STEAM CONDITIONING VALVES TECHNICAL BULLETIN
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
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
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
CONTENT STEAM CONDITIONING VALVES CONTENT Our aspiration Selection guide Application area Fundamental issues Control logic 02 03 04 06 07 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 08 09 10 11 12 13 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 14 15 16 17 18 19 20 21 22 23 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 24 25 26 27 28 29 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 30 31 32 33 34 35 36 37 38 39 Lifecycle services Reliable solutions and service Exemplary special tools 40 41 beyond the scope of the copyright law shall require the prior written consent of its respective author or creator. Rev: 01 05/18 05
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
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
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
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 1 2 3 4 5 6 7 110 150 200 230 280 65 80 DN 50-150 65-200 NPS 2-6 2,5-8 3-10 4-12 6-12 8-14 10-16 DN 250 250 350 450 650 700 NPS 10 10 14 18 20 26 28 80-250 100-300 150-300 200-350 250-400 DN 25 NPS 1 DN as per project specific requirements NPS 65 80 110 150 200 230 280 2,56 3,15 4,33 5,91 7,87 9,06 11,02 40 50 60 80 100 100 150 1,57 1,97 2,36 3,15 3,94 3,94 5,91 kvs 26 42 66 105 263 335 523 cv 30 49 76 122 304 388 605 kvs 33 51 104 200 290 405 565 cv 38 59 120 232 336 469 654 3 (up to 6 possible) linear mod. / special characteristic on request 09
SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE SECTIONAL DRAWING STANDARD DUTY 706 601 405 516 515 308 306 305 100 101 400 102 304 303 300 211 211 210 110 120 10
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 1.7711 / 1.4923 / 1.4986 SA 193 B16 516 Hexagon nut 1.7711 / 1.4923 / 1.4986 SA 194 Gr.4 210 Spiral wound gasket 211 Injection lance 1.4057 / 1.4922 ~ 400 series SS / ~SA182 F9 300 Seat 1.4122 hardened 1.4922 armoured ~ 400 series SS hardened ~ SA182 F9 armoured 303 Sealing cap 304 Perforated cage 1.7383 / 1.4903 SA 182 F22 / F91 305 Guide cylinder 1.4122 hardened 1.4922 armoured ~ 400 series SS hardened ~ SA182 F9 armoured 306 Sealing cap 308 Guide cylinder 1.4922 hardened Stellite ~ SA182 F9 hardened Stellite 400 Plug 1.4122 hardened 1.4922 coated ~ 400 series SS hardened ~SA182 F9 coated 405 Valve stem 1.4122 / 1.4923 ~ 400 series SS / ~ SA182 F9 601 Stem packing 706 Actuator EN ASME 1.5415 1.7335 1.7383 1.4903 SA182 F12 SA182 F22 SA182 F91 Graphite / K80S COMMISSIONING RECOMMENDED Other materials on request 11
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 300 11,8 450 17,7 450 17,7 1450 57,1 1100 2 350 13,8 19,7 19,7 1 59,1 600 1300 3 400 15,7 600 23,6 550 21,7 1550 61,0 650 1400 4 450 17,7 650 25,6 700 27,6 1800 70,9 1200 2600 5 19,7 800 31,5 750 29,5 1950 76,8 1600 3 6 600 23,6 900 35,4 800 31,5 2000 78,7 1900 4200 7 650 25,6 900 35,4 1000 39,4 2300 90,6 2200 4900 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
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 1 2 3 4 5 6 5. 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
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
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 1 2 3 4 5 6 7 110 150 200 230 280 65 80 DN 50-150 65-200 NPS 2-6 2,5-8 3-10 4-12 6-12 8-14 10-16 DN 250 250 350 450 650 700 NPS 10 10 14 18 20 26 28 80-250 100-300 150-300 200-350 250-400 DN 25 NPS 1 DN as per project specific requirements NPS 65 80 110 150 200 230 280 2,56 3,15 4,33 5,91 7,87 9,06 11,02 40 50 60 80 100 100 150 1,57 1,97 2,36 3,15 3,94 3,94 5,91 kvs 33 51 82 162 290 405 565 cv 38 59 95 188 336 469 654 kvs 40 65 141 282 365 560 795 cv 46 75 163 326 422 648 920 3 (up to 6 possible) linear mod. / special characteristic on request 15
SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER SECTIONAL DRAWING STANDARD DUTY 706 601 405 516 515 308 306 305 100 101 400 102 304 303 300 104 201 110 120 202 16
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 1.7711 / 1.4923 / 1.4986 SA 193 B16 516 Hexagon nut 1.7711 / 1.4923 / 1.4986 SA 194 Gr.4 201 Sealing cap 202 Nozzle 300 Seat 303 Sealing cap 304 Perforated cage 1.7383 / 1.4903 SA 182 F22 / F91 305 Guide cylinder 1.4122 hardened 1.4922 armoured ~ 400 series SS hardened ~ SA182 F9 armoured 306 Sealing cap 308 Guide cylinder 1.4922 hardened Stellite ~ SA182 F9 hardened Stellite 400 Plug 1.4122 hardened 1.4922 coated ~ 400 series SS hardened ~ SA182 F9 coated 405 Valve stem 1.4122 / 1.4923 ~ 400 series SS / ~ SA182 F9 601 Stem packing 706 Actuator EN ASME 1.5415 1.7335 1.7383 1.4903 SA182 F12 SA182 F22 SA182 F91 COMMISSIONING RECOMMENDED 1.4571 316Ti 1.4122 hardened 1.4922 armoured ~ 400 series SS hardened ~ SA182 F9 armoured Graphite / K80S Other materials on request 17
DIMENSIONS STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER DIMENSIONS STANDARD DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB 300 11,8 450 17,7 450 17,7 1450 57,1 1100 2 350 13,8 19,7 19,7 1 59,1 600 1300 3 400 15,7 600 23,6 550 21,7 1550 61,0 650 1400 4 450 17,7 650 25,6 700 27,6 1800 70,9 1200 2600 5 19,7 800 31,5 750 29,5 1950 76,8 1600 3 6 600 23,6 900 35,4 800 31,5 2000 78,7 1900 4200 7 650 25,6 900 35,4 1000 39,4 2300 90,6 2200 4900 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
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 1 2 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 3 4 5 6 7 7. Reliability Water injection downstream including natural protective steam sheath for long term protection of downstream equipment without the use of liners 19
SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER SECTIONAL DRAWING HEAVY DUTY 706 405 601 505 100 308 306 101 305 400 102 304 303 300 104 120 110 201 202 20
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 1.7383 / 1.4903 SA 182 F22 / F91 305 Guide cylinder 1.4922 coated ~ SA182 F9 coated 306 Sealing cap 308 Guide cylinder 400 EN ASME 1.5415 1.7335 1.7383 1.4903 SA182 F12 SA182 F22 SA182 F91 COMMISSIONING 1.4571 316Ti 1.4922 armoured RECOMMENDED ~ SA182 F9 armoured 1.4922 hardened Stellite ~ SA182 F9 hardened Stellite Plug 1.4922 coated ~ SA182 F9 coated 405 Valve stem 1.4923 / 2.4668 601 Stem packing 706 Actuator ~ SA182 F9 / ~SB637 Graphite / K80S Other materials on request 21
DIMENSIONS STEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER DIMENSIONS HEAVY DUTY A C B D DIMENSIONS SIZE 1 A B C D WEIGHT KG LB 350 13,8 450 17,7 550 21,7 1550 61,0 1100 2 400 15,7 19,7 600 23,6 1600 63,0 700 1 3 450 17,7 600 23,6 650 25,6 1650 65,0 1000 2200 4 19,7 650 25,6 800 31,5 1900 74,8 1 3300 5 550 21,7 800 31,5 850 33,5 2050 80,7 2200 4900 6 650 25,6 900 35,4 900 35,4 2100 82,7 2 5 7 700 27,6 900 35,4 1100 43,3 2400 94,5 2800 6200 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
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 2 3 4 5 6 7 7. Reliability Water injection downstream including natural protective steam sheath for long term protection of downstream equipment without the use of liners 23
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
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 1 2 3 4 5 110 130 150 180 200 DN 80-200 100-300 150-350 200-400 250-400 NPS 3-8 4-12 6-14 8-16 10-16 DN 450 600 700 850 NPS 18 20 24 28 34 DN 25 NPS 1 DN as per project specific requirements NPS 86 106 106 136 140 3,39 4,17 4,17 5,35 5,51 110 130 150 180 200 4,33 5,12 5,91 7,09 7,87 kvs 160 250 345 490 650 cv 185 289 399 567 752 kvs 200 290 390 570 750 cv 232 336 451 660 868 3 linear mod. / special characteristic on request 25
SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER SECTIONAL DRAWING SEVERE DUTY 706 405 601 505 100 306 101 304 102 400 306 300 110 151 152 908 901 900 26
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 1.4901 SA182 F92 Connection 1.4903 / 1.4901 SA182 F91 / F92 110 Injection connection 1.7380 / 1.4903 SA182 F22 / F91 151 Perforated disc / cage 152 Funnel 1.4903 SA182 F91 Bonnet 1.4901 SA182 F92 505 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 2.4668 COMMISSIONING ~ SB637 1.4922 coated ~ SA182 F9 coated ~ SA182 F9 armoured + coated 2.4668 coated ~ SB637 coated Graphite / K80S SS 1.4922 armoured + coated RECOMMENDED SS Other materials on request 27
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 550 21,7 1100 43,3 650 25,6 2100 82,7 1 3300 2 600 23,6 1100 43,3 700 27,6 2200 86,6 1900 4200 3 600 23,6 1100 43,3 700 27,6 2200 86,6 2100 4600 4 650 25,6 1100 43,3 850 33,5 2300 90,6 2300 5100 5 650 25,6 1150 45,3 850 33,5 2300 90,6 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
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 1 2 3 4 5 6 7 7. 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
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
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 4 5 6 275 330 350 380 400 435 490 550 200-450 250-250 - 300-550 300-550 350-600 400-650 450-700 NPS 8-18 10-20 10-20 12-22 12-22 14-24 16-26 18-28 DN 650 700 700 750 750 850 950 1000 NPS 26 28 28 30 30 34 38 40 DN 25 40 50 NPS 25 40 50 DN as per project specific requirements NPS 250 300 300 350 350 400 450 9,84 11,81 11,81 13,78 13,78 15,75 17,72 19,69 170 200 200 200 200 250 280 300 6,69 7,87 7,87 7,87 7,87 9,84 11,02 11,81 kvs 1150 1550 1650 2000 2250 2700 3600 4250 cv 1331 1794 1910 2315 2604 3125 4167 4919 kvs 1400 2200 2200 2900 2900 3 4600 5 cv 1621 2547 2547 3357 3357 4051 5325 6366 1 (up to 3 possible) linear mod. / special characteristic on request 31
SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE SECTIONAL DRAWING STANDARD DUTY 706 405 516 515 601 308 306 305 100 102 400 304 303 101 300 104 809 813 800 806 804 32
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 1.7711 / 1.4923 / 1.4986 SA 193 B16 516 Hexagon nut 1.7711 / 1.4923 / 1.4986 SA 194 Gr.4 300 Perforated cage 1.4122 / 1.4903 ~ 400 series SS / ~ SA182 F91 303 Sealing cap 304 Seat with perforated cage 1.4122 hardened 1.4922 armoured ~ 400 series SS hardened ~SA182 F9 armoured 305 Guide cylinder 1.4122 hardened 1.4922 coated ~ 400 series SS hardened ~ SA182 F9 coated 306 Sealing cap 308 Guide cylinder 1.4922 hardened Stellite ~ SA182 F9 hardened Stellite 400 Plug 1.4122 / 1.4922 hardened / coated ~ 400 series SS / ~ SA182 F9 hardened / coated 405 Valve stem 1.4122 / 1.4923 ~ 400 series SS / ~ SA182 F9 601 Stem packing 800 Injection lance 804 Nozzle 806 Spiral wound gasket 809 813 706 Actuator EN ASME 1.7335 1.7383 1.4903 SA182 F12 SA182 F22 SA182 F91 COMMISSIONING Graphite / K80S RECOMMENDED Spiral wound gasket Sealing 1.7335 / 1.7383 / 1.4903 SA 182 F12 / F22 / F91 1.4571 316Ti Other materials on request 33
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 650 25,6 1200 47,2 19,7 1850 72,8 2850 6300 2 700 27,6 1200 47,2 19,7 1950 76,8 3000 6600 2B 650 25,6 950 37,4 700 27,6 2300 90,6 2700 6000 3 750 29,5 1250 49,2 19,7 2100 82,7 3200 7100 3B 650 25,6 965 38,0 700 27,6 2 98,4 3200 7100 4 800 31,5 1250 49,2 600 23,6 2200 86,6 3600 7900 5 850 33,5 1300 51,2 700 27,6 2400 94,5 4300 9 6 900 35,4 1300 51,2 750 29,5 250 9,8 5400 11900 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
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 1 2 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 3 4 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 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 5 6 7 7. Reliability Water injection downstream with optimum spray coverage to avoid that spray water impinge on valve body or pipe wall 35
SECTIONAL DRAWING STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE SECTIONAL DRAWING HEAVY DUTY 706 405 601 505 308 306 305 100 102 400 304 303 101 300 104 809 813 800 806 804 36
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 1.4922 coated ~ SA182 F9 coated 305 Guide cylinder 1.4922 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 1.4903 1.4901 SA182 F91 SA182 F92 1.4903 COMMISSIONING RECOMMENDED ~ SA182 F91 Stellite Stellite 1.4922 armoured + coated ~ SA182 F9 armoured + coated ~ SA182 F9 / 2.4668 coated ~ SA182 F9 / ~SB637 coated Graphite / K80S 1.7383 / 1.4903 SA 182 F22 / F91 1.4571 316Ti Other materials on request 37
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 650 25,6 1200 47,2 950 37,4 2300 90,6 3000 6600 2 700 27,6 1200 47,2 950 37,4 2400 94,5 3200 7100 3 800 31,5 1250 49,2 1000 39,4 2600 102,4 3400 7 4 800 31,5 1250 49,2 1000 39,4 2600 102,4 3800 8400 5 850 33,5 1300 51,2 1200 47,2 2900 114,2 4 9900 6 900 35,4 1300 51,2 1250 49,2 3000 118,1 5600 12300 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
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. 1 2 3 4 5 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 6 7. Efficiency Water injection is optimized for huge water amounts and stable control 7 8 8. Reliability Water injection downstream with optimum spray coverage to avoid that spray water impinge on valve body or pipe wall 39
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
LIFECYCLE SERVICES STEAM CONDITIONING VALVES Steam blow through kit Combined blow out & hydro test kit Hydro test kit Steam blow out kit 41
Holter Regelarmaturen GmbH & Co. KG Helleforthstraße 58-60 33758 Schloß Holte-Stukenbrock Phone +49 5207 8903-0 mail@hora.de www.hora.de