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MIL Controls Limited

A KSB Company

MAJOR SYSTEMS
VALVE SELECTION
MATERIAL SELECTION
INSTALLATION & MAINTENANCE
VALVES FOR POWER PLANTS
CONTROL VALVES FOR POWER PLANTS

MIL Controls Limited. The Machining Shop, a part of the world class manufacturing
facility at Meladoor near Cochin in Kerala.

MIL CONTROLS LIMITED, 2002. All rights reserved

ABOUT THIS HANDBOOK


Forthepast15years,MILControlsLimitedhasbeenoneofthepremiersuppliersofhighspeciality
ControlvalvesfortheIndianPowerPlantsector.Overtheseyearsourengineershavegained
enormousexperienceinallaspectsofvalvedesign,selectionandmaintenance.
The MIL Power Plant Application Handbook triestotranslatethisexperienceintoareadily
accessiblereferencetool,theneedforwhichhaslongbeenexpressedbymanyofourclientsand
associates.thehandbookthusencapsulatesMILscontinuingfocusonthepowersector.
Atasecondlevel,TheMILPowerPlantApplicationHandbook,alsoservesasaminicataloguefor
MILs wide range of products. It offers specific data on Valve Selection and Operational
Characteristics.
REFERENCE DOCUMENT: ISA HANDBOOK FOR CONTROL VALVES.

MIL Controls Limited


A KSB Company

RegisteredOffice&Works.Meladoor,Mala,PIN680741,ThrissurDistrict, Kerala,India
Tel: 91 (0)488 890272, 890772, 891773. Fax: 91 (0)488 890952. Email: milf@vsnl.com

MarketingHeadOffice.P.B.No.04,Aluva,PIN683101ErnakulamDist,Kerala,India
Tel: 91 (0)484-624955, 624876. Fax: 91 (0)484-623331. Email: ksbmil@sancharnet.in
APPLICATION HANDBOOK

Contents Page

1.1 Company overview................................................. 8


2.0 Introduction ........................................................... 9
3.1 Major systems ...................................................... 13
3.2 Condensate system ............................................... 14
3.3 Feed Water system................................................ 17
3.4 Main Steam system ............................................... 22
3.5 Heater Drain system .............................................. 31
4.1 Typical applications. 67.5 MW ................................ 35

1.0 Contents
4.2 Typical applications. 116 MW ................................ 36
4.3 Typical applications. 210 MW ................................ 38
4.4 Typical applications. 250 MW ................................ 40
4.5 Typical applications.500 MW ................................. 42
5.1 Body material specs ............................................... 47
5.2 Allowableworkingpressure ................................... 48
5.3 Trimmaterialselection ........................................... 51
6.1 Handling&Installation .......................................... 55
7.1 PreventiveMaintenance ........................................ 61
7.2 Shop Overhaul ..................................................... 62
8.1 MIL 21000 Series .................................................. 67
8.2 MIL 41000 Series .................................................. 68
8.3 MIL 78000 Series .................................................. 69
8.4 MIL 91000 Series .................................................. 70
9.0 Index & List of Illustrations ..................................... 72
CONTROL VALVES FOR POWER PLANTS

1.1 Company overview

MIL Controls Limited. The factory premises at Meladoor near Cochin in Kerala

E ver since its inception in 1983, MIL has been unrivalled as a supplier of
high performance Control Valves to the Indian power sector.
The company, which stamped its class in its very first set of major project
supplies to the 210 MW Neyveli TPS (Unit III&IV), the 210 MW MSEB
Chandrapur TPS (Stage II), the 210 MW GEB Wanakbori TPS (Stage II)
and the 120 MW NALCO CPP (all 5 units) way back in 1984-85, has gone
on to excel in the design and manufacture of custom-built special
application Control Valves to meet the challenging process control
requirements in thermal power stations.
In May 2000, MIL achieved another milestone when it unveiled the
MATRIX Series extreme pressure, multi stage, multi path axial flow Control
Valves. A product of months of specialised R&D, the MATRIX Series valves
have been designed to kill upto 420 Kg/cm2 pressure in 40 stages. This
ingenious and unique design has a progressively declining resistance flow
path and is designed to eliminate Cavitation and limit Velocity in any
severe service condition.
In December 2001, MIL had its crown of glory when it became the first
Indian company to be accredited with the coveted CE marking (refer page
71) for Control Valves, mandatory for exports to the European Union
beyond May 2002. The first lot of MIL valves with CE marking is being
installed in high pressure steam / Feed Water service in a power plant at
Salvimona, Finland being built by M/s Foster Wheeler.
Today MIL is the preferred vendor in the country for the rugged, critical
application Control Valves for thermal power stations, be it a 33 MW
captive power plant or a 250/500 MW utility power plant.
With a comprehensive product range, world-class manufacturing and
testing facilities, and a highly skilled work force, we are today fully geared
to meet any critical process control requirements in the power plant sector.
APPLICATION HANDBOOK

POWER PLANT APPLICATIONS

Factorsdetermining
selectionofValves.
Extraordinary demands are placed on Control Valves

2.0 Introduction
usedintheEnergySector.Theiroperational parameters
vary widely in terms of pressure, pressure drops, flow
rates and temperature.
In addition, other crucial factors like Noise, Cavitation,
Wire drawing, Leakage Class and Flashing also play an
important part in the selection of Control Valves for
power station applications.

1. HIGH TEMPERATURE

2. HIGH PRESSURE

3. HIGH PRESSURE DROP

4. COMBINED HIGH TEMPERATURE, PRESSURE & PRESSURE DROP

5. CONTINUOUS THROTTLING

6. TIGHT SHUT OFF CAPABILITIES

7. AERODYNAMIC NOISE

8. HIGH RANGEABILITY

9. CAVITATION AND FLASHING


FIG. 1. GENERAL BOILER (DRUM STYLE) FLOW DIAGRAM
Powerplantapplications
4 major systems, their characteristics
and valves used in such applications.
APPLICATION HANDBOOK

3.1 Major systems


The 4 major systems and critical valves .
1. CONDENSATE SYSTEM
Condensate Pump Minimum Recirculation Valve
Deaerator Level Control Valve

2. FEED WATER SYSTEM


Boiler Feed Pump Minimum Recirculation Valve.
Boiler Feed Water Startup Valve.
Boiler Main Feed Water Control Valve.

3. MAIN STEAM SYSTEM


SuperheaterAttemperatorSprayValve
ReheaterAttemperatorSprayValve.
Turbine Bypass Valves.
Deaerator Pegging Steam Valves.
Soot Blower Steam Pressure Reducing Valves.
PRDS System valves

4. HEATER DRAIN SYSTEM


High pressure heater drain valves.
Low pressure heater drain valves.
CONTROL VALVES FOR POWER PLANTS

3.2 Condensate system

Fig. 2. Condensate System.

Condensatesystem The Condensate Pump must


The Condensate system consists haveaminimmumRecirculation
of the Feed Water Circuit starting orFlow toavoidoverheatingof
from the Condenser Hotwell to the
thepumpandprotectitfrom
Deaerator. The Condenser is a
form of heat exchanger that
Cavitation. The Condensate
condenses the exhaust steam of RecirculationValve recirculates
the Turbine. waterfromthepumpbacktothe
The exhaust steam of the Turbine Condenser toensureminimum
which is very low in pressure and Recirculationofthepump.The
temperature passes on its heat to CondensateRecirculationValve
the cooling water, is condensed
hastoabsorbthefullpressure
and collects in the hotwell. The
low pressure steam which is very dropie.,frompumpdischarge
high in volume creates a vacuum pressuretotheCondenser
when it is condensed into water. pressure. Due to very near
The vacuum in the Condenser saturatedconditionsexistingin
increases the Thermodynamic
thedownstreamsideofthevalve
efficiency of the cycle. The most
critical valves which have a bearing andrelativelyhigherpressure
on the smooth operation of the drops, the valve is subject to
plant are Condensate Extraction Cavitation andFlashing.
3.2 Condensate system

Pump Minimum Recirculation Valve


and Deaerator Level Control Valve. ControlValvesforthisapplication
Condensate RecirculationValve
shouldalsohavegoodshutoff
The Condensate Pump extracts capabilitytoeliminateseat
theFeedWaterfromthe damageduringshutoffconditions.
CondensateHotwelland Anyleakageshouldbetakeninto
dischargestotheDeaerator. accountasaformoflostenergy.
APPLICATION HANDBOOK

ThefunctionofthisControlValve
istomaintain correctlevelsinthe
Deaerator.
TheDeaeratorisanopencontact
typeFeedWaterHeaterwhich
purgesanynoncondensableand
dissolved gases. Also the

3.2 Condensate system


Deaeratoractsas areservoirfor
FeedWatertosmoothentheFeed
Watersupplyatvaryingloads.
Fig. 3. MIL 78000 Series. Condensate TheFeedWaterlevelinthe
Minimum Recirculation Valve.
Deaeratoralsohelpsin
TYPICAL PARAMETERS
maintainingtheNetPositive
Inlet Pressure: 40- 45 bar( a) Suction Head (NPSH) of the
BoilerFeedWaterPump. The
Outlet Pressure: 0.1 bar(a)
DALCV has to cater to the widely
Temperature: 40- 50o C
varyingflowdemandfrom
startupconditionsto
The typical valves for such
fullloadconditions.
applicationshaveantiCavitation
featureswhicheliminateany Valveselectionanddesign should
possibilityofCavitationby bebasedonthefollowingfactors:
droppingpressureoverstages. Duringthestartupthepump
Alsomaterialselectionshouldbe dischargepressurewillbehigh
verydiscreteinsuchapplications owingtolowflowrequirements.
takingintoaccountofhighly Deaeratorpressureduringthe
ErosiveCavitatingconditions. startupoftheplantwillbelow.
Use of 17-4PH and 440C These factors result in the valve
MartensiticSteelhaveyielded working at very low Cvs and the
excellentresults. associatedlowliftoperations.
The typical valves for such Alsotherelativelyhigherpressure
applications are 3 or 4 78000 dropsintheseconditonscanlead
Series Multi Step / Multi Stage tooccuranceofCavitation.
design or 41008 Series Whenthepumppicksupload,
MultiCage/Multi stage design.
theflowrateincreasesandthe
DeaeratorLevelControlValve. pumpdischargepressuregoes
Theapparentlymildservice down.Atthesametime,theback
conditionsmisleadmanyControl pressureintheDeaerator
Valvemanufacturersinthe increases. This obviously
design of valves for this service. warrants ahigherflowcapacity.
CONTROL VALVES FOR POWER PLANTS

3.2 Condensate system

Fig. 4. MIL 41000. Deaerator level Control Valve.

Such extremeconditionscallfor TYPICAL PARAMETERS


valveswithexceptionallyhigh Inlet Pressure: 20- 42 bar (a)
Rangeability,besidesCavitation
Pressure drop: 7- 42 bar (a)
protectionatlowerflow
Temperature: 50 -100 o C
conditions.
Typicaldesignsforsuch TheCagedesigncombinessmall
applications are the MIL 41921 or sized,drilled,antiCavitationholes
the MIL 41621 Series which inthelowerportion,andlarger
incorporateanequalpercentage holes athigherlifts.
characterizedTrimwhichtakes This design gives the necessary
careofthehighRangeability. Cavitationprotectionatlowerlifts
The basic design is a Cage Guided andhigherflowcapacityathigher
PlugwiththeCagehaving liftsensuring verywide
characterizedports. Rangeability.
APPLICATION HANDBOOK

3.3 Feed Water system


Fig. 5. Boiler Feed Pump Minimum Recirculation System.

FeedWatersystem HenceeveniftheFeedWater
The Feed Water system includes
requirementsareverylow(dueto
those parts of the system from lowloadconditions)thepump
Deaerator to the Boiler inlet. shouldhandleaminimumflow.
The system consists of Feed Water Toensurethisminimumflow,a
piping, Feed Water pumps, high certainamount ofFlowhastobe
pressure heaters and the associated recirculated backtothe
accessories. DeaeratorastheFlow
The Feed Water pressure is raised to requirementsoftheBoilermay
the Boiler pressure and the notbesufficienttosatisfythe
temperature is also raised to near minimumRecirculation
saturation conditions by the high
requirementsofthepump.
pressure heaters and Economisers.
Theparametersareobviously
The critical Control Valve
verydetrimental foranyvalveto
applications in this system are Boiler
Feed Pump Minimum Recirculation
handle. The valve has to drop a
Valve, Boiler Feed Water Startup pressure of 220-250 bar to 10 bar
Valve & Boiler Main Feed Water (Deaeratorpressure).Alsoitmay
Control Valve. benotedthat theoutlet
conditionsofthevalvearenear
BoilerFeedPumpMinimum saturation,andhencethevalveis
Recirculation Valve.
verysusceptibleto highenergy
Themostcriticalapplicationina CavitationandFlashing.
PowerStationistheBoilerFeed
PumpMinimumRecirculation TYPICAL PARAMETERS

Service. A pump should have a Inlet Pressure: 220-250 bar (a)


minimumFlowthroughittotake Outlet Pressure: 10-12 bar (a)
careofthecoolingrequirements Temperature: 200o C
ofthePump.
CONTROL VALVES FOR POWER PLANTS

3 methods of providing 3. A third method employed by


Feed Pump olderpowerplants, recirculatesa
Recirculation. constantflow,regardlessofthe
plantload. Thepressureiskilled
1. The Modulating Type System bySeriesof multiholeplates.
employsaModulatingValve
whichthrottlestheFlowtothe Oftheabovemethodstheideal
minimumrequiredwhichisa systemwouldbetheModulating
3.3 Feed Water system

functionoftheFlowrequiredby System, since it is the most energy


theBoiler. efficient . However it exerts
taxingdemandsonControlValve
Supposethe requiredminimum
functioning.
Recirculation of the pump is 100
tons/hr,and theBoiler Valvearesubjectedto high
requirement is 90 tons/hr, the pressuredropthrottling ofvery
minimumRecirculationvalvewill lowflowsto fullflowconditions.
open so that it passes 10 tons/hr Thehighpressuredropthrottling
andtheminimumRecirculation atlowliftconditions adversely
condition is satisfied (90 tons/hr affectTrimdurabilityduetowire
throughthemainlineand10 drawingeffectsandTrimErosion.
tons/hr through the bypass line.
Totalflowthroughthepumpwill
be 100 tons/hr ie., 90 + 10).
2. The On/Off System employs
an On-Off valve which passes a
constantRecirculationFlow.
Supposethe requiredminimum
Recirculation of the pump is 100
tons/hr,and theBoiler
requirement is 90 tons/hr, the
MinimumRecirculationValvewill
fully open so that it passes 100
tons/hr so that the minimum
Recirculationconditionis
satisfied.OncetheBoiler
requirementgoesabove 100
tons/hr the Recirculation Valve
closesfullysincetheBoiler
requirementissufficienttosatisfy
theminimumRecirculation Fig. 6. MIL 78000. Boiler feed pump
requirementsofthepump. minimum Recirculation valve.
APPLICATION HANDBOOK

3.3 Feed Water system


Fig. 7. MIL 91000. Multi stage multi path, axial flow MATRIX Series valve for Boiler
feed pump minimum Recirculation service

In this context, the most cost MILscontinuousresearchand


effectivesolutionisobviouslythe innovationsinPowerPlant
On-Off system. applicationvalves hasbornefruit
The typical valve for such inthesuccessfuldevelopmentof
application is the MIL 78000 theAxialFlow,MultiStage,
VariableResistancedesign,the
Serieswhichincorporatesa
MATRIX Series Valve which is
uniqueMultiStep,MultiStage
suitableforaModulatingSystem.
designwhichkillspressureovera
numberofstages. Theprototypewasdevelopedfor
aPumpRecirculationapplication
The 78000 Series ensures a metal
withpressuredropsof420bar.
to metal Class V leakage. The salientfeatureofthisdesign
Anothersalientfeatureisthe isthewidescopeforcustomizing
uniqueSlidingCollarSeatRing the valve to suit specific process
designforClassVIleakageshutoff. applications.
CONTROL VALVES FOR POWER PLANTS

TheTrimcanbecustomizedto Anothervalveisusedduringfull
varioushighpressuredrop loadconditions.Apparentlythe
applicationsbyvaryingthe applicationsmayseemsimilar.
numberofstages.
Howevertheselection
Thecharacteristiccanbe
philosophyanddesignare
customizedbyreallocatingthe
entirelydifferentforthetwo
pressuredropratioindifferent
stages. Theexpandingflow valves. This is because of the
3.3 Feed Water system

passagesalsoenhance the differentpressuredropconditions


Rangeabilityallowingsmooth existingatthetimeofStartupand
andpreciseFlowControlevenat Full Load.
lowliftoperatingflowconditions. ThetypicalparametersofLow
FeedWaterRegulatorValve LoadFeedWaterControlValve
Anothercritical applicationinthe andFullLoadFeedWaterControl
FeedWaterSystemistheBoiler Valvearegivenbelow.
FeedWaterRegulatingValve
which controlsflowtotheBoiler LOW LOAD FEED WATER VALVE
for varying loads of the system.
TYPICAL PARAMETERS
Thevalvetakesthe signalfrom Inlet Pressure: 170-200 bar (a)
theFeedWaterControlwhich
Outlet Pressure: 30-110 bar (a)
employsathree-elementcontrol.
Thesignalisgeneratedasa Temperature: 230o C
functionof Drumlevel,Steam
flowandFeedWaterflow. FULL LOAD FEED WATER VALVE
Twokindsofvalvesareusedfor TYPICAL PARAMETERS
FeedWaterregulation. Inlet Pressure : 220-250 bar (a)
Onevalveisemployedduringthe Outlet Pressure: 210- 230 bar (a)
low loadconditionsorthestartup
Temperature: 247o C
conditionsoftheBoiler.

Fig. 8. Feed Water Regulating System.


APPLICATION HANDBOOK

3.3 Feed Water system


Fig. 9. MIL 41008. Multi stage, Low Load, Feed Water regulating valve.

Thetypicaldesignforlowloadandfullloadapplicationsisthe
MIL 41000 Series Valves which employ Heavy Duty Cage Guided
features.
TheCageGuideddesignensures goodThrottlingStabilityandgood
Rangeabilitytocatertowidelyvaryingflowconditions.
Wherethepressuredropduringstart-upconditionisveryhigh,which
can be detrimental in conventional valves, 41008 Series Multi Cage
designfindsitstypicalapplicationforthelowloadvalve.
ThisdesignwhichfeaturesaMultiStagePressureDropTrim,willtake
careoftheveryhighpressuredropsencounteredduringstart-up
conditionswherethedrumpressureisverylowandthepump
dischargepressureisveryhigh.
CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system

Fig. 10. Critical Control Valves in Main Steam Line

MainSteamSystem Boilermanufacturersemploy
The Main Steam System consists of variousmethods likeburnertilt
the steam circuit from the Boiler mechanism, spray water systems
outlet, Superheater System, Soot
etc.tocontrolthetemperatureof
Blowing system, Turbines, Reheater
System to Condenser. The steam
the Main Steam . A poor
fully extracted of the energy is finally temperaturecontrolsystemmay
dumped into the Condenser, which resultindamagestoTurbine
is the heat sink. blades,Superheatertubes,
The most critical application valves Reheatertubesetc.
in this system are: Superheater
Spray Control Valves, Superheater Hence Attemperator valves are
Spray Block Valves, Reheater Spray of critical relevance
Control Valves, Reheater Spray
The typicalproblemsfacedby
Block Valves, Soot Blower Pressure
Control Valves, PRDS System superheatersprayControlValves
Control Valves, Main Steam arethrottlinginstability andwide
Pressure Reducing Valves, PRDS Rangeability.
Spray Control Valves and Deaerator
Pegging Steam Valve. The designparametersofthe
spray system include those
SuperHeaterAttemperatorValve
conditions whichaccountforthe
Thetemperature ofthemain
excessiveheatingoftheTurbine
steamcomingoutoftheBoileris
verycritical fromthepointof atfull load,withtheFeedWater
Thermodynamic Efficiencyofthe atitsmaximumtemperature,
heatcycleandtheTurbineblade cleanBoilertubesandmost
protection. favourableconditions.
APPLICATION HANDBOOK

3.4 Main steam system


Fig. 11. MIL 41100. Superheater Attemperator valve.

Fig. 12. MIL 41200. Superheater Attemperator valve.


CONTROL VALVES FOR POWER PLANTS

Howevertheaboveconditions
seldomcomeintoplaydueto
deteriorationofBoilertubesdue
toScalebuildupandthe
consequentheattransferloss.
Alsothesituationisfurther
compoundedby withdrawalof
3.4 Main steam system

heat throughtheSootBlower.All
thesefactorsresultinadrastic
reductionofspraywater
requirements.
Hence in practice the Spray
Fig. 13. MIL 41400. Superheater
WaterValvewillbeseldomtaken Attemperator block valve.
intofullcapacity.Thevalvewillbe
For higher sizes (2 and above)
workingatlowerliftconditions theActuator thrustrequirements
duetoabovesaidreasons. willbeveryhighduetothe
Anothercriticalfactorinfluencing unbalanced design of the 41100
theselectionofControlValveis Seriesdesign.
the Leakage Class. The 41200 features a balanced
Anyexcessiveleakagewillresult design withanovelStaticSeal
inthermalshocksin Secondary concept. The 41200 design has
thesameadvantagesthatthe
SuperheaterTubesanderosionof
41100 Series besides the added
Turbineblades.
featureofabalancedplug.
MIL offers special designs like the AnotherapplicationofSpray
41100 Series and the 41200 System is the block valve.
Seriesforsuchapplications.
The block valves assists the spray
The 41100 Series features an ControlValves effectingatight
unbalancedCageGuideddesign. shutoff.Another requirementof
Thiscombinesthetwinbenefits a block valve is faster response.
ofthegoodthrottling stability of Hence the Spray System employs
Cage Guided valves with the shut apneumaticallyoperatedOnOff
offcapabilityofsingleseated ControlValveforthisapplication.
unbalanceddesigns. The typical MIL designs for block
valve applications are the 41400
TYPICAL PARAMETERS Series and the 41200 Series. The
Inlet Pressure:181-200 bar (a) 41400 design is a Cage Guided
Outlet Pressure: 161-180 bar (a) designwherethemainplugis
assistedbyanauxiliarypilotplug
Temperature: 247o C
toeffecttightshutoff.
APPLICATION HANDBOOK

3.4 Main steam system


Fig. 14. MIL 78000. Reheater Fig. 15. MIL 41008. Reheater
Attemperator Control Valve. Attemperator Control Valve.

ReheaterAttemperatorValves ThesourceoftheSprayWater
Thisapplicationisalsosimilarto caneitherbetheFeedWater
theSuperheaterSprayControl pumpoutletortheinterstage
tappingofthepump.
Valveapplication.
Incaseoftheformer,thepressure
However fluctuationsin
drop can be as high as 100-120
temperatureis notvaryingasin bar, andlatter,itcanbeupto
SuperheaterSprayControl. 60-70 bar.
The Leakage Class is very critical The MIL solution to such
since excessive leakage can lead applications are the 78000 Series
toErosionoflowpressureTurbine or the 41128 Series for high
blades. pressure drops (100-120 bar). In
thecaseofmoderatepressure
Thevalveselectiondependson drops, it is the 41121 Series or the
thepressuredropacrossthe 41221 Series.
valve.Itmaybenotedherethat TheReheaterSprayBlockValve
reheaterpressureistheoutlet applicationissimilarto
pressureofthehighpressure SuperheaterSprayBlock
Turbine. Thepressuredropacross applications,andtheselection
thevalvedependsonthesource philosophyissimilartothatfor
ofthespraywater. SuperheaterSprayBlockservice.
CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system

Fig. 16. Deaerator Pegging Steam System.

DeaeratorPeggingSteamValve Normallythesteamistakenfrom
TheDeaerator isadirectcontact theAuxiliarySteamHeaderupto
typeheaterwhichremovesnon 15% MCR condition. Above this
condensable gases like Oxygen and upto 40% MCR, the steam is
andCarbondioxidefromthe takenfromtheColdReheat
Feed Water. These gases, if not Header(Steamtappedafterthe
expelled,willattackandcorrode HighPressureTurbine).Infull
pipingandBoilertubes.Thehot loadconditions,steamistaken
steamismixedwiththeFeed directlyfromtheTurbine
WaterenteringtheDeaerator extractionline.
bringingittosaturation Typical valves in this system are:
temperatureandthereby 1. DEAERATOR PEGGING FROM
AUXILLIARY STEAM HEADER
liberatinganyundissolvedornon
condensablegases. TYPICAL PARAMETERS
Inlet Pressure: 16 bar (a)
Steamissupplied tothe
Deaeratorfordeaeration ofFeed Outlet Pressure: 3.5 bar (a)

Waterandalsotomaintaina Temperature: 220o C


positivepressureinthe 2. DEAERATOR PEGGING FROM
Deaearator.Deaerator actsasa COLD REHEAT STEAM HEADER
FeedWaterstoragetanktothe TYPICAL PARAMETERS
BoilerFeedPump.Maintaininga Inlet Pressure: 21 bar (a)
higherpressureintheDeaerator Outlet Pressure: 3.6 bar (a)
helpsinmaintainingtheNPSHof
Temperature: 330o C
thepump.
APPLICATION HANDBOOK

SootBlowerValve
Theeffectivenessoftheheat
transferthroughBoilertubesis
adverselyaffectedbythebuildup
ofsoot.Alsotherapidbuildupof
sootinthetubescanleadtothe
developmentofhotspotsinthe

3.4 Main steam system


Boilertubes.TheBoilertubes
shouldbefrequently cleaned to
remove thesoot.Thenormal
practice is to use high velocity
Fig. 17. MIL 41003. Deaerator pegging
steam Control Valve steamjetstoblowthesootfrom
the tubes. The soot removal is
Theproblemsencounteredin
effectedthroughSootBlowers.
valve selection for such
SomeSootBlowersuseairalsofor
applicationsare thehighnoise
levels associated with this valve. theremovalofsoot.
MIL offers special low noise Trims Oneofthemajorchallengeshere
(Lo-dB Design) for such is to select and design a Control
applications. The 41000 Series ValvefortheSteamSootBlowers.
Cage Guided valves with special Theproblemsuniquetothis
LowNoiseTrimhavebeenfound serviceareHighpressuredrop,
excellent for such services.
HighnoiselevelsandThermal
Additionalnoiseattenuationcan
cycling of the valve body and
beachievedwithdouble stage
valveinternals.
pressuredropdesignssuchas
doubleCageordiffuseroptionsin Sootblowingvalvesarenormally
the 41000 Series. isolatedbyanupstreamisolation
valve. Hence the valve is not
Anotherproblemassociatedwith
subjectedtohighpressureand
this service is high exit velocities
temperature whennotinservice.
duetovolumetricexpansionof
HoweverwhentheSootBlowing
thesteamwhenthepressure
is being done, the valve is
drops. MIL offers special low
subjected to very high pressures
noisecartridges whichdividethe
andtemperatures.
pressuredropbetweenthevalve
andthecartridges.
TYPICAL PARAMETERS
Theeffectivepressuredropratio Inlet Pressure - 170 bar (a)
across the valve is reduced which
Outlet Pressure - 20 bar (a)
resultsinlowexitvelocitiesand
Temperature - 540o C
noiselevels.
CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system

Fig. 18. MIL 71114. Soot blower pressure reducing Control Valve

Hence the valve is subjected to Here MIL offers its 41114 Series
thermal cycling which can cause (CageGuidedinlinebodywith
WarpageandCreepinthe doublestagepressuredrop),or
conventional castglobevalve its 71114 Series (Cage Guided
bodies. anglebodywithdoublestage
Theobvioussolutionwouldbeto pressuredrop).Thebodyshallbe
useforgedanglebodiesorforged forgeddesignandchrome
inlinebodieswithspecialmulti molybdenum steel (ASTM A 182
stagelownoiseTrims. Gr. F22)
APPLICATION HANDBOOK

3.4 Main steam system


Fig. 19. Typical Auxiliary PRDS System

PRDSStationValves. ThesteamDesuperheating is
Apartfromsteambeingusedfor effectedthroughPRDSstations
powergenerationandsoot PressureReducing
blowing,steamisusedforother DesuperheatingSystem.
auxiliaryserviceslikegland The PRDS system consists of a
sealingofTurbines,Steam Desuperheaterpressurereducing
EjectorsinCondensersand valveandatemperatureControl
Valve. Thepressurereducing
Deaerator pegging.
valvereducesthepressureofthe
Themainsteamhastobe steambeforeentryintothe
Desuperheatedbyreducingits Desuperheater.
pressureandtemperature to ThetemperatureControlValve
utilisethesteamfortheabove regulatesthespraywater
mentionedapplications. quantityintotheDesuperheater.

MAIN STEAM PRESSURE TEMPERATURE CONTROL VALVE


REDUCING VALVE (SPRAY WATER)

TYPICAL PARAMETERS TYPICAL PARAMETERS


Inlet Pressure - 170 bar (a) Inlet Pressure - 185 bar (a)
Outlet Pressure - 16 bar (a) Outlet Pressure - 16 bar (a)
Temperature - 540o C Temperature - 170o C
CONTROL VALVES FOR POWER PLANTS

3.4 Main steam system

Fig. 20. MIL 41914 Main Steam Pressure Reducing Valve.

The critical factors that govern A seat ring - basket diffuser is


selection of Main Steam PRV are: provided foreffectivenoise
High pressure drop, High attenuationathigherpressure
temperature, High noise levels dropratios.
and Material selection for high ThetemperatureControlValveis
temperature.
anothercriticalvalvecomingin
MIL offers the 41912 Series or the the system. As in the case of
41914 Series for this application. ReheaterSprayControlValve,
ThisdesignfeaturesaCage the selection of this valve is also
GuidedTrimwith specialLow governedbythe sourceofthe
Noisemultipleholescontrolling SprayWater.Thesourceofthe
theflow.Optionaldoublestage SprayWatercaneitherbefrom
designisalsoavailablewhichis FeedWaterPumpoutletorinter
veryeffectiveinnoiseattenuation stagetappingofthepump.
athigherpressuredropratios.
Inthecaseoftheformer,the
For Class V leakage, the 41413
pressuredropcanbeashighas
Series istheappropriate
100-120 bar, and in the latter
selection. The 41413 Series
case, it can be upto 60-70 bar.
design is a Cage Guided design
wherethemainplugisassistedby The MIL solution to such
an auxiliarypilotplugtoeffect applications are the 78000 Series
thetightshutoff. or the 41128 Series for high
pressure drops (100-120 bar).
The Cage design includes
multipleholestoattenuatethe Inthecaseofmoderatepressure
noise.Theflowdirectionofthe dropsthe designshallbethe
valve is Over the Plug. 41121 Series or the 41221 Series.
APPLICATION HANDBOOK

Thecriticalfactorsthat influence
theselectionofthevalvesare:
Body andTrimmaterial,Valve
sizeandValveflowcapacity
Flashingproblemsencountered
intheseservicescausematerial

3.5 Heater drain system


erosion.
The liquid dropletsaccelerated
byrelativelyhighvelocityvapour
Fig. 21. MIL 21000. Heater Drain Valve phase,impingesonthematerial
TheHeaterDrainSystem surface ofbodyand Trimcausing
The heater drain system consists of heavywear.
the Feed Water heaters coming in
the Condensate system and Feed GenerallyChromeMolybdenum
Water system. The Feed Water steelshaveexhibitedexcellent
heaters coming in the Condensate
system are called low pressure
resistancetoFlashingErosion.
heaters which heats the Condensate Even though ASTM A 217 Gr C5
to saturation point before entry into
Deaerator. is recommended by some users, it
The heaters coming in the Feed isbeing increasinglyreplacedby
Water system are the High pressure ASTM A 217 Gr WC9 material as
heaters which heat the Feed Water
C5 has some significant
to near saturation point before the
entry into Boiler. manufacturingproblems,in
The HP heaters and LP heaters are additiontopoorweldability,and
basically heat exchangers shell and isthusdifficulttoweldrepair.
tubetype. The heating media for HP
heaters is the steam extracted from Anotherissueistheselectionof
the reheat cycle, whereas for LP valve body size. It is always
heaters the steam is extracted from
the low pressure Turbine.
recommendedtoselecthigher
The heating media, i.e., the steam is bodysizeswithareduced
introduced into the heaters, cooled capacityTrim.
and ultimately condensed back to
liquid. The level in the heaters are to Thebodysizeselectioncriteriais
be closely controlled to maintain the theoutletFlashingvelocity.
Thermodynamic efficiency of the
system. The Condensate in the MIL offers its 21000 Series and
heaters are at saturation condition, the 4100 Series Valves for these
and when the Condensate is drained
to either Deaerator or the
applications. Thebodymaterialis
Condensate flash tank, the fluid either WC6 or WC9.
losses pressure and flashes.
CONTROL VALVES FOR POWER PLANTS

3.5 Heater drain system

Fig. 22. LP Heaters System

Fig. 23. HP Heaters System


TypicalInstallations
Choosingtherightvalvemakesallthedifference
Capacity 67.5 MW
FEEDWATER CONTROL VALVES Project: TISCO 1X67.5MW Customer: BHEL Madras
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
1 FW-5 LOW LOAD FEED WATER FLOW CONTROL 38-78101 3 in. 1500 F11 15 170 kg/cm2 2350C 1
2 0
2 FW-2 FULL LOAD FEED WATER FLOW CONTROL 38-41921 6x3 in. 1500 WC6 140 170 kg/cm 235 C 1
2 0
3 FW-8 FULL LOAD FEED WATER FLOW CONTROL (BY-PASS) 90-41921 6x3 in. 1500 WC6 140 170 kg/cm 235 C 1
SPRAY & SOOT BLOWER VALVES Project: TISCO 1X67.5MW Customer: BHEL Trichy
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 0
1 SD-5.SD-6 SH SPRAY CONTROL 38-41024 2 in. 1500 WCC 8 185 kg/cm 250 C 4
2 0
2 SD-23 SH SPRAY BLOCK 38-414X1 2 in. 1500 WCC 40 185 kg/cm 250 C 2
2 0
3 SD-7 INTERMITTENT BLOWDOWN VALVE 38-78001 2 in. 1500 A105 4 110 kg/cm 350 C 2
2 0
4 S57. S69 SH SPRAY BYPASS VALVES 90-41024 2.5 in. 1500 WCC 20 186 kg/cm 242 C 4
5 SB4 SOOT BLOWER STEAM PR.REDUCING VALVE 38-70571 2 in. 2500 F11 6 173 kg/cm2 4130C 2
6 SD-8 SOOT BLOWER STEAM PR.REDUCING VALVE 38-70571 2 in. 2500 F22 10 110 kg/cm2 4200C 4
PRDS VALVES Project: TISCO 1X67.5MW Customer:BHEL Madras
APPLICATION HANDBOOK

No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 0
1 AS-9 HIGH CAPACITY STEAM PRESSURE REDUCING 38-41912 6x3 in. 1500 WC9 120 100 kg/cm 520 C 1
2 0
2 AS-3 LOW CAPACITY STEAM PRESSURE REDUCING 38-41412 2 in. 1500 WC9 12 100 kg/cm 520 C 1
2 0
3 BV-01 COMMON BLOCK VALVE FOR PRDS SPRAY 37-211X4 2 in. 1500 WCC 15 185 kg/cm 175 C 1
2 0
4 SW-10 HIGH CAPACITY SPRAY WATER CONTROL VALVE 38-78101 1.5 in. 1500 A105 1.2 185 kg/cm 150 C 1
2 0
5 SW-4 LOW CAPACITY SPRAY WATER CONTROL VALVE 38-78101 1 in. 1500 A105 0.3 185 kg/cm 150 C 1

* ANSI

4.1 Typical applications. 67.5 MW


4.2 Typical applications. 116 MW
Capacity 116 MW
FEED CONTROL VALVES Project: Ahemedabad Electricity Company. Customer: BHEL Bangalore
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 0
1 CV-5.6 FEED REGULATING VALVE IN HP BFP DISCH.LINE 38-41621 2 in. 300 WCC 26 15 kg/cm 121 C 2
2 o
2 CV-7.8 FEED REGULATING VALVE IN HP BFP DISCH.LINE (FULL LOAD) 37-41612 3 in. 900 WC6 95 115 kg/cm 121 C 2
2 o
3 CV-9.10 FEED REGULATING VALVE IN HP BFP DISCH.LINE (LOW LOAD) 38-78001 2 in. 900 A105 4 115 kg/cm 120 C 2
SPRAY VALVES Project: Ahemedabad Electricity Company. Customer:BHEL Bangalore
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 CV-11.12 HP STEAM BYPASS VALVES 38-41412 6 in. 1500 WC6 145 70 kg/cm 480 C 2
2 o
2 CV-13.14 HP BYPASS SPRAY VALVES 37-211X5 2 in. 600 WCC 46 13 kg/cm 50 C 2
2 o
3 CV-15.16 LP STEAM BYPASS VALVES 38-41421 8 in. 150 WCC 640 7 kg/cm 147 C 2
2 o
4 CV-17.1 LP BYPASS SPRAY VALVES 38-211X5 1 in. 600 WCC 3.8 13 kg/cm 50 C 2

PRDS VALVES Project: Ahemedabad Electricity Company. Customer:BHEL Bangalore


No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 CV-23 PRDS PR. REDUCING VALVE IN HP STEAM LINE TO AUX.HDR. 38-41412 2 in. 1500 WC6 30 70 kg/cm 480 C 1
2 o
2 CV-24 PRDS SPRAY CONTROL VALVE 38-78003 1 in. 900 A105 0.3 119 kg/cm 121 C 1
CONTROL VALVES FOR POWER PLANTS

* ANSI
Capacity 116 MW
FEED PUMP RECIRCULATION VALVES Project: Ahemedabad Electricity Company. Customer: BHEL Bangalore
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 CV-25.26.27 RECIRCULATION VALVE FOR HP BFP 37-78003 1.5 in. 900 A105 4.5 115 kg/cm 122 C 3
2 o
2 CV-28.29.30 RECIRCULATION VALVE FOR LP BFP 37-211X5 1in. 600 WCC 3.8 18 kg/cm 122 C 3
HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES Project: Ahemedabad Electricity Company. Customer:BHEL Bangalore
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
1 CV-1 MAIN CONDENSATE CONTROL VALVE 38-41621 6 in. 300 WCC 360 13 kg/cm2 48oC 1
2 o
2 CV-2 MIN. FLOW RECIRCULATION CONTROL VALVE 37-41612 2 in. 300 WCC 25 13 kg/cm 48 C 1
2 o
3 CV-3 EXCESS RETURN CONTROL VALVE 37-41621 2 in. 300 WCC 65 13 kg/cm 48 C 1
2 o
4 CV-4 DEAERATOR OVERFLOW TO DM STORAGE TANK 38-414X1 3 in. 150 WCC 155 7 kg/cm 120 C 1
2 o
5 CV-19 PRESSURE REDUCING VALVE TO DEAERATOR 38-41621 3 in. 150 WCC 95 7 kg/cm 147 C 1
2 o
6 CV-20 PRESSURE REDUCING VALVE TO DEAERATOR 38-41621 8 in. 150 WCC 500 7 kg/cm 147 C 1
2 o
7 CV-21.22 PREHEATER INLET CONTROL VALVE 37-41621 4 in. 300 WCC 225 13 kg/cm 118 C 2
8 CV-31 NORMAL MAKE-UP VALVE 37-21125 1 in. 600 CF8M 6 10 kg/cm2 40oC 1
APPLICATION HANDBOOK

9 CV-32 DUMP MAKE-UP VALVE 38-21125 2 in. 600 CF8M 46 10 kg/cm2 40oC 1

* ANSI

4.2 Typical applications. 116 MW


4.3 Typical applications. 210 MW
Capacity 210MW
FEED CONTROL VALVES Project : Raichur TPS Unit IV Customer: BHEL Madras
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 FW-FCV-1 FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS) 38-41921 12x8 in. 2500 WC6 575 286 kg/cm 250 C 2
2 o
2 FW-FCV-2 LOW LOAD FEED WATER FLOW CONTROL 38-41412 6x4 in. 2500 WC6 45 285 kg/cm 250 C 1
SPRAY & SOOT BLOWER VALVES Project : Unchahar TPS 2x210 MW Customer:BHEL Trichy
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 SD-4 SH STAGE I BLOCK 38-410X4 6x4 in. 2500 WCC 195 265 kg/cm 260 C 2
2 o
2 SD-5.6.7.8 SH STAGE I CONTROL 38-41024 2.5 in. 2500 WCC 30 265 kg/cm 260 C 8
2 o
3 SD-9 SH STAGE I I BLOCK 38-410X4 2.5 in. 2500 WCC 60 265 kg/cm 260 C 2
2 o
4 SD-10.11.12.13 SH STAGE II CONTROL 38-41024 1.5 in. 2500 WCC 3.8 265 kg/cm 260 C 8
5 SD-14 RH BLOCK COMMON 38-410X4 2.5 in. 2500 WCC 60 265 kg/cm2 260oC 2
6 SD-15.16.17.18 RH BLOCK BRANCH 38-410X4 1.5 in. 2500 WCC 40 265 kg/cm2 260oC 8
2 o
7 SD-19.20.21.22 RH CONTROL 38-78103 1.5 in. 2500 A105 3.6 265 kg/cm 260 C 8
2 o
8 PCV-8502A.B SOOT BLOWER STEAM PR.REDUCING VALVE 38-41012 2 in. 2500 F11 25 185 kg/cm 440 C 4
PRDS VALVES Project : Raichur TPS. Unit IV Customer:BHEL Madras
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
CONTROL VALVES FOR POWER PLANTS

1 MSPCV-1 AUX.PRDS 100%STEAM PR. CONTROL VALVE 38-41412 6x3 in. 2500SPL WC9 50 165 kg/cm2 540oC 1
2 MSPCV-2 AUX.PRDS 10%STEAM PR. CONTROL VALVE 38-41012 2 in. 2500SPL WC9 6 165 kg/cm2 540oC 1
3 SPTCV-1 AUX.PRDS 100%SPRAY FLOW CONTROL VALVE 38-78102 1.5 in. 2500 A105 2.4 286 kg/cm2 250oC 1
4 SPTCV-2 AUX.PRDS 10%SPRAY FLOW CONTROL VALVE 38-78101 1 in. 2500 A105 0.3 286 kg/cm2 250oC 1
2 o
5 V2505111 BLOCK VALVE ON SPRAY WATER TO AUX. PRDS 37-211X4 2 in. 2500 WCC 15 286 kg/cm 250 C 1

* ANSI
Capacity 210 MW
FEED PUMP RECIRCULATION VALVES Project : Ropar TPS Customer: BHEL Hyderabad
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 FEED PUMP MINIMUM RECIRCULATION 37-78103 4x2 in. 2500 A105 15 260 kg/cm 250 C 2
HEATER DRAIN VALVES & CONDENSATE SYSTEM VALVES Project : Vijayawada TPS Stage II Unit V&VI Customer:BHEL Delhi
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 PAS-1 PEGG. STEAM FROM AUX. STEAM HEADER TO DEAERATOR 38-41912 6 in. 300 WCC 300 20 kg/cm 230 C 2
2 o
2 PCR-1 PEGG. STEAM FROM CRH TO DEAERATOR 38-41912 10 in. 600 WCC 430 48 kg/cm 350 C 2
2 o
3 DR-2 HPH-6 NORMAL DRAIN TO HPH-5 38-41321 3 in. 600 WC6 56 48 kg/cm 215 C 2
4 DR-6 HPH-6 NORMAL DRAIN TO DEAERATOR 38-41321 3 in. 600 WC6 56 48 kg/cm2 215oC 2
5 DR-9 HPH-6 NORMAL DRAIN TO FLASH BOX-2 38-41321 3 in. 600 WC6 56 48 kg/cm2 215oC 2
2 o
6 DR-12 HPH-5 NORMAL DRAIN TO DEAERATOR 38-41321 4 in. 300 WC6 90 20 kg/cm 180 C 2
2 o
7 DR-15 HPH-5 NORMAL DRAIN TO FLASH BOX-2 38-41321 4 in. 300 WC6 90 20 kg/cm 180 C 2
2 o
8 DR-17 LPH-3 NORMAL DRAIN TO LPH-2 38-41621 3 in. 300 WCC 140 8 kg/cm 130 C 2
2 o
9 DR-20 LPH-5 NORMAL DRAIN TO FLASH BOX-1 37-41621 4 in. 300 WCC 225 8 kg/cm 130 C
2
10 DR-22 LPH-2 DRAIN TO LPH-1 38-41621 8 in. 300 WCC 575 8 kg/cm 100oC 2
APPLICATION HANDBOOK

11 DR-25 LPH-2 DRAIN TO FLASH BOX-1 37-41621 8 in. 300 WCC 575 8 kg/cm2 100oC 2
2 o
12 DR-41 DEAERATOR OVERFLOW TO DRAIN TANK 38-416X1 10 in. 300 WCC 1000 11 kg/cm 170 C 2
2 o
13 CD-14 MAIN CONDENSATE 38-41621 10 in. 300 WCC 900 25 kg/cm 55 C 2
2 o
14 CD-23 CONDENSATE EXCESS RETURN 38-41612 6x4 in. 300 WCC 145 25 kg/cm 55 C 2
15 CD-19 CONDENSATE MINIMUM RECIRCULATION 37-78003 6 in. 300 A105 70 25 kg/cm2 55oC 2
16 CD-78 HP DRAINS MANIFOLD SPRAY 37-211X5 1 in. 300 WCC 12 25 kg/cm2 55oC 2
2 o
17 DM-1 DM MAKE-UP TO HOTWELL (LC) 37-41611 2 in. 300 CF8M 30 10 kg/cm 50 C 2
2 o
18 DM-2 DM MAKE-UP TO HOTWELL (HC) 37-41611 3 in. 300 CF8M 60 10 kg/cm 50 C 2
2 o
19 CD-47 CONDENSATE FOR VALVE GLAND SEALING 38-41621 1.5 in. 300 WCC 14 25 kg/cm 55 C 2

4.3 Typical applications. 210 MW


4.4 Typical applications. 250 MW
Capacity 250 MW
FEED CONTROL VALVES Project : CESC Budge Budge TPS. 2*250 MW Customer: BHEL Delhi
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 0728.1&2 FULL LOAD FEED WATER FLOW CONTROL (MAIN&BYPASS) 38-41921 14x10in. 2500 WC6 900 330 kg/cm 248 C 4
2 o
2 728.3 LOW LOAD FEED WATER FLOW CONTROL 38-41921 6x4in. 2500 WC6 225 330 kg/cm 248 C 2
SPRAY & SOOT BLOWER VALVES Project : BSES DAHANU 2x250 MW Customer:BHEL Trichy
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 SD-4 SH SPRAY STAGE I BLOCK 38-414X1 6in. 2500 WC6 240 262 kg/cm 260 C 2
2 o
2 SD-5 TO SD-8 SH STAGE I SPRAY CONTROL 38-41024 2.5in. 2500 WC6 30 182 kg/cm 260 C 8
2 o
3 SD-9 SH STAGE II SPRAY BLOCK 38-414X1 3in. 2500 WC6 75 262 kg/cm 350 C 2
2 o
4 SD-10 TO SD-13 SH STAGE II SPRAY CONTROL 38-41024 1.5in. 2500 WC6 8 182 kg/cm 350 C 8
2 o
5 SD-14 RH SPRAY MAIN BLOCK 38-414X1 3in. 2500 WC6 30 282 kg/cm 350 C 2
2 o
6 SD-15 TO SD-18 RH BRANCH BLOCK 38-211X4 2in. 2500 WC6 15 282 kg/cm 350 C 8
7 SD-19 TO SD-22 RH SPRAY CONTROL 38-78003 2in. 2500 F11 3.5 182 kg/cm2 350oC 8
8 SD-23 SOOT BLOWER STEAM PR.REDUCING VALVE 38-70571 2in. 2500 F22 13 182 kg/cm2 450oC 2
PRDS VALVES Project : BSES DAHANU 2x250 MW Customer:BHEL Bangalore
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
CONTROL VALVES FOR POWER PLANTS

1 AS-22 MS PRDS STEAM CONTROL 38-41412 6x4in. 2500SPL WC9 110 169 kg/cm 545 C 2
2 FD-22 MS PRDS SPRAY CONTROL 38-78002 1.5in. 2500SPL A105 2.4 267 kg/cm2 170oC 2
3 FD-23 MS PRDS SPRAY CONTROL 38-41024 1.5in. 2500 WCC 6 267 kg/cm2 170oC 2
4 AS-32 CRH STEAM PRDS 38-41012 2.5in. 600 WCC 20 48 kg/cm2 360oC 2
2 o
5 FD-29 CRH PRDS SPRAY CONTROL 38-78001 1in. 2500 A105 0.3 267 kg/cm 170 C 2
2 o
6 FD-30 CRH PRDS SPRAY CONTROL 38-78001 1in. 2500 A105 0.3 267 kg/cm 170 C 2
Capacity 250 MW
FEED PUMP RECIRCULATION VALVES Project : Kothagudem TPS, 2*250 MW Customer: BHEL Hyderabad
1 FEED PUMP MINIMUM RECIRCULATION 37-78103 4x2 in. 2500 A105 15 260 kg/cm2 250oC 2
HEATER DRAIN & CONDENSATE SYSTEM VALVES Project : Kothagudem TPS, 2*250 MW Customer: BHEL Delhi
1 AS-2 PEGG. STEAM FROM AUX. STEAM HEADER TO DEAERATOR 38-41912 8 in. 300 WCC 315 14 kg/cm2 220oC 2
2 o
2 CRH-2 PEGG. STEAM FROM CRH TO DEAERATOR 38-41912 10 in. 600 WCC 500 48 kg/cm 360 C 2
2 o
3 DR-2 HPH-6 NORMAL DRAIN TO HPH-5 38-41521 3 in. 600 WC6 50 48 kg/cm 215 C 2
4 DR-6 HPH-6 ALT. DRAIN TO DEAERATOR 38-41921 3 in. 600 WC6 50 48 kg/cm2 215oC 2
5 DR-9 HPH-6 ALT. DRAIN TO HP FLASH TANK 37-41921 3 in. 600 WC6 56 48 kg/cm2 215oC 2
6 DR-13 HPH-5 NORMAL DRAIN TO DEAERATOR 38-41521 4 in. 300 WC6 120 20 kg/cm2 175oC 2
7 DR-16 HPH-5 ALT. DRAIN TO HP FLASH TANK 37-41921 4 in. 300 WC6 120 20 kg/cm2 175oC 2
8 DR-19 LPH-3 NORMAL DRAIN TO LPH-2 38-41521 4 in. 150 WCC 170 8 kg/cm2 130oC 2
9 DR-22 LPH-3 ALT. DRAIN TO LP FLASH TANK 37-41621 4 in. 150 WCC 170 8 kg/cm2 130oC 2
10 DR-25 LPH-2 NORMAL DRAIN TO LPH-1 38-41521 8 in. 150 WCC 575 8 kg/cm2 105oC 2
11 DR-28 LPH-2 ALT. DRAIN TO LP FLASH TANK 37-41621 8 in. 150 WCC 575 8 kg/cm2 105oC 2
APPLICATION HANDBOOK

2 o
12 DR-38 DEAERATOR OVERFLOW TO LP FLASH TANK 38-419X1 3 in. 300 WCC 100 11 kg/cm 170 C 2
2 o
13 CD-14&CD-17 MAIN CONDENSATE CONTROL 38-41521 12 in. 300 WCC 900 27 kg/cm 55 C 4
2 o
14 CD-25 CONDENSATE EXCESS PUMP MIN. RECIRCULATION 37-78003 3 in. 600 A105 45 27 kg/cm 55 C 2
2 o
15 CD-21 EXCESS CONDENSATE DUMP CONTROL 38-41612 6x3 in. 300 WCC 95 27 kg/cm 55 C 2
2 o
16 CD-53 HP DRAINS FLASH TANK SPRAY 37-211X5 1 in. 300 WCC 1,7 30 kg/cm 55 C 2
2 o
17 CD-58 EMERGENCY MAKE-UP TO CONDENSATE HOTWELL 37-41612 3 in. 150 WCC 95 8 kg/cm 55 C 2
2 o
18 DM-2 (LOW) DM MAKE-UP TO HOTWELL (LC) 37-41512 3 in. 300 CF8M 45 8 kg/cm 40 C 2
2 o
19 DM-5 (HIGH) DM MAKE-UP TO HOTWELL (HC) 37-41612 4 in. 150 CF8M 120 8 kg/cm 40 C 2

4.4 Typical applications. 250 MW


4.5 Typical applications. 500 MW
Capacity 500 MW
FEED CONTROL VALVES Project :NTPC Talcher TPS 2x500 MW STPP Customer: Keltron Controls
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 FCV-0657 LOW LOAD FEED WATER FLOW CONTROL 37-41512 12x8 in. 2500 C5 475 360 kg/cm 200 C 2
SPRAY & SOOT BLOWER VALVES Project : NTPC Vindhyachal TPS 2x500 MW STPP Customer:BHEL Trichy
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
1 SD-10 SH SPRAY BLOCK 38-414X1 8 in. 2500 WCC 380 340 kg/cm2 260oC 2
2 SD-11 TO SD-14 SH SPRAY CONTROL 38-41621 4x3 in. 2500 WCC 26 340 kg/cm2 260oC 8
2 o
3 SD-15 RH SPRAY BLOCK 38-414X1 4x3 in. 2500 WCC 155 340 kg/cm 260 C 2
2 o
4 SD-16 TO SD-19 RH BRANCH BLOCK VALVE 38-414X1 3 in. 2500 WCC 75 340 kg/cm 260 C 8
2 o
5 SD-20 TO SD-23 RH SPRAY CONTROL 38-41024 2.5 in. 2500 WCC 12 340 kg/cm 260 C 8
2 o
6 SD-24 SOOT BLOWER STEAM PR.REDUCING VALVE 38-41012 4x2 in. 2500 F11 25 213 kg/cm 482 C 4

HEATER DRAIN & CONDENSATE SYSTEM VALVES Project : NTPC Talcher TPS 2x500 MW STPP Customer:Keltron Controls
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 PCV-0326A AUX. STEAM TO DEAERATOR 37-41512 12 in. 300 WCC 725 20 kg/cm 295 C 2
2 o
2 PCV-0326B CRH FLOW TO DEAERATOR 38-41512 16 in. 600 WC6 1200 57 kg/cm 410 C 2
3 FCV-01514/0519/0524 CONDENSATE PUMPS A.B.C MINIMUM FLOW RECIRCULATION 37-78103 4 in. 600 A105 55 47 kg/cm2 47oC 6
CONTROL VALVES FOR POWER PLANTS

4 FCV-0559A/B CONDENSATE FLOW TO DEAERATOR 38-41521 10 in. 300 WCC 900 47 kg/cm2 47oC 4
5 LCV-0507 CONDENSATE SPILL TO CONDENSATE STORAGE TANK 38-41612 8 in. 300 WC6 315 47 kg/cm2 50oC 2
2 o
6 LCV-0508 CONDENSATE NORMAL MAKE-UP 37-41621 4 in. 300 CF8M 140 10 kg/cm 40 C 2

* ANSI
Capacity 500 MW
HEATER DRAIN & CONDENSATE SYSTEM VALVES Project : NTPC Talcher TPS 2x500 MW STPP Customer:Keltron Controls
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
7 LCV-0509 CONDENSATE EMERGENCY MAKE-UP 38-41621 8 in. 150 CF8M 575 10 kg/cm 40 C 2
2 o
8 LCV-0526 GSC MAIN FLOW 37-78103 4 in. 600 WC6 55 47 kg/cm 50 C 2
9 1-HDH-LCV-0701/23 HP HEATER 6A & B NORMAL LEVEL 38-41512 3 in. 600 WC6 45 57 kg/cm2 230oC 4
10 LCV-0703/0722 HP HEATER 6A & B EMERGENCY LEVEL 37-78103 4 in. 600 C5 55 57 kg/cm2 240oC 4
11 1-HDH-LCV-0712/34 HP HEATER 5A & B NORMAL LEVEL 38-41512 3 in. 300 WC6 60 34 kg/cm2 190oC 4
2 o
12 LCV-0714/0736 HP HEATER 5A & B EMERGENCY LEVEL 38-78103 4 in. 600 C5 55 34 kg/cm 190 C 4
2 o
13 1-HDL-LCV-0746A LP HEATER 3 NORMAL LEVEL 38-41511 3 in. 300 WC6 155 4 kg/cm 110 C 2
2 o
14 1-HDL-LCV-0746B LP HEATER 3 EMERGENCY LEVEL 37-41611 3 in. 300 C5 155 4 kg/cm 110 C 2
2 o
15 1-HDL-LCV-0757A LP HEATER 2 NORMAL LEVEL 38-41511 6 in. 300 WC6 400 3 kg/cm 90 C 2
2 o
16 1-HDL-LCV-0757B LP HEATER 2 EMERGENCY LEVEL 37-41611 6 in. 300 C5 400 3 kg/cm 90 C 2
2 o
17 1-HDL-LCV-0722 LP HEATER 1 NORMAL LEVEL 37-41511 8 in. 300 WC6 640 3 kg/cm 60 C 2
18 1-HDL-LCV-0768 LP HEATER 1 EMERGENCY LEVEL 37-41611 8 in. 300 C5 640 3 kg/cm2 60oC 2
APPLICATION HANDBOOK

2 o
19 1-CO-PCV-0530 VALVE GLAND SEALING PRESSURE CONTROL 37-41612 2 in. 300 WC6 12 47 kg/cm 50 C 2
2 o
20 FCW-PCV-8701 EQUIPMENT COOLING WATER DIFFERENTIAL PR. CONTROL 37-41521 12 in. 150 CF8M 1660 10 kg/cm 40 C 2
21 LCV-8701 DM WATER OVERHEAD LEVEL CONTROL 37-41621 1.5 in. 300 CF8M 35 10 kg/cm2 46oC 2
SCAPH CONTROL VALVES Project : NTPC Vindhyachal TPS 2x500 MW STPP Customer:BHEL Trichy
No. Tag Service Model Size Rating* Body Cv Pr. Temp. Qty.
2 o
1 ASS-2 TO ASS-7 SECONDARY SCAPH 38-41921 8 in. 300 WCC 575 20 kg/cm 250 C 4
2 o
2 ASS-20 TO ASS-25 PRIMARY SCAPH 38-41321 4 in. 300 WCC 200 20 kg/cm 250 C 4

* ANSI

4.5 Typical applications. 500 MW


MaterialselectionGuidelines
StandardisedMaterialsforhighperformance
APPLICATION HANDBOOK

MATERIAL SELECTION

Correctmaterialselectionisextremelyimportanttoensure
properfunctioningandlongevityofControlValvesinPower
Plantapplications.Theserviceconditionsvarywidelyin

5.1 Body material specs


pressureandtemperatures,designpressurecangoupashigh
as360kg/cm2 andtemperaturesupto566oC.TheBodyand
Trimmaterialselectionshouldalsotakeintoaccountthe
detrimentaleffectsofCavitation/Flashing/HighVelocity
whichareinherenttosuchsevereapplications.

CONTROL VALVE. PRESSURE CONTAINING MATERIAL

General Classification Castings Forgings Max. Operating Temp.

Carbon Steel ASTM A 216 Gr. WCB / WCC ASTM A 105 427C

Alloy Steel, 1 Cr - Mo ASTM A 217 Gr. WC6 ASTM A 182 Gr. F11 566C

Alloy Steel, 2 Cr - 1 Mo ASTM A 217 Gr. WC9 ASTM A 182 Gr. F22 566C

Alloy Steel, 5 Cr - Mo ASTM A 217 Gr. C5 ASTM A 182 Gr. F5a 566C

Stainless Steel, Ty. 316 ASTM A 351 Gr. CF8M ASTM A 182 Gr. F316 566C

PRESSURE RATING. CEILING VALUES *


Temp. 150#ANSI 300#ANSI 600#ANSI 900#ANSI 1500#ANSI 2500#ANSI

< 93C 18.3 52.7 105.5 158.2 263.7 439.4

149C 16.2 51.3 102.3 153.6 255.9 426.8

204C 14.1 49.6 99.1 148.7 248.2 413.4

260C 12.0 46.8 93.5 140.3 233.8 389.5

316C 9.8 42.5 85.1 127.6 212.7 354.4

371C 7.7 40.1 79.8 119.9 199.7 332.6

427C 5.6 35.9 71.4 107.2 178.6 297.4

482C 3.5 31.6 63.3 94.9 157.8 263.3

538C 1.4 25.7 51.0 76.6 128.0 213.0

593C 0.0 22.9 45.3 67.8 113.2 188.8

2
* Max.. Working Pressure in Kg/cm for ANSI 150# to ANSI 2500#, Extracted from ANSI B16.34 - 1996. Varies
with material, See pages 48-50 for max. allowable working pressures for WCC, WC6 & WC9, the most
common body material used for Control Valves in power plant applications.
CONTROL VALVES FOR POWER PLANTS

Allowable working pressure for ASTM A 216 Gr. WCC


5.2 Allowable working pressure

Allowable working pressure (Kg/cm2)

Operating temperature (oC)


APPLICATION HANDBOOK

Allowable working pressure for ASTM A 217 Gr. WC6

5.2 Allowable working pressure


Allowable working pressure (Kg/cm2)

Operating temperature (oC)


CONTROL VALVES FOR POWER PLANTS

Allowable working pressure for ASTM A 217 Gr. WC9


5.2 Allowable working pressure

Allowable working pressure (Kg/cm2)

Operating temperature (oC)


GENERAL CLASSIFICATION. ASTM CODE MAX. TEMP. HARDNESS GENERAL APPLICATION
GENERAL SERVICE
SS 316 Bar Stock: ASTM A 479Ty. 316 593C 14 HRC max. Non-Erosive, Corrosive,Mod. Press. Drop.
Castings: ASTM A 351 Gr. CF8M Most corrosion resistant of 300 Series
TOUGH SERVICE
Ty. 410 Stainless Steel Bar Stock: ASTM A 479 Ty. 410 400C 35 HRC min. Corrosive & Non- Corrosive Service
(Hardened&Tempered)
Ty. 416 Stainless Steel Bar Stock: ASTM A 582 Ty. 416 400C 31-38 HRC Erosive & Non- Corrosive Service
(Hardened&Tempered)
No.6 Stellite Hard Facing NA 650C 38-47 HRC Slightly Erosive & Corrosive Service
No.6 Stellite Solid (< 2) NA 650C 38-47 HRC Erosive & Corrosive Service
No.5 Colmonoy Hard Facing NA 650C 45-50 HRC Erosive & Corrosive Service.
Corrosion resistance similar to Inconel
No.6 Colmonoy Hard Facing NA 650C 56-62 HRC Erosive & Corrosive Service.
Corrosion resistance similar to Inconel
17.4 PH Stainless Steel Bar Stock: ASTM A 564 Gr. 630 400C 40 HRC min (H900) Erosive & Corrosive Service
Castings: ASTM A 747 CB7CU1 32 HRC min (H1075)
CA6NM Stainless Steel Casting: ASTM A743 Gr. CA6NM 650C 28 HRC min. Erosive & Corrosive Service.
APPLICATION HANDBOOK

(HeatTreated) (700-1000 HV After case hardening, excellent for high


afterNitriding) temperatureservice.

Ty. 440C Stainless Steel Bar Stock: ASTM A276 Ty.440C 400C 58 HRC min. Very Erosive Service.

5.3 Trim material selection


HandlingandInstallation
A list of safe practices
APPLICATION HANDBOOK

6.1 Handling & Installation


Fig. 24. Clearance requirements for Globe Control Valves

1. Do not lift large size valves 6. While choosing the


by the Actuator. Lifting Lugs location to mount the valve,
providedontheActuatorsare provideadequatespacefor
forliftingtheActuatoralone. future occasions when it may
become necessary to remove
2. The Actuator Diaphragm
theBodyandActuator
case, Eye Bolts etc. are not
forrepairs.
designedtolifttheheavy
valve body assembly. 7. Ensure that recommended
3. Do not turn the Actuator, mountingorientationsare
keepingthecouplingtight. alwaysfollowed.

4. In case of Bellow Sealed 8. Ensure that the Flange


Valves,neverrotatetheValve Bolts or Tie Rods can be
stem. removedeasily.

5. Valves on smaller piping 9. Leave adequate space for


andtubingmayneedtobe opening/adjusting
mountedinBrackets. Positioners and Accessories.
CONTROL VALVES FOR POWER PLANTS

6.1Handling & Installation

Fig. 25. Alternate orientations for Control Valves (position-1 is preferred)

10. Positioner Gauges and 13. Special attention must be


Travel Indicators must always given not to place an elbow
remainclearlyvisible. or pipeT less than 5 pipe
diameters downstreamofa
11. Careful choice of
locationhelpsprevent valvetoavoidinterference
Cavitation. When flow is withtheValvesFlow
upward,andifthefluid Capacity. In high pressure gas
partiallyvaporizesbecauseof orsteampressurereducing
lowerhydrostatichead, applications, try to have only
locatingtheValvetowards straightpipesdownstreamof
thelowestpartofthepiping the valve, or alternatively use
canpreventtwophaseflow alongsweepingelbowto
throughtheValvethereby avoidaddedpipenoise.
minimizingCavitation. 14. In critical applications,
12. Valves in Flashing service provideamanuallyoperated
are to be located as close to throttling valve in a bypass
the receiving vessel as around the valve. This allows
possible. A very short length forreplacementorrepairof
of Discharge Pipe, and an theControlValvewithout
IsolationValvearepermitted. shutting down the process.
APPLICATION HANDBOOK

6.1 Handling & Installation


Fig. 26. Typical satisfactory arrangement of upstream and downstream piping

Fig. 27. Less satisfactory arrangement of upstream and downstream piping

15. Since Control Valves will require maintenance from time


to time, Block Valves at Upstream and Downstream are
essential. Bleed and drain valves may be necessary for safety.
16. On occassions when the Control Valve is out of service, if
a Bypass Valve is being provided along with isolation valves in
order to have flow, the style of the Bypass Valve should be
similar to that of the Control Valve. Or else an identical
Control Valve should be chosen as the Bypass Valve.
17. In cases of extreme ambient temperatures (over 80C)
where a valve is located, the valve and accessory
manufacturersshouldbeconsultedforproper,high
temperaturereplacementmaterial.
MaintenanceGuidelines
Howtoensurepeakperformance of
Control Valves in power plant applications
APPLICATION HANDBOOK

1. PREVENTIVE MAINTENANCE
BEFORE START-UP

1. It should be appreciated 3. Ensure that the


thatduringplantstartups, recommendedmounting
abnormaloperating orientationisfollowed.If a

7.1 Prevetive maintenance


conditions can adversely valve is mounted with its
affecttheperformanceofthe stemtravellinginthe
Control Valve and some times horizontalplane,itmustbe
properlysupported.
severely damage the valve. It
is very important that these 4. Ensure that the mandatory
abnormalconditionsbe flowthroughdirection
recognizedandtheControl indicatedontheControl
Valveisselectedtakinginto Valve (by an arrow mark) is
account these conditions. alwaysfollowed.

2.Ensure that misalignment 5. Piping should be flushed


alongthepipelineisnot before installing the valve. If
corrected using the valve. additionalflushingisdone
afterinstallation,itmaybe
Pipeline stress on the valve
necessary to remove the
maycausemisalignmentof internals, Especially if anti-
the stem or plug/seat joint. It Cavitation or low noise Trim is
can also cause flange leak or inplace.
packingleak. Continuedinnextpage
AFTER START-UP

1.Periodicfieldinspections 4. Cover the valve suitably


shouldbemade. whenprocessdrippingor
corrosiveatmospheric
2. Rememberthathigh-
conditionsprevail.Specialcare
frictionpackingneedstobe
tobegiventothevalve
compressedafterinsertion.
accessories.
Packingwillcompressfurther
inservice,andthepacking 5. Airsetsusuallyhavefilters
compressionmayhavetobe thatcanclog;thedraincock
readjusted.Tightenthe shouldbeopenedfromtimeto
packingnutswhenfound timetobesuretrappedliquidis
necessary. drained.
3. It dusty or dirty conditions 6. Monitor the performance
prevail,providearubberboot of the valve accessories as it
aroundthestemtoprotectthe hasa significanteffecton the
packing. valveperformance.
CONTROL VALVES FOR POWER PLANTS

2. SHOP OVERHAUL
1. Valves and valve internal in 4. Remove the bonnet from
hazardousserviceshouldbe thebody,andthenthegland
cleanedthoroughlybefore packingcomponents.
undertakinganyrepair. Further removetheTrimand
Dependingoncontaminant, thebottomflange.
waterwash,steamingor
5. Disassemble the Actuator
specialheattreatmentmay
andexaminecomponentsfor
beresortedto.
7.2 Shop overhaul

damage.Afterwardsclean
2. Ensure that the person thepartscarefully
whoisdisassemblingthe
6. Inspect the disassembled
ControlValveisthorough
componentsthoroughlyand
withthereleventprocedure.
determinetheextentof
3. Before disassembly, mark reconditioningandrepair
theActuatororientationwith thatisrequired.
respect to the body flanges. Continuedinfacingpage

Maintenance.Beforestartup CONTINUED FROM PREVIOUS PAGE

6. If line trash like weld chips, 8. Air lines to be connected to


rust etc. are expected in the the Control Valves should be
pipeline,temporarystrainers blowncleanofoilanddebris
shouldbeinstalledupstream. beforetheyareattached.
If the process stream
normally contains Scale, dirt 9. Avoid using Teflon tapes
orotherforeignmaterial,itis ininstrumentairlines.While
recommendedthat Teflon tapeisanexcellent
permanentstrainersorfilters threadlubricantandsealfor
beinstalled.Strainersshould screwed connections, it
beinstalledfarenoughto neverthelesscanbreakoffin
allownon-swirlflowatthe small bits if not carefully
valve inlet. Note that
applied.Andthesebitsoften
strainersthatefficiently
protectthepumpmaynotbe migratetoorificesin
adequatewhenitcomesto pneumatic accessories and
removingdebristhatcan can clog them.
damagethevalveTrim. 10. Do not start up a Control
7. Ensure that the air supply is Valvewithoutfirstchecking
clean and devoid of oil. thepackingtightness.
APPLICATION HANDBOOK

ShopOverhaul CONTINUED FROM PREVIOUS PAGE

7. If the body is rusted, 12. Avoid use of non


descalethebody.While standard Trims. These cannot
handlingthebody, theflange matchthemetallurgyand
surfaces must be protected to workmanshipoffactory
preventanygasketleakage. finishedspares.
8. Assess the need for 13. Reassemble the valve
remachiningofBodyand bodyusingthereconditioned
Trims. First the plug and seat /new parts. Ensure that gland

7.2 Shop overhaul


shouldbeperfectlymatched, packingandgasketsare
by precise machining, then by changed every time the valve
handgrindingorlapping. isopenedandreassembled.
Make sure that even fine Use only OEM* gland
tracesoflappingcompound packing and gaskets. Low
is cleaned off. quality gaskets can cause
9. The lapped contact should irreversibledamagetothe
not be too wide. If the contact valve by seat area Erosion,
band is too wide, a machine bodybonnetErosionetc.
cuttorenewtheanglesofthe 14. While tightening the
mating pieces is necessary. bonnetandbottomflanges,
Theanglesofthemating itisimportanttotightenthe
piecesareslightlydifferentto diagonallyoppositeboltsto
allowanarrowseatingband. ensureevengasketloading.
10. For problems like marred Over tightening can cause
stemsurface,replacement excessive elongation of the
with a factory finished stem is gasketstherebyresultingin
theonlypracticalsolution. poorjoints.
The finish of the Control 15. Assemble parts of the
Valve stem is so fine that Actuatorbarrel,installthe
highlypolishedsurfacesare diaphragmcaseusingnew
requiredtogivethebest cap screws and nuts, and
possible packing seal, and to
check for pneumatic leaks.
minimizethehysteresis.
16. Adjust the spring range
11. If the Trims are beyond
andstrokeoftheActuator.
repair,replacethemwith
genuinespareparts.Valve 17. Giving air supply to the
Trimsareamongstthemost Actuator, keeptheActuator
precisionofinstrumentation inmidstrokeandmountthe
components. Actuatoronthevalvebody.
*Original Equipment Manufacturer
CONTROL VALVES FOR POWER PLANTS

ShopOverhaul CONTINUED FROM PREVIOUS PAGE

18. Tighten (finger tight) the 21. Carry out hydrotest, seat
coupling.Applyairorremove leakagetestandcalibration
airtoensureproperseatingof as per relevant standards.
the valve. Then tighten the 22. When repair to an
couplingandadjustthetravel existing valve is
indicator. uneconomical,replaceitwith
19. Mount the accessories a new valve from a high-
back on to the Control Valve. quality OEM to avail of better
7.2 Shop overhaul

Several of the most common sizing,bettermaterials,


betterdesign,andmostlikely,
accessories (Air Sets,
better service too. Process
Positioners, Transducers etc.)
conditionsshouldbe
haveRubberDiaphragms
stabilizedanddetermined
thatwillhardenandcrack. accurately in case they were
Some have O Rings that notcorrectlyanticipated
deteriorate.Itwouldbe whentheoriginalvalve
economicaltoreplacethe was specified.
whole accessory with spares
(andrepairfaultymodels 23. Do not buy valves or
replacementpartsfrom
duringslacktime)ratherthan
non OEMs. Overemphasis
repairing them On Site.
on short-term cost savings
20. Tubing connections for cansometimesleadto
signalandoperatingair hazardousworking
shouldbecheckedwith environmentsforpersonnel,
soapywaterorotherleak processdowntimeand
detectingfluids. increased operating costs.
TheMILRange
HighperformanceControlValvesfor powerplants
APPLICATION HANDBOOK

For severe service, special double


MIL 21000
stagevalveswithsimultaneous
Rugged,heavytopGuided,single
seatedControlValves throttlingintheplugandCage
alsoisavailable.
Tight Shut-Off: Class IV leakage
isstandard.Optional
constructions meet Class V &
Class IV leakage.

8.1 MIL 21000 Series


Quick Change Trim. Optional
clampedseatringfacilitateseasy
Trimremoval.
Angle Body (70000 Series).
Optionalanglebodydesignwith
Venturiseatisideallysuitedfor
specialapplicationslikeFlashing
liquidsandotherchokedflow
conditions.

Available Sizes & Rating


to 2
2: ANSI 150# to ANSI 2500#
3 to 1 0
0: ANSI 150# to ANSI 600#
SeatleakageclassasperANSI/FCI70.2
Standard:ClassIV.
Optional:ClassV&ClassVI

FEATURES

Heavy Top Guiding.The Valve


plugshankisGuidedwithinthe
lowerportionofthebonnet and
thisheavyandruggedguiding
ensuresplugstabilityand
eliminatesTrimvibration.
AntiCavitation/Low Noise Trims
replacingconventionalplug with
theLo-dBplugprovidesexcellent
noiseattenuationandCavitation
control.
CONTROL VALVES FOR POWER PLANTS

Standardisedhighperformance
MIL 41000
material. Thisensurestrouble
HeavyDutyCageGuided
ControlValves. freeoperationevenin
applicationswithinherenthigh
pressuredropsandextreme
temperatures.
Tight shut off valves. For lower
sizes,unbalanceddesignresults
in Class V leakage.
8.2 MIL 41000 Series

Forhighersizes,theexceptional
singleseatedleaktightnessof
Class V is achieved by the
followingspecialoptions:
1.Auxiliaryshut-offpilotplug
closesthebalancingholeslocated
inthemainpluginshut-off
conditions.
2.Selfenergisedsealrings
pressingagainstwallsoftheCage
&Plugarrestsleakagepastthe
Available Sizes & Rating sealring.
to 14: ANSI 1 50# to ANSI 2500# Lo-dB/Anti-Cavitation Cages:
20: ANSI 150# to ANSI 600#
16 to 20 NoiseattenuationandCavitation
SeatLeakageClassasperANSI/FCI70.2 controlachievedbyreplacing
Standard:ClassIII&ClassIV conventional Cages with Lo-dB
Optional:ClassV Cages.
SPECIAL OPTIONS
FEATURES
Static Seal Ring, Double Cage design,
High allowable pressure drops. Two stage design with diffuser seat
Cage Guided valves provide ring, Multi-Stage Valves
exceptionalperformanceovera MIL 41008 . These Multi-Stage valves
widerangeofpressuredropsin incorporateauniqueTrimdesignto
absorb high pressure drops that
severe services. They also handle prevent Cavitation and maintain
mostshutoffpressureswith constantvelocitythroughoutthe
standardpneumaticspring pressure dropping stages.
Concentric Cages incorporate a
diaphragmActuators. tortuous flow path, which causes
High capacity with low pressure numerous velocity head losses
withoutappreciablepressurerecovery.
recovery.Flowcapacitiesremain High pressure recovery factors at lower
attoplevels,andareattained lifts eliminates Cavitation. High
impedance flow path reduces pressure
withminimumpressurerecovery
by friction and turbulence,
reducingthepossibilityof maintaining constant velocity
Cavitationinliquidservice. throughout.
APPLICATION HANDBOOK

MIL 78000 High Noise Levels commonly


associatedwithconventionally
AntiCavitation&LowNoise
Multi-stepHighPressureDrop designedControlValves.
ControlValves
High allowable pressure drops.
Noindividualstageisexposedto
thefullpressuredrop,thus
extendingTrimlifesubstantially.
Adiabatic Flow with Friction
Friction.

8.3 MIL 78000 Series


Reducespressuremuchinthe
same way as pressure loss
occurringinalongpipeline.
Low pressure recovery. This
minimisesCavitationpotential
andcontributestowards
reductionofNoiseforallfluids.
Pressure recovery factors as high
as 0.998.
Standardisedhighperformance
material:Toensurematerial
integrity, 78000 Series valves are
machinedfromsolidsteel
Available Sizes & Rating forging.HighperformanceTrim
to 6
6: ANSI 900# to ANSI 2500# materialensuresdurabilityinany
SeatleakageClassasperANSIIFCI70.2 severeapplication.
Standard:ClassV Balanced Trims: Availablefor
Optional:ClassVI sizes 2" and above, allow much
highershut-offpressureswith
FEATURES
conventionalActuators.
Multi Step Axial Flow High
SPECIAL OPTIONS.
Resistance Trim. Pressure
Soft seat construction with
reductionoccursalongthelength encapsulated inserts, Angle & Inline
ofthepluginaseriesofthrottling bodyconfigurations.
stages. The fluid also takes a
tortuousflowpath,whichadds
resistanceandthereforevelocity
headloss.
Thespecialdesignprovides
controlofhighpressurefluids
withouttheErosion,Vibrationor
CONTROL VALVES FOR POWER PLANTS

MIL 91000 MATRIX Series valves


ExtremePressureMulti-stage,Multi-path,AxialFlowAnti-Cavitation
HighPressureDropControlValves
8.4 MIL 91000 Series

FEATURES. Flow to Open flow direction.


Varyingandexpandingflow Eliminates DynamicInstability
passage. This enables near Zero inherent to Flow to Close valves.
Pressure Recovery thus ensuring TortuousflowpathwithHigh
thatstagewisePressureDropsare Impedance forenergy
limitedbelowtheCriticalPressure absorption limits Trim Velocity
Velocity.
Drop.LikelihoodofCavitationis
Modified equal %
ruledouteveninextreme
characteristics with 100 : 1
conditions.
Rangeability. Characteristics can
Ingenious Flow Path. Reduces be customised to suit specific
downstreamVelocity.Exit process applications.
VelocityandKineticEnergykept
Self energised body and seat
underlimits.Erosioneliminated.
gaskets
gaskets. Ensures Zero Leak, and
Pressure recovery factor (Cf) as optimisesbonnet/boltingdesign.
high as 0.9999. Ingenious design. Results in a
As many as 50 Pressure Dropping simplermanufacturingprocess.
stages. Consequentlythismakes
Ruggedness of design. Ensures MATRIXSeries Valvesbetter
longevityevenintheseverestof pricedthanothervalvesinthis
applications. league.

Axial Flow design. Eliminates SPECIAL OPTIONS.


Available with Soft Seat with a special
wiredrawingeffectsonthe sliding collar to protect the Soft Seat
leadingedgesoftheplug. from high pressure fluids.
MIListhefirstControlValvemanufacturerinIndiatohavebeenawardedtheprestigiousCEMarkingCertificate byRWTUV,Germany.
CONTROL VALVES FOR POWER PLANTS

P
INDEX Positioner Gauges 56
PRDS Spray Control Valves 22
A PRDS Station Valves 29
Allowable working pressure 48 PRDS System Control Valves 22
PRDS System Valves 13
B Pressure Reducing Desuperheating System 29
9.1 Index & List of Illustrations

Preventive Maintenance 61
Block Valve 24
Body Material Specs 47 R
Boiler Feed Pump Min. Recirculation Valve 13, 17, 18
Boiler Feed Pump Minimum Recirculation System 17 Reheater Attemperator Control Valve 25
Boiler Feed Water Startup Valve 13, 17 Reheater Attemperator Spray Valve 13
Boiler Main Feed Water Control Valve 13, 17 Reheater Spray Block Valves 22
Reheater Spray Control Valves 22
C Reheater System 22
Remachining 63
CE Marking 8, 71 RWTUV 71
Company overview 8
Condensate Recirculation Valve 13, 14 S
Condensate system 13, 14
Condenser 14 Shop Overhaul 62
Sliding Collar Seat Ring 19
D Soot Blower 24, 27
Soot Blower Pressure Control Valves 22
Deaerator 14, 15, 17 Soot Blower Steam Pressure Reducing Valves. 13
Deaerator Level Control Valve 13, 14, 15, 16 Soot Blower Valve 27
Deaerator Pegging Steam System 26 Soot Blowing System 22
Deaerator Pegging Steam Valve 13, 22, 26, 27 Soot Blowing Valves 27
Steam Ejectors 29
E Steam Soot Blowers 27
Economisers 17 Strainers 62
Super Heater Attemperator Valve 22, 23
F Superheater Attemperator Block Valve 22, 24
Feed Pump Recirculation 18 Superheater Attemperator Spray Valve 13
Feed Water Control 20 Superheater Spray Control Valves 22
Feed Water Heaters 31 Superheater System 22
Feed Water Pumps 17
Feed Water Regulating System 20 T
Feed Water Regulator Valve 20 Teflon tapes 62
Feed Water System 13, 17 Temperature Control Valve(Spray water) 29
Foster Wheeler 8 Trim material selection 51
Full Load Feed Water valve 20 Turbine Bypass Valves. 13
Typical Applications 116 MW 37
G Typical Applications 210 MW 39
General Boiler Flow Diagram 10 Typical Applications. 250 MW 41
Typical Applications. 500 MW 43
H Typical Applications. 67.5 MW 35
Handling and Installation 53 U
Heater Drain System 13, 31
Heater Drain Valve 31 Upstream Piping 57
High pressure heater drain valves. 13
HP Heaters 31
HP Heaters System 32, 55

L ILLUSTRATIONS
Low Load Feed Water valve 20
Low pressure heater drain valves. 13 Fig. 1. GeneralBoiler(Drumstyle)FlowDiagram 10
LP heaters 31 Fig. 2. CondensateSystem 14
LP Heaters System 32
Fig. 3. MIL 78000 15
M Fig. 4. MIL 41000 16
Fig. 5. BoilerFeedPumpMin.RecirculationSystem 17
Main Steam Line 22 Fig. 6. MIL78000.FeedpumpMin.RecirculationValve 18
Main Steam Pressure Reducing Valve 22, 29, 30
Main Steam System 13, 22 Fig. 7. MIL 91000 19
Maintenance Guidelines 59 Fig. 8. FeedWaterRegulatingSystem. 20
Martensitic Steel 15 Fig. 9. MIL 41008. Multi stage, Low Load Valve21
Material Selection Guidelines 45, 47 Fig. 10. CriticalControlValvesinMainSteamLine 22
MATRIX Series 8, 19, 70 Fig. 11. MIL41100.SuperheaterAttemperatorvalve 23
MIL 21000 31, 67 Fig. 12. MIL41200.SuperheaterAttemperatorvalve 23
MIL 41000 16, 21, 27, 31, 68 Fig. 13. MIL41400.SuperheaterAttemperatorblock 24
MIL 41003 27 Fig. 14. MIL78000.ReheaterAttemperatorControl 25
MIL 41008 15, 21, 25 Fig. 15. MIL41008.ReheaterAttemperatorControl 25
MIL 41100 23, 24 Fig. 16. DeaeratorPeggingSteamSystem 26
MIL 41114 28
MIL 41121 30 Fig. 17. MIL 41003 27
MIL 41128 25 Fig. 18. MIL 71114 28
MIL 41200 23, 24 Fig. 19. TypicalAuxiliaryPRDSSystem 29
MIL 41221 30 Fig. 20. MIL 41914 30
MIL 41400 24 Fig. 21. MIL 21000 31
MIL 41621 16 Fig. 22. LP Heaters System 32
MIL 41912 30 Fig. 23. HP Heaters System 32
MIL 41914 30 Fig. 24. ClearancerequirementsforValves 55
MIL 41921 16 Fig. 25. AlternateorientationsforControlValves 56
MIL 70000 67 Fig. 26. Typicalsatisfactorypiping57
MIL 71114 28
MIL 78000 15, 18, 19, 25, 69 Fig. 27. Lesssatisfactoryarrangementofpiping57
MIL 91000 19, 70
MIL Controls Limited 6, 8
Modulating Type System 18

O
On/Off System 18
Original Equipment Manufacturer 63
MIL Controls Limited
A KSB Company

HB/Power/Rev-A/032002
Control Valves for Power Plants.
ApplicationHandbook
TheMILPowerPlantHandbookprovides
a broad overview of the various systems
in a Thermal Power Plant to help you
selecttherightvalveforeachapplication.
The handbook also offers expert tips for
proper Installation and Maintenance of
your Control valves.
Registered Office & Works.
Meladoor , Mala, PIN 680 741, Thrissur District, Kerala, India.
Tel: + 91 (0)488 890272, 890772, 891773. Fax: + 91 (0)488 890952.
Email: milf@vsnl.com
Marketing Head Office.
P. B. No. 04, Aluva, PIN 683 101, Ernakulam Dist, Kerala, India.
Tel: + 91 (0)484-624955, 624876, 628041. Fax: + 91 (0)484-623331.
Email: ksbmil@sancharnet.in

MIL CONTROLS LIMITED, 2002. All rights reserved