Pressure

Reducing &
De-superheating
Stations

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 ARI Steamline Pressure Reducing &
De-Superheating Stations

THE NEED FOR A PRS ECONOMIC BENEFITS OF PRESSURE REDUCTION?

Most modern boilers operate at high pressures, typically 10.5 to
17.5 kg/cm2g. Pressure Reducing Stations or PRD stations are
an integral part of any steam system. They reduce the pressure
and hence, the temperature of steam just before the process.
WHY IS STEAM GENERATED AT HIGH PRESSURE?
1. LP steam has higher latent heat and can tend to reduce the
amount of steam produced by the boiler, ie higher efficiencies.
2. All steam equipment have a MAWP - maximum allowable
working pressure. A PRS is used so that safe working
pressures are not exceeded downstream of the PRV.

8Steam at high pressure (HP) has a relatively higher density,
or low volume than at atmospheric pressure.This means that
the higher the pressure, the smaller the bore of pipework
required for distribution of a given mass of steam. Smaller bore
means smaller, therefore cheaper steam equipment.
8The boiler size stays small as HP steam has low volume.
3. Less flash steam is lost if the plant is operated on LP steam.
Reduced pressure lowers the temperature of the downstream
pipework and reduces radiation losses.
4. The temperature of saturated steam varies with the pressure,
so this also provides a simple method of controlling temperature
of steam going to a process.

8HP steam is drier than LP steam.
8Smaller bore pipes have much lower heat losses.
8HP boilers have fewer reduced output / ‘carryover’ problems.
Therefore it is energy efficient to produce and distribute HP
steam and reduce pressure upstream of any items of plant
designed to operate at a lower pressure.
5.For the same output, LP steam equipment may be larger, but
is still cheaper as it follows a lower design specification.
6.Plants are normally built in stages. Starting with the HP stage,
we flash HP condensate and use the LP flash steam in the LP
stage. This saves energy. At times the flash steam being
generated is not enough and a PRV is used to maintain
continuity of supply in the LP system.

THE PHYSICS OF STEAM e Critical Point

Sa

tu
lin D’

ra t
uid D

ed v
When water is heated, its temperature rises (region Liquid liq
A – B ). As its temperature reaches the boiling point, d
region te

a p ou r lin e
ra

Lines of constant pressure

its phase changes to steam (region B – C), with no u
rise in temperature, and it boils at its saturation at
S
Temperature

temperature. Here a large amount of heat is added

with no rise in temperature, but a change in phase.
This steam is called Saturated steam.
B’ C’
Two-phase
The Bell Curve to the left shows this, with each line region
representing a constant pressure. The total energy
B C
in saturated steam is the sum of the enthalpy of
water and the enthalpy of evaporation. Superheat
region
hg = h f + h f g
Where:
h g = Total enthalpy / Total heat of sat steam (kJ/kg) A
hf hfg Lower pressure, but more energy!!
h f = Enthalpy of Water (Sensible heat) (kJ/kg)
h f’ h f g’ hsuper
h f g = Enthalpy of Evaporation (Latent heat) (kJ/kg)
hg

THE PHYSICS OF PRESSURE REDUCTION WHAT IS SUPERHEATED STEAM?

Steam imparts heat to the process by condensing into water, When more heat is added to saturated steam in the region B-C,
thus giving off its latent heat. Thus, the work done by steam in a its temperarure rises further to reflect the amount of heat added.
process is primarily done by latent heat (h f g ). Steam in the region C – D is called Superheated steam.

In the graph, follow the higher pressure line A’ – B' – C' – D' on
the curve. The total energy in saturated steam at the higher
pressure still remains h g , but the h f ’ increases and the h f g’
decreases.
Hence, lower the pressure of steam, the higher the latent heat
content (h f g) or the Enthalpy of Evaporation. This is why use
steam at lower pressures.
So, to conserve fuel, if the process demands a certain ∆T for
efficient heat transfer, then we have to find out the lowest
pressure that satisfies the temperature demand.
Thus, Superheated steam is steam that is at a temperature
higher than its boiling point (or saturation temperature) at the
given pressure. For example, saturated steam at a pressure of
32 bar g has a temperature of 238.5°C. If further heat is added
to this, its temperature could be 300°C at a pressure of 32 barg.
ADVANTAGES OF SUPERHEATED STEAM
Superheated steam has more energy, higher specific volume
and can be transmitted in smaller lines, as higher velocities are
possible. Typically, it is used in steam turbines for power
generation. Its higher energy means a more efficient turbine,
and since it has no possibility of moisture, it protects against
damage/ misbalancing of turbine blades from water (pitting).
WORKING PRINCIPLE OF A PRS MATERIALS

A typical PRS with a self-acting PRV - diaphragm type, is shown
below. The moisture separator (1) traps moisture and provides
dry steam to the process. Inlet and outlet press gauges (2, 8)
check generation pressure and PRV operation. The inlet/ outlet
valves (3, 7) can be used to shut-off steam supply to the PRS/
process, and the bypass valve (10) is used during maintenance
to provide another flow path. The strainer (4) removes dirt,
welding slag and other particles that could damage the PRV (5).
Piping Materials – typically ASTM A 106 Gr B, Sch 40 or Sch 80
Valve and Flange Standards – typically ASA 300 / 600
Valve body MoC – typically CS to ASTM A 216 WCB
or NI to EN - JS1049 for lower pressures
Valve Trim – typically hardened SS or stellited trim for higher
pressure drop / temperatures
STANDARD SUPPLIES FOR PRS

A balancing line from the outlet is returned to the PRV actuator, Sr. Description
as feedback to balance pressure to set pressure. This balancing 1 Fab. Moisture Separator 8 Outlet Pressure gauge
line is taken 0.7–1m downstream of the PRV to have minimum
2 Inlet pressure gauge 9 Safety Valve
turbulence. A condensing pot (6) is used in the balancing line to
cool the steam. This enhances the PRV diaphragm’s life as it 3 Bellow sealed stop valve 10 Bellow sealed valve
does not come in direct contact with high temperature steam. 4 Fabricated Strainer 11 Trap inlet stop valve
A safety valve (9) ensures that outlet pressure never exceeds 5 Pressure reducing valve 12 Ball float steam trap
set-point, even if the PRV fails. This would normally be set to 6 Condensing pot 13 Trap outlet stop valve
blow at 10% above the PRV set pressure.
7 Bellow sealed stop valve 14 Interconnecting piping
Pressure Reducing Station (PRS) 10
O A
C Z

14
9
2 8
Bypass
Valve 7
1
Moisture
3
4
O A

Separator
C Z
O A
C Z

High Pressure 5
Low Pressure
Steam In Steam Out
Inlet PG Outlet PG Safety
Inlet Outlet
Valve Valve
11 Strainer
Valve

12 6
13
Predu
PRV or CV? Predu - Pressure
Reducing Valve

A PRV based system is
preferred when:
— compressed air or power
is not available at usage
point
— your maintenance team
are primarily mechanical
engineers
— outlet pressures do not
vary in normal conditions
— flow turndown required is
within 10:1
— flows are smaller and
capital cost is to be kept
low
A CV based system is ARI STEAMLINE PRV - THE HEART OF THE SYSTEM
preferred when:
P1 P2 WORKING OF A PRV
10 barg 3 barg
— pressure control is critical
P1 = Inlet pressure
and fast response is required P2 = Outlet / feedback press
— a wide range of downstream Plug P3 = PRV’s spring tension
pressure variations is (adjustable set point)
required i.e. set pressure is The outlet pressure which is to
variable be controlled is tapped
— flow turndown ratio required downstream and transmitted
via control line to the operating
is more than 10:1 diaphragm. Here it converts to
— you want to remotely read, a positioning force (P2). This
adjust, control the pressures Spring force pushes up the plug
— your process requires against the downward force of
the spring (P3).
variable and high flowrates Diaphragm Control
and/or variable or high Line When P2>P3, the valve closes
upstream pressure proportionately to the change
P3 in pressure. The valve plug
— remote control via PLC / P2>P3 hence modulates to achieve
P2
SCADA is required Upward force constant outlet pressure.
on diaphragm

4Increased diaphragm area opens a larger main valve, allows

KEY BENEFITS OF AN
greater capacity per line size than an internally piloted valve.
PRV sizes up to 150 NB can be offered using this design.
4Diaphragm operated externally piloted valves are more
ARI STEAMLINE PRS sensitive to pressure changes - typical accuracy of ±3%.
4Perfectly suited for a large range of simple applications where
4Assures dry steam at the desired set pressure critical control is not paramount.
4All components are CS or NI 4No external power requirement.
4Steam is not in direct contact with diaphragm - enhances life 4Frictionless plug stem sealed by SS bellows - Zero leaks.
4High quality of all components ensures reliability 4Plug is guided V-port by default, to handle high pressure drop
4Field proven with over 1000 installations 4A wide set-point range and easy adjustment.
4Extended warranty options available 4Low-maintenance, rugged construction with a simple design.
4Packaged system with IBR approval 4Very good resolution for set pressure selection.
4Also available for water, air and gas 4No small ports which could get blocked - feedback line 15NB
 ARI Steamline Pressure Reducing &
De-Superheating Stations

WHAT IS A DESUPERHEATING STATION? KEY BENEFITS OF AN

A Desuperheating station (DSH) 'de-superheats', in other ARI STEAMLINE PRDSH
words, cools superheated steam back to its saturated state.
Water is injected in a controlled manner, to take up extra heat,
by evaporating into saturated steam. A temperature feedback is
provided from the DSH outlet to a Control Valve in the Spray
Water line, thus automatically varying the quantity of water as
required. The Spray Water is atomised using one or more
nozzles in the center of the steam path, to ensure complete
mixing, and better evaporation of the water. This is done just
after pressure reduction, when velocity is high and the flow is
turbulent. The lance that holds the nozzle in the steam path,
leads to further turbulence and better evaporation of the water.
WHAT IS A PRDSH?
A PRDSH combines two steam condition devices – a Pressure
Reducing Valve and a Desuperheater. Typically, a PRDS will
also have some steam conditioning like a strainer, isolation and
bypass valves, a safety valve at the outlet, pressure and
temperature monitoring, etc.
Bypass
Valve
O A
C Z
4 Assures steam at the desired set pressure and temp
4 Full alloy steel pressure reducing stage
4 Good turndown ratios on steam and water flow
4 Excellent control of pressure and temperature of steam due to
high accuracy of Sensors & Electronic PID Controllers
4 Designed specifically for critical applications with high pressure
ratios
4 Purpose designed industrial grade control valves, with stellited
trim where required, V-port or perforated plug options
4 Simple and rugged desuperheating, with no moving parts in
desuperheater
4 Easy integration with plant DCS or PLC Control Systems due to
open standards
4 High quality of all components ensures reliability
4 Field proven with over 160 installations
4 Extended warranty options available
4 Packaged system with IBR approval
4 Single vendor with complete package responsibility and
guarantee
Stevi
Control
Valve

Outlet Safety
O A O A

Water
C Z C Z

Inlet
Pressure Valve
ARI

Pressure
Inlet
Temp
Outlet
O
C
A
Z
Strainer O
C
A
Z

Temp
ARI
NRV

High Pressure Inlet Stevi Outlet Temp Low Pressure

Superheated Valve Control Valve Valve Sensor Saturated
Pressure
Steam In Steam Out
Transmitter
Pressure Temperature
Controller Controller
References

Food & Beverage Chemicals OEMs

Cadbury India, Baddi / Pune
Dugar Foods & Beverages, Nepal
Dynamix Dairy, Pune
Explicit Trading & Mktg, Ghaziabad
Godrej Consumer Products, Pune
Godrej Foods, MP
Morya Distilleries, Paithan (PRDSH)
Oaisis Alcohol Ltd., Satara (PRDSH)
Padmesh Beverages, Guwahati
Parag Milk Foods P Ltd, Pune
Parakh Foods, Pune
Parle Agro Mumbai (Fortune), Nasik
Parle Agro, Bhopal/ Mandideep
Parle Agro, Mumbai / Patalganga
Parle Agro Frooti Beverages, Chennai
Swastik Fruits Products, Ranchi
Victoria Agro Food, Latur (PRDSH)
Pharma
Cadila Zydus, Ankleshwar
Cipla, Patalganga
Fresenius Kabi, Pune (PRDSH)
Intervet, Pune
IPCA Laboratories Ltd, Ratlam
Kores India Limited, Roha
Sajjan India Ltd, Ankleshwar
Viva Drugs, Chandigarh
Zydus, Mumbai
1/2 Arcoy Biorefinery, Panoli (PRDSH) 1 Atlas Copco (I) Ltd, Pune 2
2 Benzo Chem Industries, Mumbai 1 Cee Dee Vaccum, Pune 1
4 Clean Science & Tech P Ltd, Kurkumbh 1 Eclipse, Pune 1
4 Croda Chemicals, Navi Mumbai 5 Filtron Engineers, Pune 7
2 Foods, Fats & Fertilisers, AP (PRDSH) 1 Jasubhai Engg Pvt Ltd, Mumbai 1
1 Gujarat Insecticides, Ankleshwar 2 KBK Chem Engg, Pune (PRDSH) 2+8
3 Inventys Research Co P Ltd, Mumbai 1 Nestler Limited, Mumbai (PRDSH) 6+2
3 Jaimurthy Min, HP 1 Praj Industries Ltd, Pune (PRDSH) 5+5
1 Jubilant Organosys, Mysore 1 Praj R&D, Pune 2
1 Lona Industries, Patalganga 5 Precision Controls, Pune 3
7 Multi Organics, Chandrapur 2
1 Orchid Chemicals, Aurangabad 1 Auto
3/3 Privi Aromatic, Mahad 6 Suvarna Fibrotech, Pune 8
2/1 Shalina Laboratories, Mum (PRDSH) 2+4 Tata ACSI, Pune 48
2 Shriram Trading & Mfg. Co., Kolhapur 2 Tata ACSI, Uttaranchal 16
3 Thermax Chemicals, Khopoli 2
3 UPL, Ankleshwar, Jhagadia, Vapi 7 Textile
Vimal Organics, Ghaziabad 3 Alok Industries, Vapi 16
Warna, Kolhapur 2 Arjuna Cotton, Pune 2
1 Oswal Denims, Punjab 1
1 Vegetable Oils Leela Dye House, Chandigarh 1
5+1 Arian Engineering, Bhopal 5 Mtex Machines P Ltd, Navi Mumbai 1
8 Cargill Foods India Ltd, Kurkumbh 2
1 Dynamic Systems, Kolhapur 1 Others
1 Ruchi Soya, Indore / Patalganga 2/1 Ammunition Factory Khadki 16
1 Shivani Oil Mills, Kolhapur 2 Brown Paper Tech, Pune 1
1 Govind Rubber Ltd, Mumbai 2
4 Power
A2Z Powercom Pvt Ltd, Delhi 1
ARI Armaturen Steamline LLP
Allrights reserved.

ARI Armaturen Steamline LLP TM • Survey No. 32/3/14, Kondhwa Budruk, Pune 411048 India
Phone: + 91 20 2693 2213 • Fax: + 91 20 2963 2214 • Email: sales@ari-steamline.com • Web: www.ari-steamline.com
ARI-Armaturen Albert Richter GmbH & Co. KG • Mergelheide 56-60 D-33758 Schloß Holte-Stukenbrock, Germany