Variable Nozzle Desuperheater

Model 38 and 48
Operation and Maintenance Manual
Energy Conservation | Environment | Process Efficiency
Forbes Marshall Forbes Marshall Arca Forbes Marshall Codel Krohne Marshall

www.forbesmarshall.com
Spirax Marshall Forbes Vyncke

VARIABLE NOZZLE DESUPERHEATER

Table of Contents

1] 2]

Forbes Marshall Variable Nozzle Desuperheater. Installation 2.1 2.2 2.3 Unpacking Installing Commissioning

3]

System Usage 3.1 Good engineering practices

4]

Trouble Shooting 4.1 Back-up and Recovery

5]

Maintenance 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Disassembly Spray Cylinder Piston Set Stuffing box Reassembly Tack welding Reinstallation

6] 7] 8]

Operational Safety Spares Contact Details

VARIABLE NOZZLE DESUPERHEATER

1) Variable Nozzle Desuperheater

The Forbes Marshall Variable Nozzle Desuperheater (further referred to as VND) is a sophisticated device which injects cooling liquids into streams of hot steam or gas to reduce the temperature. The cooling liquid is a controlled injection through its variable nozzle head, which ensures a well contoured spray pattern and well atomized injection in the hot media.

handling and transit. If however, it is found damaged during shipment this should be reported immediately to your forwarder or Forbes Marshall representative. Check that the information on the documentation, identification plate and tag number complies with the ordered specifications. Remove the VND carefully from its packaging, lifting by means of straps around the body or use of hoisting lug, if provided. Leave the flange covers in place during internal transportation, until ready to install. Special attention must be given to check for any possible damage on the flange faces, threading, nozzle head, actuator and pipe connections etc. Please identify the parts and check as per the packing list or part list (See figure 2.1)

2) Installation
2.1 Unpacking The Forbes Marshall VND is packed with the greatest care in wooden boxes or cartons for protection during

Figure 2.1- VND Part List

VARIABLE NOZZLE DESUPERHEATER

Do not use the water inlet connection, yoke, actuator or any of its accessories for lifting purposes. 2.2 Installing Please verify there is sufficient space, height and proper configuration in accordance with the Forbes Marshall Desuperheater (further referred to as DSH) outline drawing. Flush the water line with recommended pipeline pressure before connecting the water side with all isolation valves 100% open to remove any possible foreign particles. While installing the VND ensure gaskets and bolting material are in accordance with the relevant piping code. Place the gasket onto the mounting flange and carefully insert the nozzles into the stub of the branch pipe. Align the water side connection with the water supply pipeline, Ensure that the spray cylinder is pointed in the direction of the steam flow and then tighten the mounting bolts. (See fig 2.2.1)

The VND should be free from any externally induced moments, torque or forces. The minimum pipe run required downstream of the DSH varies with each individual application and would have been specified by us at the offer stage. The straight run is required to prevent erosion due to impingement of water droplets against pipe walls, valves and other fittings and is normally in the order of 4 metres (13.2 ft) as a minimum (no upstream straight length is normally required but the DSH should not installed immediately after a bend). The distance from the Desuperheater to the temperature sensor should be 12 Metres (39.39 ft) to ensure the atomized water is homogenized with the hot media. Longer distances will ensure that full evaporation of the water will take place at lower steam velocities. The temperature sensor should be located in the upper half of the pipe at 45 to the pipeline in the flow direction with insertion tip reaching the center of the pipeline. Avoid branching of the steam pipework between the DSH and the temperature sensor. Pipe run should be straight or bends should always be of

Figure 2.2.1- VND nozzle position

NOZZLE POSITIONS STEAM FLOW SP3 SP6 SP9 SP12

the long radius type to assist in keeping the water droplets in suspension, until complete evaporation has taken place. Installation should preferably be in horizontal piping but can be in vertical piping, ensuring the direction of water injection is with the steam flow. The VND may be mounted at 90 degrees to the steam pipe, for all steam flow orientations, but avoid installation in the vertically downward position under any

The DSH is provided with standard lower body length, as specified in the drawing and the mounting branch for the steam pipework must be manufactured to suit. The length of this branch shall be such that the centerline of the spray cylinder is located on the centerline of the steam pipe (+/- 5mm).

circumstances. The water supply shall be of good quality, clean and filtered e.g. boiler feedwater and should have a constant pressure as specified in the order. Each water supply line shall be protected with its own individual strainer with maximum element perforation size of 0.1 mm. Where there are positive shut off components in the water supply (including electric actuators) then a

VARIABLE NOZZLE DESUPERHEATER

Figure 2.2.2 - VND P&I Diagram

safety relief valve shall be fitted. As in the case of steam pipework, use gaskets and bolting in accordance with the relevant piping code. Flush out the water before connecting to the DSH mounting flange. Ensure the arrangement is as per the schematic representation as given under (See fig 2.2.2) 2.3 Commissioning 1) Ensure that all components are installed correctly.

loop controller, SCADA, PLC or DCS). Flush the pneumatic line for 2-5 minutes depending on the compressor and its stated parameters. b) Check the cabling between the temperature sensor,

transmitter and controller and verify if input signals are being received. The controller output signal should be connected with proper polarity to the I/P convertor or Electro-pneumatic positioner. c) Check if the controller is giving proportional control

Connection of electrical components and instrument air pipings shall be in accordance with the manufacturer's operation manual as provided. 2) a) Cold Testing: The control loop should be programed as per the

output signals to the VND positioner. 3) Verify and adjust, if necessary, set points for filter

regulators and valve positioners, following Forbes Marshall recommendations. Similarly calibrate the temperature transmitter and controller verifying

process requirements (single loop controller, multiple

VARIABLE NOZZLE DESUPERHEATER

automatic responses to temperature changes. 4) Keep the Transmitter and controller in the manual

5)

In case the temperature difference is higher than

230 deg C. A suitable thermal liner should be provided inside the steam pipeline to endure thermal shocks. The thermal Liner should be of a minimum length of 15 ft downstream. 3.1 Good Engineering Practices The placement of the temperature sensing element and the capacity, pressure and temperature of the cooling water are of critical importance for efficient desuperheating performance (see fig 3.1). Cooling Water: The cooling water used for desuperheating should be deaerated to avoid any corrosion on carbon steel caused by oxygen which could be released during cooling water evaporation. The cooling water should be free of dissolved or

mode. Warm up the steam main and open the valve in the water supply. Run the system on low process parameters Check the water pressure at the DSH. Verify the operation of the temperature transmitter and controller by manually increasing and decreasing the output signal and observing indicated and recorded temperatures. Increase process parameters gradually up to design parameters. 5) When satisfactory coordination between the

instrument signals and temperatures is attained, adjustment of the set point can be made and the system transferred to automatic operation. It is advisable to record the various steam coordinates over a 2-3 hour period, to verify the operation and make adjustments, if necessary.

3) System Usage:
Please ensure the DSH system is operated within the minimum and maximum operating process parameters as specified. The operating parameters should not exceed the design parameters at any point of time. 1) Avoid sudden and steep changes in the process

suspended solids, as they get deposited in the pipeline when water vaporizes. We recommend demineralized water should not contain more than 9 to 10 ppm of dissolved solids for the Forbes Marshall VND. Each DSH

Figure 3.1- Temperature Sensor

parameters as they induce thermal shocks. 2) The cooling water should be minimum 5 bar G

(72.51 psig) more than the steam pressure and the maximum recommended pressure difference between steam and water is 45 Bar G (652.66 psig). 3) The maximum water flow quantity should be

25 m/hr (14.6 cfm) to 50 m/hr (29.4 cfm) for model 38 and model 48 respectively. 4) The temperature difference between the cooling

water and steam should not be more than 446F.

VARIABLE NOZZLE DESUPERHEATER

water supply line must have its own strainer with a maximum element perforation size of 0.1mm The system should enough space to access for maintenance and monitoring purposes Piping: Minimum pipeline size can be 100mm (4) and maximum recommended steam pipeline size can be 1200mm (48). The steam pipeline size should be appropriate to ensure a minimum steam velocity of 7 meters/sec (1377.95 ft/min). Minimum straight length downstream beyond the VND should be 4 meters (13.2

ft). The temperature sensor should be at a minimum distance of about 12 meters (39.37 ft) from the VND which should increase with the number of bends within the pipeline. The steam pipeline must have a provision for condensate removal, if any. Storage: If the VND is not installed immediately upon receipt, it should be stored in a dry, closed and clean place. The equipment should not be stored in direct contact with the ground. The Protection caps on the inlet and outlet flanges should be plugged in to ensure no dirt or particles enter the VND. Unpainted parts should be protected by rust preventive compounds.

4) Trouble shooting
Trouble shooting for DSH valve
Sr No 1 2 3 4 5 6 7 Malfunction Low temperature Low temperature Low temperature Low temperature Low temperature High temperature no control High temperature no control Reason Valve cycling, low system flow, valve throttling too close to seat Controller action reversed Water pressure too high Valve does not shut off Valve seat leakage indicated Water inlet pressure at inlet less than specified Air pressure at actuator and positioner Corrective Action Reduce water pressure. Must be steam pressure plus 7 barG (14.50 psig). Check system signal sense. Reduce water pressure. Must be steam pressure plus 7 barG (14.50 psig). Check valve stroke and air pressure at the actuator at shut off. Secure system and evaluate seat leakage at shut off. Open water valve, blow down strainer, check supply pressure. Air pressure too low adjust to recommended, clean air filter, air supply line. Check for moisture in the instrument air blow down. Check valve stroke, check water temperature. Check for valve plugging, check water quality. Increase set temperature to 7 deg C above saturation (44.6 deg f). Evaluate and readjust controller action. Positioner arm link bent, loose or binding. Check packing adjustment- it could possibly leak. Check packing gland/stem clearance. Review positioner calibration. Check instrument air supply.

8 9 10 11

High temperature no control Hunting Hunting Hunting

Water pressure at valve as supplied Temperature set point too close to saturation temperature Temperature tuning not correct Valve binding or friction

VARIABLE NOZZLE DESUPERHEATER

Trouble shooting for DSH system

Sr Steam No flow 1 2 Very low Very high Steam Actual effective Temperature pressure steam temp control Low Low Low Low Low Ok Valve action Cause What is wrong/What to correct

Closed Normal

Start up Water on sensor evaporation beyond sensor/Sensor too close to valve move sensor Water on sensor evaporation beyond sensor/Sensor too close to valve move sensor

Normal

Normal

Low

Ok

Normal

Wet sensor

Very low

High

5 6 7 8 9 10 11 12 13

Normal Normal Normal Low Low Very low Normal Normal Very high

Normal Low High High Normal Normal Normal Normal Low

Low due to system heat losses Ok Ok Ok High High High High High High

Ok

Normal to flood

Ok Ok Ok High Ok High High High High

Normal Poor control Fails open floods Closes Opens floods Opens floods Open Open

High super heat Saturated steam Temperature above saturation temperature Water on sensor Water fallout Operating saturated Needs water Needs water

Poor heat transfer/raise system pressure Set point at saturation/lower system pressure Over temperature wet steam/lower system pressure Sensor too close to valve/move sensor downstream Steam velocity low/lower system pressure Wet steam lower system pressure/ raise set point Check water supply/clean the strainer Check water supply/raise water pressure

4.1 Back-up and Recovery In case of any calamity or failure which may lead to outlet pipeline parameters rise above the maximum rated parameters, check the electric connections and signals for the DSH system. If the equipment is still not operating at the desired parameters, switch to manual mode and operate the system with the manual override (handwheel) provided for the VND. If the equipment is still not operating at the desired performance, isolate the system or shut the system by operating isolation valves and contact your Forbes Marshall representative or our customer care section immediately for further assistance.

Figure 5.2- Spray Cylinder Assembly

VARIABLE NOZZLE DESUPERHEATER

Figure 5.4- Stuffing Box Assembly

firmly in the vice. Grind off the nozzle tack welds, using standard type of angle grinder. Make sure that the weld is removed sufficiently to allow rotation of the fastener ring without fouling. Unscrew the fastener ring by rotating anti-clockwise.Note that the threading on the body extension is right-handed. Tapping the fastener ring with a hammer may facilitate removal. Note that the threading on the spray cylinder is left handed. If difficulties are encountered with the removal of the fastener ring, then this item may be removed by grinding through at two diametrically opposite points. Exercise great care not to damage the body and the

5) Maintenance
Maintenance of the Forbes Marshall VND is fairly straightforward and does not require any special tools or training. Care should be taken during any maintenance operation, particularly when working with grinders, compressed air and rotating machinery. Before moving the DSH from the system ensure that both steam and water pipework are depressurized and vented. Isolate any electrical components to the actuator and / or ancillaries, prior to disconnection. Vent and remove instrument air supply piping. Loosen steam flange and water flange bolting, but vent connections before complete removal. The DSH may now be removed from the system. It is recommended that the Desuperheater is transported to a convenient workshop which has a workbench and vice. Lift the unit by means of straps around the body. Do not attempt to lift the DSH manually. Be sure to have vented the steam and water pipeline before disassembly. 5.1 Disassembly The VND can be disassembled most easily when in the horizontal position with the body extension clamped

spray cylinder threading. 5.2 Spray Cylinder Once removed, inspect the condition of the cylinder internally, using a flash light. Scratches and blemishes may be removed by either polishing or honing. The cylinder bore should not exceed 32mm with a maximum eccentricity of 0.25mm. Any debris can be removed from the nozzles by blowing through with compressed air. Inspect the nozzles atomizer outlet bores. These should not show any undue elliptical wear, roughness or damage or this will have a detrimental effect on the DSH performance. Carefully clean the cylinder threading, dressing where required, with a small file. (see fig 5.2). 5.3 Piston Set Withdraw the piston and the stem. The piston and the stem are always supplied as a complete assembly. If the piston shows no sign of wear and tear, then it may be reused. Replace piston rings as a matter of course, any time that the unit is disassembled. Take care not to overstress the piston rings when fitting. The rings are marked Top and should always face the direction of the stuffing box, for proper functioning. Examine the condition of the stem, where it runs in the stuffing box,

VARIABLE NOZZLE DESUPERHEATER

remove any graphite with a fine grade of emery cloth, polishing in the longitudinal direction. 5.4 Stuffing box Remove all the rings, lantern rings and packing material from the valve body. Clean the stuffing box carefully, using a rotating wire brush and / or honing device. Cleanliness of the packing area is vital for proper valve sealing. (see fig 5.4). 5.5 Reassembly Before reassembling the valve, lubricate all threads with a suitable high temperature nickel compound. Do not use grease or other oil based lubricants as these may lead to dismantling problems later. Apply a thin coating of the compound to the piston rings to prevent scoring. Position the slots in the piston rings such that they are 120 degrees to each other. Reassemble the spray cylinder onto the body extension. Use a fine grade polishing paste to lap the seating area of cylinder and body extension. Since the seal has metal to metal contact, a concentric seat area is vital. Always use a new fastener ring. Set the spray cylinder into the correct orientation (the water spray should always be in the same direction as the steam flow) and tighten the fastener ring. 5.6 Tack welding After reassembly, the spray cylinder should be tack welded for added security. It is essential that this welding is carried out by a competent welder. A minimum of two 8mm (0.31) long tacks are required, diametrically opposite, with one weld securing the fastener ring to the body extension and the other securing the spray cylinder to the fastener ring. After welding, use suitable dye penetrant method to check the weld. No cracks are permitted. If necessary, grind off, recheck until a

satisfactory weld is obtained. 5.7 Reinstallation Refit the actuator into the DSH, referring to the notes taken during disassembly, for resetting the stem position. If the actuator is electric, check whether the limit switches are functioning correctly by manual operation of the unit. Set at mid stroke before applying power and verify that opening and closing directions are correct and correspond with system logics. Before reinstalling the DSH, make sure that the connecting flange faces are cleaned thoroughly and any gasket material removed. Insert the DSH into the steam pipe and check that the nozzle is oriented correctly with the spray in the direction of the steam flow. Apply a high temperature lubricating compound to the bolts and nuts and tighten evenly, in accordance with the manufacturer's recommendations. Before connecting the water line, flush through and check for any contamination or restriction in the supply. Follow the procedure for Commissioning (article 2.3), as detailed earlier in the installation instructions. Check the flange and stuffing box tightness. Do not over tighten the stuffing box packing gland as this may prevent proper operation of the DSH. In the event of persistent leakage through the stem packing, then the unit should be removed to the workshop for further examination. Ensure clean and score free stuffing box packing and steam to ensure leakproof tightness.

6) Operational Safety
Please read all labels fitted on the DSH and follow the procedure as detailed in this manual 1) Use DSH for the intended purpose only in

accordance to the contract specifications.

VARIABLE NOZZLE DESUPERHEATER

2)

Handle the DSH carefully with proper lifting/ hoisting

9)

The surface temperature as defined in 94/9/CE

equipment and do not lift using yoke, actuator, water side connections etc. 3) For installation use gaskets and bolting material in

Annex II 2.3.1.2 of the desuperheater is a function of the system it is built into. When installed, the surface temperature cannot be controlled by the manufacturer.

accordance with the relevant piping code. (ASME/ANSI B31.1 or DIN/RTD) and free of any induced moments, torques and forces. 4) The line must be depressurized, drained, vented and

7) Spare Parts
Expected service may vary upon condition of service. Check unit at least once per 8000 hours of operation or longer intervals based upon site experience. We recommend the following spares for over 3 years of operation: a) b) c) d) Actuator seal kit Gland Packing Gaskets Piston Rings

cooled down before installation. 5) Handling the DSH must be carried out by trained

people in all aspects of manual, mechanical handling/lifting techniques and standard safety procedures. In case of doubt contact your supervisor or safety officer. 6) Forbes Marshall does not accept any liability for site

work performed under supervision of others. 7) Each DSH water supply line must have its own

Use only genuine Forbes Marshall components. All DSH are identified by the identification number stamped on the tag plate. Use this number when ordering spare parts. Please call our local representative or Head office as per the contact details given.

strainer with a maximum element perforation size of 100 micron (3.92 thou). 8) Insulate the DSH in accordance with the plant

requirements.

NOTES

Your local Forbes Marshall representative would be happy to provide you with further information and support.

AMERICA
USA
Forbes Marshall Inc. USA 480,California Avenue, Suite 102,P.O. Box 60670 Palo Alto CA 94306 California,USA Tel: +1 650 327 4227/ +1 650 321 4224 Fax: +1 650 327 4127/ +1 650 321 4454 Email: forbesmarshall@ix.netcom.com Allagash International, Inc. 1000 Riverside Street, Portland, Me. 04103 Tel: + 1 207-781-8831 Fax: + 1 207-781-8830

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