Control Valve

Sourcebook
Chemical Unit
Operations

Turbine
Topic Page
I How It Operates . . . . . . . . . . . . . . . . . . . . . 2
II Where Turbines are Used . . . . . . . . . . . . . . . 2
III Gas Turbine Application Review . . . . . . . . . . . 2
Photo credit: lowsun / Shutterstock.com
IV Steam Turbine Application Review . . . . . . . . . 3
Turbine

Turbine expanding the gas at high temperature and high velocity.

I. How It Operates
A turbine is a complex rotary mechanical device equipped
with a series of stationary and rotating blades. Mostly,
turbines are divided into three stages and an exhaust section.
Pressure drop of a high pressure gas or vapor occurs through
nozzles, diaphragms, or stationary blades. This pressure
drop creates high velocity gas or vapor that is directed at a
row of blades connected to a rotor, converting the energy
to mechanical work. There are several different types of
turbines commonly used in the chemical industry. The most
common turbines are gas and steam turbines.
Turbine section converts the thermal energy into shaft
energy and two-thirds of the energy is used to drive the
compressor. At the final stage exhaust gas can be used to
generate steam for power.
1. Air Extraction Valve
The air extraction valve is used to release excess air to the
atmosphere during startup and shutdown procedures to
protect the compressor. Typically, there are up to four of
these valves.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design

II. Where Turbines are Used Typical Valve Construction:

Typical plants that use turbines include:
Chemical
Power
Oil and gas
III. Gas Turbine Application
Review
The gas turbine shown in Figure 1 is made up of several
components and systems, including: turbine, compressor,
combustor, generator, air supply, fuel skid, and lube oil skid.
Air is compressed in the compressor section then fuel (gas
or oil) is injected into the combustion section and fired,
NPS 6 to 30 Fisher A81, A31A, A41, A11, or 8532
valve
Materials of construction: dependent on process
design, typically WCC
2. Inlet Bleed Heat Valve (IBHV)
The IBHV utilizes compressed air to heat inlet air to prevent
icing during cold and humid condition. Typically the inlet
bleed heat system consists of three valves: IBHV, drain valve,
and manual stop valve. The drain and manual valves are on-
off applications and the IBHV is a throttling application.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design

3 4
COMBUSTOR

FUEL SUPPLY
1 5

COMPRESSOR TURBINE

GENERATOR

2 7

HEAT
WATER EXCHANGER

AIR SUPPLY 6

OIL

WATER
E1173

Figure 1. Process Diagram of Gas Turbine

2

Typical Valve Construction:
IBHV: NPS 6x4 to 12 Fisher EW valve with
Whisper Trim I or equal percentage trim
Drain valve: NPS 2 Fisher A41 valve
Manual stop valve: Fisher 8560 or A11 valve
Materials of construction: dependent on process
design, typically Alloy 6 Whisper Trim I is used for the
IBHV, and SST material is used for the drain valve
3. Fuel Gas Control Valve
The purpose of the fuel gas control valve is to simply control
the flow of fuel to combustor. It requires a precise, linearly
characterized valve with the ability to choke very quickly at a
low pressure drop, which results in no change of Cv during a
sudden change in pressure drop.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design
Typical Valve Construction:
NPS 2 to 6 Fisher ED or ES valve with Class IV shutoff
Materials of construction: dependent on process
design, typically WCC with a 17-4 cage is used
4. Stop Ratio Valve (SRV)
The purpose of a SRV valve, also known as the pressure
ratio valve, is to control and supply fuel gas with a constant
upstream pressure based on various turbine loads. Failure
to maintain a constant pressure can lead to excess noise,
exhaust gas temperature variation and excess nitrogen oxide
(NOx) pollutant.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design
Typical Valve Construction:
NPS 3 to 8 Fisher V300, V200, or SS-260 valve with HD
metal or TCM metal seal, Fisher ED or ES valve with
ENVIRO-SEAL packing system to prevent fugitive
emission, and Class VI shutoff
Materials of construction: dependent on process
design, chromium carbide coated ball provides better
wear resistance
5. Purge Valve
The two main functions of a purge valve is to protect the fuel
nozzles and flush the fuel lines with air. It requires a design
that allows a small Cv when barely open and develops into a
modified equal percentage as the valve opens. Purge valves
operate in pairs in a double block-and-bleed arrangement to
prevent the hot air from interacting with the natural gas.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design
Turbine
Typical Valve Construction:
Fisher CV500 valve with Class V shutoff
Materials of construction: dependent on process
design, typically SST body is recommended, chrome
carbide coating on the ball, nitronic 50 shaft (NACE
option) or 17-4PH shaft (High H2S concentration
could cause corrosion with 17-4PH), Alloy 6 bearing
and seal ring
6. 3-Way Temperature Regulator Valve
Purpose of 3-way temperature regulator valve is to
maintain the appropriate temperature of the oil lubricant
by controlling flow of cooling water to the lube oil heat
exchanger. Failure of this valve can affect the bearing system
reliability.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design
Typical Valve Construction:
3-way Fisher YD valve
Materials of construction: dependent on process
design, typically WCC
7. Lube Oil Pressure Valve
The lube oil pressure valve is used to maintain the pressure of
the lube oil that is pumped to the bearing. A lube oil pressure
valve regulates the flow based on a control signal coming
from a downstream pressure transmitter. It provides high
lubricant pressure at low turbine speed and low lubricant
pressure at high turbine speed.
Typical Process Conditions:
Pressure, temperature, and flow are dependent on
process design
Typical Valve Construction:
NPS 3 to 4 Fisher easy-e valve, Fisher GX valve
Materials of construction: dependent on process
design, typically WCC
IV. Steam Turbine Application
Review
Steam turbines are utilized in a variety of industries to
capture energy associated with the expansion of process
generated steam. Turbines convert thermal energy from
steam and use it to do mechanical work on a rotating shaft.
Steam turbines are commonly classified by the condition of
the exhaust, for example non-condensing or extraction.
Non-condensing or backpressure turbines are most widely
used for process steam applications. The exhaust pressure
is controlled by a regulating valve to suit the needs of the
process steam pressure. As shown in Figure 2, high pressure
steam enters the turbine and does the work in front of
turbine and exits the turbine at the low pressure side.
3
Turbine

HIGH PRESSURE HIGH PRESSURE

STEAM STEAM

POWER
POWER

LOW PRESSURE
STEAM TO
E1174 PROCESS LOW PRESSURE STEAM TO CONDENSER
STEAM TO
Figure 2. Non-Condensing Turbine PROCESS

E1175

Figure 3. Extraction Turbine

Extracting type turbines are also used in process steam
applications. As shown in Figure 3, high pressure steam
enters the extracting type turbine and steam is released from
various stages of the turbine. Steam from each section is
used for industrial process needs or sent to boiler feedwater
heaters to improve overall cycle efficiency. In commercial
power plants the remainder of steam is directed to the
condenser, turning the steam into water that is then recycled.
A steam turbine package has several components and
systems including: a steam turbine, generator, gland steam
seal system, lube oil system, shaft seal oil system, hydraulic
system, and a control system. The three areas covered in
this document are the main steam turbine, the steam seal
system, and the lube oil system.
Main Steam Turbine
As shown in Figure 4, a main steam turbine consists
of several control systems and valve applications. The
valve applications for the main steam turbine section are
numbered from one to five.
1. Main Steam Control Valve
The purpose of main steam control valve is to control the
amount of steam from the boiler or heat recovery steam
generator (HRSG) to high pressure (HP) turbine. These valves
are usually part of the turbine casing itself and are designed
and manufactured by steam turbine original equipment
manufacturer.

1 2 2

SHAFT

PACKING IP
GLAND HP LP LP

5
5

CONDENSER

STEAM FROM HRSG

E1176

Figure 4. Process Diagram of Main Steam Turbine

4

2. Low Pressure (LP) Induction Admission Steam
Valves
The LP induction admission steam valve typically consists
of two valves in series. One controls the amount of steam
entering the LP turbine and the other quickly shuts off steam
to the turbine through an on-off application.
Typical Process Conditions:
Fluid = steam
P1 = 50 to 150 psig (3.45 to 10.34 bar)
T = 500 to 700F (260 to 371C)
Q = 0 to 120,000 lb/hr or higher ( 0 to 54.3 ton/hr)
Typical Valve Construction:
NPS 16 to 24 Fisher butterfly valve construction
Materials of construction: dependent on process
design, typical construction includes WCC or SST
3. Combined Reheat Intercept Valve
The combined reheat intercept valve is used to control the
hot reheat admission steam from a boiler or heat recovery
steam generator (HRSG) to the intermediate pressure section
of turbine.
Typical Process Conditions:
Fluid = steam
P1 = 485 to 586 psia (33.44 to 40.40 bar)
T = 950 to 1050F (510 to 565C)
Typical Valve Construction:
NPS 16 to 20 Fisher Large easy-e valve
Materials of construction: dependent on process
design, typical construction C12A and Class V shutoff
4. Packing Blowdown Valve
The packing blowdown valve slows down the turbine or
quickly discharges the turbine during a turbine trip. During
a turbine trip the main steam valve, LP induction admission
steam valve, and intercept valve will shut off, trapping
high pressure steam in the boiler and HP turbine. The high
pressure steam will flow from the HP turbine through the
packing into the IP turbine causing the turbine to spin to the
point of overspeed. In order to avoid this overspeed, flow is
diverted with the reverse flow valve.
Typical Process Conditions:
Fluid = steam
P1 = 400 to 700 psig (27.57 to 48.26 bar)
T = 650 to 950F (343 to 510C)
Typical Valve Construction:
NPS 3 to 6 Fisher HPD valve with butt weld end
Materials of construction: dependent on process
design, typical material construction includes WC9,
linear cage, and Class V shutoff
Turbine
5. Drain Valves
The purpose of the drain valve is to collect any water from
the turbine or steam system. Drain valves will be located
throughout the system.
Typical Process Conditions:
Fluid = water/ condensate
P1 = 486 to 5000 psi (33.5 to 345 bar)
P2 = condenser pressure
T = 300 to 1150F (148.8 to 621C)
Typical Valve Construction:
NPS 1 to 2 metal seated valve
Materials of construction: dependent on process
design, typically includes a WCC, WC9, or C12 body,
316 SST/CoCr-A trim
Steam Seal Turbine
Steam seal turbine section as shown in Figure 5 consists of
the valve applications numbered from six to nine.
6. Steam Seal Regulator (SSR) Valve
The purpose of this valve is to adjust the flow of steam into
the steam seal system. It is mainly used during startup and it
is closed during normal operation.
Typical Process Conditions:
Fluid = steam
P1 = main steam pressure
P2 = 3 to 5 psig (0.207 to 0.344 bar)
T = 650 to 1050F (343 to 565.5C)
Q = 0 to 50,000 lb/hr (0 to 22.68 ton/hr)
Typical Valve Construction:
NPS 1 to 6 Fisher HP valve that may require a diffuser
or Whisper Trim due to the high pressure drop
Materials of construction: dependent on process
design, typically WCC, WC9, C12A, 316SST/CoCr-A
trim
7. Auxiliary Steam Seal Feed (ASSF) Valve
The ASSF valve is used to adjust the flow of steam into the
steam seal system. Supply steam for ASSF is from a secondary
source, usually the cold reheat header. If available this is used
instead of main header steam. This valve is only open during
startup.
Typical Process Conditions:
Fluid = steam
P1 = 600 to 700 psig (41.37 to 48.26 bar)
P2 = 3 to 5 psig (0.207 to 0.344 bar)
T = 400 to 700F (204 to 371C)
5
Turbine

SPRAY WATER FROM

CONDENSATE SYSTEM

7 8

AUXILIARY STEAM

6
DS
MAIN STEAM
9
10

STEAM TO CONDENSER
OR FEEDWATER HEATER
DS

E1177 HP IP LP LP

Figure 5. Process Diagram of Steam Seal Turbine

Typical Valve Construction:
NPS 4 to 8 Fisher easy-e valve with Class IV or V shutoff
Materials of construction: dependent on process
design, typically WCC, WC9, C12A, 316SST/CoCr-A
trim
8 & 9. Steam Seal HP/LP Desuperheater
The purpose of this valve is to reduce and regulate the
temperature of steam entering the steam seal system. Water
from condensate system is typically used.
Typical Spray Water Process Conditions:
P1 = 150 to 400 psig (10.34 to 27.58 bar)
P2 = 75 psig (5.17 bar)
T = 100F (37.7C)
Typical Valve Construction:
NPS 1 Fisher easy-e valve with MicroForm trim and
Class V shutoff
Materials of construction: dependent on process
design, typically WCC, 17-4SST cage, 416 SST plug
and steam leakage from the HP packing increases, this valve
is opened to allow excess seal steam to exit to the condenser.
Typical Process Conditions:
Fluid = steam
P1= 3 to 5 psig (0.207 to 0.344 bar)
P2 = condenser pressure
T = 500 to 600F (260 to 315.5C)
Q = 0 to 50,000 lb/hr (0 to 22.68 ton/hr)
Typical Valve Construction:
Fisher Vee-Ball valve, Class II shutoff
Materials of construction: dependent on process
design, typically WCC or SST
Steam Seal Diverter Valve
Steam Seal Diverter Valve is used to maintain the pressure of
the steam steal system by diverting the flow of excess steam
to the condenser or feedwater heater. Diverting the flow
to feedwater heater helps to recapture the heat and hence
increase efficiency of the turbine.

Typical Desuperheater Selection: Typical Process Conditions:

Fisher DVI/DMA desuperheater, WCC construction Fluid = steam

P1 = 3 to 5 psig (0.207 to 0.344 bar)
10. Steam Seal Regulator Dump Valve or Steam Seal P2 = condenser pressure
Diverter Valve T = 500 to 600F (260 to 315.5C)
In this application either a steam seal regulator dump valve Q = 0 to 50,000 lb/hr (0 to 22.68 ton/hr)
or steam seal diverter valve is used. The benefit of using Typical Valve Construction:
the steam seal diverter valve is to maintain efficiency by
recapturing heat. 3-way valve
Materials of Construction: dependent on process
Steam Seal Regulator Dump Valve design, typically WCC
The steam seal regulator dump valve is used to maintain the
pressure of the steam steal system by regulating the flow of
excess steam that is discharged to the condenser. This valve is
typically closed throughout startup. As turbine load increases

6
 Turbine

RESERVOIR

13

11

12

E1178 HP IP LP LP

Figure 6. Process Diagram of Lube Oil System

Lube Oil System Typical Process Conditions:

Lube oil system valve application as shown in Figure 6 is Fluid = oil

numbered from eleven to thirteen. P1 = 100 to 400 psig (6.89 to 27.58 bar)
P2 = 25 to 30 psig (1.72 to 2.07 bar)
11. Back Pressure Valve T = 50 to 160 F (10 to 71C)
The back pressure valve is used to control amount of lube oil Q = 60 to 700 lb/hr (0.027 to 0.317 ton/hr)
that is being sent to oil reservoir. Typical Valve Construction:
Typical Process Conditions: NPS 2 to 4 Fisher easy-e valve or Fisher GX valve
Fluid = oil Materials of construction: dependent on process
P1 = 100 to 400 psig (6.89 to 27.58 bar) design, typically WCC
P2 = 25 to 30 psig (1.72 to 2.07 bar)
13. Temperature Control Valve
T = 70 to 160F (21 to 71C)
Q = 60 to 700 lb/hr (0.027 to 0.317ton/hr) The purpose of this valve is to control the temperature of the
lubricant as it can affect bearing system reliability.
Typical Valve Construction:
Typical Process Conditions:
NPS 3 Fisher easy-e valve or Fisher GX valve
Materials of construction: dependent on process Fluid = cooling water
design, typically WCC P1 = 150 psig (10.34 bar)
P2 = 135 psig (9.31 bar)
12. Lube Oil Pressure Valve T = 70 to 150F (21 to 65.5C)
The lube oil pressure control valve is self-operating and Typical Valve Construction:
regulates the flow of lube oil based on a control signal
coming from a downstream pressure transmitter. Fisher GX 3-way valve or Fisher YD valve
Materials of construction: dependent on process
design, typically WCC

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D352317X012 / MBB55 / Jul15