Pressure Reducing and Desuperheating Valves. Solutions for Steam Conditioning Applications.

Transcription

1 Pressure Reducing and Desuperheating Valves Solutions for Steam Conditioning Applications Energy Conservation Environment Process Efficiency Forbes Marshall Forbes Marshall Arca Forbes Marshall Codel Krohne Marshall Spirax Marshall Forbes Vyncke

2 For over six decades, Forbes Marshall has been building steam engineering and control instrumentation solutions that work for process industries. Today we have evolved into a leader in process efficiency and energy conservation through technology tie-ups and focused investments in manufacturing and research. Our joint ventures with the world's leading names enable us to deliver quality solutions in 18 countries. Forbes Marshall is unique in having extensive expertise in both steam and control instrumentation. The dual expertise has allowed us to engineer industry specific systems that focus on energy efficiency and utilities management for diverse sectors such as textiles, food processing, paper, power, mining, oil and gas, and chemicals. Our teams consist some of the finest engineers and talent. These highly trained professionals have developed innovative solutions to better process efficiencies and help save millions of dollars for our clients. Our business practices and processes have combined into a singular philosophy of being trusted partners who provide innovative solutions. It's a philosophy we are proud to live up to. We have long standing partnerships with some of the best names in the control instrumentation industry such as Spirax, Arca, Codel, Krohne and Shinkawa, to develop, design and supply innovative solutions for measurement and monitoring of process parameters. With a combination of specialist knowledge and the latest technology, we provide products and solutions to achieve optimum efficiency. Our products are a unique combination of hardware and software that make them reliable and accurate. How is it different from conventional pressure reducing and desuperheating? The conventional method of pressure reducing and desuperheating steam calls for a pressure reducing valve followed by a desuperheater. Forbes Marshall brings the most advanced method to reduce pressure and temperature of steam in a single unit called a 'Combined PRDS. During the process of pressure reduction in the valve water is simultaneously injected into a highly turbulent zone called the 'Vena Contracta'. This causes instantaneous evaporation of water for complete desuperheating. PRDS Valve Series Series 540- Water entry from top of PRDS : For high steam pressure drop and high spray water quantity requirement. Series 520- Water entry from bottom of PRDS : a. Through stem : For low steam pressure drop and high or low spray water quantity requirement. b. Through nozzle: For high steam pressure drop and low water quantity requirement (Available only in valve sizes 25NB (1") and 50NB (2"). Features Pressure reduction and desuperheating in a single valve Immediate response to flow changes No waterhammer No water carryover problems Efficient mixing of spray water Compact design Reduces need for separate desuperheater which reduces labour Reduces length of piping because of elimination of separate desuperheater Typical Applications Turbine Bypass Condensor Dump Main Steam Line Turbine Extraction Auxiliary PRDSH Deaerator Pegging Ejector and Gland Sealing Available in various types like water entry from top or bottom as per water quantity and pressure available at site Water is injected at the 'Vena Contracta' point which is the most turbulent zone causing complete atomization High turndown ratio possible Improved rate of heat transfer Easy maintenance Some designs don't contain a nozzle which avoids possibility of choking

3 Dimensions and Weight of Combined PRDS Valve E WATER C2 STEAM C1 STEAM B C B B STEAM WATER A A 540 series 520 series A WATER Series Combined PRDS Valve - water entry through top Ansi Class #300 #600 Size Size A A B B C C E E Wt Wt A A B B C C E E Wt Wt (NB) (Inch) mm Inch mm Inch mm Inch mm Inch Kgs Lbs mm Inch mm Inch mm Inch mm Inch Kgs Lbs Ansi Class #900 #1500 Size Size A A B B C C E E Wt Wt A A B B C C E E Wt Wt (NB) (Inch) mm Inch mm Inch mm Inch mm Inch Kgs Lbs mm Inch mm Inch mm Inch mm Inch Kgs Lbs Series Combined PRDS Valve- water entry through bottom Ansi Class #300 #600 Size Size A A B B C2 C2 C1 C1 Wt Wt A A B B C2 C2 C1 C1 Wt Wt (NB) (Inch) mm Inch mm Inch mm Inch mm Inch Kgs Lbs mm Inch mm Inch mm Inch mm Inch Kgs Lbs Ansi Class #900 #1500 Size Size A A B B C2 C2 C1 C1 Wt Wt A A B B C2 C2 C1 C1 Wt Wt (NB) (Inch) mm Inch mm Inch mm Inch mm Inch Kgs Lbs mm Inch mm Inch mm Inch mm Inch Kgs Lbs Notes: C2 = Without cooling fins, C1 = With cooling fins Mentioned weight is for subassembly of PRDS. Bottom entry through nozzle design is available only in 25 NB (1") and 50 NB (2") sizes.

4 Universal Diaphragm Actuator - Series UI, UIII UV High actuating power at an affordable cost Forbes Marshall universal diaphragm actuator series UI, UIII UV features a pneumatic actuator designed for applications that demand high actuating power. Its optional reinforced spring with compact air chamber delivers up to 2500 kgf (14000 lbf) thrust force for extreme pressure control applications. These diaphragm actuators can be fitted with standard accessories like positioner, feed-back transmitter, limit switches and airfilter regulator. Optional hand wheel is provided for emergency operation. Actuator Technical Information Temperature range -13ºC to 90ºC (8.6ºF to 194ºF) Maximum operating pressure 6 bar (g) (87.02 psi) Linearity < 2% Hysterisis Max. 3% Air supply connection ¼" NPT* *Others available on request Materials Diaphragm housing Diecast Aluminium Diaphragm Purbunan Rubber Springs Stainless Chrome Steel Spindle Stainless Chrome Steel Yoke Carbon Steel H0 H D AIR TO OPEN H - Without Hand wheel AIR IN Fig. 4 H0 H D AIR TO CLOSE H + HO - With Hand wheel H+HO H D UI (24.8) 495 (19.4) 270 (10.6) UI (25.1) 505 (19.8) 270 (10.6) UIII (36.2) 723 (28.4) 392 (15.4) UIII (37.4) 753 (29.6) 392 (15.4) UV (50.7) 995 (39.1) 530 (20.8) UV (51.1) 1005 (39.5) 530 (20.8) *All dimensions in mm (Inches) Features : Field reversible - Flexible control action High thrust forces - Usable in extreme pressure reductions Low maintenance - Less inventory Cast aluminum housing - Light weight corrosion resistant Thrust force Kgs (lbs) - Air to Close AIR IN Air Supply Standard Standard Standard Range Bar UI-20 UI-30 UIII-30 UIII-60 UV-60 UV-100 (Psi) Bar Bar Bar ( Psi) ( Psi) ( Psi) 2.8 (40.6) 560 (1232) 1270 (2794) 2540 (5588) 3.0 (43.5) 620 (1364) 1410 (3102) 2820(6204) 3.5 (50.7) 776 (1707.2) 1760 (3872) 3525 (7755) 4.0 (58.0) 930 (2046) 2115 (4653) 4230 (9306) 4.5 (65.2) 1085 (2387) 2470 (5434) 4935 (10857) 5.0 (72.5) 1240 (2728) 2820 (6204) 5640 (12408) 5.5 (79.7) 1395 (3069) 3170 (6974) 6345 (13959) 6.0 (87.0) 1550 (3410) 3525 (7755) 7050 (15510) Thrust force - Air to Open Actuator Model Spring Range Bar g (psi) Air to Open Spring to Close From To Thrust Force Kgs (lbs) UI-20.n 0.2 (2.9) 1 (14.5) 60 (132) UI-20.n 0.4 (5.8) 1.2 (17.4) 125 (275) UI-20.n 0.6 (8.7) 1.4 (20.3) 185 (407) UI-20.n 0.8 (11.6) 1.6 (23.2) 250 (550) UI-20.n 1 (14.5) 1.8 (26.2) 310 (682) UI-20.v 1.2 (17.4) 2.25 (32.6) 370 (814) UI-20.v 1.4 (20.3) 2.45 (35.5) 435 (957) UI-20.v 1.6 (23.2) 2.65 (38.4) 500 (1100) UI-20.v 1.8 (26.1) 2.25 (32.6) 560 (1232) (42) (37) UI-30.n 0.2 (2.9) 1 (14.5) 60 (132) UI-30.n 0.4 (5.8) 1.2 (17.4) 125 (275) UI-30.n 0.6 (8.7) 1.4 (20.3) 185 (407) UI-30.n 0.8 (11.6) 1.6 (23.2) 250 (550) UI-30.n 1 (14.5) 1.8 (26.1) 310 (682) UI-30.v 1.2 (17.4) 2.8 (40.6) 370 (814) UI-30.v 1.4 (20.3) 3 (43.5) 435 (957) UIII-30.n 0.2 (2.9) 1 (14.5) 140 (308) UIII-30.n 0.4 (5.8) 1.2 (17.4) 280 (616) UIII-30.n 0.6 (8.7) 1.4 (20.3) 425 (935) UIII-30.n 0.8 (11.6) 1.6 (23.2) 565 (1243) UIII-30.n 1 (14.5) 1.8 (26.1) 705 (1551) UIII-30.v 1.2 (17.4) 2 (29.0) 845 (1859) UIII-30.v 1.4 (20.3) 2.2 (31.9) 985 (2167) UIII-30.v 1.6 (23.2) 2.4 (34.8) 1130 (2486) UIII-30.v 1.8 (26.1) 2.6 (37.7) 1270 (2794) UIII-30.v 2 (29.0) 2.8 (40.6) 1410 (3102) (108) (99) UIII-30.v 2.2 (31.9) 3 (43.5) 1550 (3410) UIII-60.n 0.2 (2.9) 1 (14.5) 140 (308) UIII-60.n 0.4 (5.8) 1.2 (17.4) 280 (616) UIII-60.n 0.6 (8.7) 1.4 (20.3) 425 (935) UIII-60.n 0.8 (11.6) 1.6 (23.2) 565(1243) UIII-60.v 1 (14.5) 2.6 (26.1) 705 (1551) UIII-60.v 1.2 (17.4) 2.8 (40.6) 845 (1859) UIII-60.v 1.4 (20.3) 3 (43.5) 990 (2178) UV-60.n 0.2 (2.9) 1 (14.5) 280 (616) UV-60.n 0.4 (5.8) 1.2 (17.4) 565 (1243) UV-60.n 0.6 (8.7) 1.4 (20.3) 845 (1859) UV-60.n 0.8 (11.6) 1.6 (23.2) 1130 (2486) UV-60.n 1 (14.5) 1.8 (26.1) 1410 (3102) UV-60.v 1.2 (17.4) 2.45 (35.5) 1690 (3718) UV-60.v 1.4 (20.3) 2.65 (38.4) 1975 (4345) UV-60.v 1.6 (23.2) 2.85 (41.3) 2255 (4961) UV-60.v 1.75 (25.3) 3 (43.5) 2465 (5423) (233) (220) UV-60.v 2.4 (34.8) 4.5 (65.2) 2800 (6160) UV-60.v 2.9 (42.0) 4.55 (65.9) 3000 (6600) UV-100.n 0.2 (2.9) 1 (14.5) 280 (616) UV-100.n 0.4 (5.8) 1.2 (17.4) 1975 (4345) UV-100.n 0.6 (8.7) 1.4 (20.3) 845 (1859) UV-100.v 0.8 (11.6) 2.8 (40.6) 1130 (2486) UV-100.v 1 (14.5) 3 (43.5) 1410 (3102) Weight With Without Handwheel Handwheel Kgs Kgs (lbs) (lbs) Note: 1) Actuator weight remains same irrespective of spring range and actuator action 2) Above spring ranges are applicable for parabolic trims. For perforated, pressure balanced and 3 way trims spring ranges will be selected on a case to case basis

5 Technical data: Series 520 / 540 Kv / Cv Values for Parabolic Trim Valve Size (mm / Inch) 15 / / 1 40 / / 2 80 / / /6 200 / / / / 16 Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv Cv Kv value for Silencer basket Valve Size Parabolic Single fold Double fold NB Kvs silencer silencer mm (inches) (Cvs) LK1 Kvs (Cvs) LK2 Kvs (Cvs) 25 (1") 11 (12.7) (1") 7 (8.1) (1") 4 (4.6) 3.9 (4.5) - 40 (1½") 11 (12.7) 10.9 (12.6) - 50 (2") 43 (50.0) 41 (47.6) - 50 (2") 26 (30.2) 25 (29.0) 23.8 (27.6) 50 (2") 18 (20.9) 17.8 (20.6) 17.2 (20.0) 80 (3") 100 (116.2) (3") 68 (79.0) 63 (73.2) - 80 (3") 43 (50.0) 41 (47.6) 39 (45.3) 100 (4") 150 (174.4) 132 (153.4) (4") 100 (116.2) 94 (109.3) 86 (100.0) 100 (4") 68 (79.0) 66 (76.7) 63 (73.2) 150 (6") 380 (441.8) 317 (368.6) 250 (290.6) 150 (6") 260 (302.3) 237 (275.5) 205 (238.3) 150 (6") 150 (174.4) 145 (168.6) 137 (159.3) 200 (8") 650 (755.8) 556 (646.5) 512 (595.3) 200 (8") 380 (441.8) 358 (393.0) 329 (382.5) 200 (8") 260 (302.3) 253 (294.1) 242 (281.3) 250 (10") 380 (441.8) 358 (416.2) 329 (382.5) Notes : Noise reduction same as that of perforated trims. Use of Roboter (pneumatic pressure reducer) is possible with silencer baskets To get Cv values use following formula Cv = 1.17 x Kv Kv value for Perforated trim Valve Lift SeatDia L1 L1 L2 L3 Size (NB) mm (inches) mm (inches) 1step EP 1 step Linear 2 step Linear 3 step Linear 15 (½") 20 (0.7") 16 (0.6") 2.7 (3.1) 2.2 (2.5) 2.1 (2.4) - 20 (0.7") 19 (0.7") 3.9 (4.5) 4.5 (5.2) 4.1 (4.7) 4.1 (2.7) 25 (1") 20 (0.7") 24 (0.9") 5.5 (6.3) 6.7 (7.7) 6.1 (7.0) - 20 (0.7") 32 (1.2) 8.1 (9.4) 13.5 (15.6) 10.8 (12.5) - 40 (1½") 20 (0.7") 37 (1.4") 10.9 (12.6) 17.9 (20.8) 14 (16.2) - 30 (1.1") 32 (1.2") 15 (17.4) 15 (17.4) 13.8 (16.0) 8.4 (9.7) 30 (1.1") 37 (1.4") 17.8 (20.6) 20 (23.2) 17.9 (20.8) 9.7 (11.2) 50 (2") 30 (1.1") 48 (1.8") 25 (29.0) 40 (46.5) 23.5 (27.3) - 30 (1.1") 62 (2.4") 36 (41.8) 60 (69.7) 30.6 (35.5) 18.2 (21.1) 80 (3") 30 (1.1") 71 (2.7") 42 (48.8) 70 (81.3) 35.3 (41.0) (4") 30 (1.1") 90 (3.5") 52 (60.4) 85 (98.8) 47.1 (54.7) - 60 (2.3") 71 (2.7") 90 (104.6) 105 (122.0) 67.5 (78.4) 67 (77.9) 60 (2.3") 90 (3.5") 125 (145.3) 160 (186.0) 103 (119.7) 88 (102.3) 150 (6") 60 (2.3") 113 (4.4) 159 (184.8) 240 (279.0) 132 (153.4) 107 (124.4) 60 (2.3") 143 (5.6") 200 (232.5) 320 (372.0) 171 (198.8) (8") 60 (2.3") 172 (6.7") 250 (290.6) 400 (465.1) 209 (243.0) (3.9") 143 (5.6") 333 (387.2) 420 (488.3) 270 (313.9) (10") 100 (3.9") 172 (6.7") 485 (563.9) 560 (651.1) 395 (459.3) (12") 100 (3.9") 265 (10.4") (651.1) (16") 100 (3.9") 400 (15.7") (2906.9) - - Notes : For calculations and selection of summary Kv values, it is necessary to apply the correct x values in the calculation The Kv values mentioned in the chart are the maximum values for a particular seat diameter Intermediate Kv values shall be applicable based on customer specifications To get Cv values use following formula Cv = 1.17 x Kv

6 Cross-sectional drawings of Combined PRDS 4 Top Entry PRDS Valve (L2 Trim Design) L. No. Part Name 13 Nut 1 Valve Body 14 Stud 2 Bottom Flange 15 Gasket 3 Seat 16 Cooling Water Seat 4 Plug 17 Packing Set 5 Guide Bush 18 Guide Bush 6 Spindle 19 Lock Screw 7 Gland Nut 20 Intermediate Flange 8 Packing Set 21 Gasket 9 Slotted Nut 22 Water Chamber 10 Gasket 23 Water Inlet Pipe 11 Bolt 24 Flange S/W 12 Nut Top Entry PRDS Valve (L3 Trim Design) L. No. Part Name 1 Valve Body 2 Bottom Flange 3 Seat 4 Plug 5 Guide Bush 6 Spindle 7 Gland Nut 8 Packing Set 9 Slotted Nut 10 Gasket 11 Bolt 12 Nut 13 Nut 14 Stud 15 Gasket 16 Cooling Water Seat 17 Packing Set 18 Guide Bush 19 Lock Screw 20 Intermediate Flange 21 Gasket 22 Water Chamber 23 Water Inlet Pipe 24 Flange S/W 25 Sleeve WATER Bottom Entry through Stem PRDS Valve (Parabolic Trim Design) Bottom Entry through Nozzle PRDS Valve (L2 Trim Design) L. No. Part Name 1 Valve Body 2 Ext. Top flange 3 Bottom flange 4 Seat 5 Plug 6 Ball 7 Spindle 8 Spring Dowell Pin 9 Bottom Ring 10 Gland Packing RIngs 11 Gland Follower 12 Gland Nut 13 Slotted Nut 14 Gasket 15 Guide Bush 16 Bilts 17 Nuts 18 Gland Packing Rings 19 Sleeve 20 Cooling Water Seat 21 Gasket 22 Cooling Water Flange 23 Bolts 24 Nuts L. No. Part Name 1 Valve Body 2 Ext. Top Flange 3 Bottom Flange 4 Seat 5 Plug 6 Ball 7 Spindle 8 Spring Dowell Pin 9 Bottom Ring 10 Gland Packing Rings 11 Gland Follower 12 Gland Nut 13 Slotted Nut 14 Gasket 15 Guide Bush 16 Nut 17 Stud 18 Nozzle 19 Bolts 20 Nuts 21 Cooling water flange

7 Pressure Reducing and Desuperheating Stations We supply flange to flange Pressure Reducing and Desuperheating Stations with pressure control and temperature control instrumentation loop. Pos. Part Name 1 Pressure Gauge 2 Pressure Gauge 3 Dial Thermometer 4 Dial Thermometer 5 Stop Valve 6 Bypass Valve 7 Strainer 8 Pressure Reducing Cum Desuperheating Valve 9 Elbow 10 Stop Valve 11 Safety Valve 12 Stop Valve 13 Pressure Control Loop 14 Temperature Control Loop 15 Non-Return Valve (Loose Supply) 16 Stop Valve 17 Water Flow Control Valve 18 Strainer 19 Elbow 20 Flange 21 Expander 22 Flange 23 Condensing Pot 24 Equal Tee 25 Expander 26 Tee 27 Additional Spray Nozzle Insert Total PRDS System along with Control Loop Recommendations for efficient working of PRDS Minimum straight length at outlet should be 4 mtrs (13.12 feet). Minimum distance of Temperature Sensor from the point of water injection should be 12 mtrs (39.36 feet). Minimum distance of Pressure Sensor from PRDS Valve should be 1.5 mtrs (4.92 feet). It is recommended to install a strainer of 0.1 mm (3.93 Thou) mesh before water control valve. Spray water should be very clean (equivalent to boiler feed water). Instrument quality air is required. Minimum water pressure requirement for Combined PRDS: Top entry Bottom entry through stem Notes : Pw = [(P1+P2)/2 ] + 7 BAR ( Psi) : Pw = P2 + 7 BAR ( Psi) Bottom entry through nozzle : Pw = [P1 / 2 ] + 7 BAR ( Psi) 1 Minimum controllable temperature is Saturation Temperature + 7 C (44.6ºF). 2 The above are based on a specific set of parameters. These guidelines may change. Specifications for Combined PRDS valve Body Material Trim Material Trim Form Standard Characteristics End Connections Bonnet Packing Material Ordering Information : Carbon steel, Alloy steel, others on request : SS 410 Nitrited, SS 431 Nitrited, SS 321 Nitrited, A182 F22 : Parabolic, Perforated : Linear, Equal %, modified on request : Flanged to ANSI Standards, Butt weldable, Socket weldable : Standard, Extended (Cooling Finned), Water Cooled : Graphite Rangeability : 40:1 Process parameters needed for PRDS Valve Sizing (min/max) Steam Flow (Inlet) kg/hr (lbs/hr) Inlet Pressure bar(g) (Psig) Outlet Pressure bar(g) (Psig) InIet Temperature C (ºF) Outlet Temperature C (ºF) Water Pressure bar(g) (Psig) Water Temperature C (ºF)

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