IndiTech Valves Pvt. Ltd.

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

FIXED NOZZLE DESUPERHEATER

 Contents
Sr. No. Topic Page No.
1 Function 4
2 Storage 4
3 Unpacking 4
4 Installation Site 4
5 Piping Guidelines 5
6 Installation 6
7 Operation 6
8 Start-up 7
9 Shutdown & Removal 7
10 Troubleshooting 7
11 Nozzle Maintenance & 8
Replacement
12 Spares 9

Figures
Sr. No. Topic Page No.
1 Piping Straight Length Guidelines 9
2 FNDSH Mounting Position 10
3 Centerline Considerations 10
4 Typical FNDSH Installation 11
5A Nozzle Type A 11
5B Nozzle Type B 11
6A FNDSH with Nozzle Type A 12
6B FNDSH with Nozzle Type B 14

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Safety Notice
The installation, operation and maintenance of IndiTech
desuperheaters may involve proximity to fluids at high pressures and/or
temperatures. Safe operation of IndiTech desuperheaters can only be
guaranteed if they are properly installed, commissioned, used and
maintained by qualified personnel in compliance with the operating
instructions.

Intended Use
IndiTech desuperheaters must be used only within the admissible
temperature and pressure ratings as per the process specifications
considered during the desuperheater selection.

Warnings
Before carrying out installation and maintenance work, always ensure
that the steam and water pipelines are depressurized. The steam &
water flanged connections should not be removed while the
desuperheater is under pressure.

Precautions
Every precaution should be taken to prevent injury to personnel during
the performance of any procedure. These precautions should consist
of, but are not limited to, ear drum protection, eye protection, and the
use of protective clothing, (i.e. gloves, etc.) when personnel are in or
around a desuperheater work area.

Failure to follow instructions could result in injury or equipment damage.

3
1 Function
A fixed nozzle desuperheater (FNDSH) is used to lower the temperature
of superheated steam to the desired set point by injecting atomized
water into the superheated steam flow. The outlet steam temperature is
controlled by regulating the quantity of water that is injected using an
external control valve.

The typical features of a FNDSH are:

 Most simple and economical desuperheater.
 Probe style design suitable for directly mounting into steam pipeline
sizes 6” (150 NB) and above.
 Fabricated construction.
 High performance fixed geometry nozzles that atomize water into a
fine mist.
 Capable of maintaining steam temperature to saturation
temperature + 7°C.

2 Storage
The FNDSH must be stored in a clean, dry environment. Plywood
protectors or plastic caps are fitted to protect the flange faces and
prevent the ingress of foreign materials. These caps should not be
removed until the FNDSH is ready to be mounted into the system.

3 Unpacking
Remove the FNDSH from its packaging. Lift the FNDSH from the wooden
box / carton by means of straps around the body or by using a hoisting
lug. Be careful to avoid damage to the flange faces & nozzles during
internal transportation.

4 Installation Site
 The FNDSH should be accessible at least from one side.
 If mounted at an elevated level, a service gangway or platform
should be provided.

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5 Piping Guidelines
 Minimum steam pipeline size for using FNDSH is 6” (150 NB).
NOTE: While determining steam line size, it should be noted that the
recommended minimum steam velocity for proper mixing of
atomized water with steam is 12 m/s.
 The recommended minimum straight length upstream of the FNDSH
is 1 meter (refer Figure No. 1).
 The recommended minimum straight length downstream of the
FNDSH is 4 meters (refer Figure No. 1).
NOTE: Inadequate straight pipe length can cause incomplete
vaporization of water, thereby leading to water impingement on
the downstream pipe. This may result in thermal shock & premature
failure of equipment.
 A steam trap module should be installed downstream of the FNDSH
after a minimum distance of 4 meters.
 For precise steam temperature measurement, the temperature
sensor should be mounted at a minimum distance of 12 meters from
the point of water injection.
NOTE: Inadequate distance between the FNDSH and temperature
sensor can cause erratic temperature measurement.
 There should be no branching out from or into the steam line
between the FNDSH and temperature sensor.
 If the temperature difference between the superheated steam and
cooling water is more than 250°C, a protective thermal liner must
be installed in the steam pipeline downstream of the FNDSH.
 Strainer with 40 mesh screen must be installed in the cooling water
line.
NOTE: Failure to provide strainer may result in clogging of the
nozzles, thereby leading to poor process control.

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6 Installation
 Before connecting the FNDSH to the cooling water line, clean and
flush the water line to remove any debris or foreign particles.
NOTE: During flushing, the screen/filter of strainer should be
removed.
 For installing the FNDSH, use gaskets, bolts & nuts as per the
applicable piping standard. Place the gasket on the mounting
flange.
 Remove the flange protectors & insert the FNDSH into the mounting
stub at the desired location in the steam pipeline. The
recommended mounting position is at 90° to the steam pipe (refer
Figure No. 2).
 Ensure that the nozzles are oriented in the direction of the steam
flow (refer Figure No. 3).
 Ensure that the nozzle is centered in the steam pipe (refer Figure No.
4). In case of multiple nozzles, ensure that the central nozzle
coincides with the centerline of the steam pipe.
NOTE: The IndiTech FNDSH is provided with standard body lengths,
depending on the steam pipeline size. The mounting stub must be
manufactured at site as per the contract drawing.
 Apply a high temperature lubricating compound to the bolts & nuts
on the steam flange and water flange and tighten evenly.

7 Operation
 A typical FNDSH installation is shown in Figure No. 5. The
temperature transmitter continuously measures the downstream
steam temperature and transmits a signal to the PID controller or
DCS. The output signal from the controller is routed through the
positioner to the actuator of the cooling water control valve. The
actuator then strokes the stem of the valve, thereby regulating the
quantity of the cooling water to maintain the desired set point
temperature.
 The recommended minimum pressure drop across the FNDSH nozzle
is 2 bar.
 The recommended maximum pressure drop across the FNDSH
nozzle is 45 bar.

6
 The maximum turn down ratio that can be controlled in FNDSH is
4:1.
NOTE: Ensure that the cooling water is clean & filtered, preferably
boiler feed water quality.

8 Start-up
 Ensure that all the components are installed correctly.
 Drain the steam line and cooling water line completely.
 Put the process in the manual operation mode.
 Charge the steam line and cooling water line with the designed
process conditions.
 Open the steam valve upstream of the FNDSH slowly, thereby
increasing the flow. The cooling water control valve should also be
slowly opened simultaneously.
 When the desired steam flow is reached, adjust the opening of the
cooling water control valve until the desired set point temperature
is attained.
 Now change over from manual operation to automatic operation
mode without changing the valve opening.
 Fine adjustment of the PID controller/DCS should be done to
achieve accurate process control.
 Check flanged connections for leakage, tighten flange bolts if
necessary.

9 Shutdown & Removal

 Depressurize the steam and cooling water lines.
 Drain the steam line and cooling water line completely.
 Loosen the steam flange and water flange bolting.
 Remove the FNDSH from the steam line.

10 Troubleshooting
Perform the following actions if the FNDSH is not giving the desired
performance:
 Check the superheated steam pressure, temperature and flow.
 Check the cooling water pressure, temperature and flow.

7
 Check for proper orientation of nozzles with respect to steam flow
direction.
 Check the nozzles for fouling, wear or damage.
 Check temperature sensor location.
 Check temperature control loop (check with manufacturer for
proper installation and operation).
 Check cooling water control valve (check with manufacturer for
proper installation and operation).

11 Nozzle Maintenance & Replacement

For optimal performance, the nozzles should be inspected every 18
months and replaced every 36 months. Perform the following steps to
clean or replace the nozzle (refer Figure No. 7A and Figure No. 7B):
 Grind off the tack welds between the nozzle (5) & adapter / nozzle
holder (4).
NOTE: The adapter / nozzle holder (4) is completely seal welded to
the body (2) to ensure leak tightness. Do not remove this weld.
 Apply a penetrant type thread lubricant between the nozzle (5)
and adapter / nozzle holder (4) and allow to soak. Unscrew the
nozzle (5).
NOTE: Do not remove the tack weld on the surface of the nozzle.
 Blow out the passageway of the nozzle (5) using compressed air.
Ensure that the nozzle (5) is clean and free of any foreign particles.
Replace the nozzle (5) if it is worn or damaged.
 Inspect the body (2) for wear, leaks or cracks. Repair, or replace if
necessary.
 Apply a high temperature lubricating compound to the threads.
Re-screw the nozzle (5) onto the adapter / nozzle holder (4) &
tighten.
 Using similar weld metal, tack weld the nozzle (5) to the adapter /
nozzle holder (4) at two locations.
NOTE: Maintain low heat to prevent distortion of the nozzle (5).
 Clean the steam flange (3) and water flange (1) faces thoroughly
and remove any gasketing material, if present.
NOTE: Replace the steam side and water side gaskets every time
the FNDSH is taken out for maintenance.
 Follow the procedure for ‘installation’ & ‘start-up’ as detailed earlier.

8
12 Spares
Please mention the serial number inscribed on the name plate of the
FNDSH while ordering spares. The only available replacement part for
the FNDSH is the nozzle (refer Figure No. 6A and Figure No. 6B).
Use only genuine IndiTech spares to get the optimum performance
from the system.
NOTE: Use of spares that are not supplied by IndiTech may adversely
affect the functioning of the FNDSH.

Figure No. 1 Piping Straight Length Guidelines

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Figure No. 2 FNDSH Mounting Position

Figure No. 3 Centerline Considerations

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 Figure No. 4 Typical FNDSH Installation

Figure No. 5A Nozzle Type A Figure No. 5B Nozzle Type B

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Figure No. 6A FNDSH with Nozzle Type A

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 Parts List (FNDSH with Nozzle Type A)
Sr. No. Part Name Qty.
1 Water Flange 1
2 Body 1
3 Steam Flange 1
4 Adapter 1
5 Nozzle Type A As required

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Figure No. 6B FNDSH with Nozzle Type B

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 Parts List (FNDSH with Nozzle Type B)
Sr. No. Part Name Qty.
1 Water Flange 1
2 Body 1
3 Steam Flange 1
4 Nozzle Holder 1
5 Nozzle Type B As required

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