Pressure Reducing / De-superheating Stations

(Control Valve based)

Instruction Manual

Notice
2006 Steamline
Survey. No. 32/3/14 Behind Angraj Resort, Kondhwa Budruk Pune 411 048 INDIA Ph: 91 20 2693 2213 Fax: 91 20 2693 2214 E-Mail: info@steamline.com URL: www.steamline.com All Rights Reserved Printed in India

Proprietary Material
The information and descriptions contained herein are the property of Steamline. Such information or descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of Steamline, Survey. No. 32/3/14, Behind Angraj Resort, Kondhwa Budruk, Pune 411048, India. This document is for information only and is subject to change without notice.

Statement of Limited Warranty

Steamline warrants equipment of its manufacture, and bearing its identification to be free from defects in workmanship and material for a period of 18 months from the date of delivery, or 12 months from the date of installation, whichever is earlier, when such equipment is used in accordance with instructions furnished by Steamline and for the purposes disclosed in writing at the time of purchase, if any. Steamlines liability under this warranty shall be limited to replacement or repair, F.O.B. Pune, India, of any defective equipment or part, which having been returned to Steamline, transportation charges prepaid, has been inspected and determined by Steamline to be defective. Replaceable elastomeric parts and glass components are expendable and are not covered by any warranty. This warranty is in lieu of any other warranty, either express or implied, as to description, quality, merchantability, fitness for any particular purpose or use, or any other matter. Part No. YOPRDS Rev 1

May 2007

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Table of Contents
1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 4.0 5.0 5.1 5.2 5.3 5.4 5.5 6.0 6.1 6.2 7.0 7.1 7.2 7.3 7.4 8.0 INTRODUCTION Application Operating Principle List of Documents Attached SPECIFICATIONS Operating Conditions Applicable Standards Mechanical Specifications Materials INSTALLATION Unpacking the unit Mechanical installation Commissioning Insulation OPERATION MAINTENANCE Steam Trap Strainers Other Parts Annual Maintenance Calibration TROUBLESHOOTING Outlet Pressure is not correct Safety Valve does not operate SERVICE & SPARES Service Policy Warranty Repairs Spares Parts Service Record NOTES Page 4

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Page 10 Page 11

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1.0

INTRODUCTION 1.1 Application Pressure Reducing Stations are integral parts of any steam system. They are used to reduce the pressure (and correspondingly, the temperature) of steam. Steam is usually generated at high pressures at a central location (the boiler house) and transferred to usage points through the steam system. At the various points of steam usage, pressure is dropped according to the requirement of each process. Why cant steam be generated at low pressure? Most modern boilers operate at relatively high pressure. A typical process boiler operates at 10.5 to 17.5 kg/cm 2g (150 250 psig). The operating pressure of a boiler determines various parameters like water holding capacity, steam space, water level etc. Such an arrangement has the added advantage that smaller diameter distribution pipes can be used, as the specific volume of steam occupied by steam is less at higher pressures. So it is usual practice to generate steam at high pressures at a central location, distribute the high pressure steam in small diameter pipes, and reduce the steam pressure as required at the usage points. The temperature of saturated steam varies with the pressure, so this also provides a simple method of controlling temperature of steam going to a process. Economic benefits of Pressure Reduction If steam at a higher pressure (and temperature) than required is used in a process, the heat will be sufficient for the process. So why reduce steam pressure? There is a powerful economic argument in favour of reducing the pressure: latent heat. The work done by steam in a process is primarily latent heat, which is far greater then sensible heat i.e. steam imparts heat to the process by condensing into water, thus giving off its latent heat. Latent heat is higher at lower steam pressures, so the same amount of heat load can be catered by a smaller quantity of steam at a lower pressure. The minimum pressure to be used has to be chosen such the steam temperature at that pressure affords enough of a temperature gradient for efficient heat transfer to take place. Sometimes, steam-using equipment will have to be operated at the steam pressure specified by the manufacturer of the equipment. Superheating Superheated steam is steam that is at higher temperature compared to its saturation temperature for the given pressure. Eg, steam at 3.5 bar g has a saturation temperature of 147.71C. If further heat is added to steam at the same pressure, the extra heat raises the temperature of steam to become superheated. It is higher than saturation temperature and contains more energy. Superheated steam is mainly used to drive turbines for power plants. Here we need steam which has a high dryness fraction, so that the turbine's expensive blades are not subjected to pitting by water droplets carried by wet steam. De- superheating Once utilised for any special purpose, superheated steam must be cooled down to saturation temperatures for efficient use on heating applications. This process is

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called desuperheating. Most desuperheaters used to restore the saturated state produce discharge temperatures approaching saturation. 1.2 Operating Principle a) PRS: The figure below shows the general arrangement of a typical Pressure Reducing Station (PRS). The Moisture Separator at the inlet ensures that any water slugs (condensate) traveling with the steam does not cause damage to the rest of the PRS, and provides dry steam to the process. The inlet valve can be used to shut-off steam supply to the PRS. The strainer removes dirt, welding slag or any other particles that could damage the seat and plug of the CV. (Please refer to the enclosed User Manuals of CV.)

Pressure at the outlet is read by a Pressure Transmitter, to act as a feedback to balance pressure to the set pressure. The outlet valve shuts off supply to the process, while the bypass line and valve provide an alternative flow path in case the CV needs to be repaired or maintenance work is required. A suitably sized safety valve ensures that the outlet steam pressure does not exceed the set-point. Inlet and outlet pressure gauges are provided to check generation pressure, configure the set pressure and check CV operation. b) DSH: A measured amount of water is sprayed into the superheated steam via a mixing arrangement within the desuperheater (DSH). As it enters the DSH, the cooling water evaporates by absorbing heat from the superheated steam. Consequently, the temperature of the steam is reduced. The amount of water added is controlled precisely by using a sophisticated feedback control loop.

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Determining the amount of water to be added is usually achieved by measuring the temperature of the steam downstream of the desuperheater. The system below illustrates an arrangement of a typical DSH. Good quality water (typically condensate or boiler feedwater) is directed into the superheated steam flow, removing heat from the steam, causing a drop in the steam temperature to saturated temperature levels for given pressure.

Water

Str

c) PRDSH: This stands for Pressure Reducing and De-Superheating Station. It combines the Pressure Reducing Stage and the De-Superheating stage as shown in the diagram below.

Water

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1.3

Documents Attached Packing List (with dispatch documents) Copy of Re-Assembly Drawing of PRS / DSH / PRDSH (with dispatch documents) Copy of As Built Drawing of PRS / DSH / PRDSH User Manual of Control Valves, Type 241-1 or Type 3251 User Manual of Control Valve Positioner User Manual of Pressure Transmitter (if applicable) User Manual of PID Controller (if applicable) User Manuals of Safety Valve IBR Drawing of PRS / DSH / PRDSH (where applicable) IBR Form IIIA with material traceability (only for IBR PRS / PRDSH) Material Traceability Certificate Copies of Certificates of all materials used

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2.0

SPECIFICATIONS 2.1 Operating Conditions Steamline Pressure Reducing and De-superheating Stations are custom built to operate over a wide variety of operating conditions. To determine the Operating Conditions for the supplied PRS / PRDSH, please refer to the enclosed drawings as per section 1.3 above. Applicable Standards All Steamline Pressure Reducing and De-superheating Stations are manufactured in conformance to one or more of the following applicable standards: Quality Procedure (IBR Job) Quality Procedure (NIBR Job) Pressure & Temp Ratings Sizing of Control Valves Seat Leakage Tests Sizing of Safety Valves Design of Safety Valves Testing of Safety Valves Cast Carbon Steel Valves Mfg of Cast CS Valves Mfg of Forged CS Valves Face to face dim of valves SW or threaded Pipe Fittings Inspection of all CS Valves Design of Pressure Gauges Piping Standards Carbon Steel Pipes Sizing of Steam Pipes Steel Pipe Flanges Forged Carbon Steel Pipe Fittings Gaskets for steel piping Heat Resistant Paint Fasteners 2.3 Mechanical Specifications Mounting Protection Rating Ambient Temperature : Other Specifications Materials CV & Safety Valve Body CV & Safety Valve Internals Isolating Valves Body Separator & Strainer Body Pressure Gauges Steam Trap (where fitted) Steel Pipes Gaskets Nameplates : : : : : : : : : : : : : : : : : : : : : : : Indian Boiler Regulations 1950 or later SQC/QAP/PRSN 2000 or later ANSI 150# or 300# or 600# IEC 534 ANSI B 16.104 IBR sizing formula API 526 + ASME Sec VIII API 527 + IBR ASTM A 216 Gr. WCC API 600 / BS 1873 API 602 ANSI B 16.10 ANSI B 16.11 API 598 EN837 1 ANSI B31.1 & 31.3 ASTM A 106 SQC Software ANSI B 16.5 ASTM A 182 IS: 2712: 1979 IS: 13183: 1991 ASTM A 193/4 or IS 1367

2.2

: Outdoor (non-corrosive environment) : IP65 (Except Electronic Controllers, if any) 0 to 50 degrees C : As per enclosed drawing : : : : : : : : : ASTM A216 Gr WCC Stainless Steel ASTM A216 Gr WCB / ASTM A105 ASTM A106 Gr B Stainless Steel case + internals Thermodynamic, SS ASTM A106 Gr B CAF Metal-photo Aluminium Page 8 of 16

2.4

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3.0

INSTALLATION 3.1 Unpacking The unit is usually supplied in disassembled condition for ease of transport. If the unit is packed in a wooden case, pry open the case carefully. Great care is taken to ensure that no damage occurs in transit. However, please notify the carrier immediately if there are any signs of damage to the unit. Refer to the enclosed Packing List to check if any parts are missing. The case should contain the various parts, with each part bearing a re-assembly number, usually hand-written with a marker. Refer to the Re-Assembly drawing to assemble the syste at site. 3.2 Mechanical Installation 1. Before starting the installation, ensure that a full set of tools is available, including a full set of spanners. The installation personnel should be equipped with safety belts and helmets. Ensure that there is no possibility of steam being charged to the line where the system is being installed. 2. In case of IBR approved unit, the local IBR inspector may have to be notified before installation. The IBR certificate in Form IIIA (out of Maharashtra) or in letter form (within Maharashtra) needs to be shown to the local IBR inspector. All local inspection formalities by IBR are in the scope of the client. 3. Assemble the system in the pipeline as per the As-Built Drawing provided. Ensure that the valves and other components are installed with the flow in the correct direction, as shown on the part. If in doubt, contact Steamline. Install the isolating valves in a manner to allow convenient operation of their hand wheels. Install Pressure Gauges so that they can be seen from the normal viewing position. 4. If the system is installed at a height, fabricate a suitable platform to allow access to the unit for operation and maintenance. Provide supports before and after the CVs do not support the weight of the system on any working component like CV, valves etc. as this could cause damage to these parts over time. 5. Keep the inlet isolating valve and the bypass valve fully closed, and the outlet isolating valve fully open for now. Keep the bypass valve of the trap open for now. 3.3 Commissioning After the installation is completed, check that there is no water leak from the Condensing Pot. Slowly open the main line valve (at boiler header) to charge steam to the PRS/PRDSH. Any stored condensate in the line will now discharge through the trap bypass valve. Close the bypass valve of the trap, and fully open its inlet valve. The trap should then resume its normal blast discharge to remove the condensate. Check that there are no leaks of steam from flanged joints etc. and that the inlet pressure gauge reflects the correct inlet pressure.

Now slowly open the bypass valve. As the outlet pressure rises, the gauge should reflect this. Once the outlet pressure rises to 10% above the set pressure, the safety valve should lift check that this happens correctly. If required, adjust the safety valve pressure (Refer to the enclosed manual of the safety valve for instructions). PRS/ DSH/ PRDSH (CV based) Page 9 of 16

Once the safety valve operation has been confirmed, slowly open the inlet isolating valve of the PRS/PRDSH, while closing the bypass valve simultaneously. The outlet pressure will now be controlled by the PRV. If the outlet pressure is not correct as per the chosen set pressure, adjust the PRV (Refer to the enclosed manual of the pressure reducing valve for instructions). Now fully open the inlet valve and outlet valve of the PRS/PRDSH and fully close the bypass valve. These valves are supplied with the gland packing nuts slightly loose to allow for expansion of the gland packing tighten these nuts fully so no steam escapes through the gland. The PRS/PRDSH is now commissioned, and will automatically regulate the pressure as per the set pressure selected. 3.4 Insulation If desired, the system may be insulated in a similar manner as the insulation of the pipe. Please contact Steamline if you need information and specifications for recommended insulation materials. Do NOT insulate the CV and the Safety Valve, as this will interfere with their normal operation. While insulating the Strainer, it is advisable to make a provision for removal of insulation from the top flange, which may be required for maintenance. 4.0 OPERATION PRS / Pressure reducing Stage of PRDSH The system includes, (a) an Input the Pressure Transmitter (b) Controller (c) Steam Pressure Control Valve The steam pressure CV will be modulated by the PID controller to maintain the Set Point at the outlet of the system. To operate/ configure the controller, please refer to the controller manual. Temperature Control Stage of PRDSH / DSH In the temperature control stage there are three parts, (a) an RTD the Temperature Transmitter (b) PID Controller (c) Water spray Control Valve The Controller will modulate the quantity of water sprayed so that it is just enough to maintain the set temperature. To operate/ configure this controller, please refer to its controller manual.

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5.0

MAINTENANCE Steamline Pressure Reducing and De-superheating Stations are designed to give long periods of uninterrupted service over many years, even with little or no maintenance. However, a little care taken on the following points will ensure that the best results are achieved. 5.1 Steam Trap (in case of PRS) The steam trap on the motive steam line ensures that there is no moisture in the motive line. The operation of the trap needs to be checked regularly, as water in the motive line could cause water hammer and damage the Control Valve. We recommend a weekly inspection. 5.2 Strainers The PRS / PRDSH includes a strainer. As time passes, particulate matter and dirt will collect in the mesh of the strainer, and the mesh will have to be cleaned. This can be done on line by operating through the bypass, but it is best done during annual maintenance shut down. Any paraffin can be used to clean the SS mesh. The steam trap also has an in-built strainer, which may require cleaning. 5.3 Other parts The internals of the unit are factory assembled and tested, and should not be tampered with as far as possible. We do not recommend any user servicing of these parts, and checks are required annually, which will be conducted by Steamline personnel if the equipment is under Annual Maintenance Contract. 5.4 Annual Maintenance While the unit is warranted for a period of one year, Steamline service can be extended to ensure optimal operation of the system by entering into an Annual Maintenance Contract with Steamline. This will include periodic visits and checks on your PRS / PRDSH unit and replacement of any worn parts etc. Please contact your Steamline representative for details. In case you do not need an AMC, ensure that during the annual maintenance shutdown, the PRS / PRDSH is inspected. All strainers should be cleaned, the gaskets may need to be replaced in case of any leakage. Tighten all pipeline nuts and inspect insulation for any damage. Reconfirm operation of the safety valve at 10% above set pressure. 5.5 Calibration The Pressure Gauges and Pressure Transmitter should be calibrated at least once in two years, or in accordance with Quality Procedures followed in the plant.

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6.0

TROUBLESHOOTING 6.1 Outlet Pressure is not correct In case of minor deviation from the set point, adjust the controller settings to correct the pressure. If the system does not hold the set pressure consistently, check that the inlet and outlet valves are fully open, and the bypass valve is fully closed. Also check that the bypass valve is not leaking. Should the downstream pressure deviate significantly from the adjusted set pressure, check the set point and PID settings in the controller. Now, set up the controller in auto-tuning mode. In case the problem persists, please contact Steamline service. 6.2 Safety Valve does not operate The safety valve should operate at about 10% above the set pressure. If this does not happen, adjust the pressure setting of the safety valve. Lift the manual handle to operate the safety valve sometimes this can get jammed after a few years if the valve has not been operated or tested periodically, and lifting the valve manually can clear the jam.

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7.0

SERVICE & SPARES 7.1 Service Policy Steamline has built its reputation and growth on only three pillars the knowledge of our engineers, the quality of our products and most important of all, the quality of our service, both before and after the order. While we take a lot of care to ensure that you do not need service, by selecting the correct components, conducting rigorous inspections, dedicated manufacturing, testing and finishing, the reality of physics means that isolated failures can occur. What matters is how we deal with them. All our engineers are continuously reminded that the reason we exist and compete in a tough market is that we are available to our customer immediately when there is a problem. In case you have any grievance regarding the quality of service provided to you, or of delays in service, please contact Mr. Vikram Jain at Steamline, Pune on phone number 020 2693 2213 or mobile number 98220 56160. 7.2 Warranty Repairs The PRS / DSH / PRDSH unit has a 1 year warranty. We stock spares and other components for immediate exchange after we have isolated the cause of the problem. The parts will be immediately repaired or replaced in accordance with our Test & Guarantee Certificate, free of charge. Any incidental charges including excise duty, freight, octroi etc. are payable by the client. Any costs incurred for the visit of a service engineer shall be borne by Steamline. Factory authorized repairs that are received for service will be returned within two weeks. However, we can return the units quicker if the client pays courier charges. Out of warranty repairs are done on a flat fee basis after the warranty has expired, or under the terms and conditions of a valid Annual Maintenance Contract. 7.3 Spare Parts The following Steamline original spare parts are available: Gaskets Gasket Kit for complete PRS / PRDSH (Please specify PO No. or As built Drg. No.) SS Mesh for Strainers Please specify PO No. or As built Drg. No. Control Valve Diaphragms Please specify actuator size this is stamped on the Control Valve. Other Parts Disc or Spring of Safety Valve Seat or Plug of Control Valves

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7.4

Service Record All service provided by Steamline engineers should be recorded in the Service Record below, in order to provide continuity and knowledge of past actions to the Service Engineer. Product Model: Serial No. Commissioned On In-warranty Service Proposed visit Free Visit 1 Actual visit Date: Service Engr.: Sign: Free Visit 2 Date: Service Engr.: Sign: Free Visit 3 Date: Service Engr.: Sign: Actions Taken / Parts replaced (if any) : :

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Out of Warranty Service Date of visit Date: Service Engr.: Sign: Date: Service Engr.: Sign: Date: Service Engr.: Sign: Date: Service Engr.: Sign: Date: Service Engr.: Sign: Date: Service Engr.: Sign: Problem Reported Actions Taken / Parts replaced (if any)

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8.0

NOTES

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