steam conditioning valves...for a quick change of the steam mass ˚ow, e.g. opening of a turbine...

STEAM CONDITIONING VALVES

TECHNICAL BULLETIN

HORA | POWER TECHNOLOGY

HOLTER REGELARMATUREN GMBH & CO. KGPOWER TECHNOLOGY

OUR ASPIRATIONAIMING FOR THE TOP

ENGINEERING & DESIGN MADE IN GERMANY QUALITY

For 50 years our customers have relied on HORA as a competent partner for innovative and reliable �ow control solutions. HORA products provide superior customer bene�ts in power and other related in-dustries. From turbine bypass systems to balance of plant applications, HORA offers a comprehensive portfolio of standard and heavy duty control valve solutions. The HORA brand is increasing in global signi�cance with an export share of more than 65 percent. We develop and engineer all our own core products, which are manufactured by us in Germany enabling us to guarantee our own product quality. All processes are organized to ensure short throughput times and the highest levels of delivery reliability.

EUROPEAustriaBulgariaDenmarkFinlandGreat BritainGreeceItalyLuxemburgThe NetherlandsPortugalRomaniaRussiaSwedenSpainSwitzerlandTurkey

AMERICASCanadaUSA

ASIA-PACIFICAustraliaChinaIndiaPhilippinesSingaporeTaiwan

MIDDLE EAST & AFRICA Dubai

02HORA | POWER TECHNOLOGY

HORA utilizes the most modern modelling tools during the design of the control valves, such as Com-putational Fluid Dynamics CFD, Finite Element Analysis FEA, 3D CAD design software and virtual reality solutions. These advanced tools are decisive in optimizing the design of the valves for impro-ved �ow geometry and minimized stresses in the valve bodies.

HORA operates one of the most modern and ef�cient valve fa-cilities in the world. Continuous investment in the up to date pro-duction technologies, such as sub-merged 3D arc-welding, as well as complete machining centers ensure precision in manufacturing with higher productivity, shorter throughput times and lower costs.

HORA provides reliability and ef�-ciency for our customers through continuous and consistent advan-cement of our own development and manufacturing processes. All non-destructive material testing (NDT) and �nal testing is performed in-house. Quality management and assurance, and comprehensive cer-ti�cations underline our claim to quality of the highest level.


SELECTION GUIDESTANDARD FEATURES

HORA offers a complete portfolio of steam conditioning solutions to meet the requirements for the pressu-re and temperature control of steam. The range in severity require high attention in selection and sizing of steam conditioning valves.

Steam conditioning valve with integrated ori�ce tube

Steam conditioning valve with integrated atomizer

Steam conditioning valve with downstream radial type desuperheater

Steam conditioning valve with downstream injection lance

Description of designVariable area nozzle integ-rated in perforated plug by injection orifice

High pressure support steam (20-30% of max. water amount)

Spring loaded nozzles around diameter of pipe

Fixed area nozzles or spring loaded nozzles

Body type Angle (Globe, Z-type) Angle Angle Angle (Globe, Z-type)

Location of injection Integrated Downstream Downstream Downstream

Turn down ratio 50:1 40:1 40:1 (sequential opening) 40:1 (sequential opening)

Max. water capacity 15% (water steam ratio) 250 t/h not relevant not relevant

Required delta p (outlet steam / water)

Half of upstream pressure + 5 bar or more

Well suited when delta p between water and steam is low (atomization by kinetic energy of steam)

Downstream pressure + 15 bar or more

Downstream pressure + 8 bar or more

Set point temperature (direct control)

Minimum 5K-10K above saturation for direct temperature control




Min. downstream velocity

not relevant 4 m/s 12 m/s8 m/s 12 m/s (pipe > DN 200)

Distance to temperature sensor (rule of thumb ba-sed on �eld experience)

water/steam max. 15%:0,1s x steam velocity [m/s]

water/steam < 15% (>15%):0,15s (0,2s) x steam velocity [m/s]



Typical applicationProcess steamAuxiliary PRDS

HP turbine bypass systemAuxiliary PRDS

HP turbine bypass system(USC PP)

HRH / IP / LP bypass systemProcess steam

All the information could be subject to errors or omissions and are given only for title of indication. Solutions can be be customized for special applications.Please refer to HORA for on any questions, concerns or more detailed information regarding the proper selection of the steam conditioning valve.

04

APPLICATION AREAOF HORA POWER TECHNOLOGY PRODUCTS

HORA is focused on providing customized �ow control solutions for the energy-focused market sectors. Through our product line we offer a full spread of comprehensive high-grade products and worldwide expert advice in particular for water and steam applications for the most dif�cult technical challenges. As trusted partner for new construction, extension and technical upgrading of an ef�cient power infrastructure, HORA offers utilities and the industry the portfolio they need.

The main purpose of a valve is to control media �ow through a system. The valve may be used to start, stop, or throttle the �ow. The requirements for control val-ves have increased signi�cantly over the past years and demand higher �exibility in order to guarantee short response times and extended life. In addition higher process parameters are targeted in order to increase the ef�ciency of the plants signi�cantly compromising compliance with environmental protection like redu-cing CO2 emissions in the power sector. HORA control technology allows a safe and material-saving mode of operation for an economically viable plant operation.

HORA organized and structured its portfolio manage-ment in the following product groups:

• Single seat control valves• Water pressure reducing valves• Desuperheaters• Steam conditioning valves• Automatic recirculation valves• Actuators

Power Technology

• Coal-�red power plants

• Combined cycle power plants

• Combined heat and power plants

• Concentrated solar power plants

• Biomass power plants

(incl. waste incineration plants)

Oil and Gas

• Extraction and

distribution

• Petrochemicals

Process and general industry

• Pulp and Paper

• Chemicals

• Food and Beverages

• Desalination

• Steel and Aluminium

• Cement

• Others

Service

• Spare Parts

• Repair, upgrades and retro�t

• Assembly

APPLICATION AREAMARKET AND PRODUCT SEGMENTS


CONTENTSTEAM CONDITIONING VALVES

Steam conditioning valve with integrated ori�ce tube Description of design 08Technical data - Standard duty 09Sectional drawing - Standard duty 10Parts list - Standard duty 11Dimensions - Standard duty 12Features and bene�ts - Standard duty 13

Steam conditioning valve with integrated atomizerDescription of design 14Technical data - Standard and heavy duty 15Sectional drawing - Standard duty 16Parts list - Standard duty 17Dimensions - Standard duty 18Features and bene�ts - Standard duty 19 Sectional drawing - Heavy duty 20Parts list - Heavy duty 21Dimensions - Heavy duty 22Features and bene�ts - Heavy duty 23

Steam conditioning valve with downstream radial type desuperheaterDescription of design 24Technical data - Severe duty 25Sectional drawing - Severe duty 26Parts list - Severe duty 27Dimensions - Standard duty 28Features and bene�ts - Standard duty 29

Steam conditioning valve with downstream injection lanceDescription of design 30Technical data - Standard and heavy duty 31Sectional drawing - Standard duty 32Parts list - Standard duty 33Dimensions - Standard duty 34Features and bene�ts - Standard duty 35Sectional drawing - Heavy duty 36Parts list - Heavy duty 37Dimensions - Heavy duty 38Features and bene�ts - Heavy duty 39

Lifecycle servicesReliable solutions and service 40Exemplary special tools 41

CONTENT

05

Liability for content - We make

every effort to keep the informa-

tion in this document current, but

accept no liability whatsoever for

the content provided.

Copyrights - The content and works

provided in this document are go-

verned by the copyright laws of

Germany. Duplication, processing,

distribution, or any form of com-

mercialization of such material

beyond the scope of the copyright

law shall require the prior written

consent of its respective author or

creator.

Rev: 01 | 05/18


Our aspiration 02Selection guide 03 Application area 04Fundamental issues 06Control logic 07

06

GENERAL DESCRIPTIONSTEAM CONDITIONING VALVES

Steam conditioning valves, also referred to as pressure reducing and desuperheating stations (PRDS), are used for temperature and pressure control of steam in the whole energy-focused market to meet the conditions required for the process.The fundamental principle is a steam conditioning system consists of a steam reduction valve to reduce the steam pressure, a downstream or integrated cooler to reduce the temperature, an injection control valve to regulate the steam temperature and, if applicable, the related shut-off valves and the corresponding actuator technology.


GENERAL DESCRIPTIONFUNDAMENTAL ISSUES

Due to the polydisperse droplet distribution, it is dif-�cult to determine the minimum distance between the injection point and the temperature measuring point. The complete evaporation time and distance to reach target temperature depends mainly on the size of the individual droplets, the water tempera-ture, and the turbulence.• Small droplets create a bigger surface area for the heat transfer and thus have a good cooling effect. The diameters are determined by the pressure drop between water and steam in�uenced by the diameter of the injection nozzle, called primary atomization. • A high water temperature reduces the surface ten- sion and the consequences of impacts on the hot metal parts. • Due to high turbulence, called secondary atomization, by steam velocity and rotation/ twist of the water, the water droplets burst open. Smaller droplets stay evenly distributed in the steam �ow.

In order to minimize the thermal stresses (thermal shock due to alternating stress) on the pressure bear-ing body and the internal parts, the water admix-ture procedures requires special attention. The shape of the body design, reduced and equal wall thick- nesses and the selected material, together with conse- quently avoiding the notches and small radii, allow for smaller thermal transient induced stresses. Pre- heating has an additional effect, which helps to reduce thermal stresses.

Comprehensive system consideration

====

WpTh

Mass �ow ratePressureTemperatureEnthalpy

SIV

SCV

TCV

DT

WIV

SIVSCVWIVTCVDT

=====

Steam Isolation ValveSteam Conditioning ValveWater Isolation ValveTemperature Control ValveDump Tube (to condenser)

07

GENERAL DESCRIPTIONSTEAM CONDITIONING VALVES

Next to the desired degree of superheating of the steam, the ratio of water to steam amount, the pipeline routing and the control logic is an important factor. The valves are controlled by the central process control system with function logics, interlocks and priority operations. In the following two common methods are described. The use of the target value of the steam temperature after water injection is called direct temperature control. If this temperature sensor feedback control is not possible, due to short distances after the water injection not allowing enough time to fully evaporate the water, an indirect tem-perature control by a feed-forward control strategy is required.


GENERAL DESCRIPTIONCONTROL LOGIC

For a direct temperature measurement the sensors have to be arranged in the outlet pipe in a distance ensuring full evaporation of the injected water. They record the temperature curve and control the target position of the spray water control valve through a control loop.Depending on the application based with downstream saturated or slightly wet conditions (5-15K superheated) the more accurate method is an indirect temperature control. The injected amount of water is calculated with an algorithm supplied by HORA programmed to the cen-tral process control system. An analogue output signal can be linked in order to compare the actual value with the target value of the water mass �ow. For a quick change of the steam mass �ow, e.g. opening of a turbine bypass valve during a turbine fault, the risk of thermal shock can be reduced with an electronic re-mote pilot control regulation, also referred to feed-for-ward control. In such a scenario, the following points should be observed:

• Interlock: Without steam �ow, no water may be sprayed.• First stroke: The water injection should be transferred with a delay into the main direct control (proportional opening). • The steam conditioning valve closes with a delay to avoid residual water remaining in the piping.• In order to protect plant parts either upstream or downstream, it‘s important to de�ne a safety position of the valve.

The direct one as well as the ratio control can be super- imposed by the remote control.

HORA has the engineering know-how to select the right steam conditioning system to avoid malfunction due to improper design details and wrong installation of the valves, sensors and piping layout.

Schematic diagram of direct and indirect temperature control

P1

T2

P1 T1

P2 ww hh

hhmm--

´=2

211!!

Steam Isolation ValveSteam Conditioning ValveWater Isolation ValveTemperature Control ValveDump Tube (to condenser)

08

DESCRIPTION OF DESIGNSTEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE

DESCRIPTION OF DESIGN STEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE


An advanced steam conditioning system is developed by HORA by means of a proportional water injection directly after the �rst stage of pressure reducing. This point of highest velocity is used to create the smallest water droplets.The cooling water is supplied through an ori�ce tube which is �xed within the valve body. The turbulence is par-ticularly strong at this location. The holes to let in the cooling water are covered by a perforated plug. A variable number of holes are opened through the axial movement of the plug. The appropriate number, size and arran-gement of the holes determine the amount of injected water so as to ensure the right ratio to the amount of steam reduced at any time. Thus the atomization and evaporation is optimal over the complete range. In case of supercritical pressure drops of the steam a further reduction of pressure and noise is implemented by use of addi-tional perforated cages and discs. The water droplets are further reduced passing through the resistance structure and exit evenly across the entire cross-sectional area. This system achieves downstream temperatures very near to saturation. Although the superheated steam protects the water from contact with the valve body (internal liner) the water amount should not exceed 15% in comparison the steam amount to avoid thermal stresses.

STANDARD DUTYThe valve with bolted bonnet is speci�cally developed for use on medium / high pressure applications with mo-derate steam temperatures but with high demand on rangeability and accuracy in temperature control. The valves are primarily used in combined heat and power plants (CHP) for consumption of auxiliary and process steam very near to saturation. Reliability of this valve is of the utmost importance in many industries such as petro-chemical facilities, pulp and paper and sugar.

Pressure class:Up to PN 400 / Class 2500(Intermediate class as per design data)

Max. design temperature:550°C / 1022°F

TECHNICAL DATASTEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE


DESCRIPTION TECHNICAL DATA

Max pressure class PN 400 / Class 2500

Max. design temperature 550°C / 1022°F

Size 1 2 3 4 5 6 7

Nominal size mm 65 80 110 150 200 230 280

Nominal size inletDN 50 - 150 65 - 200 80 - 250 100 - 300 150 - 300 200 - 350 250 - 400

NPS 2 - 6 2,5 - 8 3 - 10 4 - 12 6 - 12 8 - 14 10 - 16

Nominal size outletDN 250 250 350 450 500 650 700

NPS 10 10 14 18 20 26 28

Pre warming / drain studDN 25

NPS 1

Water studDN

as per project specific requirementsNPS

Seat diametermm 65 80 110 150 200 230 280

inch 2,56 3,15 4,33 5,91 7,87 9,06 11,02

Rated travelmm 40 50 60 80 100 100 150

inch 1,57 1,97 2,36 3,15 3,94 3,94 5,91

Minkvs 26 42 66 105 263 335 523

cv 30 49 76 122 304 388 605

Maxkvs 33 51 104 200 290 405 565

cv 38 59 120 232 336 469 654

Stages 3 (up to 6 possible)

Characteristics linear mod. / special characteristic on request

TECHNICAL DATASTANDARD DUTY

10

SECTIONAL DRAWINGSTEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE

SECTIONAL DRAWINGSTANDARD DUTY


706

516

405

515

306

100

110

400

304

102

300

211

210

120

211

303

101

305

308

500

601

PARTS LISTSTEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE


PARTS LISTSTANDARD DUTY

POS. DESCRIPTIONMATERIAL SPARE PARTS

EN ASME COMMISSIONING RECOMMENDED

100 Body

1.54151.73351.73831.4903

SA182 F12SA182 F22SA182 F91

101 Welded end

102 Connection

104 Funnel

110 Injection connection

120 Perforated disc

500 Bonnet

515 Stud bolt 1.7711 / 1.4923 / 1.4986 SA 193 B16

516 Hexagon nut 1.7711 / 1.4923 / 1.4986 SA 194 Gr.4

210 Spiral wound gasket Graphite / 1.4541 X X

211 Injection lance 1.4057 / 1.4922 ~ 400 series SS / ~SA182 F9 X

300 Seat1.4122 hardened1.4922 armoured

~ 400 series SS hardened~ SA182 F9 armoured

X

303 Sealing cap Graphite / 1.4541 X X

304 Perforated cage 1.7383 / 1.4903 SA 182 F22 / F91 X

305 Guide cylinder1.4122 hardened1.4922 armoured


X


308 Guide cylinder1.4922 hardened

Stellite~ SA182 F9 hardened

StelliteX

400 Plug1.4122 hardened

1.4922 coated~ 400 series SS hardened

~SA182 F9 coatedX

405 Valve stem 1.4122 / 1.4923 ~ 400 series SS / ~ SA182 F9 X

601 Stem packing Graphite / K80S X X

706 Actuator

Other materials on request

12

DIMENSIONSSTEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE

DIMENSIONSSTANDARD DUTY


DIMENSIONS

SIZEA B C D WEIGHT

mm inch mm inch mm inch mm inch KG LB

1 300 11,8 450 17,7 450 17,7 1450 57,1 500 1100

2 350 13,8 500 19,7 500 19,7 1500 59,1 600 1300

3 400 15,7 600 23,6 550 21,7 1550 61,0 650 1400

4 450 17,7 650 25,6 700 27,6 1800 70,9 1200 2600

5 500 19,7 800 31,5 750 29,5 1950 76,8 1600 3500

6 600 23,6 900 35,4 800 31,5 2000 78,7 1900 4200

7 650 25,6 900 35,4 1000 39,4 2300 90,6 2200 4900

A

B

C

D

NOTESGiven dimensions to be considered as a rough guide.Dimensions for standard inlet / outlet sizes with pneumatic double acting actuator (without handwheel)Depending on the actuator type dimension “D” may vary significantly!All dimensions are subject to changes due to project specific requirements!

FEATURES AND BENEFITSSTEAM CONDITIONING VALVE WITH INTEGRATED ORIFICE TUBE


FEATURES AND BENEFITSSTANDARD DUTY

2. Ease of maintenance Quick change internals (cartridge-style) minimizes service time applicable to both vertical and horizontal orientations.

1. Modularity Customized solutions to meet project speci�c requirements: body (globe, angle, z-type), actuator (pneumatic, electric, hydraulic), control (FSO, FSC), materials (up to F92), pipe interfaces and optional dump tube downstream

3. Tight shutoff Balanced system with an integrated pilot plug design used to ensure a repeatable tight closing under all operational conditions and reduces actuator size signi�cantly

7. Reliability Water injection within the high turbulence area of the plug resul-ting in short mixing and evaporation length downstream

5. High rangeability Injection proportional to the steam �ow in the most turbulent area of the valve ensuring small-est water droplets by secondary atomization

6. Ef�ciencyPrecise temperature control close to the saturation point with an even temperature distribution

4. Low noise emission Multi-stage and multi-path trim ensured by drilled cages / discs with free expansion to minimize noise level and vibration

1

7

2

3

5

6

4

14

DESCRIPTION OF DESIGNSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER

DESCRIPTION OF DESIGNSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER


When critical requirements have to be ful�lled an integrated atomizer unit for the cooling water injection offers the best possible results by using the kinetic energy of the upstream high pressure steam with the shortest distan-ce for evaporation of any downstream desuperheating system. The steam is reduced super-critically and thereby generates a pressure drop with its high velocity. Due to strong turbulences, the cooling water is atomized, drawn into the steam �ow and mixed effectively.The required steam is taken downstream to the valve seat, generally after the �rst reduction stage. That is why a additional support steam shut-off valve is not required. The higher pressure is available during the entire load regi-me in every control position and ensures excellent partial load behaviour. The water enters the centre of the spray head and the number of radial holes are sized to suit quantity and pressure drop in accordance to the requested �ow. There at the narrowest cross section (highest speed) the water is dragged along and atomized by the tapped high pressure steam. The evaporation of the �nest droplets is rapid. The �ow of the water is controlled by a sepa-rate spray water valve.





HEAVY DUTYThe valve with pressure sealing bonnet is speci�cal-ly developed for use on high pressure applications with high steam temperatures. It maintains tight-ness under extreme conditions such as quick temperature changes. The heavy duty valve is ideal for HP turbine bypass applications in super critical power plants with a particular focus on �exible operation at all �ow conditions.

STANDARD DUTYThe valve with bolted bonnet is speci�cally developed for use on medium / high pressure applications with moderate steam temperatures. It combines a multi stage pressure control and the most advanced desu-perheating technology. The standard duty valve is widely used for process steam and HP turbine bypass applications in combined cycle plants.

TECHNICAL DATASTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER



Max pressure classSTANDARD DUTY PN 400 / Class 2500

HEAVY DUTY PN 630 / Class 4500

Max. design temperatureSTANDARD DUTY 550°C / 1022°F

HEAVY DUTY 600°C / 1112°F

Size 1 2 3 4 5 6 7

Nominal size mm 65 80 110 150 200 230 280

Nominal size inletDN 50 - 150 65 - 200 80 - 250 100 - 300 150 - 300 200 - 350 250 - 400

NPS 2 - 6 2,5 - 8 3 - 10 4 - 12 6 - 12 8 - 14 10 - 16

Nominal size outletDN 250 250 350 450 500 650 700

NPS 10 10 14 18 20 26 28


NPS 1

Water studDN


Seat diametermm 65 80 110 150 200 230 280

inch 2,56 3,15 4,33 5,91 7,87 9,06 11,02

Rated travelmm 40 50 60 80 100 100 150

inch 1,57 1,97 2,36 3,15 3,94 3,94 5,91

Minkvs 33 51 82 162 290 405 565

cv 38 59 95 188 336 469 654

Maxkvs 40 65 141 282 365 560 795

cv 46 75 163 326 422 648 920



TECHNICAL DATASTANDARD DUTY / HEAVY DUTY

16

SECTIONAL DRAWINGSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER



706

516

405

515

306

110

400

304

303

102

300

201

120

104

101

305

308

500

601

202

100

PARTS LISTSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER





100 Body

1.54151.73351.73831.4903

SA182 F12SA182 F22SA182 F91

101 Welded end

102 Connection

104 Funnel


120 Perforated disc

500 Bonnet

515 Stud bolt 1.7711 / 1.4923 / 1.4986 SA 193 B16

516 Hexagon nut 1.7711 / 1.4923 / 1.4986 SA 194 Gr.4


202 Nozzle 1.4571 316Ti X

300 Seat1.4122 hardened1.4922 armoured


X



305 Guide cylinder1.4122 hardened 1.4922 armoured


X




StelliteX

400 Plug1.4122 hardened


~ SA182 F9 coatedX



706 Actuator


18

DIMENSIONSSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER



DIMENSIONS

SIZEA B C D WEIGHT


1 300 11,8 450 17,7 450 17,7 1450 57,1 500 1100

2 350 13,8 500 19,7 500 19,7 1500 59,1 600 1300

3 400 15,7 600 23,6 550 21,7 1550 61,0 650 1400

4 450 17,7 650 25,6 700 27,6 1800 70,9 1200 2600

5 500 19,7 800 31,5 750 29,5 1950 76,8 1600 3500

6 600 23,6 900 35,4 800 31,5 2000 78,7 1900 4200

7 650 25,6 900 35,4 1000 39,4 2300 90,6 2200 4900

A

B

C

D


FEATURES AND BENEFITSSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER






7. Reliability Water injection downstream including natural protective steam sheath for long term protection of downstream equipment without the use of liners

5. High rangeability Injection with steam assisted desuperheater ensuring smallest water droplets over the full ope-rating range at low spray water pressures



1

6 7

2

3

4

5

20

SECTIONAL DRAWINGSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER

SECTIONAL DRAWINGHEAVY DUTY


706

405

110

308

305

120

104

101

100

306

505

500

601

202

201

400

304

303

102

300

PARTS LISTSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER


PARTS LISTHEAVY DUTY



100 Body

1.54151.73351.73831.4903

SA182 F12SA182 F22SA182 F91

101 Welded end

102 Connection

104 Funnel


120 Perforated disc

500 Bonnet

505 Sealing cap Graphite X


202 Nozzle 1.4571 316Ti X

300 Seat 1.4922 armoured ~ SA182 F9 armoured X



305 Guide cylinder 1.4922 coated ~ SA182 F9 coated X




StelliteX

400 Plug 1.4922 coated ~ SA182 F9 coated X

405 Valve stem 1.4923 / 2.4668 ~ SA182 F9 / ~SB637 X


706 Actuator


22

DIMENSIONSSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER

DIMENSIONSHEAVY DUTY


DIMENSIONS

SIZEA B C D WEIGHT


1 350 13,8 450 17,7 550 21,7 1550 61,0 500 1100

2 400 15,7 500 19,7 600 23,6 1600 63,0 700 1500

3 450 17,7 600 23,6 650 25,6 1650 65,0 1000 2200

4 500 19,7 650 25,6 800 31,5 1900 74,8 1500 3300

5 550 21,7 800 31,5 850 33,5 2050 80,7 2200 4900

6 650 25,6 900 35,4 900 35,4 2100 82,7 2500 5500

7 700 27,6 900 35,4 1100 43,3 2400 94,5 2800 6200

A

B

C

D


FEATURES AND BENEFITSSTEAM CONDITIONING VALVE WITH INTEGRATED ATOMIZER


FEATURES AND BENEFITSHEAVY DUTY




7. Reliability Water injection downstream including natural protective steam sheath for long term protection of downstream equipment without the use of liners

5. High rangeability Injection with steam assisted desuperheater ensuring smallest water droplets over the full ope-rating range at low spray water pressures



1

3

4

5

6 7

2

24

DESCRIPTION OF DESIGNSTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER

DESCRIPTION OF DESIGNSTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER


The steam conditioning valve with downstream radial type desuperheater presents a solution for high steam temperatures in ultra supercritical power plants. The injection is executed radially over the circumference through pressure-controlled nozzles, which are characterized by changing the open nozzle area with the �ow. The pressure reduction is realized in 3 stages. The radial type desuperheater consists of multiple spring loaded nozzles that are circumferentially wall mounted downstream of the pressure reducing stages. The spraywater is uniformly distributed over the cross-sectional area. The plug of the nozzles, executed in combination with a non-return function, is pre-loaded with a spring and moves up to an adjustable mechanical stop. Due to the different spring loads and nozzle areas, the individual nozzle is opened sequentially and enables good partial load behaviour.

SEVERE DUTYThe valve with pressure sealing bonnet is speci�cally developed for applications in ultra super critical power plants with highest steam pressures and temperatures. It maintains tightness under extreme conditions such as quick temperature changes. The severe duty valve is ideal for HP bypass applications to handle huge water amounts and at the same time to provide a high ef�ciency and reliability in temperature control.

Pressure class:Up to max. PN 630 / Class 4500(Intermediate class as per design data)


TECHNICAL DATASTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER


TECHNICAL DATASEVERE DUTY


Max pressure class PN 630 / Class 4500

Max. design temperature 610°C / 1130°F

Size 1 2 3 4 5

Nominal size mm 110 130 150 180 200

Nominal size inletDN 80 -200 100 - 300 150 - 350 200 - 400 250 - 400

NPS 3 - 8 4 - 12 6 - 14 8 - 16 10 - 16

Nominal size outletDN 450 500 600 700 850

NPS 18 20 24 28 34


NPS 1

Water studDN


Seat diametermm 86 106 106 136 140

inch 3,39 4,17 4,17 5,35 5,51

Rated travelmm 110 130 150 180 200

inch 4,33 5,12 5,91 7,09 7,87

Minkvs 160 250 345 490 650

cv 185 289 399 567 752

Maxkvs 200 290 390 570 750

cv 232 336 451 660 868

Stages 3


26

SECTIONAL DRAWINGSTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER

SECTIONAL DRAWINGSEVERE DUTY


706

405

400

304

300

151

152

101

100

306

505

500

601

102

110

306

900

908

901

PARTS LISTSTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER


PARTS LISTSEVERE DUTY



100 Body1.4901 SA182 F92

101 Welded end

102 Connection 1.4903 / 1.4901 SA182 F91 / F92

110 Injection connection 1.7380 / 1.4903 SA182 F22 / F91

151 Perforated disc / cage1.4903 SA182 F91

152 Funnel

500 Bonnet 1.4901 SA182 F92


300 Seat 2.4668 ~ SB637 X


304 Perforated cage 1.4922 coated ~ SA182 F9 coated X


400 Plug1.4922

armoured + coated~ SA182 F9

armoured + coatedX

405 Valve stem 2.4668 coated ~ SB637 coated X


900 Nozzle SS SS X

901 Gasket Graphite X X

908 Gasket Graphite X X

706 Actuator


28

DIMENSIONSSTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER



DIMENSIONS

SIZEA B C D WEIGHT


1 550 21,7 1100 43,3 650 25,6 2100 82,7 1500 3300

2 600 23,6 1100 43,3 700 27,6 2200 86,6 1900 4200

3 600 23,6 1100 43,3 700 27,6 2200 86,6 2100 4600

4 650 25,6 1100 43,3 850 33,5 2300 90,6 2300 5100

5 650 25,6 1150 45,3 850 33,5 2300 90,6 2500 5500

NOTES Given dimensions to be considered as a rough guide. Dimensions for standard inlet / outlet sizes with hydraulic cylinder (without spring return)Depending on the actuator type dimension “D” may vary significantly! All dimensions are subject to changes due to project specific requirements!

A

B

C

D

FEATURES AND BENEFITSSTEAM CONDITIONING VALVE WITH DOWNSTREAM RADIAL TYPE DESUPERHEATER



1

7 8

2

4

3

5

6




8. Reliability Water injection downstream with optimum spray coverage to avoid that spray water impinge on valve body or pipe wall

3. High fatigue strength Stress optimized thin walled contoured valve body designed with FEM suitable for ultra supercritical steam parameter in start/stop operation.

6. High rangeability Injection by sequentially opening of multiple spring loaded nozzles ensuring smallest water droplet over the full operating range

7. Ef�ciencyWater injection is optimized for huge water amounts and stable control


30

DESCRIPTION OF DESIGNSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE



The steam conditioning valve with downstream injection lance represents a solution for relatively low upstream steam pressure and large �ow rates. The injection is executed downstream in the direction of the steam �ow through pressure-controlled nozzles, which are characterized by changing the open nozzle area with the �ow. The pressure reduction is usually carried out in 2 stages. The injection lance consists of multiple spring loaded nozzles located downstream the pressure reducing stages. The spraywater is uniformly distributed over the cross-sectional area. The plug of the nozzles, executed in combination with a non-return function, is pre-loaded with a spring and moves up to an adjustable mechanical stop. Due to the different spring loads and nozzle areas, the individual nozzle is opened sequentially and enables good partial load behaviour

STANDARD DUTYThe valve with bolted bonnet is speci�cally developed for use on low / intermediate pressure applications with high steam temperatures. It is capable to handle huge water amounts and at the same time to provide a high ef�ciency and reliability in temperature control.

HEAVY DUTYThe valve with pressure sealing bonnet is speci�cal-ly developed for use on low / intermediate pressure applications with highest steam temperatures. The heavy duty valve is capable to be operated under ex-treme conditions which make it ideal for the HRH/ IP turbine bypass application in ultra super critical pow-er combined cycle plants and conventional fossil �red plants with a focus on �exible operation.

Pressure class:Up to PN 160 / Class 900)(Intermediate class as per design data)




TECHNICAL DATASTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE

31




Max pressure classSTANDARD DUTY PN 160 / Class 900

HEAVY DUTY PN 250 / Class 1500

Max. design temperatureSTANDARD DUTY 580°C / 1076°F

HEAVY DUTY 630°C / 1166°F

Size 1 2 2B 3 3B 4 5 6

Nominal size mm 275 330 350 380 400 435 490 550

Nominal size inletDN 200 - 450 250 - 500 250 - 500 300 - 550 300 - 550 350 - 600 400 - 650 450 - 700

NPS 8 - 18 10 - 20 10 - 20 12 - 22 12 - 22 14 - 24 16 - 26 18 - 28

Nominal size outletDN 650 700 700 750 750 850 950 1000

NPS 26 28 28 30 30 34 38 40

Pre warming / drain studDN 25 40 50

NPS 25 40 50

Water studDN


Seat diametermm 250 300 300 350 350 400 450 500

inch 9,84 11,81 11,81 13,78 13,78 15,75 17,72 19,69

Rated travelmm 170 200 200 200 200 250 280 300

inch 6,69 7,87 7,87 7,87 7,87 9,84 11,02 11,81

Minkvs 1150 1550 1650 2000 2250 2700 3600 4250

cv 1331 1794 1910 2315 2604 3125 4167 4919

Maxkvs 1400 2200 2200 2900 2900 3500 4600 5500

cv 1621 2547 2547 3357 3357 4051 5325 6366



TECHNICAL DATASTANDARD DUTY / HEAVY DUTY

32

SECTIONAL DRAWINGSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE



706

405

400

100

300

809

101

104

500

601

102

305

804806

516

515

303

304

800813

308

306

PARTS LISTSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE





100 Body

1.73351.73831.4903

SA182 F12SA182 F22SA182 F91

101 Welded end

102 Connection

104 Funnel

500 Bonnet

515 Stud bolt 1.7711 / 1.4923 / 1.4986 SA 193 B16

516 Hexagon nut 1.7711 / 1.4923 / 1.4986 SA 194 Gr.4

300 Perforated cage 1.4122 / 1.4903 ~ 400 series SS / ~ SA182 F91 X


304 Seat with perforated cage1.4122 hardened1.4922 armoured

~ 400 series SS hardened~SA182 F9 armoured

X



~ SA182 F9 coatedX




StelliteX

400 Plug1.4122 / 1.4922

hardened / coated~ 400 series SS / ~ SA182 F9

hardened / coatedX



800 Injection lance 1.7335 / 1 .7383 / 1.4903 SA 182 F12 / F22 / F91

804 Nozzle 1.4571 316Ti



813 Sealing Graphite / 1.4541 X X

706 Actuator


34

DIMENSIONSSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE



DIMENSIONS

SIZEA B C D WEIGHT


1 650 25,6 1200 47,2 500 19,7 1850 72,8 2850 6300

2 700 27,6 1200 47,2 500 19,7 1950 76,8 3000 6600

2B 650 25,6 950 37,4 700 27,6 2300 90,6 2700 6000

3 750 29,5 1250 49,2 500 19,7 2100 82,7 3200 7100

3B 650 25,6 965 38,0 700 27,6 2500 98,4 3200 7100

4 800 31,5 1250 49,2 600 23,6 2200 86,6 3600 7900

5 850 33,5 1300 51,2 700 27,6 2400 94,5 4300 9500

6 900 35,4 1300 51,2 750 29,5 250 9,8 5400 11900

A

B

C

D


FEATURES AND BENEFITSSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE










1

5 6 7

2

3

4

36

SECTIONAL DRAWINGSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE

SECTIONAL DRAWINGHEAVY DUTY


706

405

400

100

300

809

101

104

500

306

601

305

804806

505

303

304

800813

308

102

PARTS LIST STEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE


PARTS LIST HEAVY DUTY



100 Body

1.49031.4901

SA182 F91SA182 F92

101 Welded end

102 Connection

104 Funnel

500 Bonnet


300 Perforated cage 1.4903 ~ SA182 F91 X


304 Seat with perforated cage 1.4922 coated ~ SA182 F9 coated X

305 Guide cylinder 1.4922 coated ~ SA182 F9 coated X


308 Guide cylinder Stellite Stellite X

400 Plug1.4922

armoured + coated~ SA182 F9

armoured + coatedX

405 Valve stem ~ SA182 F9 / 2.4668 coated ~ SA182 F9 / ~SB637 coated X


800 Injection lance 1 .7383 / 1.4903 SA 182 F22 / F91

804 Nozzle 1.4571 316Ti



813 Sealing Graphite / 1.4541 X X

706 Actuator


38

DIMENSIONSSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE

DIMENSIONSHEAVY DUTY


DIMENSIONS

SIZEA B C D WEIGHT


1 650 25,6 1200 47,2 950 37,4 2300 90,6 3000 6600

2 700 27,6 1200 47,2 950 37,4 2400 94,5 3200 7100

3 800 31,5 1250 49,2 1000 39,4 2600 102,4 3400 7500

4 800 31,5 1250 49,2 1000 39,4 2600 102,4 3800 8400

5 850 33,5 1300 51,2 1200 47,2 2900 114,2 4500 9900

6 900 35,4 1300 51,2 1250 49,2 3000 118,1 5600 12300

A

B

C

D


FEATURES AND BENEFITSSTEAM CONDITIONING VALVE WITH DOWNSTREAM INJECTION LANCE


FEATURES AND BENEFITSHEAVY DUTY





3. High fatigue strength Stress optimized thin walled contoured valve body designed with FEM suitable for ultra supercritical steam parameter in start/stop operation.




1

3

6 7 8

2

4

5


EXEMPLARY SPECIAL TOOLS

LIFECYCLE SERVICESSTEAM CONDITIONING VALVES

LIFECYCLE SERVICES RELIABLE SOLUTIONS AND SERVICE

The HORA brand stands both for the longevity and reliability of its products as well as for the quality of our services, which support our valves and actuators in plants around the globe. We cover the entire value chain of a plant from engineering through to construction and operation of energy-focused facilities. More than a conventional service provider, HORA offers a complete range of excellent consultation, support and assistance throughout the lifecycle of the product. The HORA service department offers regular inspection and maintenance to ensure the reliable operation of its products. Any required special component beyond the scope of our normal spare parts needed, tools or machines for commissioning or repair work is available.At the completion of water-tube steam generating plants, the associated pipework and system is contamina-ted with debris: Residual material from fabrication, assembly and corrosion products. Typically water systems are �ushed with high velocity water, boiler surfaces are chemically cleaned and steam pipes are blown with steam to remove particulate material that would potentially damage sensitive devices.

HORA‘s service tools include:

Assembly tool for trim Assembly tool for bolting

• Kits to hydro test of the inlet and outlet system• Kits for �ushing during chemical cleaning• Blow-out/ blow-through devices and sacri�cial trims to operate during steam blows

• Instrumentation and calibration equipment• Removal and compression tool for internals• Machining based on assessment


Steam blow through kit Combined blow out & hydro test kit

LIFECYCLE SERVICESSTEAM CONDITIONING VALVES

Hydro test kit Steam blow out kit

41

Holter Regelarmaturen GmbH & Co. KGHelleforthstraße 58-60 | 33758 Schloß Holte-StukenbrockPhone +49 5207 8903-0 | [email protected]


steam conditioning valves...for a quick change of the steam mass ˚ow, e.g. opening of a turbine...

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