Desuperheaters Fixed Nozzle,

Minicooler Design and Variable Nozzle

Dynamic Temperature Control
for your Entire System

Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

Forbes Marshall Forbes Marshall Arca Forbes Marshall Codel J N Marshall Krohne Marshall Spirax Marshall Forbes Vyncke
For over six decades, Forbes Marshall has been building steam engineering and control instrumentation solutions that work for process industry.
Today we have evolved into a leader in process efficiency and energy conservation through technology tie-ups and focused investments in
manufacturing and research. Our joint ventures with the world’s leading names enable us to deliver quality solutions in 14 countries. Forbes
Marshall is probably the only company in the world to have extensive expertise in both steam and control instrumentation. The dual expertise has
allowed us to engineer industry specific systems that focus on energy efficiency and utilities management for sectors as diverse as textiles, food
processing, paper, power and chemicals.

Our teams are peopled by some of the nest engineers in the land. These highly trained professionals have developed innovative solutions and saved
millions of rupees in process costs for our clients. Our business practices and processes have combined into a singular philosophy of being trusted
partners who provide innovative solutions. It’s a philosophy we are proud to live up to.

For decades, we have partnered with some of the best names in the control instrumentation industry such as Arca, Codel, Krohne and Shinkawa,
to develop, design and supply innovative solutions for measurement and monitoring of process parameters. With a combination of specialist
knowledge and the latest technology, we provide products and solutions to achieve optimum efficiency. Our products are a unique combination of
hardware and software that make them reliable and accurate.

Forbes Marshall ranks amongst the world's leading suppliers of steam desuperheaters. We specialize in designing and manufacturing such
equipment for power, process and co-generation plants. Forbes Marshall has supplied more than 5000 desuperheaters since 1990.

Steam Desuperheating
The most practical way of reducing the superheat value of steam is by the direct addition of water. To achieve temperature stability of the
conditioned steam and prevent thermal shock in downstream pipes, cooling water must be atomized. It is also necessary to have a correct mix of
superheated steam and cooling water.

Fixed Nozzle Desuperheater - FND

Standard Nozzle Kv’s Features

Water in
Sr. Kv per Nozzle • Single nozzle Kv as low as 0.0162 m³ / hr and as high as
Water Flange 1 0.0162 1.6 m³ / hr
2 0.0348
• Number of nozzles limited only by pipeline diameter
3 0.0714
Steam Flange 4 0.106 • For use on all pipe sizes 6" and above
5 0.138
• Ideal for use in conjunction with water control valve and
6 0.175
control system
7 0.204
Nozzles
8 0.233 • Turndown ratio upto 4:1 (depending on water quality)
9 0.273
10 0.312
12 0.864 Notes
Typical FND 13 1.6
• Minimum pipe size required for installation of FND is150mm

• Water pressure should be minimum 7 bar (100 psig) more

10 than the steam pressure
AIR SUPPLY
4 11
• Maximum recommended pressure difference between steam
and water is 45 bar (653 psig). If it exceeds 45 bar (653 psig)
3 4
AIR SUPPLY WATER then install pressure control valve in waterline to reduce
5 4 INLET water pressure within limits
6
STUB WITH SORF FLANGES
7
• Spray water should be very clean (equivalent to boiler
(LOOSE SUPPLY) feedwater)
8
1 9 2 • Turndown ratio upto 4:1

STEAM STEAM

INLET OUTLET

Total Desuperheating system along with control loop

Bill of Materials Typical Sizes
Sr. DESCRIPTION Sr. DESCRIPTION • Steam side flange: 4” and water side flange 1” / 1 ½”
1 DIAL THERMOMETER 7 PID CONTROLLER OR
• Steam side flange: 6” and water side flange 2”
2 DIAL THERMOMETER 8 SPRAY NOZZLE INSERT
3 NON-RETURN VALVE 9 TEMPERATURE SENSOR • Pressure rating: upto ANSI #2500
4 STOP VALVE 10 I / P CONVERTOR
5 WATER FLOW CONTROL VALVE 11 PIPE WORK Advantages
6 STRAINER
• Custom made for any size, standard or range

• Simple installation

• Can be used for higher pipe sizes and low steam pressure

• No moving parts

Minicooler Desuperheater (MCD)

Standard Nozzle Kv’s

Sr. Kv per Nozzle This is a unique device for

1 0.0162 specific applications like the

2 0.0348 Ejector / Gland Sealing Steam
3 0.0714
where the cooling water
4 0.106
injection quantity is too low.
5 0.138
6 0.175 This simple design involves fixed

7 0.204 nozzle and cools the Steam by

8 0.233 injecting a little water in the
9 0.273
zone where steam has highest
10 0.312
turbulence.
12 0.864
13 1.6

Bill of Materials
11 AIR SUPPLY Sr. DESCRIPTION Notes
12
4 1 DIAL THERMOMETER • For use with pipe sizes
2 DIAL THERMOMETER 1” to 4”
3 4
AIR SUPPLY WATER
3 NON-RETURN VALVE • Single nozzle Kv as low
INLET as 0.0162 and as high
5 4 4 STOP VALVE
6 7
as 1.6
5 WATER CONTROL VALVE
6 STRAINER • Ideal for use with
2
10 Forbes Marshall make
1 8 7 TEMPERATURE CONTROLLER water control valve and
9
8 MINI COOLER DESUPERHEATER control system
STEAM STEAM
9 STEAM PIPELINE • Turndown ratio upto
INLET OUTLET
10 TEMPERATURE SENSOR 1:4
11 I / P CONVERTOR • Spray water should be
12 PIPE WORK very clean (equivalent
to boiler feedwater)

Advantages

• Instantaneous water mixing

• Less straight length requirement

• Absence of moving parts avoids possibility of choking

Variable Nozzle Desuperheater - VND
Forbes Marshall has incorporated the latest technology in the spray
nozzle design. The high quality surface finish minimises frictional
losses, thereby ensuring that the total pressure difference between
water and steam is available for atomisation of water.
The nozzle assembly consists of three components:
A) Spray head B) Nozzle C) Nozzle cap
Each nozzle assembly is served by individual feed holes in the spray
cylinder. Water enters the chamber through these openings. The
relatively large volume of this chamber ensures that water is
proportioned evenly through each orifice. The pressure drop across
this spray cylinder head results in an increase in the fluid velocity.
Water is subsequently rotated in the nozzle chamber before
being emitted through the central hole. The combination of
splitting the feed flow, increasing velocity and rotating effect
ensures that water is injected into the system in a ne
symmetrical hollow cone spray. The nozzles are finally
assembled with the spray cylinder and are sealed.
The Variable Nozzle Desuperheater may be equipped with a
variety of spray heads. The uniform threading accepts spray
cylinder heads with a wide range of Kv values. Standard
configurations are with either 6 or 9 equally sized spray
nozzles. Special combinations are available to suit customers’
requirements. This feature enables the VND to be customised
for specific system requirement.

A) Spray head
B) Nozzle
C) Nozzle cap

Special Kv Values for Variable Nozzle Desuperheater

NOZZLE POSITIONS 4A 0.043

STEAM
4B 0.091
4C 0.176
FLOW
4D 0.337
SP3 SP6 SP9 SP12 4Dx 0.696
1D+2E+3G 3.232
1A+2C+1D+2E+3G 3.330
3A+3C+3DX 0.686
• Spray water must be injected in the direction of the
Steam flow. 2A+2C+2DX 0.457

• To facilitate installation of the water supply line, one of the 1C+1D+1DX+3F 1.529
following four positions have to be indicated before ordering: 1A+2C+1DX+2F+1H 4.895
SP3 - Along direction of flow 1A+2B+2C+2D 0.313
SP6 - Transverse right to direction of flow
SP9 - Opposite to direction of flow 1A+2B+1C+2D+1DX+2E 0.989
SP12 - Transverse left to direction of flow
3B+3D+3E 1.141
3B+3D+1E+2F 1.412
The commonly available Kv's are...
3B+3DX+3G 3.191
VND Standard Capacity Range 3D+3F+3G 4.081
6A Kv = 0,065 9A Kv = 0,097 3DX+3F+3G 4.350
6B Kv = 0,137 9B Kv = 0,205 3D+3E+3G 5.123
6C Kv = 0,263 9C Kv = 0,395 3DX+3F+3H 2.002
6D Kv = 0,505 9D Kv = 0,758
3A+3B+3D 0.353
6Dx Kv = 1,000 9Dx Kv = 1,500
1A+2C+1DX+2F+3H 1.637
6E Kv = 1,640 9E Kv = 2,460
2B+2D+2E 0.761
6F Kv = 2,450 9F Kv = 3,680
1A+2B+3D+3F 1.536
6G Kv = 5,200 9G Kv = 7,800
3A+3D+3DX 0.807
6H Kv = 8,100 9H Kv = 12,150
Other mixed nozzle combinations available on request
6K Kv = 11,570 9K Kv = 17,440
Features

• Available in 6 and 9 nozzle design

ACTUATOR
• Compatible with both pneumatic and electric actuators AIR TO OPEN
AIR FILTER
AND REGULATOR
1/4" NPT(F) POSITIONER
Highlights
18 11
• Design as per ANSI B 16.34

• Graphite packing provided for optimal sealing with stem 13

17
• Suitable to fit a variety of yokes. (ideal with - Forbes 10
14 15
Marshall make pneumatic diaphragm actuator) 9
12
WATER
• Fabricated body - available in Carbon Steel / Alloy Steel /
Stainless Steel (other materials available on request) 16

• Stem - ground, hardened and roller burnished to a fine 19

finish for optimum performance 8

• Ensures back-seat sealing due to fine machining and

7
lapping of the seat after welding
5
• High performance spray head assembly. Gives fine 6
4
atomisation of spray water
X 3
1 2

Typical Sizes Typical VND

• For Model 38: Detail ‘X’
Steam Side Flange: 3”
Water Side Flange: 1”, 1 ½”
• For Model 48:
Sr. DESCRIPTION Sr. DESCRIPTION
Steam Side Flange: 4”
01 SPRAY CYLINDER 11 NUT
Water Side Flange: 1”, 1 ½”, 2”
02 NOZZLE ASSY. 12 PACKING SET
• Pressure Rating: Upto ANSI #2500
03 PISTON RING (3) 13 STUD
• Available Forbes Marshall Pneumatic Actuators For
04 PISTON 14 GLAND
Mounting
05 FASTENER RING 15 PLATE
A. 'A' To 'Dx' Nozzles: UIII-60 n/v
06 SEAT 16 NAME PLATE
B. 'E' To 'K' Nozzles: UV-100 n/v
07 STEM 17 NUT
• Rangeability
08 BODY 18 SECURING WASHER
For 6 Nozzle Head: 1:18
09 WATER FLANGE 18 SECURING WASHER
For 9 Nozzle Head: 1:27 10 SPACER
For Mixed Nozzle Head: More Than 1:27
(as Per Customer's Specifications).
Bill of Materials

Sr. DESCRIPTION
1 DIAL THERMOMETER
Schematic Diagram
2 DIAL THERMOMETER
3 TEMPERATURE SENSOR
5
4 PID CONTROLLER
AIR SUPPLY

6
5 I / P CONVERTOR
4

WATER INLET
6 AIR FILTER and REGULATOR

1 2
3

STEAM STEAM

INLET OUTLET

Total Desuperheating system along with control loop

Notes Required Sizing Parameters

• Maximum recommended steam pipe size is 1200mm Steam Data Water Data

• Minimum pipe size required for installation of VND is Inlet Pressure Bar(g) Inlet Pressure Bar(g)

150mm Inlet Temperature °C Inlet Temperature °C

• VND can be fitted in 100mm pipe size for nozzle upto Outlet Temperature °C
4Dx Steam flow (Inlet) kg/hr (Min/Nor/Max)

• Water pressure should be minimum 5 bar more than

the steam pressure General
• Maximum recommended pressure difference between Pipe Size mm
steam and water is 45 bar. If it exceeds 45 bar then
Pipe Schedule
install pressure control valve in waterline to reduce
water pressure within limit Turndown Ratio

Water Flange Orientation: SP3 / SP6 / SP9 / SP12

• Spray water should be very clean (equivalent to boiler
feedwater) (for detail refer to figure below)

• Model 38 with a maximum water flow capacity of 25 m³

/ hr in continuous service

• Model 48 with a maximum water flow capacity of 50 m³ Governing Formula for Desuperheater
/ hr in continuous service
Mw = Mst x (h1 -h2 )

(h2- hw)

Advantages

• Custom designed for any size, standard or range where

Mw = Water Injection mass in kg/hr

• Simple installation
Mst = Inlet Steam Mass in kg/hr
• VND ensures a fine conical spray that evaporates almost
instantaneously, avoiding pipe impingement h1 = Enthalpy of Inlet Steam in Kcal/kg

h2 = Enthalpy of outlet steam in Kcal/kg

• Eliminates need of a separate coolant valve
hw = Enthalpy of injection Water in Kcal/kg
• More turndown ratio possible

• Large desuperheating range because of number of

available nozzles
Good engineering practices for efficient Desuperheating

• Minimum inlet velocity should be 15 meters / sec for

FND and 7 meters / sec for VND

• Minimum straight length downstream beyond the

Applications
Desuperheater should be 4 meters
• Turbine Bypass
• Optimum distance between water injection point to
• Turbine Exhaust the temperature sensor mounted downstream should
be 10 meters
• Turbine Bleed Steam

• Auxillary Steam • It is necessary to keep the steam flow rates (for max.
and min conditions) as practical as possible. Else the
• Process Steam
turndown ratio increases unnecessarily which
• Attemperator necessitates the selection and use of a combination of
nozzles in the same spray cylinder
• Pressure Reducing Valve Outlet Steam
• Installation of a strainer with a mesh size of
• Boiler Superheaters
approximately 100 ì in the water supply line to prevent
• Boiler Re-heaters the nozzles from clogging is essential
System Comparison Variable Nozzle
Conventional FND Desuperheater valve regulates the amount of injection
Conventional injection water systems consist of: water by varying the number of injection nozzles. This
• Fixed size spray nozzle enables the water pressure to remain constant,
• Control valve independently of the number of injection nozzles in
• Steam pipe section operation. This results in an excellent and near uniform

spray quality over the entire operating range. Control of

The water injection quantity is regulated by the control nozzle opening is achieved by the positioning of a piston
valve. As a consequence of this ow, regulating the which is operated directly by an actuator mounted onto
downstream water pressure P2 varies as a function of the the valve.
valve plug position. At reduced capacity, the control valve

starts to throttle reducing P2 and hence the available Through this simple design no separate water control
water to steam pressure difference resulting in larger valve is necessary.
droplet size and poor atomisation. The water evaporation

rate slows down and temperature control becomes

troublesome.

This typical system problem becomes compounded as

nozzles and valves are usually sized for the design

capacity but normally operate significantly below these

design conditions. This oversizing results in a partially

open control valve even at normal operating conditions.

With reducing load, downstream water pressure P2

decays rapidly resulting in larger droplet size.

Conventional systems therefore will work satisfactorily

only at relatively steady load conditions.

www.forbesmarshall.com

Forbes Marshall Pvt. Ltd.

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Tel.: 91(0)20 - 27442020
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