2 x 60 MW Nafra HE Project Spherical Valve Technical Description

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 -
Spherical Valve as MIV
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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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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 Valve Body
2 Counterweight
3 Upstream pipe
4 Dismantling pipe
5 Valve Servomotor
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Typical
Spherical Valve Arrangement
2 Design Data
2.1 Main Dimensions
Nominal diameter DN 2200 mm

Design pressure PN 250.3 mwc
Test Pressure Ptest 375.5 mwc
Oil pressure rating p 80 to 120 bar
Maximum Discharge Qmax 40 m3/s
2.2 Operation Conditions
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Normal closing: By counter weights
Normal opening: By servomotor(s) oil pressure under no-flow & balanced

condition (closed wicket gates).
Emergency Closing: 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:
σ V = σ 2 + 3τ 2
and must not exceed the allowable stresses shown in the diagram below.
σ V ≤ σ allow = K ⋅ Yield
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b) Definition of load cases
Normal Operation Severe Operation

Spherical Valve
Operating Loading Exceptional Extreme Loading
Components
Cases Loading Cases Cases
• Maintenance Seal
engaged (effective
• Max. static Head + Penstock Pressure with
Valve Body • Pressure Test
Water Hammer Valve closed and other
Units facing Full Load
Rejection)
• Effective Pressure
• Closing under rupture of
during closing at Max.
• Maintenance Seal Pipe (200% of max
static Head at normal
engaged (Penstock discharge)
Flow
Valve Rotor and Pressure with Valve
Trunnion closed and other Units • Pressure Test with Rotor
• Penstock Pressure with
facing Full Load closed (if no
Valve closed and other
Rejection) downstream Test Head
Units facing Full Load
foreseen)
Rejection
Servomotor and Drive • Closing under full Flow • Pressure Test
• Closing under Rupture
of Pipe (200% of max
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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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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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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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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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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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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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2 x 60 MW Nafra HE Project Spherical Valve Technical Description

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Nafra Hydro Electric Project (2 x 60 MW)

Techno-Commercial Bid Document

Nominal diameter DN 2200 mm

2.2 Operation Conditions

Normal closing: By counter weights

Normal opening: By servomotor(s) oil pressure under no-flow & balanced

2.3 Allowable stresses

b) Definition of load cases

Normal Operation Severe Operation

Typical Spherical Valve Design

3.2 Rotor with Trunnions

Typical Rotor Design

3.3 Valve Seals

3.3.1 Service Seal

3.3.2 Maintenance Seal

3.5 Valve Servomotor

3.7 Control and Monitoring

3.8 Downstream Pipe with Dismantling Joint

3.9 Upstream Pipe

4 Shop Assembly and Tests

6 Operation and Maintenance

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