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WEIR CONTROL & CHOKE VALVES
Excellent solutions
providing optimum
performance for
all Turbine Bypass
applications
ExcellentPower & IndustrialSolutions
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Weir Turbine Bypass Valves & Desuperheaters
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Quality assurance
Weir is qualified to industry standards andworking practices including:
ASME BPVC Section III (N and NPT Stamp)
NQA-1 Quality system
10CFR50 App. B
10CFR50 Part 21
RCC-E
RCC-M
CSA Z299
Performance testing and qualification to:
ASME QME-1
ASME B16.41
IEEE 323
IEEE 344
IEEE 382
ISO 9001:2008
ISO 14001
PED 97/23/CE
API Q1 TO API LICENCES:
API 6D (6D-0182)
API 6A (64-0445)
OHSAS 18001
ATEX 94/9/CE
Lean manufacturing practices
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A proven track record
We have extensive references and a proven trackrecord in the supply of valves across a number ofkey industries.
Our valves are industry renowned brands,
each with an established reputation for qualityengineering and reliability.
Valve testing
All pressure containing items are hydrostaticallytested, seat leakage tested and functionally tested.
We can also perform gas, packing emission,cryogenic and advanced functional testing, aswell as seismic testing for nuclear applications.
Material testing
Non-destructive examination by radiography,ultrasonics, magnetic particle and liquidpenetrant.
Chemical analysis by computer controlleddirect reading emission spectrometer.
Mechanical testing for tensile properties atambient and elevated temperatures, bend andhardness testing. Charpy testing at ambient,elevated and sub-zero temperatures.
Aftermarket solutions
Our valve aftermarket solutions are based onour engineering heritage, applying our OEMknowledge and expertise to maintenance
strategies, life extension and upgrade projects.
Weir Control & Choke Valves provides a
wide range of control valves for the process
industry. These include severe service,
choke, desuperheating and turbine bypass
applications.
Our world-wide reputation is based
on engineering excellence applied to a
comprehensive range of specialist products
and effective customer support.Weir UK purpose built factory at Elland
ContentsTurbine bypass valve description 3
Reasons for Turbine bypass valve 4
Trim types 5
Plug seals 6
Outlet diffuser 6
Bonnet types 6
Water injection nozzles 7
Design options 8
Sizing and configuration 9
Weir Control & Choke Valves Weir Turbine Bypass Valve
Member of
Weir International, South Korea
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The Turbine Bypass Valve
The turbine bypass valve is designed to bypass the steam cycle from the boiler
to the turbine and dump the steam directly into the condenser. The valve is
used on start-up and turbine trips.
The BV994 (Globe) and BV995 (Angle) range of turbine bypass valveshave been developed to handle the most severe process conditions
while maintaining valve stability, tight shut off, noise reduction and fast
operating speeds. The valves have a combined pressure letdown and steam
temperature reduction system. Water is injected through a series of nozzles
located towards the valve outlet.
Conditions usually associated with turbine bypass systems are high pressure
drop in the critical flow regime leading to sonic conditions across the valve
trim. Weir can offer a wide range of trims to eliminate the detrimental effects
of dropping the pressure. Available trims are:
Multi flow (single stage of pressure letdown)
Cascade (up to 5 stages of pressure letdown)
X-Stream (multi-stage pressure letdown)These trims are selected based on the valve sizing conditions but are selected
to handle the pressure drop without generating the detrimental by products
of dropping pressure such as vibration, erosion and high noise levels.
To maintain the station efficiency turbine bypass valves are usually specified
with a tight shut off (normally Class V). Depending on the valve size and the
actuation mechanism then the valves are designed with either a balanced or
unbalanced trim.
On balanced valves Weirs unique sealing mechanism ensures that Class V
closure can be maintained while ensuring actuation forces are minimised. The
valve is positionally controlled by either a pneumatic or hydraulic actuator
which ensures repeatable positional control.
Depending on the amount of water to be injected into the steam then a
selection of spray nozzle options can be offered. These nozzles ensure that the
water is effectively atomised to minimise the absorption time into the steam.
The turbine bypass valves are supplied with an associated spraywater valve
that is used to reduce the spray water pressure before injection into the
steam.
Standard Design Options
Pressure Ratings
ASME Class 150 to ASME Class 4500
Sizes
Inlet 40mm to 500mm (1 to 20)
Outlet 40mm to 1000mm (1 to 40)
Trim Options
Multiflow
Cascade
X-Stream
Actuation
Pneumaticdouble actingpiston
Electro hydraulic
BV995
Angle Turbine Bypass Valve
High pressure Turbine Bypass valve
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Reasons for Turbine Bypass Valves
Turbine bypass valves are used to reduce thetemperature of steam by injection of water into thesteam flow. Where steam supply exists at a relativelyhigh temperature for driving the turbine, it needs
to contain a large amount of superheat to ensurethat dry steam is used. Any entrained water woulddamage the turbine blades. Steam is used for heattransfer which is a function that requires the steamto be cooled close to its saturation point. When theturbine bypass valve is used it must dump steaminto the condenser or cold re-heat system. Thereforeall superheat must be removed from the steam.
The object of a desuperheater is therefore to removesome or nearly all of the superheat. The process ofadding water to steam to lower its temperature isquite a complex process due to the two stage flowthat is generated at the point of water injection.
Desuperheaters are therefore selected to: Reduce the steam temperature to protectdownstream equipment from excesstemperature.
To prevent superheat steam from reducing thepressure of the steam.
To improve the thermal efficiency of the heattransfer process by reducing the overall steamtemperature close to the saturation point.
In order for the temperature to be reduced and
controlled effectively several conditions must be
met. These include:
Efficient atomization of the cooling medium
A vapour velocity that promotes mixing
The correct cooling medium temperature
Pressure Reducing Trim
The ratio between inlet and outlet pressure for bothhigh and low pressure turbine bypass applicationscan be significant. The steam mass flow range canalso be significant, and these two factors suggestthat the steam pressure reduction must be done in anumber of stages. These stages must be active overthe complete flow range, unlike fixed baffle plates
which are optimised for one flow rate only.
Spraywater Injection Nozzles
It is usually important for the spraywater to be
evaporated within a very short distance from its
injection point. It is also critical to ensure that water
does not impinge on the valve body or pipe wall. It
is normal practice to locate the spraywater injection
nozzles downstream of all the valve pressure
reducing trim, and the use of atomising steam spray
nozzles is used for efficient water absobtion.
Seat Tightness
When Turbine Bypass Valves are discharging into
the condenser it is imperative that they have a tightshutoff to ensure that the partial vacuum existing
in the condenser is maintained. The tight shut off is
achieved with a Class V sealing system.
Valve Body design
The valve body design must take into
consideration the thermal cycling that will occur
during its lifetime. The flow path must be as
smooth as possible to ensure that noise and
vibration levels caused by turbulent flow areminimised.
As with most types of high pressure valve used
in the power industry, a pressure seal bonnet is
preferred at least for the HP Bypass Valves.
Materials are selected to ensure the valve body has
a minimum wall thickness. This minimises the risk
of a large temperature gradient across the valve.
Temperature gradients can cause thermal stress
in the body and result in cracking due to the rapid
changes in temperature.
ActuationOne of the major differences between the US
market and Europe is that in Europe Turbine
Bypass Systems are predominantly actuated by
Hydraulic Power Units and cylinders. In the US
Combined Cycle market Pneumatic systems are
preferred for cost reasons, although in the US Fossil
fired stations, hydraulic units are required due to
the higher actuation forces required.
In addition to the main bypass and spraywater
valves there are a number of other significant
elements that make up a Bypass system.
Hydraulic Power Units including PLC systems Pressure Safety Device
Steam Blowthrough Trim
Acid Cleaning Trim
Condenser Dump Tubes
Special Features
Warming Line
In order to prevent thermal stress on startup,
turbine bypass warming lines can be
incorporated to pass a small steam volume into
the downstream pipe.
Orientation
Turbine bypass valves are often required to lay
horizontal due. Stable seat guiding ensures
this can be achieved without special design
modifications.
Fully Accessible Trip and Diffuser
The valve incorporated a fully serviceable trim
and diffuser.
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Trim Design
Control valve trims for turbine bypass valves are selected
according to the valve process conditions. Cage designs are
described below.
Multiflow and Single Stage MultiflowThe Multiflow and Single Stage Multiflow trim gives a single
stage of pressure letdown. In this design the flow is broken up
into multiple jets by a number of radial holes in the valve cage.
On turbine bypass valves the flow is usually from outside to in so
that jet impingement and high turbulence levels are controlled
with the confines of the trim. Impingement of the jets within the
centre of the trim gives a more stable downstream flow, reduces
the effect of large scale separation and produces a smaller scale
turbulence structure in the valve outlet. This in turn leads to a
reduction in acoustic efficiency and changes the power spectrum
of the generated noise both of which contribute to an overall noise
reduction of 15 to 20dBA compared to contoured trim valves.
Further noise reductions in this style of valve can be achieved bydrilling smaller holes in the valve cage. This design is referred to as
Single Stage Multiflow.
Cascade
The cascade trim is used in applications which require up to 5
stages of pressure letdown. The cascade trim has been designed to
eliminate problems such as noise, vibration and erosion by staging
the pressure drop through a series of discrete pressure drop
stages. The cascade trim is manufactured to a close tolerances
and consists of a series of drilled sleeves. The number of sleeves
(pressure drop stages) required depends on the amount of
treatment required for a particular application. Each successive
sleeve has a number of radial holes and a carefully calculated
increase in flow area to ensure correct apportionment of the
pressure drop. The small radial jets pass through a tortuous path
resulting in high frictional and impingement losses. At the same
time the impingement of the jets onto the outer radial sleeves
control the shock wave formation which has a major influence on
the overall noise reduction.
X-Stream
The X-Stream trim is specifically designed for severe service
applications where detrimental valve factors such as noise, erosionand vibration need to be eliminated. Using a series of stacked discs,
multiple stages of pressure letdown are provided using a series of
complex flow paths. The flow path of the X-Stream is designed
with a series of columns which ensure a smooth flow pattern.
This ensures that if dirt/debris should enter the trim then it will be
washed through to the valve outlet.
On steam applications the X-Stream trim has a special jet control
row. This eliminates shock cells at the outlet of the trim. These
shock cells are responsible for high noise and vibration at the valve
outlet.
Further details of the X-Stream can be found in the X-Stream
trim brochure.
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Weir Turbine Bypass ValveWeir Control & Choke Valves
Class V Sealing
In order to maintain a condenser vacuum and ensure
maximum power station efficiency turbine bypass
valves often require a tight shut off which is referred
to as Class V. Due to the high temperatures associated
with a turbine bypass valve conventional resilientseals cannot be used, therefore many valve suppliers
use pilot balanced trim designs. Depending on the
stability of the process flow, pilot balanced trims can
often generate trim instability and poor control.
Weirs solution is to use a conventional balanced
valve trim and install a metallic seal to prevent leakage
between the valve plug and cage. The seal is pressure
energised so that higher pressures across the valve
trim result in increased sealing load and therefore
tighter shut-offs.
Controlling the Outlet Steam Conditions
Due to the pressure drops associated with turbine
bypass valves then additional noise and velocity
control is often required in the outlet of the valve.
Existing turbine bypass valve suppliers often weld
diffusers into the valve outlet. This can result in
thermal cracking and when these diffusers require to
be serviced then the complete valve outlet section
must be completely removed.
In the Weir system trim components have been
designed for ease of service. All trim components are
clamped into the valve body. The seat ring extends
into the valve outlet section which contains the trim
outlet diffusers. These can incorporate a number ofbasket style diffusers. Diffusers are designed so that
steam expansion due to pressure drop is achieved in
the expanded outlet section resulting in lower steam
velocities. The location of the holes in the diffuser
results in minimum jetting against the walls of the
outlet section.
Stable Plug Guiding
To ensure the most stable trim the valve plug is
guided in the seat rather than in the valve cage. An
additional stage of pressure letdown is incorporated
on an articulated section of the plug nose which
ensures stable pressure letdown and thereforeelimination of pressure induced vibration.
Bonnet Designs
Bonnet designs are selected according to the pressure
rating, size and operating temperature of the valve.
On high temperature steam applications then a
normalizing bonnet is used to lift the valve packings
away from the main temperature gradient. In high
pressure and temperature applications a pressure
seal bonnet is used to simplify the bonnet assembly,
remove weight from the bonnet neck and to eliminate
the requirement for special torque equipment.
Outlet diffuser
Normalising bonnet Pressure seal bonnet
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Water Injection Options
BV984 Spring Loaded Nozzle
The BV984 nozzle gives high capacity water injection while
offering protection of the water system in case of loss ofwater supply. The superior pressure of the water system
lifts the spring loaded nozzle away from its seat which
results in a cone shape jet of water being injected into the
steam. The system requires a separate spray water control
valve to control the amount of water injection. This system
ensures a high rangeability while ensuring the water
droplet size is kept to a minimum. On loss of water pressure
the water system is protected against high temperatures
due to spring loading of the nozzle.
BV985 Variable Area Nozzle
The BV985 spray nozzle is used on applications where high
rangeability is required with direct control across the spraynozzle. The BV985 is designed so that steam is injected into
the centre of the pipe resulting in minimum droplet contact
against the pipe walls. Water is injected across a series of 12
variable area nozzles which atomises the water into micro
fine droplets resulting in faster absorption rates and shorter
outlet steam pipe lengths. The amount of water injected
into the pipe is directly controlled by the valve plug which
is in turn controlled by the actuator. Where the pressure
differential between the cooling medium and the vapour
exceeds 60 bar, a two stage nozzle is available that extends
the available pressure drop range to 100 bar. The two stage
nozzle ensures erosion across the valve plug is maximised.
The BV985 unit is fitted into steam pipes greater than150mm (6).
BV986 Mini Desuperheater
The BV986 unit is a simplified spray nozzle where the spray
water is circulated around an internal gallery and then
injected into the steam through a series of radial holes.
The BV986 unit fits between conventional flanges and
is therefore easy to remove for service and maintenance
purposes. The unit is connected to a stand alone
spraywater valve which controls the amount of water being
injected into the vapour. The BV986 can also be directly
mounted onto the outlet of a pressure control valve so that
water is injected into the turbulent vapor flow at the outletof the valve. The BV986 is used on pipe sizes from 25mm
(1) and above.
BV988 Fixed Area Spray Nozzle
The BV988 unit offers good spraywater atomisation but
with separate spray water control. The valve is similar to
the BV985 unit but with all spraywater control removed
from the unit. A flanged or butt weld connection is used
to connect the spraywater which in turn is controlled via
a separate control valve. This allows for high technology
control valve trims to be used to eliminate the detrimental
effects of erosion sometimes created by high pressure
drops. The unit is also used in situations where spacearound the desuperheating system is limited.
BV984 Spring Loaded Nozzle
BV985 Variable Area Nozzle
BV986 Mini Desuperheater
BV988 Fixed Area Sparay Nozzle
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Special Applications
Pressure reducing and desuperheating units are often
specified and selected according to the application.
Customer requirements often require special designs
to accommodate unusual requirements. Selected
special designs are shown below.
Condenser Steam Dump
End User S2 Ruwais Power Company
Customer Samsung C & T
Project Shuweihat S2 IWPP U.A.E.
Product 4 off 1400mm Inlet x 1000mm Body x2700mm Outlet ANSI 150
Angles Control Valves c/w Electro-HydraulicActuators and Control Panels
Application LP Process Steam Dump toCondensator
Materials ASTM A216 WCB with 410 SS Trim Total Weight 15 metric tonnes each
Delivery completed in 28 weeks
Special Shape
Turbine bypass valves are often required to lie
horizontally due to the nature of steam systems in
a power station. This can cause premature wear on
seals and cause increased friction through the valve
trim. Producing a special body design with the flow
turned through 90 degrees in the horizontal plane
allows for the trim and actuator to be mounted
vertically in the pipe. This in turn ensures more stable
control through the full valve stroke range.
Actuation
There are two main types of actuators used on
turbine bypass valves, either pneumatic actuators or
hydraulic actuators. In both cases to ensure stable
control and protection of the turbine the actuators
are selected for fast stroke speeds often below 3
seconds for full stroke.
Hydraulic actuators have the advantage of delivering
a high thrust capability while maintaining stable
valve control.
Pneumatic systems are used where hydraulicsupplies are limited but where plant air is readily
available. Pneumatic systems are specified with
a high thrust piston actuator which is
controlled via a series of high capacity
instruments. Stable control is
achieved due to the responsiveness
of the instruments through the full
stroke of the valve.
Condenser Steam Dump valve
Condenser Steam
Dump valve section
90 degree mounted
valve with vertical
actuator
Hydraulic actuation Fast operating pneumatic system
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Initial Sizing of Desuperheaters
Information required at enquiry stage
Initial calculations
Calculate the required flow of water WW, kg/hr (lb/hr), needed to
control the steam temperature at the outlet, by the heat balance
method.WW = WS (h1 - h2)
(h2 - hF)
where:
h1 = enthalpy of superheated steam at inlet
h2 = enthalpy of steam mixture at outlet
hF = enthalpy of spraywater at inlet
values in kJ/kg (Btu/lb)
Total outlet steam flowrate WM = WS + 2W kg/hr (lb/hr)
Sizing of low pressure pipeline
This is the recommended pipe size for BV985, BV986 and BV988
pipeline types, or the outlet size for the BV995 design for efficient
desuperheating.
The pipe is sized so that the steam velocity does not exceed 90m/s
(300ft/s) or, for BV984, BV985, BV986, BV988 types, fall below 4.5m/s
(14ft/s). The preferred velocity is 75m/s (250ft/s).
The minimum pipe diameter is calculated using the following formulae.
For BV984, BV985, BV986 and BV988 desuperheaters there is a selection
of standard trim sizes available
BV994 and BV995 units are often associated with outlet silencer
sections depending upon the ratio of inlet and outlet pressures and
the maximum permissible sound pressure. For these reasons each unit
receives individual considerations based upon customer requirements.
D = 18.8 mm or D = 0.225 in.
where:
WM = outlet steam flowrate kg/hr (lb/hr)
VS = outlet specific volume m3/kg (ft3/lb)
Velocity m/sec (ft/sec)
Location in pipework
The desuperheater should be installed so that the
spray nozzle is located at the steam inlet of the tube (if
supplied). A filter should be fitted in the spray water inlet
line to prevent ingress of dirt.
Pipe Joints
Owing to the severe expansion strains which may be
imposed on the joints when starting up it is essential that
all flange joint bolts are manufactured from high tensile
alloy steel irrespective of the steam pressure. These
remarks also apply to the water joint flanges which are
also subject to sudden temperature changes.
Drainage and drainage systems
Efficient drainage of the pipework following the
desuperheater is essential. To ensure that water cannot
accumulate at any point the pipe should be arrangedto fall in the direction of flow approximately 20mm per
metre (14 per foot) under actual working conditions
and be provided with an efficient large capacity trap
(10% of maximum flow to facilitate start-up and shut
down of plant) at the lowest point. To prevent the trap
becoming airbound the drain pipe should have ample
capacity to deal with the drainage and be fixed as near
to vertical as possible. There must be sufficient space
in the drain pipe for water to flow down and air to pass
up the pipe.
When starting up the plant it is advisable to open the
trap by-pass valve to deal with any excess water. If aby-pass valve is not fitted the trap should be inspected
to ensure that it is passing water and has not become
airbound. When the pipework has warmed through to
working temperature and a reasonable amount of steam
is flowing the drainage of water should practically cease
and the trap by-pass valve can then be closed.
Successful operation of a desuperheater depends to
a large extent on the injection of water being hot,
preferably near to the saturation temperature of the
steam to be cooled so that it is mainly the latent heat
which is extracted from the steam to evaporate the
injected water. This minimises the time of the suspension
of the water particles in the steam so that all the wateris evaporated and none falls to the inside walls of the
pipework. As mentioned below the pipes connecting the
water supply to the injection nozzle should be efficiently
lagged to minimise the loss of heat.
The water pressure and temperature should be no less
than the values originally specified at the enquiry/order
stage since these figures are used for design purposes
in sizing the injection nozzle. The pipes connecting
the water supply to the injection nozzle should be no
less in diameter than the water isolating valve flange
connections indicate.
Condensate supply should be free from debris and
effectively filtered to less than 0.25mm.
P1 Inlet Pressure Bara (Psia)
T1 Inlet temperature C (F)
P2 Required outlet pressure Bara (Psia)
T2 Required outlet temperature C (F)
PW Available spraywater pressure Bara (Psia)
TW Spraywater temperature C (F)
WS Maximum inlet steam flow kg/hr (lb/hr)
WM x VS
Velocity
WM x VS
Velocity
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NotesWeir Control & Choke Valves
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TBV
2-031
2
Copyright 2012 Weir Valves & Controls UKLtd.
Britannia House
Huddersfield Road
Elland, West Yorkshire
HX5 9JR England
Tel: +44 (0) 1422 282 000
Fax: +44 (0) 1422 282 100
Email: [email protected]
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