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

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

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

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. A further 25% is the result of oil refinery, oil power generation ti and d other th oil il consumption. ti Clean Gas

Water air i Additive Raw Gas FGD S System

Gypsum

Waste Water

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!

Gas flow

A flow diagram of a FGD

(Source: Penwell)

Flow diagram of a typical wet FGD plant

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

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

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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, air Type of valve RS, IDV RS IDV RS, IDV, R 201 RS, MS, 108G RS IDV RS, RS, IDV, R 201 IDV, , KV RS, MS, 108G, KV
108G = Xomox Lined Butterfly Valve R201 = Xomox Lined Ball Valve KV = Xomox Ball Valve

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

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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. They meet requirements regarding: Corrosion Abrasion Velocity Temperature
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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, a low ph-value, fluorides and operating temperatures of more than 40C (104F) Why risk of abrasion? high contents of solid particles in form of calcium hydroxide or limestone in the media.
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Requirements Why y risk of corrosion? Corrosion originates from FGD process conditions: Chloride concentration ph values ph-values Fluorides Temperatures up to 100,000 ppm 1 ... 6 0 ... 500 ppm > 45 45 C ... < 72 72 C (>113 F .<162 F)

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Requirements Why risk of abrasion? Abrasion originates from FGD process conditions: Solid particles (Calcium Hydroxyd) Operating pressures Velocities up to 50 % 2 ... 8 bar (29 116 psi) 2.3 m/s ... 3.5 m/s (7 5 f/s11.5 (7.5 f/ 11 5 f/ f/s) )

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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, contact corrosion and stress corrosion

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

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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

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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

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

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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

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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
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Superduplex and Hastelloy in FGD Service Corrosion Public literature Pitti f Pitting factor t (P (P.F.) F ) of f di disc materials t i l used di in CenterLine RS
P.F. = % Cr + 3,3x (% Mo + 0,5% W) + 2x %Co + 16 x %N

Material Super-Duplex UNS J93404 y Hastelloy UNS N26022

Cr % 25.00 21.35

Mo % 4.00 13.67

W % 0.00 2.84

Cu % 0.30 0.00

N % 0.27 0.00

Pitting Factor 43.00 71.00

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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 6.5 4.5 30 3.0 1.5

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 65C 65 C (122 (122 F - 149 149 F) Materials for FGD- and Denox-Installations

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Corrosion H t l GUR Hostalen

( (UHMWPE) )

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

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Hostalen GUR, 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.

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Hostalen GUR, a excellent material ! Alt Alternative ti material t i lf for slurries l i Especially at lignite coal-fired power plants, medium t temperatures t are at t 68 C (155F) , th the ph-value h l i is l less than 3.5; Chloride contents of more than 55 55,000 000 ppm and fluorides of up to 500 ppm are normal here. Gas cleaning plants for copper plants and for the cement industry operate with high acid concentrations and low phvalues.
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Hostalen GUR, a excellent material ! Alternative material for slurries Advantages of Hostalen GUR compressed disc Butterfly valves: no danger of corrosion, no wear, no abrasion suitable for p ph = 0 temperature up to 80 C (+176F) Competitive Valve solution vs High Alloy materials e.g. Hastelloy etc. material surcharges
Example: NPS 40/#150 cost of Valve with Hostalen Gur, app. 40% cheaper than same Valve V l with ith H Hastelloy t ll C22 di disc i incl. l surcharges h

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Actual field experiences RS Butterfly Valves in an FGD plant

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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

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After field operation

Despite deposits on the disc no pitting corrosion

Removing partially hardend Slurry suspension is really a hard job.

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Our RS delivery programme f FGD systems for t

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CenterLine RS Series Butterfly Valves for FGD application

Size range: Pressure range: Pressure Class: Temp. range: Body material: Body types: NPS 1.50 to 54.00 up to 150 psi ANSI B 16.47-A #150 - 30 F to 300 F Ductile Iron Wafer Tapped Lug Flanged All short pattern
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Face to face:

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

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Features of our RS design

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CenterLine RS Series Butterfly Valves Features

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

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CenterLine RS Series Butterfly Valves Features 1. 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

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CenterLine RS Series Butterfly Valves Features 2. 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

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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

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CenterLine RS Series Butterfly Valves Features 4. Replaceable Liner

Maintenance friendly Easy assembly due to solid cartridge seat No pins - interlocking assembly Body, shaft and bushing do not contact the process medium Self lubricating bushings result in lower torques

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CenterLine RS Series Butterfly Valves Features 5. Low Cost of Ownership

Standard spare parts Only wetted parts requires replacement

g Seat (rubber ( liner) ) Cartridge Disc Service life 2.5x longer vs boot seat

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

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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. Crane is able to give for every y existing g service / operating p g condition a material recommendation. They meet requirements regarding: Corrosion Abrasion Velocity Temperature
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References

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Crane Process Flow Technologies - Dusseldorf

User List for RS Series , Flowseal MS and Revo Actuators

Enduser

Country

Location/Project

Contractor

Market segment
CLRS

Products
FSMS Revo

Continent
(Enduser)

Electrabel

Belgium Blast Furnace,Unit 2 FGD Belledune FGD Beijing FDG Banshan FGD Chongqing gq g FGD Guang An,Sichuan FGD Jiangyin;Jiangsu FGD GuiZhou YaXi FGD XuZhou FGD Guang Zhou FGD JianBi FGD Ligang Ligang,Jiangsu Jiangsu FGD Changzhou,Jiangsu Lurgi Lentjes Bischoff / Ferrostahl Preussag Noell Steinmller Steinmller Steinmller

Power Power Power Power Power Power

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. Energy & Environment Beijing Longyuan (L&C S) Beijing Longyuan (L&C S) Power Power Power Power Power Power Power

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Crane Process Flow Technologies - Duesseldorf

User List for RS , Flowseal MS and Revo Actuators

Enduser
CEZ CEZ Elektrarna Milnik Elkraft Elkraft Fynsvrket 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,Lnen and others FGD Mannheim and Heilbronn FGD Lippendorf FGD Boxberg,Schwarze Pumpe FDG Weisweiler FGD Ibbenbren Lurgi Lentjes Bischoff L&C Steinmller Lurgi Lentjes Bischoff Thyssen Eng. 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

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Crane Process Flow Technologies - Duesseldorf

User List for RS , Flowseal MS and Revo Actuators

Enduser

Country
Greece

Location/Project
FGD Megalopolis FGD Paiton FGD Tangjin gj ,Units 1 - 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 Yeniky ,Units 1 & 2

Contractor
Preussag Noell Lurgi Lentjes Bischoff Samwhan Corp. p Babcock Wilcox E.P.Z. Saarberg-Hlter L&C Steinmller / Rafako Saarberg-Hlter 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.P.Z. 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

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

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Pictures of Installation

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

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

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

RS Butterfly Valves, NPS 32 in Power Station Ibbenbren, RWE in 1994 after pump discharge

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

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

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

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

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

Our competition..

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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

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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. deterioration

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Knifegate Valve, Typical Installations

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Same size DN800 (32)

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Competitive situation There are some differences between the design of the CenterLine RS butterfly valve and that of competitors. 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)

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Positioning of CRANE Valves today

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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, FGC, copper plants etc.). , CRANE Energy gy feels at home and can offer Here, comprehensive expertise.
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