STEAM CONDITIONING VALVES TECHNICAL BULLETIN HORA POWER TECHNOLOGY

Transcription

1 STEAM CONDITIONING VALVES TECHNICAL BULLETIN

2 HOLTER REGELARMATUREN GMBH & CO. KG POWER TECHNOLOGY OUR ASPIRATION AIMING FOR THE TOP For 50 years our customers have relied on HORA as a competent partner for innovative and reliable flow control solutions. HORA products provide superior customer benefits in power and other related industries. From turbine bypass systems to balance of plant applications, HORA offers a comprehensive portfolio of standard and heavy duty control valve solutions. The HORA brand is increasing in global significance with an export share of more than 65 percent. We develop and engineer all our own core products, which are manufactured by us in Germany enabling us to guarantee our own product quality. All processes are organized to ensure short throughput times and the highest levels of delivery reliability. EUROPE Austria Bulgaria Denmark Finland Great Britain Greece Italy Luxemburg The Netherlands Portugal Romania Russia Sweden Spain Switzerland Turkey AMERICAS Canada USA ASIA-PACIFIC Australia China India Philippines Singapore Taiwan MIDDLE EAST & AFRICA Dubai ENGINEERING & DESIGN MADE IN GERMANY QUALITY HORA utilizes the most modern modelling tools during the design of the control valves, such as Computational Fluid Dynamics CFD, Finite Element Analysis FEA, 3D CAD design software and virtual reality solutions. These advanced tools are decisive in optimizing the design of the valves for improved flow geometry and minimized stresses in the valve bodies. HORA operates one of the most modern and efficient valve facilities in the world. Continuous investment in the up to date production technologies, such as submerged 3D arc-welding, as well as complete machining centers ensure precision in manufacturing with higher productivity, shorter throughput times and lower costs. HORA provides reliability and efficiency for our customers through continuous and consistent advancement of our own development and manufacturing processes. All non-destructive material testing (NDT) and final testing is performed in-house. Quality management and assurance, and comprehensive certifications underline our claim to quality of the highest level. 02

3 SELECTION GUIDE STANDARD FEATURES HORA offers a complete portfolio of steam conditioning solutions to meet the requirements for the pressure and temperature control of steam. The range in severity require high attention in selection and sizing of steam conditioning valves. Steam conditioning valve with integrated orifice tube Steam conditioning valve with integrated atomizer Steam conditioning valve with downstream radial type desuperheater Steam conditioning valve with downstream injection lance Description of design Variable area nozzle integrated in perforated plug by injection orifice High pressure support steam (20-30% of max. water amount) Spring loaded nozzles around diameter of pipe Fixed area nozzles or spring loaded nozzles Body type Angle (Globe, Z-type) Angle Angle Angle (Globe, Z-type) Location of injection Integrated Downstream Downstream Downstream Turn down ratio 50:1 40:1 40:1 (sequential opening) 40:1 (sequential opening) Max. water capacity 15% (water steam ratio) 250 t/h not relevant not relevant Required delta p (outlet steam / water) Half of upstream pressure + 5 bar or more Well suited when delta p between water and steam is low (atomization by kinetic energy of steam) Downstream pressure + 15 bar or more Downstream pressure + 8 bar or more Set point temperature (direct control) Minimum 5K-10K above saturation for direct temperature control Minimum 10K-15K above saturation for direct temperature control Minimum 15K-30K above saturation for direct temperature control Minimum 15K-30K above saturation for direct temperature control Min. downstream velocity not relevant 4 m/s 12 m/s 8 m/s 12 m/s (pipe > DN 200) Distance to temperature sensor (rule of thumb based on field experience) water/steam max. 15%: 0,1s x steam velocity [m/s] water/steam < 15% (>15%): 0,15s (0,2s) x steam velocity [m/s] water/steam < 15% (>15%): 0,2s (0,3s) x steam velocity [m/s] water/steam < 15% (>15%): 0,2s (0,3s) x steam velocity [m/s] Typical application Process steam Auxiliary PRDS HP turbine bypass system Auxiliary PRDS HP turbine bypass system (USC PP) HRH / IP / LP bypass system Process steam All the information could be subject to errors or omissions and are given only for title of indication. Solutions can be be customized for special applications. Please refer to HORA for on any questions, concerns or more detailed information regarding the proper selection of the steam conditioning valve. 03

4 APPLICATION AREA MARKET AND PRODUCT SEGMENTS APPLICATION AREA OF HORA POWER TECHNOLOGY PRODUCTS HORA is focused on providing customized flow control solutions for the energy-focused market sectors. Through our product line we offer a full spread of comprehensive high-grade products and worldwide expert advice in particular for water and steam applications for the most difficult technical challenges. As trusted partner for new construction, extension and technical upgrading of an efficient power infrastructure, HORA offers utilities and the industry the portfolio they need. Oil and Gas Extraction and distribution Petrochemicals Power Technology Coal-fired power plants Combined cycle power plants Combined heat and power plants Concentrated solar power plants Biomass power plants (incl. waste incineration plants) Process and general industry Pulp and Paper Chemicals Food and Beverages Desalination Steel and Aluminium Cement Others The main purpose of a valve is to control media flow through a system. The valve may be used to start, stop, or throttle the flow. The requirements for control valves have increased significantly over the past years and demand higher flexibility in order to guarantee short response times and extended life. In addition higher process parameters are targeted in order to increase the efficiency of the plants significantly compromising compliance with environmental protection like reducing CO2 emissions in the power sector. HORA control technology allows a safe and material-saving mode of operation for an economically viable plant operation. Service Spare Parts Repair, upgrades and retrofit Assembly HORA organized and structured its portfolio management in the following product groups: Single seat control valves Water pressure reducing valves Desuperheaters Steam conditioning valves Automatic recirculation valves Actuators 04

5 CONTENT STEAM CONDITIONING VALVES CONTENT Our aspiration Selection guide Application area Fundamental issues Control logic Liability for content - We make every effort to keep the information in this document current, but accept no liability whatsoever for the content provided. Copyrights - The content and works provided in this document are governed by the copyright laws of Germany. Duplication, processing, distribution, or any form of coercialization of such material Steam conditioning valve with integrated orifice tube Description of design Technical data - Standard duty Sectional drawing - Standard duty Parts list - Standard duty Dimensions - Standard duty Features and benefits - Standard duty Steam conditioning valve with integrated atomizer Description of design Technical data - Standard and heavy duty Sectional drawing - Standard duty Parts list - Standard duty Dimensions - Standard duty Features and benefits - Standard duty Sectional drawing - Heavy duty Parts list - Heavy duty Dimensions - Heavy duty Features and benefits - Heavy duty Steam conditioning valve with downstream radial type desuperheater Description of design Technical data - Severe duty Sectional drawing - Severe duty Parts list - Severe duty Dimensions - Standard duty Features and benefits - Standard duty Steam conditioning valve with downstream injection lance Description of design Technical data - Standard and heavy duty Sectional drawing - Standard duty Parts list - Standard duty Dimensions - Standard duty Features and benefits - Standard duty Sectional drawing - Heavy duty Parts list - Heavy duty Dimensions - Heavy duty Features and benefits - Heavy duty Lifecycle services Reliable solutions and service Exemplary special tools beyond the scope of the copyright law shall require the prior written consent of its respective author or creator. Rev: 01 05/18 05

6 GENERAL DESCRIPTION STEAM CONDITIONING VALVES GENERAL DESCRIPTION FUNDAMENTAL ISSUES Steam conditioning valves, also referred to as pressure reducing and desuperheating stations (PRDS), are used for temperature and pressure control of steam in the whole energy-focused market to meet the conditions required for the process. The fundamental principle is a steam conditioning system consists of a steam reduction valve to reduce the steam pressure, a downstream or integrated cooler to reduce the temperature, an injection control valve to regulate the steam temperature and, if applicable, the related shut-off valves and the corresponding actuator technology. SCV W p T h = = = = Mass flow rate Pressure Temperature Enthalpy SIV SCV WIV TCV DT = = = = = Steam Isolation Valve Steam Conditioning Valve Water Isolation Valve Temperature Control Valve Dump Tube (to condenser) SIV TCV DT WIV Comprehensive system consideration Due to the polydisperse droplet distribution, it is difficult to determine the minimum distance between the injection point and the temperature measuring point. The complete evaporation time and distance to reach target temperature depends mainly on the size of the individual droplets, the water temperature, and the turbulence. Small droplets create a bigger surface area for the heat transfer and thus have a good cooling effect. The diameters are determined by the pressure drop between water and steam influenced by the diameter of the injection nozzle, called primary atomization. A high water temperature reduces the surface tension and the consequences of impacts on the hot metal parts. Due to high turbulence, called secondary atomization, by steam velocity and rotation/ twist of the water, the water droplets burst open. Smaller droplets stay evenly distributed in the steam flow. In order to minimize the thermal stresses (thermal shock due to alternating stress) on the pressure bearing body and the internal parts, the water admixture procedures requires special attention. The shape of the body design, reduced and equal wall thicknesses and the selected material, together with consequently avoiding the notches and small radii, allow for smaller thermal transient induced stresses. Preheating has an additional effect, which helps to reduce thermal stresses. 06

7 GENERAL DESCRIPTION STEAM CONDITIONING VALVES GENERAL DESCRIPTION CONTROL LOGIC Next to the desired degree of superheating of the steam, the ratio of water to steam amount, the pipeline routing and the control logic is an important factor. The valves are controlled by the central process control system with function logics, interlocks and priority operations. In the following two coon methods are described. The use of the target value of the steam temperature after water injection is called direct temperature control. If this temperature sensor feedback control is not possible, due to short distances after the water injection not allowing enough time to fully evaporate the water, an indirect temperature control by a feed-forward control strategy is required. P1 P1 T1 T2 P2 m! w = m! 1 h1 - h2 h2 - hw Schematic diagram of direct and indirect temperature control For a direct temperature measurement the sensors have to be arranged in the outlet pipe in a distance ensuring full evaporation of the injected water. They record the temperature curve and control the target position of the spray water control valve through a control loop. Depending on the application based with downstream saturated or slightly wet conditions (5-15K superheated) the more accurate method is an indirect temperature control. The injected amount of water is calculated with an algorithm supplied by HORA prograed to the central process control system. An analogue output signal can be linked in order to compare the actual value with the target value of the water mass flow. For a quick change of the steam mass flow, e.g. opening of a turbine bypass valve during a turbine fault, the risk of thermal shock can be reduced with an electronic remote pilot control regulation, also referred to feed-forward control. In such a scenario, the following points should be observed: Interlock: Without steam flow, no water may be sprayed. First stroke: The water injection should be transferred with a delay into the main direct control (proportional opening). The steam conditioning valve closes with a delay to avoid residual water remaining in the piping. In order to protect plant parts either upstream or downstream, it s important to define a safety position of the valve. The direct one as well as the ratio control can be superimposed by the remote control. HORA has the engineering know-how to select the right steam conditioning system to avoid malfunction due to improper design details and wrong installation of the valves, sensors and piping layout. 07

8 DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE An advanced steam conditioning system is developed by HORA by means of a proportional water injection directly after the first stage of pressure reducing. This point of highest velocity is used to create the smallest water droplets. The cooling water is supplied through an orifice tube which is fixed within the valve body. The turbulence is particularly strong at this location. The holes to let in the cooling water are covered by a perforated plug. A variable number of holes are opened through the axial movement of the plug. The appropriate number, size and arrangement of the holes determine the amount of injected water so as to ensure the right ratio to the amount of steam reduced at any time. Thus the atomization and evaporation is optimal over the complete range. In case of supercritical pressure drops of the steam a further reduction of pressure and noise is implemented by use of additional perforated cages and discs. The water droplets are further reduced passing through the resistance structure and exit evenly across the entire cross-sectional area. This system achieves downstream temperatures very near to saturation. Although the superheated steam protects the water from contact with the valve body (internal liner) the water amount should not exceed 15% in comparison the steam amount to avoid thermal stresses. STANDARD DUTY The valve with bolted bonnet is specifically developed for use on medium / high pressure applications with moderate steam temperatures but with high demand on rangeability and accuracy in temperature control. The valves are primarily used in combined heat and power plants (CHP) for consumption of auxiliary and process steam very near to saturation. Reliability of this valve is of the utmost importance in many industries such as petro-chemical facilities, pulp and paper and sugar. Pressure class: Up to PN 400 / Class 2 (Intermediate class as per design data) Max. design temperature: 550 C / 1022 F 08

9 TECHNICAL DATA STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE TECHNICAL DATA STANDARD DUTY DESCRIPTION TECHNICAL DATA Max pressure class PN 400 / Class 2 Max. design temperature 550 C / 1022 F Size Nominal size Nominal size inlet Nominal size outlet Pre warming / drain stud Water stud Seat diameter Rated travel Min Max Stages Characteristics DN NPS 2-6 2, DN NPS DN 25 NPS 1 DN as per project specific requirements NPS ,56 3,15 4,33 5,91 7,87 9,06 11, ,57 1,97 2,36 3,15 3,94 3,94 5,91 kvs cv kvs cv (up to 6 possible) linear mod. / special characteristic on request 09

10 SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE SECTIONAL DRAWING STANDARD DUTY

11 PARTS LIST STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE PARTS LIST STANDARD DUTY MATERIAL SPARE PARTS POS. DESCRIPTION 100 Body 101 Welded end 102 Connection 104 Funnel 110 Injection connection 120 Perforated disc Bonnet 515 Stud bolt / / SA 193 B Hexagon nut / / SA 194 Gr Spiral wound gasket 211 Injection lance / ~ 400 series SS / ~SA182 F9 300 Seat hardened armoured ~ 400 series SS hardened ~ SA182 F9 armoured 303 Sealing cap 304 Perforated cage / SA 182 F22 / F Guide cylinder hardened armoured ~ 400 series SS hardened ~ SA182 F9 armoured 306 Sealing cap 308 Guide cylinder hardened Stellite ~ SA182 F9 hardened Stellite 400 Plug hardened coated ~ 400 series SS hardened ~SA182 F9 coated 405 Valve stem / ~ 400 series SS / ~ SA182 F9 601 Stem packing 706 Actuator EN ASME SA182 F12 SA182 F22 SA182 F91 Graphite / K80S COMMISSIONING RECOMMENDED Other materials on request 11

12 DIMENSIONS STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE DIMENSIONS STANDARD DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB , , , , ,8 19,7 19,7 1 59, , , , , , , , , , , , , , , , , , , , , NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with pneumatic double acting actuator (without handwheel) Depending on the actuator type dimension D may vary significantly! All dimensions are subject to changes due to project specific requirements! 12

13 FEATURES AND BENEFITS STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE FEATURES AND BENEFITS STANDARD DUTY 1. Modularity Customized solutions to meet project specific requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream 2. Ease of maintenance Quick change internals (cartridgestyle) minimizes service time applicable to both vertical and horizontal orientations. 3. Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size significantly 4. Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration High rangeability Injection proportional to the steam flow in the most turbulent area of the valve ensuring smallest water droplets by secondary atomization 6. Efficiency Precise temperature control close to the saturation point with an even temperature distribution 7 7. Reliability Water injection within the high turbulence area of the plug resulting in short mixing and evaporation length downstream 13

14 DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER When critical requirements have to be fulfilled an integrated atomizer unit for the cooling water injection offers the best possible results by using the kinetic energy of the upstream high pressure steam with the shortest distance for evaporation of any downstream desuperheating system. The steam is reduced super-critically and thereby generates a pressure drop with its high velocity. Due to strong turbulences, the cooling water is atomized, drawn into the steam flow and mixed effectively. The required steam is taken downstream to the valve seat, generally after the first reduction stage. That is why a additional support steam shut-off valve is not required. The higher pressure is available during the entire load regime in every control position and ensures excellent partial load behaviour. The water enters the centre of the spray head and the number of radial holes are sized to suit quantity and pressure drop in accordance to the requested flow. There at the narrowest cross section (highest speed) the water is dragged along and atomized by the tapped high pressure steam. The evaporation of the finest droplets is rapid. The flow of the water is controlled by a separate spray water valve. STANDARD DUTY The valve with bolted bonnet is specifically developed for use on medium / high pressure applications with moderate steam temperatures. It combines a multi stage pressure control and the most advanced desuperheating technology. The standard duty valve is widely used for process steam and HP turbine bypass applications in combined cycle plants. HEAVY DUTY The valve with pressure sealing bonnet is specifically developed for use on high pressure applications with high steam temperatures. It maintains tightness under extreme conditions such as quick temperature changes. The heavy duty valve is ideal for HP turbine bypass applications in super critical power plants with a particular focus on flexible operation at all flow conditions. Pressure class: Up to PN 400 / Class 2 (Intermediate class as per design data) Pressure class: Up to PN 630 / Class 4 (Intermediate class as per design data) Max. design temperature: 550 C / 1022 F Max. design temperature: 600 C / 1112 F 14

15 TECHNICAL DATA STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER TECHNICAL DATA STANDARD DUTY / HEAVY DUTY DESCRIPTION TECHNICAL DATA STANDARD DUTY PN 400 / Class 2 HEAVY DUTY PN 630 / Class 4 Max pressure class STANDARD DUTY 550 C / 1022 F HEAVY DUTY 600 C / 1112 F Max. design temperature Size Nominal size Nominal size inlet Nominal size outlet Pre warming / drain stud Water stud Seat diameter Rated travel Min Max Stages Characteristics DN NPS 2-6 2, DN NPS DN 25 NPS 1 DN as per project specific requirements NPS ,56 3,15 4,33 5,91 7,87 9,06 11, ,57 1,97 2,36 3,15 3,94 3,94 5,91 kvs cv kvs cv (up to 6 possible) linear mod. / special characteristic on request 15

16 SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER SECTIONAL DRAWING STANDARD DUTY

17 PARTS LIST STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER PARTS LIST STANDARD DUTY MATERIAL SPARE PARTS POS. DESCRIPTION 100 Body 101 Welded end 102 Connection 104 Funnel 110 Injection connection 120 Perforated disc Bonnet 515 Stud bolt / / SA 193 B Hexagon nut / / SA 194 Gr Sealing cap 202 Nozzle 300 Seat 303 Sealing cap 304 Perforated cage / SA 182 F22 / F Guide cylinder hardened armoured ~ 400 series SS hardened ~ SA182 F9 armoured 306 Sealing cap 308 Guide cylinder hardened Stellite ~ SA182 F9 hardened Stellite 400 Plug hardened coated ~ 400 series SS hardened ~ SA182 F9 coated 405 Valve stem / ~ 400 series SS / ~ SA182 F9 601 Stem packing 706 Actuator EN ASME SA182 F12 SA182 F22 SA182 F91 COMMISSIONING RECOMMENDED Ti hardened armoured ~ 400 series SS hardened ~ SA182 F9 armoured Graphite / K80S Other materials on request 17

18 DIMENSIONS STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER DIMENSIONS STANDARD DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB , , , , ,8 19,7 19,7 1 59, , , , , , , , , , , , , , , , , , , , , NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with pneumatic double acting actuator (without handwheel) Depending on the actuator type dimension D may vary significantly! All dimensions are subject to changes due to project specific requirements! 18

19 FEATURES AND BENEFITS STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER FEATURES AND BENEFITS STANDARD DUTY 1. Modularity Customized solutions to meet project specific requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream Ease of maintenance Quick change internals (cartridgestyle) minimizes service time applicable to both vertical and horizontal orientations. 3. Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size significantly 4. Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration 5. High rangeability Injection with steam assisted desuperheater ensuring smallest water droplets over the full operating range at low spray water pressures 6. Efficiency Precise temperature control close to the saturation point with an even temperature distribution Reliability Water injection downstream including natural protective steam sheath for long term protection of downstream equipment without the use of liners 19

20 SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER SECTIONAL DRAWING HEAVY DUTY

21 PARTS LIST STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER PARTS LIST HEAVY DUTY MATERIAL SPARE PARTS POS. DESCRIPTION 100 Body 101 Welded end 102 Connection 104 Funnel 110 Injection connection 120 Perforated disc Bonnet 505 Sealing cap Graphite 201 Sealing cap 202 Nozzle 300 Seat 303 Sealing cap 304 Perforated cage / SA 182 F22 / F Guide cylinder coated ~ SA182 F9 coated 306 Sealing cap 308 Guide cylinder 400 EN ASME SA182 F12 SA182 F22 SA182 F91 COMMISSIONING Ti armoured RECOMMENDED ~ SA182 F9 armoured hardened Stellite ~ SA182 F9 hardened Stellite Plug coated ~ SA182 F9 coated 405 Valve stem / Stem packing 706 Actuator ~ SA182 F9 / ~SB637 Graphite / K80S Other materials on request 21

22 DIMENSIONS STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER DIMENSIONS HEAVY DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB , , , , ,7 19, , , , , , , , , , , , , , , , , , , , , , , NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with pneumatic double acting actuator (without handwheel) Depending on the actuator type dimension D may vary significantly! All dimensions are subject to changes due to project specific requirements! 22

23 FEATURES AND BENEFITS STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER FEATURES AND BENEFITS HEAVY DUTY 1. Modularity Customized solutions to meet project specific requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream 1 2. Ease of maintenance Quick change internals (cartridgestyle) minimizes service time applicable to both vertical and horizontal orientations. 3. Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size significantly 4. Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration 5. High rangeability Injection with steam assisted desuperheater ensuring smallest water droplets over the full operating range at low spray water pressures 6. Efficiency Precise temperature control close to the saturation point with an even temperature distribution Reliability Water injection downstream including natural protective steam sheath for long term protection of downstream equipment without the use of liners 23

24 DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER The steam conditioning valve with downstream radial type desuperheater presents a solution for high steam temperatures in ultra supercritical power plants. The injection is executed radially over the circumference through pressure-controlled nozzles, which are characterized by changing the open nozzle area with the flow. The pressure reduction is realized in 3 stages. The radial type desuperheater consists of multiple spring loaded nozzles that are circumferentially wall mounted downstream of the pressure reducing stages. The spraywater is uniformly distributed over the cross-sectional area. The plug of the nozzles, executed in combination with a non-return function, is pre-loaded with a spring and moves up to an adjustable mechanical stop. Due to the different spring loads and nozzle areas, the individual nozzle is opened sequentially and enables good partial load behaviour. SEVERE DUTY The valve with pressure sealing bonnet is specifically developed for applications in ultra super critical power plants with highest steam pressures and temperatures. It maintains tightness under extreme conditions such as quick temperature changes. The severe duty valve is ideal for HP bypass applications to handle huge water amounts and at the same time to provide a high efficiency and reliability in temperature control. Pressure class: Up to max. PN 630 / Class 4 (Intermediate class as per design data) Max. design temperature: 610 C / 1130 F 24

25 TECHNICAL DATA STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER TECHNICAL DATA SEVERE DUTY DESCRIPTION TECHNICAL DATA Max pressure class PN 630 / Class 4 Max. design temperature 610 C / 1130 F Size Nominal size Nominal size inlet Nominal size outlet Pre warming / drain stud Water stud Seat diameter Rated travel Min Max Stages Characteristics DN NPS DN NPS DN 25 NPS 1 DN as per project specific requirements NPS ,39 4,17 4,17 5,35 5, ,33 5,12 5,91 7,09 7,87 kvs cv kvs cv linear mod. / special characteristic on request 25

26 SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER SECTIONAL DRAWING SEVERE DUTY

27 PARTS LIST STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER PARTS LIST SEVERE DUTY POS. DESCRIPTION 100 Body 101 Welded end 102 MATERIAL SPARE PARTS EN ASME SA182 F92 Connection / SA182 F91 / F Injection connection / SA182 F22 / F Perforated disc / cage 152 Funnel SA182 F91 Bonnet SA182 F Sealing cap 300 Seat 303 Sealing cap 304 Perforated cage 306 Sealing cap 400 Plug 405 Valve stem 601 Stem packing 900 Nozzle 901 Gasket Graphite 908 Gasket Graphite 706 Actuator COMMISSIONING ~ SB coated ~ SA182 F9 coated ~ SA182 F9 armoured + coated coated ~ SB637 coated Graphite / K80S SS armoured + coated RECOMMENDED SS Other materials on request 27

28 DIMENSIONS STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER DIMENSIONS STANDARD DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB , , , , , , , , , , , , , , , , , , , ,6 2 5 NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with hydraulic cylinder (without spring return) Depending on the actuator type dimension D may vary significantly! All dimensions are subject to changes due to project specific requirements! 28

29 FEATURES AND BENEFITS STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER FEATURES AND BENEFITS STANDARD DUTY 1. Modularity Customized solutions to meet project specific requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream 2. Ease of maintenance Quick change internals (cartridgestyle) minimizes service time applicable to both vertical and horizontal orientations. 3. High fatigue strength Stress optimized thin walled contoured valve body designed with FEM suitable for ultra supercritical steam parameter in start/stop operation. 4. Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size significantly 5. Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration 6. High rangeability Injection by sequentially opening of multiple spring loaded nozzles ensuring smallest water droplet over the full operating range Efficiency Water injection is optimized for huge water amounts and stable control 8 8. Reliability Water injection downstream with optimum spray coverage to avoid that spray water impinge on valve body or pipe wall 29

30 DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE The steam conditioning valve with downstream injection lance represents a solution for relatively low upstream steam pressure and large flow rates. The injection is executed downstream in the direction of the steam flow through pressure-controlled nozzles, which are characterized by changing the open nozzle area with the flow. The pressure reduction is usually carried out in 2 stages. The injection lance consists of multiple spring loaded nozzles located downstream the pressure reducing stages. The spraywater is uniformly distributed over the cross-sectional area. The plug of the nozzles, executed in combination with a non-return function, is pre-loaded with a spring and moves up to an adjustable mechanical stop. Due to the different spring loads and nozzle areas, the individual nozzle is opened sequentially and enables good partial load behaviour STANDARD DUTY The valve with bolted bonnet is specifically developed for use on low / intermediate pressure applications with high steam temperatures. It is capable to handle huge water amounts and at the same time to provide a high efficiency and reliability in temperature control. HEAVY DUTY The valve with pressure sealing bonnet is specifically developed for use on low / intermediate pressure applications with highest steam temperatures. The heavy duty valve is capable to be operated under extreme conditions which make it ideal for the HRH/ IP turbine bypass application in ultra super critical power combined cycle plants and conventional fossil fired plants with a focus on flexible operation. Pressure class: Up to PN 160 / Class 900) (Intermediate class as per design data) Pressure class: Up to PN 250 / Class 1 (Intermediate class as per design data) Max. design temperature: 580 C / 1076 F Max. design temperature: 630 C / 1166 F 30

31 TECHNICAL DATA STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE TECHNICAL DATA STANDARD DUTY / HEAVY DUTY DESCRIPTION TECHNICAL DATA STANDARD DUTY PN 160 / Class 900 HEAVY DUTY PN 250 / Class 1 Max pressure class STANDARD DUTY 580 C / 1076 F HEAVY DUTY 630 C / 1166 F Max. design temperature Size Nominal size Nominal size inlet Nominal size outlet Pre warming / drain stud Water stud Seat diameter Rated travel Min Max Stages Characteristics DN 1 2 2B 3 3B NPS DN NPS DN NPS DN as per project specific requirements NPS ,84 11,81 11,81 13,78 13,78 15,75 17,72 19, ,69 7,87 7,87 7,87 7,87 9,84 11,02 11,81 kvs cv kvs cv (up to 3 possible) linear mod. / special characteristic on request 31

32 SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE SECTIONAL DRAWING STANDARD DUTY

33 PARTS LIST STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE PARTS LIST STANDARD DUTY MATERIAL SPARE PARTS POS. DESCRIPTION 100 Body 101 Welded end 102 Connection 104 Funnel Bonnet 515 Stud bolt / / SA 193 B Hexagon nut / / SA 194 Gr Perforated cage / ~ 400 series SS / ~ SA182 F Sealing cap 304 Seat with perforated cage hardened armoured ~ 400 series SS hardened ~SA182 F9 armoured 305 Guide cylinder hardened coated ~ 400 series SS hardened ~ SA182 F9 coated 306 Sealing cap 308 Guide cylinder hardened Stellite ~ SA182 F9 hardened Stellite 400 Plug / hardened / coated ~ 400 series SS / ~ SA182 F9 hardened / coated 405 Valve stem / ~ 400 series SS / ~ SA182 F9 601 Stem packing 800 Injection lance 804 Nozzle 806 Spiral wound gasket Actuator EN ASME SA182 F12 SA182 F22 SA182 F91 COMMISSIONING Graphite / K80S RECOMMENDED Spiral wound gasket Sealing / / SA 182 F12 / F22 / F Ti Other materials on request 33

34 DIMENSIONS STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE DIMENSIONS STANDARD DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB , ,2 19, , , ,2 19, , B , , , , , ,2 19, , B , , ,6 2 98, , , , , , , , , , , , , NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with pneumatic double acting actuator (without handwheel) Depending on the actuator type dimension D may vary significantly! All dimensions are subject to changes due to project specific requirements! 34

35 FEATURES AND BENEFITS STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE FEATURES AND BENEFITS STANDARD DUTY 1. Modularity Customized solutions to meet project specific requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream Ease of maintenance Quick change internals (cartridgestyle) minimizes service time applicable to both vertical and horizontal orientations. 3. Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size significantly Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration 5. High rangeability Injection by sequentially opening of multiple spring loaded nozzles ensuring smallest water droplet over the full operating range 6. Efficiency Water injection is optimized for huge water amounts and stable control Reliability Water injection downstream with optimum spray coverage to avoid that spray water impinge on valve body or pipe wall 35

36 SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE SECTIONAL DRAWING HEAVY DUTY

37 PARTS LIST STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE PARTS LIST HEAVY DUTY MATERIAL SPARE PARTS POS. DESCRIPTION 100 Body 101 Welded end 102 Connection 104 Funnel Bonnet 505 Sealing cap 300 Perforated cage 303 Sealing cap 304 Seat with perforated cage coated ~ SA182 F9 coated 305 Guide cylinder coated ~ SA182 F9 coated 306 Sealing cap 308 Guide cylinder 400 Plug 405 Valve stem 601 Stem packing 800 Injection lance 804 Nozzle 806 Spiral wound gasket 809 Spiral wound gasket 813 Sealing 706 Actuator EN ASME SA182 F91 SA182 F COMMISSIONING RECOMMENDED ~ SA182 F91 Stellite Stellite armoured + coated ~ SA182 F9 armoured + coated ~ SA182 F9 / coated ~ SA182 F9 / ~SB637 coated Graphite / K80S / SA 182 F22 / F Ti Other materials on request 37

38 DIMENSIONS STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE DIMENSIONS HEAVY DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB , , , , , , , , , , , , , , , , , , , , , , , , NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with pneumatic double acting actuator (without handwheel) Depending on the actuator type dimension D may vary significantly! All dimensions are subject to changes due to project specific requirements! 38

39 FEATURES AND BENEFITS STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE FEATURES AND BENEFITS HEAVY DUTY 1. Modularity Customized solutions to meet project specific requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream 2. Ease of maintenance Quick change internals (cartridgestyle) minimizes service time applicable to both vertical and horizontal orientations. 3. High fatigue strength Stress optimized thin walled contoured valve body designed with FEM suitable for ultra supercritical steam parameter in start/stop operation Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size significantly 5. Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration 6. High rangeability Injection by sequentially opening of multiple spring loaded nozzles ensuring smallest water droplet over the full operating range 6 7. Efficiency Water injection is optimized for huge water amounts and stable control Reliability Water injection downstream with optimum spray coverage to avoid that spray water impinge on valve body or pipe wall 39

40 LIFECYCLE SERVICES STEAM CONDITIONING VALVES LIFECYCLE SERVICES RELIABLE SOLUTIONS AND SERVICE The HORA brand stands both for the longevity and reliability of its products as well as for the quality of our services, which support our valves and actuators in plants around the globe. We cover the entire value chain of a plant from engineering through to construction and operation of energy-focused facilities. More than a conventional service provider, HORA offers a complete range of excellent consultation, support and assistance throughout the lifecycle of the product. The HORA service department offers regular inspection and maintenance to ensure the reliable operation of its products. Any required special component beyond the scope of our normal spare parts needed, tools or machines for coissioning or repair work is available. At the completion of water-tube steam generating plants, the associated pipework and system is contaminated with debris: Residual material from fabrication, assembly and corrosion products. Typically water systems are flushed with high velocity water, boiler surfaces are chemically cleaned and steam pipes are blown with steam to remove particulate material that would potentially damage sensitive devices. HORA s service tools include: Kits to hydro test of the inlet and outlet system Kits for flushing during chemical cleaning Blow-out/ blow-through devices and sacrificial trims to operate during steam blows Instrumentation and calibration equipment Removal and compression tool for internals Machining based on assessment EEMPLARY SPECIAL TOOLS Assembly tool for trim Assembly tool for bolting 40

41 LIFECYCLE SERVICES STEAM CONDITIONING VALVES Steam blow through kit Combined blow out & hydro test kit Hydro test kit Steam blow out kit 41

42 Holter Regelarmaturen GmbH & Co. KG Helleforthstraße Schloß Holte-Stukenbrock Phone