Hopkinsons CONTENTS SCHEDULE OF SHELL BOILER MOUNTINGS. Hopkinsons. Safety Valves 5. Boiler Stop Valves 17. Feed Check Valves 18. Blowdown Valves 20

Transcription

1

2 Hopkinsons SCHEDULE OF SHELL BOILER MOUNTINGS Quality assurance Weir Power & Industrial operates quality programmes to cover the full scope of their activities. Comprehensive quality systems have been developed to serve the power, oil and gas and industrial markets which they serve. The company holds approvals to: ASME Section III N, NPT, NV ASME Section I V ASME Section VIII UV, SQL, UDT BS EN ISO 900:994 API Q TO API LICENCES API 6D (6D-082) AND API 6A (6A-0445) TUV - AD MERKBLATT WRD HP 0 Hopkinsons Hopkinsons manufacture valves and boiler mountings for use on steam raising plant of any size and type. Hopkinsons brand products, renowned for long and dependable service life, can be seen on installations ranging from shell boilers for heating and process steam up to the highest capacity units on electricity generating stations. In the nuclear power industry, Hopkinsons has particular expertise in the design and production of safety related items such as fast operating main steam and main feed isolation valves. The company also produces valves for isolation, regulating, pressure relief, instrument and drain, and specific plant protection duties on the new generation of Combined Cycle Gas Turbine Power Stations. 6A D-082 The Quality systems have been approved for the supply of products to meet the requirements of the Pressure Equipment Directive (PED) and compliance modules A, D, H, B&D have been applied in categories I through IV respectively. The company is committed to compliance with legislation and has an established environment and health and safety policy. An ongoing commitment to customer care is met through the process of continuous improvement and the further development of our systems and processes towards meeting ISO 900:2000. Valve Testing Facilities All pressure containing items are hydrostatically tested, seat leakage tested and functionally tested. In addition, gas, packing emission, cryogenic and advanced functional testing can be arranged. Material testing facilities Non-destructive examination by radiography, ultrasonics, magnetic particle and liquid penetrant. Chemical analysis by computer controlled direct reading emission spectrometer. Mechanical testing for tensile properties at ambient and elevated temperatures, bend and hardness testing. Charpy testing at ambient, elevated and sub-zero temperatures. Further technical information can be obtained from our Web site: CONTENTS Safety Valves 5 Boiler Stop Valves 7 Feed Check Valves 8 Blowdown Valves 20 Water Gauge Assemblies 22 Air release Valves 26 SBM Weir Power & Industrial First choice for power and industrial protection 3

3 SCHEDULE OF SHELL BOILER MOUNTINGS Hopkinsons Evaporation of boiler kg/h 909 to lb/h 2000 to Working Pressure bar lb/in 2 Size and figure number Safety valve mm 32mm 40mm 40mm 50mm 50mm 40mm 40mm 50mm 50mm 50mm 65mm 65mm 65mm 65mm 65mm Set press Set press 57 M52506 M52506 M52506 M52506 M52506 M52506 M55506 M55506 M55506 M55506 M55506 M55506 M55506 M55506 M55506 M mm 32mm 32mm 40mm 40mm 40mm 32mm 40mm 40mm 40mm 50mm 50mm 50mm 50mm 65mm 65mm Set press 4.5 Set press 20 M M M M M M M M M M M M M M M M mm 32mm 32mm 32mm 32mm 40mm 32mm 32mm 40mm 40mm 40mm 50mm 50mm 50mm 50mm 65mm Set press 8 Set press 262 M M M M M M M M M M M M M M M M Boiler Stop mm 80mm 80mm 80mm 00mm 00mm 00mm 25mm 25mm 50mm 50mm 50mm 75mm 75mm 200mm 200mm valve M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M0406 M mm 65mm 65mm 80mm 80mm 80mm 00mm 00mm 00mm 25mm 25mm 25mm 50mm 50mm 50mm 75mm (2 ) (2 2 ) (2 2 ) (3 ) (3 ) (3 ) (4 ) (4 ) (4 ) (5 ) (5 ) (5 ) (6 ) (6 ) (6 ) (7 ) M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M mm 50mm 50mm 80mm 80mm 80mm 80mm 00mm 00mm 00mm 00mm 25mm 25mm 25mm 50mm 50mm (2 ) (2 ) (2 ) (3 ) (3 ) (3 ) (3 ) (4 ) (4 ) (4 ) (4 ) (5 ) (5 ) (5 ) (6 ) (6 ) M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 M04025 Feedcheck mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 50mm 50mm 50mm 50mm 50mm 50mm 50mm valve ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) (2 ) (2 ) (2 ) (2 ) (2 ) (2 ) (2 ) M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M4206 M mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 50mm 50mm 50mm 50mm 50mm 50mm 50mm ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) ( 2 ) (2 ) (2 ) (2 ) (2 ) (2 ) (2 ) (2 ) M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 M42040 Blowdown mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 50mm 50mm 50mm 50mm 50mm 50mm 50mm valve M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M25406 M mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 50mm 50mm 50mm 50mm 50mm 50mm 50mm M M M M M M M M M M M M M M M M Key for Blowdown valve Figure 6202 or Figure 6203 Water Gauge 0 50 Water gauges M Assembly Protectors (complete with pointers) M Water gauge pillar M6479 Pressure gauge syphon M Pressure gauge M4000 If required, pillar type pointer M6253 Air Release mm ( 2 ) 829 valve Weir Power & Industrial First choice for power and industrial protection SBM 2-205

4 Hopkinsons HIGH LIFT SPRING LOADED SAFETY VALVES Incorporated on all valves supplied for all applications at temperatures up to 224 C (435 F). Fail-safe features of the design ensure a stable set pressure. Spring load is taken on the metal-to-metal seating with the PTFE facing functioning only as an efficient seal. The possibility of set pressure altering because of spring extension - which can occur in other designs when the facing material extrudes or compresses is, therefore, eliminated. In the unlikely event of the PTFE insert becoming damaged the valve will still function with a metalto-metal standard of sealing. If replacement of the insert becomes necessary the valve head can be returned to Hopkinsons in part exchange for a reconditioned unit. Ratings Metric ratings: PN6 (Iron) PN40 (Steel) Features Discharge capacities in accordance with BS 6759 Part 984 Sizes Nominal size range DN 32 to 80 4 to 3 Description These high lift safety valves are our standard recommendation for shell boilers and other plant items with design pressures up to a maximum 24 bar (348 lb/in 2 ). The valve design gives a greatly increased discharge capacity enabling the customer to use a smaller valve size than was previously necessary. Blowdown adjustment Normally a feature of more expensive valves - is incorporated to allow control of blowdown performance. Adjustment is set at the factory and in the majority of cases will not require further adjustment. For on-site alteration, access to the blowdown ring is gained by removal of the screw which also incorporates a locking pin. Set pressure The valve is supplied correctly adjusted and hydraulically tested to the customer s required set pressure. Flanges Normally supplied drilled. Trim Seating components are high grade nickel alloy (Hopkinsons Platnum ). Spindle is stainless steel. Single Spring Type (Shown with metal-to-metal sealing Durable valve insert of high grade PTFE on type Double Spring Type Body Material Set Pressure Temperature Type of Figure no. & Flanges (Gauge) Sealing Single Spring Double Spring Cast iron Up to 3 bar Up to C Polymeric M2506 M55506 BS 452 Grade 220 (88.5 lb/in 2 ) (428 0 F) Flanged: BS0 (Cast-on Cl ) BS4504 Cast steel to ASME Up to 24 bar Up to C Polymeric M M specification (348.0 lb/in 2 ) (435 0 F) Flanged: BS0 A26-WCB BS4504 (Cast-on WCB ) BS560 Part 2 Above C M M (435 0 F) Metal-to-metal Flanged: BS0 Up to C* BS4504 (652 0 F) BS560 Part 2 *For higher temperatures please contact the factory SBM Weir Power & Industrial First choice for power and industrial protection 5

5 HIGH LIFT SPRING LOADED SAFETY VALVES Hopkinsons Single spring Fig. M Cast iron body - - Max. temp. 220 C (428 F) Fig. M Cast steel body - - Max. temp. 224 C (435 F) Outlet flange V = No. of holes W = Dia. of holes X = Pitch circle dia. Fig. M Metal-to-metal sealing - Max. temp. 345 C (652 F) Please refer to flange standards for pressure/temperature ratings taking into account the maximum temperatures stated above and maximum pressure of 3 bar gauge for cast iron bodies. Drain boss, Tapped 2 Rp (BS2 973) Inlet flange N = No. of holes O = Dia. of holes P = Pitch circle dia. B J G E M L H S A K R F T Inlet Outlet Nominal size K F T R S N O P E J M G L V W X A B H Weight mm (Kg) M Iron body Flanged BS M Iron body Flanged BS M & M Flanged BS M & M Flanged BS M & M Flanged BS (ins) (lbs) M Iron body Flanged BS M Iron body Flanged BS M & M Flanged BS M & M Flanged BS M & M Flanged BS When ordering please state: The total discharge capacity to meet all possible conditions of test and use. Obtain guidance if necessary. 2 Type of fluid to be discharged (steam, water etc.) 3 Working pressure and temperature 4 Set pressure. This should not be less than 5% above the working pressure of the boiler (minimum 5lb/in 2, 0.35 bar) or, in the case of a hot water boiler, not less than 0% above working pressure (minimum 20lb/in 2,.3 bar). 6 Weir Power & Industrial First choice for power and industrial protection SBM 2-205

6 Hopkinsons HIGH LIFT SPRING LOADED SAFETY VALVES Single spring for dry saturated steam Discharge capacity to BS6759 Part 984. Coefficient of discharge Kdr = 0.37 Overpressure 0%. Set Pressure Nominal Nominal Nominal Nominal Nominal Recommended (gauge) Size Size Size Size Size Valve DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" bar lbs/in 2 kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h For temperatures up to C (428 0 F): M52506 Iron body For temperatures up to C (435 0 F): M For temperatures up to C (435 0 F): M For temperatures above C (435 0 F) up to C (652 0 F): M Metal-to-metal sealing Superheated steam capacity = Saturated steam capacity (from the table above) x Superheat correction factor SBM Weir Power & Industrial First choice for power and industrial protection 7

7 HIGH LIFT SPRING LOADED SAFETY VALVES Hopkinsons Single spring for air at 5 C (60 f) Discharge capacity to BS6759 Part 984. Coefficient of discharge Kdr = 0.37 Overpressure 0%. Set Pressure Nominal Nominal Nominal Nominal Nominal Recommended (gauge) Size Size Size Size Size Valve DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" bar lbs/in 2 kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h For temperatures up to C (428 0 F): M52506 Iron body For temperatures up to C (435 0 F): M M Maximum temperature C (435 0 F) Details for other gases are available on request. 8 Weir Power & Industrial First choice for power and industrial protection SBM 2-205

8 Hopkinsons HIGH LIFT SPRING LOADED SAFETY VALVES For other temperatures: Multiply value form tables below by value of G corresponding to G (specific gravity). G for water at 5 C (60 F) = (compressibility ignored). Single spring for water at 5 C (60 f) Discharge capacity to BS6759 Part 984. Set Pressure Nominal Nominal Nominal Nominal Nominal Recommended (gauge) Size Size Size Size Size Valve DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" Specific Gravity Table bar lb/in 2 kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h G G For temperatures up to C (428 0 F): M52506 Iron body Polymeric sealing For temperatures up to C (435 0 F): M Polymeric sealing M Polymeric sealing Maximum temperature C (435 0 F) Details for other liquids are available on request. SBM Weir Power & Industrial First choice for power and industrial protection 9

9 HIGH LIFT SPRING LOADED SAFETY VALVES Hopkinsons Double spring Fig. M Cast iron body - Max. temp. 220 C (428 F) Outlet flange Q = No. of tapped holes U = Thread size V = No. of plain holes W = Dia. of plain holes Fig. M Cast steel body - Max. temp. 224 C (435 F) H G E L M Fig. M Metal-to-metal sealing - Max. temp. 345 C (652 F) Please refer to flange standards for pressure/temperature ratings taking into account the maximum temperatures stated above and maximum pressure of 3 bar gauge for cast iron bodies. S K R F T C D Drain boss, Tapped 2 Rp (BS2 973) Inlet flange N = No. of holes O = Dia. of holes P = Pitch circle dia. Figure Nominal Inlet Outlet Weight Number Size (kg) mm K F T R S N O P E J M G L Q U V W X C D H M /8 B.S.F (Iron Body) /8 B.S.F Flanged /8 B.S.F B.S /8 B.S.F /8 B.S.F M M6 x (Iron Body) M6 x Flanged M6 x B.S M6 x M6 x M & /8 B.S.F M /8 B.S.F (Steel Body) /8 B.S.F Flanged /4 B.S.F B.S /4 B.S.F M & M6 x M M6 x (Steel Body) M6 x Flanged M20 x B.S M20 x M & /8 U.N.C M /8 U.N.C (Steel Body) /4 U.N.C Flanged /4 U.N.C B.S /4 U.N.C (ins) K F T R S N O P E J M G L Q U V W X C D H (lbs) M B.S.F (Iron Body) B.S.F Flanged B.S.F B.S B.S.F B.S.F M (Iron Body) Flanged B.S M6 x M6 x M6 x M6 x M6 x M & B.S.F M B.S.F (Steel Body) B.S.F Flanged B.S.F B.S B.S.F M & M (Steel Body) Flanged B.S M6 x M6 x M6 x M20 x M20 x M & U.N.C M U.N.C (Steel Body) U.N.C Flanged U.N.C B.S U.N.C When ordering please state: The total discharge capacity to meet all possible conditions of test and use. Obtain guidance if necessary. 2 Type of fluid to be discharged (steam, water etc.) 3 Working pressure and temperature 4 Set pressure. This should not be less than 5% above the working pressure of the boiler (minimum 5lb/in 2, 0.35 bar) or, in the case of a hot water boiler, not less than 0% above working pressure (minimum 20lb/in 2,.3 bar). 0 Weir Power & Industrial First choice for power and industrial protection SBM 2-205

10 Hopkinsons HIGH LIFT SPRING LOADED SAFETY VALVES Double spring For dry saturated steam Discharge capacity to BS6759 Part 984. Coefficient of discharge Kdr = 0.37 Overpressure 0%. Set Pressure Nominal Nominal Nominal Nominal Nominal Recommended (gauge) Size Size Size Size Size Valve DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" bar lbs/in 2 kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h For temperatures up to C (428 0 F): M55506 Iron body For temperatures up to C (435 0 F): M For temperatures up to C (435 0 F): M For temperatures above C (435 0 F) up to C (652 0 F): M Metal-to-metal sealing Superheated steam capacity = Saturated steam capacity (from the table above) x Superheat correction factor (from table at the end of this publication). SBM Weir Power & Industrial First choice for power and industrial protection

11 HIGH LIFT SPRING LOADED SAFETY VALVES Hopkinsons Double spring For air at 5 C (60 C) Discharge capacity to BS6759 Part 984. Coefficient of discharge Kdr = 0.37 Overpressure 0%. Set Pressure Nominal Nominal Nominal Nominal Nominal Recommended (gauge) Size Size Size Size Size Valve DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" bar lbs/in 2 kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h kg/h lbs/h For temperatures up to C (428 0 F): M55506 Iron body For temperatures up to C (435 0 F): M M Maximum temperature C (435 0 F): Details for other liquids are available on request. 2 Weir Power & Industrial First choice for power and industrial protection SBM 2-205

12 Hopkinsons HIGH LIFT SPRING LOADED SAFETY VALVES Double spring for hot water boilers - fully flooded - externally pressurised Discharge capacity to BS6759 Part 984. Coefficient of discharge Kdr = 0.37 Overpressure 0%. Set Pressure Nominal Size Nominal Size Nominal Size Nominal Size Nominal Size Recommended (gauge) DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" Valve Boiler Output Boiler Output Boiler Output Boiler Output Boiler Output bar lbs/in 2 kw BTU/h kw BTU/h kw BTU/h kw BTU/h kw BTU/h x0 6 x0 6 x0 6 x0 6 x For temperatures up to C (428 0 F): M55506 Iron body For temperatures up to C (435 0 F): M Maximum temperature C (435 0 F): M Details for other water duties are available on request. SBM Weir Power & Industrial First choice for power and industrial protection 3

13 HIGH LIFT SPRING LOADED SAFETY VALVES Hopkinsons Installation Having chosen the appropriate safety valve to suit the working conditions it is equally important to ensure that the mounting to the pressure vessel and the discharge pipework are of the correct design, size and length. Mounting The valve must be mounted on a standpipe or other suitable connection which should be free from any obstruction so as to provide a smooth flow without any drop in pressure. Any variation from the preferred design of standpipe shown should be referred to Hopkinsons for comment. Discharge piping Safety valve pipework must be correctly designed, otherwise valve performance and consequently plant protection may be affected. Reference should be made to BS6759 and BSB8806 for the discharge piping. The information following provides guidance for the the selection of discharge piping for the range of valves in this publication. Please note, it is the responsibility of the pipework designer to ensure any pipework is fit for its purpose, is properly anchored and does not apply undue loading to the safety valves. On discharge piping for liquid duties, hot water boilers etc. there must be a continuous fall to avoid standing water. If the latter is a possibility it will be necessary to install additional drain points. Selecting the discharge pipe size The bore of the discharge piping must not be less than the bore of the outlet flange of the safety valve and must be as short and as straight as possible. The following data for the selection of pipe size against maximum length relates only to basic direct mounted escape pipe systems for saturated steam duties. Advice on pipework for other conditions will be supplied on request. The tables give the maximum lengths of discharge pipework and already include an allowance for any taper pieces which may be necessary to connect a larger discharge pipe to the outlet of the safety valve. Maximum 4K In calculating the total length of discharge pipework, allowances must be made for any bends incorporated as stated in the table, plus any other components used such as silencers, filters, etc., for which, data should be obtained from the appropriate manufacturer. The equivalent length given for a bend must be added to the straight length used and the resulting total equivalent length compared to the maximum allowable length from the tables. If the calculated length exceeds the maximum for a given pipe size then it will be necessary to re-calculate using the data stated for a larger size of pipe (see example below). Example Valve inlet bore dia. A 65mm M55506 safety valve, set at 0 bar g, is to have a discharge pipe rise vertically for 2m, turn horizontal and run 5m through the side wall of the boiler house where a 45 bend deflects the discharge slightly upwards. With reference to the table for 65mm size valves set at 0 bar, 50mm and 200mm bore discharge pipes are listed. x 90 bend 4.5m x 45 bend 2.4m Run of pipe 7.0m Total equivalent length 3.9m This is in excess of the 9m given in the table and therefore unacceptable. Consider then a 200mm bore pipe:- x 900 bend 6.0m x 450 bend 3.2m Run of pipe 7.0m Total equivalent length 6.2m K Radius K/4 minimum 4 Weir Power & Industrial First choice for power and industrial protection SBM 2-205

14 Hopkinsons HIGH LIFT SPRING LOADED SAFETY VALVES Installation Allowance must be made also for any other components used (silencers, filters etc.). Maximum equivalent lengths of discharge piping for saturated steam duties. Note: Figures for equivalent lengths (from previous table) of any ****** used must be included in the total equivalent length. Single spring valves Set Pressure Nominal Size Nominal Size Nominal Size Nominal Size Nominal Size (gauge) DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" Bore of discharge pipe mm bar lbs/in Maximum equivalent length of Discharge Pipe m Double spring valves Set Pressure Nominal Size Nominal Size Nominal Size Nominal Size Nominal Size (gauge) DN 32 4" DN 40 2" DN50 2" DN " DN 80 3" Bore of discharge pipe mm bar lbs/in Maximum equivalent length of Discharge Pipe m SBM Weir Power & Industrial First choice for power and industrial protection 5

15 HIGH LIFT SPRING LOADED SAFETY VALVES Hopkinsons Superheat correction factors Superheated steam capacity = Saturated steam capacity (from the tables on previous pages) x Superheat correction factor (from table below). Pressure Saturation Total Steam Temperature C (Gauge) Temperature Total Steam Temperature F bar lb/in 2 C F Weir Power & Industrial First choice for power and industrial protection SBM 2-205

16 Hopkinsons BOILER STOP GLOBE VALVES - CAST STEEL Description Body: Bonnet: Stem: Gasket Seats: Disc Gland Packing Bonnet bolts Materials Cast steel ASTM A26 Gr WCB ASTM A05 Aluminium Bronze Exfoliated Graphite Nickel Alloy Nickel Chrome Alloy Exfoliated Graphite ASTM A93 GR B7 Pressure/temperature ratings (general applications) PN Temperature 0 C (see notes) -0 to Maximum non-shock gauge pressures bar 6 6* * * * Maximum permissible working pressure (gauge) at temperature stated. Intermediate values can be obtained by linear interpolation. Alternative flange connections to BST.F and H can be supplied on request. NB. Maximum design temperature on which any valve may be used irrespective of rating is C. Description The valves in this range are ideally suitable for boiler stop valve and also general purpose stop/regulating valve duties. The combination of simple design, high quality materials and high standard of production results in an easily maintained valve, capable of long and efficient service under high load conditions. Ratings Metric ratings: Sizes PN6/25/40 Nominal size range DN 50 to 200 2" to 8" Angle type Figure no. M0406/25/40 A W Straight type Figure no. M0606/25/40 W T K H Open H2 Open R F F R R F K A R E K K T T T L Flanges drilled: N = No. of holes O = Dia. of holes P = Pitch circle dia. Chain/padlock locking device supplied as extra when required Products illustrated are Stop valves. Combined Stop & Non-return versions are available when required. Angle Straight Flanged BS 4504 Table PN6 Flanged BS 4504 Table PN25 Flanged BS 4504 Table PN40 Type Type Weight Weight Weight Nominal A H L H2 W F T R K N O P angle F T R K N O P angle F T R K N O P angle Size straight straight straight mm kg kg kg 7 9 inch lb lb lb mm kg kg kg inch lb 53 6 lb lb mm kg kg kg 35 4 inch lb lb lb mm kg kg kg inch lb 2 23 lb lb mm kg kg kg inch lb lb lb mm kg kg 7 42 inch lb lb Not applicable mm kg kg kg inch lb lb lb When ordering, please give the following information: Fluid and working conditions 2 If the drain boss is to be tapped 3 4 Rp (BS2) SBM Weir Power & Industrial First choice for power and industrial protection 7