CCI DRAG® DA-90DSV Attemperator

often caused by poor attemperator performance 50 n Poor atomization of the cooling water leading to large amounts of unevaporated water in the steam line n Poor installation with short distances to downstream elbows. Whether it is a constantly leaking attemperator that must be repaired or replaced every outage. � � � Lowers Maintenance 0 5 600 40 Costs 10 Time. kpph Temperature. reliability and operability of the 20 superheat (SH) and reheat (RH) inter-stage attemperators consistently 30 come into question. be it cycling daily or operating at reduced loads for extended hours. and maintenance personnel. minutes Reduces Erosion Damage30 SH1 SH2 Increases Plant outlet Efficiency inlet 20 Spraywater flow. the limits of inter-stage attemperators in Heat Recovery Steam Generators (HRSG’s) are being tested. As plants search for the most economical operation. operators. Scheduled inspections often reveal: n Damaged spray nozzles n Cracked attemperator housings n Damaged seals n Cracked steam pipes and boiler tubes n Cracked/broken thermal liner The root cause of most inter-stage attemperator problems can be traced to four main system/installation parameters: n High pressure drop through the spraywater control portion of the attemperator n High thermal stresses caused by large temperature differences between the steam and the cooling water Figure 2: Illustrations of damage due to thermal cycling.2 DA-90DSV Attemperator application discussion 1100 50 1000 40 � � � � � Minimizes Leakage Handles High Thermal Stresses Enhances Controllability 800 Prevents Cavitation Damage 700 50 Meets Common Face-to-face Dimensions 900 With each new operating season. kpph . or HRSG reentry points 40 30 flow. the headaches and frustrations associated with inter-stage attemperation are becoming all 15 20 25 30 0 too familiar to plant managers. deg F From HP Turbine Exhaust Reheater Superheater Spraywater DA-90 DSV SH-Interstage Attemperator Reheater Superheater Spraywater 10 0 10 15 20 25 30 DA-90DSV RH-Interstage Attemperator IP/LP Turbine HP Turbine Time. kpph Economizer Boiler Final steam Flash Vessel Spraywater flow Steam Generator Spraywater flow. or a more catastrophic 10 failure like a boiler tube leak or a ruptured steam line. temperature sensors. minutes SH2 inlet Final steam Spraywater flow HRSG Figure 1: Typical HRSG schematic Symptoms of Faulty Attemperators CCI DRAG® DA-90DSV Attemperator Some of the first signs of trouble start with uncontrolled spraywater flow and leakage.

leakage. and the heat affected zones around them. An attemperator design. and cavitation damage (See Figure 3). interstage attemperators will always be exposed to thermal cycling. Valve Trim in the Steam Flow – Problem As allowable operating temperatures increase. To avoid these problems. inter-stage attemperators can see steam to spraywater temperature differences near 700ºF (390ºC). that locates tight clearance control elements (i. valve trim) in an environment that sees these drastic temperature swings will fail. Common failures such as cracked attemperator bodies. cracked attemperator welds. Welds. stuck or seized plug and stem elements.e. The key to eliminating this root cause of failure is to incorporate multiple stages of pressure drop in a control valve trim. This high pressure drop will severely damage and prematurely wear a single stage control element causing wire draw.DRAG® DA-90DSV Attemperator 3 Faulty Attemperator Design Many of the common interstage attemperator systems overlook several or all of the root causes of failure listed on the previous page. and even packing leaks can all be attributed to a design that neglects to account for the high temperature difference in this application. are vulnerable to cracking when put through thermal cycles while also being exposed to high pressure loads and bending stresses. the pressure drop in some inter-stage attemperator spraywater systems can reach levels greater than 2000 psi (133 bar). it’s only a matter of time! Consider the following: Single Stage Pressure Drop – Problem When using fixed speed pumps. A properly designed interstage attemperator eliminates all welds by using a one-piece Chrome Moly forging. location is the key. Tight clearance valve trim components should be moved out of the steam pipe and away from the hot steam temperatures. such as the one shown in Figure 4. thus removing the risk of cracking in the attemperator body. Pressure Boundary and Tack Welds – Problem Due to the nature of the application and the operation of today’s HRSGs. Such designs will lead to problems in your plant. Solution Use multiple stages of pressure drop in a DRAG® Velocity Control Trim Move the valve trim to a safer environment outside of the steam pipe and away from harsh thermal stresses Eliminate all welds by using a one-piece Chrome Moly forging Figure 3: Cavitation damage on plug CCI DRAG® DA-90DSV Attemperator Figure 4: Section view of a conventional attemperator design Problems High pressure drop in a single stage Expose attemperator to high thermal stresses by locating trim components in the hot steam pipe Use pressure boundary welds and tack welds . cracked attemperator nozzles. CCI’s DRAG® Velocity Control Trim can easily package up to 20 stages of pressure drop in attemperator systems to handle the large pressure drop of the spraywater system. This high temperature difference in conventional attemperator designs will lead to high thermal stresses.

with a 500 PLI (9 kg/mm) loading force to achieve tight shut-off Water Inlet Disk Stack Labyrinth Grooves This section of the disk stack has no flow passages.4 DRAG® DA-90DSV Attemperator features Multi-stage DRAG® Disk Stack Technologies Limits fluid velocities. CCI works with plant operators to improve plant performance. . By controlling fluid velocities. controls vibration and erosion. CCI works in accordance with ISA guidelines to ensure cavitation is avoided. erosion is eliminated. reliability and output. in their place labyrinth grooves break up clearance flow. Eliminates Erosion Damage. Multiple Cv disks throughout disk stack allow for characterized design with optimum control throughout all operating conditions Stem Packing Graphite packing is standard for high temperature service Class V Shut-off A metal seat is standard. preventing seat ring damage Customer Connections CCI DRAG® DA-90DSV Attemperator Benefits DRAG™ DA-90DSV Competition n n n Provides the Valve Doctor Solution. Prevents Cavitation Damage.

The DA-90DSV moves all tight clearance trim components out of the steam flow and out of the harmful thermal environment High Flow CCI DRAG® DA-90DSV Attemperator Benefits DRAG™ DA-90DSV Competition n n n n Thermal Stress Analysis. Control element is located outside of the hot steam flow. CCI valves are designed and sized to provide longer intervals between maintenance and allow easy access to all components. and eliminates the risk of welds failing due to the high thermal cycling and stress of the surrounding environment Spray Nozzle The variable orifice spray nozzle used in the DA-90DSV provides excellent primary atomization and high rangeability. Stops Costly Maintenance Cycles. This becomes especially important as pipe sizes increase and the length of the attemperator increases Low Flow No Trim in Steam Flow Many probe designs place valve trims in the steam flow.Use check list to evaluate the benefits of CCI’s DRAG™ DA-90DSV Attemperator 5 Forged Design A fully forged one-piece Chrome Moly design eliminates the need for welding. Proven Desuperheating Experience. Multiple nozzle designs (as pictured) are available for high capacity installations Tapered Profile The attemperator is designed with a tapered profile to minimize any vibrations caused by harmonic frequencies associated with vortex shedding. The design is proven through decades of installation in high temperature steam applications. CCI accounts for all thermal stresses in the attemperator design. Eliminate Thermal Damage to the Trim. . exposing them to high steam temperatures and very large thermal stresses.

The disks at the bottom of the disk stack. Each turn causes a pressure loss in the fluid.e. as recommended by ISA guidelines. thus avoiding cavitation and the destruction to the valve and trim that can come with it. linear. or modified equal percentage (Figure 6). Thus. equal percentage.6 DA-90DSV Attemperator Solutions Multiple Inlet Flow Channels Eliminate Cavitation with DRAG® DRAG® trim forces the fluid to travel through a torturous path of turns (Figure 5). i. Benefits of DRAG® Velocity Control Trim n n ® Prevents Cavitation Damage Improves Plant Performance Eliminates Erosion Damage Lowers Operating Costs Reduces Maintenance Costs Reduces System Complexity Avoids Plant Shutdowns Provides Accurate Temperature Control % Stroke Figure 6: Characterized Equal Percentage DRAG disk stack trim n n n n n n . protects the seating surfaces from cutting and pitting due to erosion or wire draw. eliminating potentially harmful kinetic energy ® CCI DRAG® DA-90DSV Attemperator % Flow 100 90 80 70 60 50 40 30 20 10 0 0 10 Linear Modified Linear Modified Equal % 20 30 40 50 60 70 80 90 100 The DRAG® control valve uses a hard seat material and a very high seat loading to provide reliable and repeatable long term shutoff in very high pressure differential applications. This is accomplished by configuring disks with various numbers of turns within the stack (Figure 6). and the pressure gradually reduces as the fluid flows through the multiple turns. As the valve strokes open. providing good control over the entire range of flow conditions. close to the valve seat. The DRAG® velocity control trim design. the DRAG® control valve disk stack can be designed for many different flow characteristics. are equipped with a higher number of pressure letdown stages (up to 20 stages or more) to provide critical protection of the seating surfaces on the plug and seat ring. Independent and isolated flow paths are used to eliminate short circuits between flow paths and provide the best result in pressure letdown. The DRAG® multistage pressure drop trim provides a clear benefit in terms of performance and maintenance costs when cavitation is a concern. This series of multiple pressure drops controls the fluid velocity and allows the pressure to reduce without falling below the vapor pressure. fewer pressure letdown stages are used for more capacity as the process requires. The actuator is sized to provide a minimum seating load of 500 lb/in (9 kg/mm) of seat ring circumference. combined with the high seating force for shut-off. Reliable Long Term Shutoff Pressure Equalizing Ring (PER) Grooves Figure 5: Each turn in the DRAG trim is a single stage of pressure drop. Accurate Control and Reliable Operation at all Flow Conditions with the CCI DRAG® Disk Stack DRAG® disk stacks can be customized to provide the required Cv throughout the valve stroke.

9” (73.0” (178) 12. .5” (241) 12.5” RF (40) 2.0” (152) 7. Numbers in brackets give dimensions in millimeters 6. 10-14”(250-350) 16-20”(400-500) >20” (>500) 9 10 11 12 14.0” RF (80) 4. 25) 1. (10. Pipe Dia. Custom probe lengths available for retrofit projects .4) C Dia. Given is maximum.75”(450.25” (311. D(4) 2. Customer supplied flanged connection 5.5” RF (65) Steam Flange 3.0” RF (100) ANSI 600-1500 2500 600-2500 A 9. Spacer Yoke Nozzle Housing Spray Nozzle Material ASME-SA217-WC9/C12A ASME-SA182-F22/F91 INCONEL 718 300 SS Graphite/300 SS 300 SS INCONEL 718 Graphite Carbon Carbon Steel ASME-SA182-F22/F91 ANSI 616 4 5 6 7 8 Length (see note 3 & 6) STEAM CONNECTION Nom. Customer flange height will vary to center nozzle(s) in steam pipe 4.81” (96.2) B 6.8) Height (2) Weight 3/8” 5/8” 1” .8) 21.0” (229) 9.6) 17. add 15” (380 mm) for manual override 3. D 2 4 3 1 7 6 5 11 12 HEIGHT No 1 2 3 WATER INLET B Name Body Bonnet Spindle Guide Bushing Gaskets Seat Disk Stack Packing.25” (539. Contact factory for other sizes 2. Stem Packing.5” (40) 19.7” (500) 34” (865) 51” (1295) ~300 lbs (140 kg) ~500 lbs (230 kg) Notes: 1.25” (276.7) 3.8) CCI DRAG® DA-90DSV Attemperator A Trim Size Water Flange 1.12”(358.Technical Specifications 7 C 6” (153mm) MIN 10 8 9 5 MIN BORE. 15.

Nishi-ku Kobe City Hyogo 651-2271 Japan CCI Japan .Throughout the world. Gyeonggi-Do Korea CCI Middle East .ccivalve. Box 603 SE-661 29 Saffle Sweden CCI Switzerland (Formerly Sulzer Valves) Fossil Fuel Phone: 41 52 264 95 00 Fax: 41 52 264 95 01 lm Link 11. Box 65 8404.Florence Phone: 39 0571 5953203 Via Dell’Industria 13 50056 Montelupo Fiorentino (Fl) Italy CCI Italy – Milan Phone: 39 02 4671 2274 Via Vincenzo Monti 8 20123 Milano Italy CCI KK – Kobe City Phone: 81 78 991 5910 6-2-2 Takatsukadai. companies rely on CCI to solve their severe service control valve problems. Dubai FZS1 UAE CCI RSM – World Headquarters Phone: 949 858 1877 Fax: 949 858 1878 22591 Avenida Empresa Rancho Santa Margarita. Winterthur Switzerland CCI Technology Centre – UK Phone: 44 (0) 161 655 1690 Unit A3. CCI Australia Phone: 61 2 9918 4094 21 Catalina Crescent Avalon. ©2007 CCI 880 05/11/07 . 14 & 15. CCI sales offices worldwide.Beijing Phone: 86 10 6501 0350 Fax: 86 10 6501 0286 Fortune Plaza. TX 77018 USA CCI India Phone: 0091 80 4030 3500 SJR iPark. CCI has provided custom solutions for these and other industry applications for nearly half a century. CA 92688 USA CCI Russia Phone: 7 495 941 8660 Europe Square 2. 7 Dong San Huan Zhong Room 606 Office Tower Chao Yang District 100020 Beijing China CCI China – Shanghai Phone: 0086 21 64851331 Fax: 0086 21 64851328 Room 1003-1004 Xinyuan Technology Tower No.Tokyo Phone: 81 3 5402 3100 4th Floor Terada Bldg. Tokyo 105-0011 Japan CCI Korea – Seoul Phone: 82 (0)31 980 9960 10F. P. 6th Floor. Hangangno-2GA Yongsan-Gu Seoul Korea CCI Korea – Gimpo City Phone: 82 31 980 9800 # 26-17. 2-3-3 Shibakoen Visit us online for sales and service locations at: www. Brookside Business Park Greengate. 418 Guiping Road Shanghai 200233 China CCI Houston (Repair Center) Phone: 713 869 5233 3409 Brinkman Houston. Warp Tower Plot No. 210-1. Office 611 Moscow 121059 Russia CCI South Africa Phone: 27 13 690 3305 Shop 4.O. Middleton Manchester M24 1GS UK CHP Contact us at:info@ccivalve. 13. NSW 2107 Australia CCI Italy . Pungmu-Dong Gimpo-Si. EPIP Zone Phase 1.Dubai Phone: 9714 886 1477 Light Industrial Unit: BJ04 Jebel Ali Free Zone. Sinwon B/ DRAG is a registered trademark of CCI. 14 Arnhem Singel Die Heuwel Witbank 1035 South Africa CCI Sweden (Formerly BTG Valves) Oil & Gas CCI Austria (Formerly Spectris Components GmbH) Phone: 43 1 869 27 40 Fax: 43 1 865 36 03 Lembockgasse 63/1 AT-1233 Vienna Austria CCI China . Whitefield Road Bangalore East Bangalore 560 066 India Nuclear Phone: 46 533 689 600 Fax: 46 533 689 601 Industrigatan 1-3.

Sign up to vote on this title
UsefulNot useful