastelloy.

Requirements Are these conditions fulfilled by CRANE CenterLine RS ? b) low number of wetted parts The CenterLine RS butterfly valve has only two wetted parts Disc Cartridge seat with lining 19 .

Requirements Are these conditions fulfilled by CRANE CenterLine RS ? c) avoidance of pitting corrosion Quality of disc surface according to DIN S3 eq. MSS (means smooth surface) or better Materials with hi h molybdenum high l bd content t t 20 .

21 . no use of pins or screws for connecting disc/shaft.Requirements Are these conditions fulfilled by CRANE CenterLine RS ? d) avoidance of contact corrosion minimizing metal-to-metal contact points.

Requirements Are these conditions fulfilled by CRANE CenterLine RS ? e) "floating" disc Prevention of wear. Eliminates formation of deposits between disc and li i due lining d to t the th self lf centering t i disc di (no ( pins). i ) = Even compression on the entire disc sealing surface 22 .

Different kinds of corrosion in FGD plants Valves V l d i and design d selection l i of f materials i l have h to be b chosen, to prevent:  Pitting corrosion  Contact corrosion  Stress corrosion

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Different kinds of corrosion in FGD plants Pitting corrosion Pitting corrosion is the most dangerous type of corrosion and requires high-quality high quality materials. materials
Deposits on disc The protective passive layer is not renewed. Pitting corrosion can spread. Actions to be taken: Selection of a cast material with high chrome and molybdenum content & high quality disc surface CRANE uses Superduplex S d l or Hastelloy.
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Needle

Cavity

Different kinds of corrosion in FGD plants Contact corrosion Contact corrosion is one of the most frequent types of corrosion. It occurs when connecting different components as well as at screwed connections, washers, etc.
Action to be taken: Avoidance of gaps, sealings, etc. Due to the internal power connection between disc and shaft, this type of corrosion does not affect the C t Li RS. CenterLine
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Crevice corrosion

Requirements for Butterfly Valves in FGD Service Corrosion Material selection is a function of…  Recommendation in Public literature  Fi ld Experience Field E i 26 .

00 N % 0.00 2. = % Cr + 3.5% W) + 2x %Co + 16 x %N Material Super-Duplex UNS J93404 y Hastelloy UNS N26022 Cr % 25.00 71.00 13.) F ) of f di disc materials t i l used di in CenterLine RS P.27 0.Superduplex and Hastelloy in FGD Service Corrosion  Public literature Pitti f Pitting factor t (P (P.00 27 .30 0.F.F.35 Mo % 4.67 W % 0.3x (% Mo + 0.00 21.84 Cu % 0.00 Pitting Factor 43.

149 149º F) Materials for FGD.0 1.5 4.and Denox-Installations 28 .5 30 3.5 Temperature: Literature: 1000 34 35 40 45 chloride level in ppm 5000 10000 35 40 40 45 45 51 51 - 50000 45 51 Blue = SuperDuplex Red = Hastelloy 50 to 65°C 65 C (122 (122º F .Superduplex and Hastelloy in FGD Service When to use which material in Slurry Service ? Corrosion  Public literature says: Pitting g factor is a function of p pH-value and Chloride level pH-value 6.

Corrosion H t l GUR® Hostalen ( (UHMWPE) ) 29 .

000 .Hostalen GUR®. p An additional fluoride share of > 50 ppm reduces the lifetime of valves many times. a trend setting material ! Alternative disc material for Slurries With washing temperatures of more than 60° C (140°F) and a ph-value ph value of < 3 3. ppm pp are possible. 30 . metal cast materials turn out to be unsuitable very soon  picture Chloride concentrations up p to 100.

a trend setting material ! Installation of Hastelloy disc in a FGD system with pH-value 2.5 causes in a strong corrosion after a short service time. 31 .Hostalen GUR®.

32 . Gas cleaning plants for copper plants and for the cement industry operate with high acid concentrations and low phvalues. Chloride contents of more than 55 55. a excellent material ! Alt Alternative ti material t i lf for slurries l i Especially at lignite coal-fired power plants.Hostalen GUR®. medium t temperatures t are at t 68° C (155°F) .000 000 ppm and fluorides of up to 500 ppm are normal here. th the ph-value h l i is l less than 3.5.

a excellent material ! Alternative material for slurries Advantages of Hostalen GUR® compressed disc Butterfly valves: no danger of corrosion. l surcharges h 33 . app.  material surcharges Example: NPS 40”/#150 cost of Valve with Hostalen Gur. 40% cheaper than same Valve V l with ith H Hastelloy t ll C22 di disc i incl. Hastelloy etc. no abrasion suitable for p ph = 0 temperature up to 80 °C (+176°F) Competitive Valve solution vs High Alloy materials e.g.Hostalen GUR®. no wear.

Actual field experiences RS Butterfly Valves in an FGD plant 34 .

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After field operation Deposits in washer sump in front of closed RS Butterfly Valve View from inside scrubber towards recycling pump impeller 36 .

37 .After field operation Despite deposits on the disc no pitting corrosion Removing partially hardend Slurry suspension is really a hard job.

Our RS delivery programme f FGD systems for t 38 .

CenterLine RS Series Butterfly Valves for FGD application Size range: Pressure range: Pressure Class: Temp.47-A #150 . range: Body material: Body types: NPS 1.30° F to 300° F Ductile Iron Wafer Tapped Lug Flanged All short pattern 39 Face to face: .50” to 54.00” up to 150 psi ANSI B 16.

Value and Performance Features  Low price  Low freight charges  Low installation costs  Reduced footprint  Easy E operation ti  Simple conversion from manual to automatic operation  Positive shut off 40 .

Features of our RS design 41 .

Flattened disc design 4. Maintenance free 6. Square disc/shaft connection 3.CenterLine RS Series Butterfly Valves Features 1. Replaceable cartridge seat 5. ISO top flange/square shaft 42 . Cartridge g Seat design g with solid backup p ring g 2.

Cartridge seat design with solid backup ring  Secures seat in position  Eliminates seat distortion  Minimizes stresses on rubber seat for longer life  Suitable for vacuum service  Easier to assemble and dismantle 43 .CenterLine RS Series Butterfly Valves Features 1.

Square disc/shaft connection  No pins Only y two wetted p parts  O  Corrosion free  Self centering disc/uniform seat compression  Easy to assemble and dismantle 44 .CenterLine RS Series Butterfly Valves Features 2.

CenterLine RS Series Butterfly Valves Features 3. Flattened vs round disc  Even compression p around disc and at disc bosses C t ll d stresses Controlled t Reduced wear Excellent shut off performance    45 .

interlocking assembly  Body. Replaceable Liner  Maintenance friendly  Easy assembly due to solid cartridge seat  No pins . shaft and bushing do not contact the process medium  Self lubricating bushings – result in lower torques 46 .CenterLine RS Series Butterfly Valves Features 4.

Low Cost of Ownership  Standard spare parts  Only wetted parts requires replacement g Seat (rubber ( liner) )  Cartridge  Disc  Service life 2.CenterLine RS Series Butterfly Valves Features 5.5x longer vs boot seat 47 .

CenterLine RS Series Butterfly Valves Features eatu es 6. ISO top flange / square shaft  Direct mounting of actuation possible  Easy change of operators 48 .

Crane is able to give for every y existing g service / operating p g condition a material recommendation.Requirements for Butterfly Valves in FGD Service Summary Material guidelines for wetted parts of the CenterLine RS Series Butterfly Valve are based on field experience since 1980. They meet requirements regarding: Corrosion Abrasion Velocity Temperature 49 .

References 50 .

Crane Process Flow Technologies . Energy & Environment Beijing Longyuan (L&C S) Beijing Longyuan (L&C S) Power Power Power Power Power Power Power 51 .Jiangsu FGD GuiZhou YaXi FGD XuZhou FGD Guang Zhou FGD JianBi FGD Ligang Ligang.Sichuan FGD Jiangyin.Jiangsu Jiangsu FGD Changzhou. Flowseal MS and Revo Actuators Enduser Country Location/Project Contractor Market segment CLRS Products FSMS Revo Continent (Enduser) Electrabel Belgium Blast Furnace.Jiangsu Lurgi Lentjes Bischoff / Ferrostahl Preussag Noell Steinmüller Steinmüller Steinmüller Power Power Power Power Power Power X Companhia Siderurgia de Brasil Tubarao NB Electric Power Canada X X X X X X X X X X X X X Beijing First Cogeneration China Banshan Power Plant Chongqing gq g Power Plant Guang Power Plant Huaiyin Power Plant GuiZhou YaXi Power Plant XuZhou Huaxin Power Plant HuangPu Power Plant JianBi Power Plant Ligang Power Plant Changzhou Power Plant China China China China China China China China China China Beijing Guohua Ebara (LLB) Power Beijing Boqi (AE+E) Shandong Sanrong Wuhan Kaidi Shanghai Longking Env.Unit 2 FGD Belledune FGD Beijing FDG Banshan FGD Chongqing gq g FGD Guang An.Dusseldorf User List for RS Series .

Lünen and others FGD Mannheim and Heilbronn FGD Lippendorf FGD Boxberg. Flowseal MS and Revo Actuators Enduser CEZ CEZ Elektrarna Milnik Elkraft Elkraft Fynsværket Imatran Voima Oy Imatran Voima Oy E ON ( Preussen Elektra ) E ON ( VKR ) RWE STEAG EnBW Vattenfall Europe Generation ( VEAG ) Vattenfall Europe Generation ( VEAG ) RWE RWE Country Czech Republic Czech Republic Czech Republic Denmark Denmark Denmark Finland Finland Germany Germany Germany Germany Germany Germany Germany Germany Germany Location/Project FGD Pocerady FGD Prunerov FGD Milnik FGD Amager Block Section 3 Contractor Lurgi AG Lurgi Lentjes Bischoff ABB Babcock Anlagen Market segment CLRS Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power X Products FSMS Revo Continent (Enduser) X X X FGD Aesnes Block Section 5 Flaekt FGD Odense Block Section 7 Flaekt FGD Meri Pori FGD Inkoo FGD Staudinger. Rostock and others FGD Scholven and others FGD Frimmersdorf FGD Herne.Duesseldorf User List for RS .Crane Process Flow Technologies . Lurgi Lentjes Bischoff Babcock Anlagen Babcock Anlagen Lurgi Lentjes Bischoff Preussag Noell Babcock Anlagen Thyssen Eng. X X X X X X X X X X X X X X X X X X X X X X X 52 .Schwarze Pumpe FDG Weisweiler FGD Ibbenbüren Lurgi Lentjes Bischoff L&C Steinmüller Lurgi Lentjes Bischoff Thyssen Eng.

P. Saarberg-Hölter L&C Steinmüller / Rafako Saarberg-Hölter Lurgi Lentjes Bischoff Black + Veatech Lurgi Lentjes Bischoff Market segment CLRS Power Power Power Power Power Power Power Power Power Power Power X X X X X X X X X X Products FSMS Revo Continent (Enduser) Paiton Private Power Kepco ( Korean Electric Power Corp ) Kepco ( Korean Electric Power Corp ) E.Z.Crane Process Flow Technologies .Duesseldorf User List for RS .P.4 FGD Hadong and TAEN FGD Borselle FGD Siarkopol FGD Jaworzno 3 FGD Opole Block Section 14 FGD Madinat Yanbu AlSinaiyah Steam Power Plant Unit 4 FGD Taichung FGD Yeniköy .Units 1 .Units 1 & 2 Contractor Preussag Noell Lurgi Lentjes Bischoff Samwhan Corp. Borselle Kopaolnie i Zaklady Przetworcze Siarki Indonesia Korea Korea Netherlands Poland Poland Elektrownia Opole Kingdom of Saudi Arabia Royal Commission for Jubail and Yanbu Taiwan Power Poland Saudi Arabia Taiwan TEAS ( Turkiye Elektrik AS Turkey X TEAS ( Turkiye Elektrik AS Turkey FGD Yatagan Lurgi Lentjes Bischoff Power X TEAS ( Turkiye Elektrik AS Turkey TEAS ( Turkiye Elektrik AS National Power Power Gen Southern Indiana G&E Sigeco Turkey UK UK USA USA FGD Cayhiran FGD Orhaneli Drax Ratcliffe FGD Culley Station FGD Birlik Um Pirdop Lurgi Lentjes Bischoff Babcock Borsig Power Babcock Wilcox John Brown Babcock Wilcox Steuler Lurgi Lentjes Bischoff Power Power Power Power Power Power Power Power X X X X X X X X 53 . p Babcock Wilcox E. Flowseal MS and Revo Actuators Enduser Country Greece Location/Project FGD Megalopolis FGD Paiton FGD Tangjin gj .Z.

Pictures of Installation 54 .

RS Butterfly Valves.Typical situation after shut down of scubber. NPS 32“ .

EON in 1997 .RS Butterfly Valves. NPS 32“ during shut down for inspection of the scrubber in Power Station Wilhelmshaven.

Bremen in 1999 . Stdw. View from inside scrubber to pump recycling valve in Power Station Hafen.RS Butterfly Valve during shut down.

NPS 32“ in Power Station Ibbenbüren. RWE in 1994 after pump discharge .RS Butterfly Valves.

RS Butterfly Valves. RWE in 1993 after 10 years in service. Babcock system with scrubber . NPS 48“ in Power Station Weisweiler.

. NPS 48“ in Power Station Weisweiler.RS Butterfly Valves. RWE in 1993 after 10 years in service.

NPS 48“ in Power Station Weisweiler. Typical abrasion of pump impeller .RS Butterfly Valves. RWE in 1993 after 10 years in service.

RWE in 1993 after 10 years in service. NPS 48“ in Power Station Weisweiler.RS Butterfly Valves. .

RWE in 1993 after 10 years in service. .RS Butterfly Valves. NPS 48“ in Power Station Weisweiler.

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RubberRubber -lined disc Why no rubber rubber-lined disc? Rubber lined discs (hard rubber) are ineffective in this WFGD Rubber-lined service. Why y does CRANE Energy gy not offer this option? p 65 .

deterioration 66 .Why no rubber rubber-lined disc? Rubber-lined Rubber lined discs have the following disadvantages: when the valve is closed. disc and rubber lining can stick together (temperature) a rubber-lined disc is not resistant against penetration of slurry corrosion damages of the disc surface are the reason for its rapid deterioration.

Knifegate Valve. Typical Installations 67 .

Same size DN800 (32“) 68 .

These are as follows: two-part body disc-shaft connection with pins or screws body lining as a loose part (a simple "rubber ring" without support) 69 .Competitive situation There are some differences between the design of the CenterLine RS butterfly valve and that of competitors.

Positioning of CRANE Valves today 70 .

. 71 . comprehensive expertise. CRANE Energy gy feels at home and can offer Here. FGC.Where CRANE (CPFT) stands today Worldwide among the "Top Top Five Five" Number #2 in Europe L Long-term t experience i since i 1978 Flue gas cleaning plants are our center of excellence (FGD. copper plants etc…….).

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