IN THIS PRESENTATION & CONTROL VALVES co NOISE & CONTROL VALVE SIZING © END PREPARATION & VALVE CONSTRUCTION 5 VALVE ACTUATORS 3 TOP GUIDED CONTROL VALVE © CONTROL VALVE a CAGE GUIDED VALVES DOUBLE a DOUBLE SEATED CONTROL VALVE ACCESSORIES o _CAGES/TRIM © TESTS 3 GLAND PACKING | TURNDOWN RATIO 5 STANDARDS 5 CAVITATION a BODY/TRIM MATERIALCONTROL VALVES 7 Diaphragm 5 Control valves are 3 valves used to control Stop = Diaphraom Plate conditions such as flow, pressure, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "setpoint" to a "process variable" whose value is ~~ valve stem PackingCONTROL VALVE SIZING Qo The control valve shall be of globe body design with single port. The valve trim, shall be suitable for quick removal without any cutting or welding. © Sizing shall be accordance with ANSI/ISA 75.01,01. © Valve outlet velocity does not excesed 8CONTROL VALVE SIZING 0 The valve sizing shall be suitable for obtaining maximum flow conditions with valve opening at approx 80% of total valve stem travel and minimum flow conditions with valve stem travel not less than 10% of total valve stem travel. © All valves shall capable of handling at least 120% of required maximum flow.VALVE CONSTRUCTION | Conform to requirement of ANSI for dimensions, material thickness and material specification for their respective pressure class. | All valves shall be globe body design and straightway pattern with single or double port or angle body design. 5 All valves connected to vacuum on down stream side shall be provided with packing suitable for vacuum application (e.g double vee type chevon packing). 5 Extension bonnets shall be provided when the maximum temperature of flowing fluid is greater thanTOP GUIDED CONTROL VALVE Top-guided, single- ported valves may be used for tight shutoff applications; however, because these valves are unbalanced, they can require more force from the actilator to achieveCAGE GUIDED VALVES 5 Cage-guided valves have a cylindrical plug guided through a guide. | The increased aidieg area is desirable for high pressure drop, high noise, and anticavitation applications 5 Unbalanced Hypes can provide a tight shutoff if sufficient oO Ear halancad ctyvloc thaDOUBLE SEATED CONTROL VALVE 5 Double-seated control valves are used to a lot of industrial applications due to advantages of reduction in actuator force, a great flow capadly and a deal of slurry fluids. 4 Double-seated valves cannot provide theCharacterized Cages/Trim for Globe valve FULL FLOW AT CONSTANT PRESSURE DROPGLAND PACKING o PTFE if fluid temperature is less than 180 deg C. ay © Graphite if fluid fy temperature is more Mee i ene 5 All valves connected to Vee ings (chevrons vacuum on down stream side shall be 4 -f MALE ADAPTOR provided with packing + PACKING SPRING suitable for vacuum SSTURNDOWN RATIO O The valve-sizing coefficient for globe valves should be selected to limit turndown to a ratio of about 30:1. QO This limits the valve opening to approximately 10% of maximum for globe valves with equal percentageCAVITATION © Cavitation is a two stage phenomena with liquid flow. 5 The first stage is the formation of vapor bubbles in the liquid as the fluid passes Soa the trim and the pressure is reduced below the fluid's vapor pressure. | The second stage is the collapse of the vapor bubbles as the fluid passes the vena contracta and the pressure recovers and increases above the vapor pressure.Cavitation 5 Cavitation in control valves can have four negative effects; * Restricts fluid flow © Causes severe vibrationsANTI CAVITY TRIM 5 The anti cavity trim of control valve shall be multi stage ,multi path type. 5 ISA=RE 757251995; “Considerations for Evaluating Control Valve Cavitation”, Recommended Practice, Tina 1006Cavitation is alleviated by anti- cavitation valve trimAnti cavitation. Trim éCONTROL VALVES WITH ANTI CAVITY TRIM IN THERMAL POWER PLANTS 500 MW CEP /BFP Min recirculation valve Excess dump control Condenser for SD flash tank HP/LP heater alternate drain to drain flash tank. D M normal/emergency makeup to hotwell. SS eae ee Se Le | oOBODY/TRIM MATERIAL & SEVERE FLASHING/CAVITATION SERVICES BODY MATERIALS- Alloy steel as per ASTM - A217 GR WC 9 TRIM MATERIAL-- 440 C series SS LOW FLASHING/CAVITATION SERVICES BODY MATERIALS--Alloy steel as per ASTM A - 217 GR WC 6 TRIM MATERIAL- 17-4 PH SS CONDENSATE & DM SERVICES BODY MATERIALS--316SS for condensate service below 275 deq CBoiler startup valve for supercritical boiler OQ Once through boilers require a minimum evaporator flow for cooling of boiler tubes during startup . © Recirculation of the water from the separator back to the feedwater tank O the start up is operating continuously at high differentialSevere services control Valves 0 SEVERE FLASHING/CAVITATION SERVICES low load and full load feed water control, HP and LP heaters emergency drains, Deaerator overflow drain to Hotwell, CRH flow to Deaerator, Spray control valve (SH, RH, HPBP), RH block valve etc. & LOW FLASHING/CAVITATION SERVICES HP heaters & LP heaters normal drain control, drain cooler normal level contro! aland cteam cooler minimiimCONTROL VALVE SEAT LEAKAGE CLASSIFICATION (Ansi/Fci 70-2-1991) S.N LEAKAGE CLASS MAX LEAKAGE Al 1 2 3 4 I II Ill IV LLOWABLE 0.5 % of rated capacity 0.1 % of rated capacity 0.01 % OF RATEDLEAKAGE CLASS OF VALVES 0 Control Valves Ee ues wan with leakage rate © ‘SH/RH spray control, . Heavy oil pressuring & control as per leakage ; "HP/LP hector ee Class-V to a._.CEPS/BFP minimum flow increase cycle =e » GSC minimum flow, .Dearator drain to condenser hotwell, «condensate spill to condensate recarva tank contrat efficiency of plant and safety ofFAIL TO SAFE DESIGN 5 Valve shall close if © Valve shall open if signal fails : signal fails SH/RH spray valve SO CEP/BFP recirculation HP/LP HEATERS normal valve. drains OS HP/LP HEATERS emergency drain to flash tank .NOISE 5 Control valve induced 5 VALVE with Cage-Style noise shall be limited to Noise Abatement 85 db at 1 mtr from valve surface under actual operating condition . | The noise abetment shall be achieved by valve body and trim design or by use of silencers. w Kiaiea aalantatliann skal kaHP LP BYPASS VALVEEND PREPARATION © Valve body ends shall be either butt welded/socket welded, flanged . © The welded ends wherever required shall be butt welded type as per ANSI B 16.25 for control valves of sizes 65 mm and above. 0 For valves size 50 mm and below welded ends shall be socket welded as per ANSI B 16.11VALVE ACTUATORS & The HP and LP Bypass, turbine inlet control valves shall be with electro- hydraulic actuators and all other control valves shall be furnished with pneumatic actuators. 5 proper selection and sizing of valve actuators in accordance with the pressure drop and Sa ae eeACTUATERSPERFORMANCE OF VALVE i) linearity :1% of FS. ii)Hysterisis :1% of FS. iii)Sensitivity +:0.5% of span. iv)Accuracy : 2% of span. ACONTROL VALVE ACCESSORIES a a a a a a a a a a oe Positioner, Air filter regulator, Air lock relay, Position limit switch, Position transmitter, Solenoid valve, E/P converter, Junction box, Hand wheel, Local position indicat Eee eaSMART POSITIONER o smart digital microprocessor based valve positioners and compatibility for remote calibration & superimposed HART signal on input signal 4-20 mAmp& connected with hartControl valve hookup diagram with smart positioner [* SMART POSITIONER =,TESTS i) Non destructive test - ANSI B-16.34 ii) Hydrostatic shell test - ANSI B 16.34 iii) Valve seat leakage- ANSI- B 16.34. iv) Functional test: The fully assembled valves including actuators control devices and accessories shall be functionally tested . EELIST OF CONTROL VALVES IN 500 MW THERMAL POWER PLANT goa Boog o9 1. D/A Pegging from Aux. Steam Header ay 2. D/A Pegging from CRH Line 3. Main Condensate Control 4. CEP A/B/C Minimum Recirculation 5. GSC min, flow recirculation 6. Excess Dump Control 7. Condensate for SD F/T 8. Condensate for Valve Gland Sealing 9. HPH-7A/7B Normal Drain to HPH 10. HPH-7A/7B Alt.Drain to HP Drain F/T 11. HPH-6A/6B Normal Drain to aoo00 0 pooanooo 15. LPH-2 Normal Drain to LPH-1 16. LPH-2 Alt. Drain to LP Drain F/T 17. Deaerator Overflow 18. HPH-8A/8B Normal Drain to HPH-7A/7B 19. HPH-8A/8B Alt. Drain to HP Drain F/T 20. LPH-4 Normal Drain to LPH-3 21. LPH-4 Alt. Drain to LP Drain F/T 22. DM Normal Makeup to Hotwell 23. Emergency MU to Hotwell 24. Low Load Feed Control 25 SUPER HEATER SPRAY Wee SSPUMP PERFORMANCE CURVESTANDARDS G ANSI/ISA-75.01.01 (IEC 60534-2-1 Mod) - 2007 - Flow Equations for Sizing Control Valves 5 ANSI/ISA - SP75.02, 1996, “Control Valve Capacity Test Procedure”, October 1996 9 ISA- RP75.23 - 1995, “Considerations for Evaluating Control Valve Cavitation”, Recommended Practice, June 1995 | ANSI/ISA-75.19.01-2001 (R2007) - Hydrostatic Testing of Control ValvesTHANKING YOU High pressure by-pass valve