II500.

00/7en
CCI

Installation Guidelines

Steam Conditioning Valves
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

1

Table of contents

1 General ....................................................................................................................... 3
1.1 Inlet pipe recommendations ................................................................................. 4
1. Straig!t pipe"run upstream recommendations ..................................................... #
1.3 $istance to %irst &end ........................................................................................... 7
1.3.1 $istance to %irst &end %or special cases ........................................................ 7
1.3. $ump to condenser 'it! 'et steam &e%ore dump device ............................. (
1.4 $istance to t!e temperature sensor ..................................................................... )
1.4.1 *inimum distance to temperature sensor ..................................................... )
1.4. $istance to temperature sensor %or special cases ........................................ )
1.4.3 *inimum degree o% super!eat .................................................................... 11
1.5 $istance to %lo' dividers .................................................................................... 1
1.# $istance to pressure sensor .............................................................................. 1
1.7 $o'nstream piping material .............................................................................. 1
1.( +dditional comments ......................................................................................... 13
1.) $i%%users and plates ........................................................................................... 13
1.10 $rains / Vent to atmosp!ere .............................................................................. 13
1.11 ,ipe pre"'arming .............................................................................................. 1#
1.1 -ater valve location ..........................................................................................
1.13 -ater piping connection to desuper!eater connection ......................................
1.14 Control s.stem ................................................................................................... 3
1.15 ,ressure control ................................................................................................ 4
1.1# /emperature control .......................................................................................... 4
1.17 Special %or %eed %or'ard 'it! dump to condenser .............................................. )
1.1( +ctuation ............................................................................................................ )
1.1) ,re!eating arrangement o% upstream piping ...................................................... 30

0i1 points and supports ............................................................................................. 35

3 +ccessi&ilit. .............................................................................................................. 3(



Steam Conditioning Valves
Installation
Guidelines

II500.00/7en

List of figures

0ig. 1 ,ipe el&o' upstream t!e valve ............................................................................ 4
0ig. 234 installation 'it! /"piece ................................................................................ 4
0ig. 3 23 installation 'it! /"piece .................................................................................. 5
0ig. 4 Installation 'it! stop and control valve 'elded toget!er ...................................... #
0ig. 5 Straig!t pipe runs up" and do'nstream t!e valve ................................................ #
0ig. #a $o'nstream temperature vs. time in a dump to condenser or a similar
process application .............................................................................................. (
0ig. #& $o'nstream temperature vs. time in an 5, to cold re!eat or similar
process application .............................................................................................. )
0ig. 7 $o'nstream temperature vs. time in a dump to condenser or similar
process application ............................................................................................ 11
0ig. ( ,rotective s!ield ................................................................................................. 1
0ig. ) 5ori6ontal inlet/vertical outlet ............................................................................. 14
0ig. 10 $rain/pre!eat s.stem ......................................................................................... 15
0ig. 11 $rainage s.stem 7$8 .......................................................................................... 1#
0ig. 1 Vertical inlet/!ori6ontal outlet ............................................................................. 17
0ig. 13 5ori6ontal inlet/outlet ......................................................................................... 17
0ig. 14 Vertical inlet/!ori6ontal outlet ............................................................................. 17
0ig. 15 5ori6ontal inlet9 outlet up'ards and actuator do'n'ards .................................. 1(
0ig. 1# $rain in do'nstream piping : $rip leg 7;8 .......................................................... 1)
0ig. 17 Valve in lo' installation ...................................................................................... 1)
0ig. 1( Installation 'it! &end 'elded direct to outlet ...................................................... 1
0ig. 1) <1pansion 'elded direct to outlet or closer t!an 0.1 s 1 V
ma1
............................ 1
0ig. 0 Installation 'it! an e1pansion cone in t!e outlet ................................................
0ig. 1 0eed %or'ard control : e1ample. ........................................................................ #
0ig. 0eed&ac= control : e1ample .............................................................................. 7
0ig. 3 0eed %or'ard '!en a dump device cannot &e used as a %lo' meter.
+lgorit!m &ased on valve position 'it! compensation %or variations in inlet
pressure and temperature. ,
in
and /
in
are also used in t!e !eat &alance ......... 7
0ig. 4 >.pass to condenser. ?ecommended installation ............................................. (
0ig. 5 -!en t!e valve is ver. large9 t!e &elo' installation !elps simpli%.ing
maintenance ...................................................................................................... (
0ig. # ,re!eating arrangement utili6ing t!e natural pressure drop in t!e steam pipe .. 31
0ig. 7 ,re!eating arrangement &.passing t!e control valve ........................................ 3
0ig. ( ,re!eating arrangement utili6ing a !ig!er pressure level t!an t!e valve
inlet pressure .................................................................................................... 34
0ig. ) Vertical installation ............................................................................................. 35
0ig. 30 5ori6ontal installation ......................................................................................... 3#


Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

S!stem "esign Considerations
1 General
The steam conditioning valve is an important part of the system. However, also other parts and
parameters in the system can have a significant impact on the performance of the steam
conditioning valve. In the following we have described those factors and also given some
general guidelines on how you can achieve a proper system design.

Contents:
Inlet pipe recommendations
Straight pipe-run upstream recommendations
istance to the first bend
istance to the temperature sensor
istance to flow dividers
istance to pressure sensor
ownstream piping material
!dditional comments
rains
Control system
"ressure control
Temperature control
"reheating arrangement of upstream piping
#i$ points and supports
!ccessibility

#irst rule
$ll steam valves are designed for dr! steam and e%&osing valves for 'et steam
or condensate 'ill damage t(e valve and t(is is not covered b! an! 'arranties.
Vent valves and drains are to ta)e care of &i&e &re*'arming until t(ose
conditions are fulfilled.


Steam Conditioning Valves
Installation
Guidelines

4 II500.00/7en

1.1 Inlet pipe recommendations
Steam conditioning valves re%uire straight pipe-runs both upstream and downstream to
provide good performance.
The reason for having a straight pipe-run upstream is that a pipe bend &elbow' ( fig ) (
creates a flow pattern that is non-uniform. *specially two or more pipe bends in +
dimensions &$, y, ,' ( fig - ( .ust before the steam conditioning valve is /nown to cause
very unstable flow, resulting in vibrations and other flow induced problems. 0e
normally use an inlet strainer that minimi,es the ris/ but the ris/ must be considered.


;
1
<l&o'


#ig. 1 +i&e elbo' u&stream t(e valve

The orientation of the closest pipe bend vs. the valve orientation is also very important.
!n installation such as in figure ) &two dimensional $-y' is far better than an installation
li/e the one shown in figure -.



#ig. , -./ installation 'it( T*&iece

!n installation li/e the one shown in figure - is /nown to create rotational forces in the
valve plug. If a valve for some reason must have a pipe bend oriented as in figure -,
please inform CCI about this before the valve design specification is made.
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

5

! T-piece as shown in figure + is also /nown to cause vibration and other problems, and
should always be avoided. 1pstream S-pipe bends should also be avoided.



#ig. -. installation 'it( T*&iece

If a T-piece is used, a straight pipe length of at least -2 $ 3 pipe should be used before
the valve.



0$12I2G

3ndersi4ed sto& valves 'it( reduced bore u&stream a b!&ass valve are
)no'n to cause noise and vibrations due to (ig( vena contracta
velocities and ununiform velocit! distribution.


1ndersi,ed stop valves also give the bypass valve a nonlinear characteristic due to the
strong influence of the pressure drop on the flow through the stop valve.
Stop valves of this type must be installed as far upstream as is re%uired to provide a
uniform flow pattern. It is the responsibility of the supplier of the stop valve to provide
information about necessary distance.
! stop valve of angle type and a control valve, specially designed, can be assembled as
one unit and be welded together without any distance piece. This is %uite common for
dump to condenser applications.




Steam Conditioning Valves
Installation
Guidelines

# II500.00/7en













#ig. 5 Installation 'it( sto& and control valve 'elded toget(er


1.2 Straight pipe-run upstream recommendations











#ig. 5 Straig(t &i&e runs u&* and do'nstream t(e valve

CCI recommends the upstream straight pipe to be
3 4 -22 mm 5 67 ) m 5+.-6 ft. or longer
3 -22 - 822 mm 5 6 - )97 min : $ 3
3 ; 822 mm &;)97' min + $ 3
If < : $ 3 of the inlet, the elbow can be fitted directly to the valve inlet stud.
If multiple pipe bends are located upstream, the straight pipe length before the valve
must be increased, and that distance must be estimated for each case.



;
1
?
;
3
;

;
4
,I
,/
/<
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

7

The upstream instrumentation should always be a temperature sensor to ma/e sure the
steam is dry before the valve opens. In case any /ind of algorithm is used for the
control, a pressure sensor is re%uired.

1.3 Distance to first bend
!fter the water in.ection, it will ta/e a short while for most of the water drops to evaporate. To
avoid problems with free water hitting the pipe wall, causing erosion and free water following
the pipe wall, it is necessary to have a minimum downstream distance before the first pipe
bend.
To minimi,e this problem, the distance before the first pipe bend should be a minimum of 2.) s
$ ma$imum velocity in the pipe for all valves e$cept =ST-S*, for which we recommend a
minimum distance of 2.2: s $ ma$imum steam velocity, before the first pipe bend. This
because of the internal principle which means proportioning of water into the steam flow.

1..1 "istance to first bend for s&ecial cases
1. High pressure by-pass to cold reheat or equal process application
The distance to the first bend can be reduced to 2.29> s $ ma$imum
velocity if the following conditions are fulfilled:
ownstream pressure ):-92 bar 5 -)> ( 6>2 psi &lower value normally only
occurs during sliding pressure mode or start-up'.
egree of superheat )22?C or higher.
0ater temperature )82?C 5 -68?# or higher.

2. Hot reheat to condenser, HP to condenser or equal process application
The distance to the first bend should in this application be increased to 2.)- s $
ma$imum velocity if the following conditions are fulfilled:
Typically +-9 bar 5 8+-6> psi outlet pressure before dump device at full load.
egree of superheat +2?C or lower
0ater temperature 92?C 5 )82 # or less
0ater to steam ratio ; 2.-:
#eed forward is always recommended for this type of application. See the separate
document @umping into CondenserA.
The figures on the following page show the downstream temperature as a function of
time.




Steam Conditioning Valves
Installation
Guidelines

( II500.00/7en

1.., "um& to condenser 'it( 'et steam before dum& device
0hen the steam5water mi$ture has an enthalpy below saturation, bends are not allowed
at all before the dump device since this leads to separation of steam and water resulting
in ris/s for noise and vibration in downstream piping and worst of all bloc/ing of holes
in the dump device with free water that can cause damages to dump device and inside
condenser.

#or dump to condenser 2.2: s $ Ba$imum velocity is the recommended distance from
water in.ection to condenser wall. The dump device drilling starts normally directly on
the inside of condenser wall.

If the installation does not allow for the re%uired straight distance, both the dump device
and condenser may be damaged.












#ig. 6a "o'nstream tem&erature vs. time in a dum& to condenser
or a similar &rocess a&&lication

This diagram shows the typical temperature downstream of water in.ection of a steam
conditioning valve in a dump to condenser application as a function of time when steam is
minimum )2?C superheated.

0 0905 0910 0915 090 095 0930 0935 @ sA
500
C @ A
400
300
00
1#0
4 &ar
1439#
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

7













#ig. 6b "o'nstream tem&erature vs. time in an 8+ to cold re(eat
or similar &rocess a&&lication

This diagram shows the typical temperature downstream of water in.ection of a steam
conditioning valve in an H" to cold reheat application as a function of time.

1.4 Distance to the temperature sensor
The recommended distance before the temperature sensor is 2.- s $ ma$imum steam
velocity for a ratio ):C of spray water 5 steam flow and 2.+ s $ ma$imum steam
velocity for a ratio ;):C spray water 5 steam flow for all "<S valves e$cept for =ST-
S*. This valve has an integrated steam atomi,ation and water proportional to steam flow
can be installed at a distance of 2.- s $ ma$imum steam velocity.
The values are based on a set-point of appro$. )2?C 5 )6?# above saturation for steam
and D2?C 5 )D8?# for water and a steam pressure bar 5 -6 psi.
Eower degree of superheat gives a longer distance and higher degree of superheat gives
a shorter distance.
*$act time to sensor is normally finali,ed when all parameters are /nown, but the
general rules shall normally be followed.
! higher water temperature reduces the evaporation time and a lower water temperature
increases the re%uired minimum distance to the temperature sensor. #or dump to
condenser, see @ump tube philosophyA, paper no. ")2)2.28en.
1.5.1 9inimum distance to tem&erature sensor
In valves with low outlet velocity & m5s, )22 ft5s', the re%uired distance calculated
as time can be longer than usual and minimum distance to the temperature sensor should
therefore never be shorter than )- m 5 +D ft' for process applications.
1.5., "istance to tem&erature sensor for s&ecial cases
1. High pressure by-pass to cold reheat or equal process application

0 090 0904 090# 090( 0910 091 @sA
500
C @ A
400
5093
40
440
4#0
4(0
3(0
3#0
340

Steam Conditioning Valves
Installation
Guidelines

10 II500.00/7en

The distance to the temperature sensor can be reduced to 2.): s $ ma$imum velocity if
the following conditions are fulfilled:
ownstream pressure ):-92 bar 5 -)> ( 6>2 psi &lower value normally only
occurs during sliding pressure mode or start-up'.
egree of superheat )22?C 5 -)-?# or higher.
0ater temperature )82?C 5 -68?# or higher.

2. Hot reheat to condenser, HP to condenser or equal process application
The distance to the temperature sensor should in this application be minimum 2.+ s $
ma$imum velocity.
Typically +-9 bar 5 8+-6> psi outlet pressure before dump device at full load
egree of superheat +2?C 5 69?# or lower
0ater temperature 92?C 5 )82?# or less
0ater to steam ratio ; 2.-:
#eed forward is always recommended for this type of application. See the separate
document @umping into CondenserA &from the !pplications Handboo/'.
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

11

1.5. 9inimum degree of su&er(eat













#ig. 7 "o'nstream tem&erature vs. time in a dum& to condenser or
similar &rocess a&&lication

!s can be seen from the diagram above, the temperature will decrease very %uic/ly
when water is in.ected and will then decrease slower and slower.
The reason is that the droplets after a very short time after they have been in.ected into
the flow will be e$actly at saturation temperature. The heat transfer mechanism is heat
transfer from the surrounding steam to the droplets with temperature differences as the
driving force. The closer to saturation temperature the slower the process, thus allowing
more time for the droplets to fall out.
This typically begins to be a problem when the degree of superheat is -2-+2? and
become %uite difficult at )2? or lower.
!nother problem associated with this is the effect of one droplet or more hitting the
sensor. If one &or more' droplet hitting the sensor will cause a misreading, which is
unpredictable and even not possible to calculate.
uring transient when the temperature swings around the set-point, this problem can
increase beyond stability and the system will not be possible to control with severe
water fall outs and temperature swings as a result.
0 0905 0910 0915 090 095 0930 0935 @ sA
500
C @ A
400
300
00
1#0
4 &ar
1439#

Steam Conditioning Valves
Installation
Guidelines

1 II500.00/7en

Rules
! protective shield should be used for )2? superheat or less.












#ig. : +rotective s(ield

To avoid misreading, a protective poc/et must be used for :->?C 5 D-))?# superheat to
minimi,e the effect of water hitting the sensor.
Felow :? superheat is not acceptable and no warranties will be given. *$ceptions are,
however, possible in certain cases. Therefore please contact the factory. "roblems li/e
this are always minimi,ed with a valve li/e =ST-S* with built in mechanical water
proportioning. #or less than >?C 5 ))?# special control and e$tra instrumentation often
must be used and the factory must always be contacted in such cases.
#or dump to condenser applications where cold water, typically less than :2?C 5)--?# is
used for desuperheating, the degree of superheat should be at least -2?C 5 96?# since
evaporation time otherwise can be very long. CCI strongly recommend you to avoid
feedbac/ control for dump to condenser applications due to big ris/s for thermal fatigue
damages related to difficulties in control. CCI always recommend feed forward control
for dump to condenser applications.
1.5 Distance to flow dividers
The outlet flow from a valve must never be divided by a T-piece, G-piece or any other
configuration before the outlet temperature can be properly controlled.
1. Distance to pressure sensor
To receive an acceptable and stable signal, it is necessary to have a relatively uniform
velocity gradient. The distance E8 should be at least : $ outlet 3.
1.! Downstream piping material
0e recommend : m 5 )9 ft. of downstream piping in low alloy material when the steam
temperature before cooling is ; 8-:?C 5 622?#. The reason is that the evaporation is not
instant after water in.ection.
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

1

1." #dditional comments
#or a well performing temperature loop it is also very important to consider
<esponse time for the temperature sensor during temperature gradient &T99'.
<esponse and sampling time for the controller 5 CS.
<esponse and sampling time for the actuator.
<esolution and control characteristic of the spray water control valve.
"ipe si,eH large pipes &appro$. diameter 2.6 m5 +-A' downstream of the valve,
particularly with low velocity, very fre%uently have a non-uniform temperature
distribution and should therefore have three temperature sensors installed
perpendicular to the pipe.
=elocity at minimum load. If the minimum steam velocity at the water in.ection
point is below 6 &)- bar' ( )- &8 bar' m 5 s &-9-82 ft 5 s' depending on pipe
si,e, steam-assisted steam conditioning valves &Steam Iet, =ST-S*, =EF-S*'
should be used, unless a dump device is used downstream &see ump Tube
"hilosophy, ")2)2.28en'.
"rotective poc/ets, %uic/ response type should always be used.
Stop valves and particularly drain studs upstream of the valve have
proven to be a cause of high noise and vibrations.
rains must always be si,ed to handle ma$imum fallout caused by transients,
heat losses or minimum +-:C of ma$imum water in.ection.
Temperature sensors in vertical pipes should always be avoided if technically
possible due to the ris/ of water hitting pipe wall which may affect the
measurement correctness.
1.$ Diffusers and plates
iffusers and plates can for certain applications be used downstream of the water
in.ection, but with limited service life. !lways consult the factory for this type of
applications that always re%uire feed forward control without e$ception.
1.1% Drains & 'ent to atmosphere
It is essential to /eep free water out of the steam system. The main sources for free
water are:
Condensate
Spray water that has not evaporated in the steam system.
=ent 5 drain system upstream of the valve is undersi,ed and cannot handle
condensate from the pipe warming when the plant is started from cold. his is
the most common reason !or damage o! "al"es.
2ote; #ree 'ater in t(e steam s!stem causes noise< mec(anical damage and
ma)es tem&erature measurement difficult.


Steam Conditioning Valves
Installation
Guidelines

14 II500.00/7en


The steam conditioning valve performs an important function in the steam system. It is
therefore essential to protect the valve from damage that might occur if water enters the
valve. It is e%ually important to protect the downstream system from damage caused by
a malfunctioning temperature control system &see separate section'. It is, therefore, nec-
essary to have drains both upstream and downstream of the valve.
Ba$imum condensate normally occurs during cold start-up. This must be considered
already at the design stage for si,ing of the drainage system. Condensate volume that
must be removed during start up should of course be calculated each time based on real
data but as an estimation, a mass of typically >-)8 C of the upstream piping weight
need to be removed through the condensate system. There should always be a
temperature sensor to confirm that the upstream piping is dry before the valve is opened
to prevent damages.
The following shows e$amples of drain arrangements for different valve
positions, etc.
2ote; In case of a valve &osition according to fig. 10 and 11< t(e &osition of t(e
drain connection must be e%actl! defined.









#ig. 7 8ori4ontal inlet/vertical outlet


$
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

15

Fl ash tank
To hotwell/condensate
recovery system
From DCS on/off From DCS on/off
CCI
Customer
;1
;
;IC
Y
On when contaminated
condensate
Drain
On when clean
condensate
Drain of l evel
control type

From DCS on/off
Preheat flow
To handle
start up
condensate
removal

anual or on/off
from DCS


#ig. 10 "rain/&re(eat s!stem




Steam Conditioning Valves
Installation
Guidelines

1# II500.00/7en





#ig. 11 "rainage s!stem =">

The main reason for installing a bypass to drain is normally to give e$tra capacity during start
up to get rid of the large volume of condensate formed during start-up with cold piping.
Specially combined cycle plants are difficult since the degree of superheat from H<SJ is very
low at low load of JT. That results in steam reaching saturation after a short travel through the
cold piping.
! recommended location of the drain is -5+ of the distance to the temperature sensor.
Eevel control type drains are recommended for pressure above -2 bar 5 -D2 psi.
isplacement type condensate pumps are recommended for low pressure 4 + bar 5 8+ psi
process lines.

1.11 (ipe pre-warming
Bodern fully machined forged symmetrical valves do not normally need pre-warming but
when the valve is in standby mode, the upstream piping must be preheated to avoid condensate
formation. This small flow, typically :2--22 /g 5 h 5 )+8-:+: lbs5h, should be piped to a steam
consumer as dearator or similar. The connection point can be the same as a drain stud at the
valve body if the valve is installed in a low position and should be in high position point if the
valve is installed higher than the piping. 0ithout this small flow, it is also very difficult to
confirm that steam always is superheated in the valve inlet before the valve is opened.


9anual/motori4ed b!*&ass
for start*u&
Steam tra&
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

17

The inlet steam pipe shall have a drain connection at a low point close to the valve








#ig. 1, Vertical inlet/(ori4ontal outlet








#ig. 1 8ori4ontal inlet/outlet

=alves shall have a drain stud at the bottom of the valve body















#ig. 15 Vertical inlet/(ori4ontal outlet

$

$
$

Steam Conditioning Valves
Installation
Guidelines

1( II500.00/7en



























#ig. 15 8ori4ontal inlet< outlet u&'ards and actuator do'n'ards

2ote? Generall! not
&referred but &ossible
in certain a&&lications
@ &lease contact CCI.
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

17


























#ig. 16 "rain in do'nstream &i&ing @ "ri& leg =L>















#ig. 17 Valve in lo' installation


*in 1 1 / B


Steam Conditioning Valves
Installation
Guidelines

0 II500.00/7en


Eocate the drain &' on the downstream side, at the lowest point a!ter the "al"e. 0eld
a drip leg &E' to the pipe, and connect the drain to the bottom of the drip leg.
The drip leg shall have a diameter of 2.: $ pipe-diameter. The depth of the drip leg shall
be between +22 and 922 mm 5 )-- ft.
If possible, always avoid an installation where the valve outlet is at a low point. If the
drain is undersi,ed or not wor/ing, water can accumulate and cause many serious
problems.



0$12I2G

CCI is onl! res&onsible for &roblems related to t(e eAui&ment included
in t(e CCI sco&e of su&&l!.

The weight of the accumulated water can seriously damage piping and supports.
#ree water at the bottom of the piping can cause very serious vibrations and
pressure transients in the piping.
ownstream temperature sensor can be hit by non-evaporated water causing
severe control problems.
Binimum slope to drain at a low point should never be less than )22:).
0ater hammers.
! simple closed temperature control loop is in most cases too slow for this type
of installation. ! feed forward system is always re%uired to minimi,e the effect
of transients recommended for this installation.
Transient analysis is necessary and must always be performed before designing
the control system.



Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

,1



0$12I2G

T(is t!&e of installation 'it( bend direct to outlet is ver!
dangerous and is t(erefore alwa)s forbidden.

















#ig. 1: Installation 'it( bend 'elded direct to outlet




0$12I2G

T(is t!&e of installation 'ill in most cases not 'or) or cause
severe 'ater fall out

















#ig. 17 B%&ansion 'elded direct to outlet or closer t(an 0.1 s % V
ma%




<1pansion 'elded direct to outlet
or closer t!an 0.1 s 1 V
ma1


Steam Conditioning Valves
Installation
Guidelines

II500.00/7en

B%ce&tion
In certain cases, the design below can be used after written confirmation from the
factory.











#ig. ,0 Installation 'it( an e%&ansion cone in t(e outlet



1.12 *ater valve location

0ater valves are always to be installed below the lowest point of the spray connection and
recommended distance is 8-9 m between water valve and inlet of the connection point is on the
bypass valve.

!ny pressure drop between water valve outlet and connection point on the bypass valve must
always be specified in order to include this pressure drop when si,ing.




0$12I2G

2ot &roviding correct information ma! lead to ca&acit! / control
&roblems for '(ic( CCI cannot ta)e t(e res&onsibilit!.


1.13 *ater piping connection to desuperheater connection

The water pipe routing &isometric' must be done in such a way that the forces originating from
thermal e$pansion are not transferred to the connection point.

2ote; "eviations from t(is &oint must be clearl! stated before ordering< as t(e! can be
critical for t(e design of t(e &roduct


Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

,

1.14 +ontrol s)stem

Steam conditioning valves combine two functions:
Bodulated pressure control
Steam desuperheating within a limited space
The reason for having this combination of functions is that the conditions for accurate
temperature control in a piping system with geometrical limitations by far is superior to
the use of a separate pressure reducing station and a desuperheater.
0hen designing a control system it is important to understand that the steam
conditioning "al"e and the spray water control "al"e are the tools that e$ecute the
actual pressure reduction and the water in.ection for the temperature reduction.
The pressure and temperature controllers give the input to the valve on how much to
open or close. The valves only do what they are told to do, i.e. the pressure and
temperature control loops must operate correctly in order to help the valves achieve
desired pressure and temperature reductions.
#alance in all systems is always ad"isable when designing control systems.
It is always advisable to use a feed forward system to position the water valve to a
predicted correct position during a transient to minimi,e deviations in the water flow.
*$cessive over or under spraying can cause severe problems of thermal cycling, impact
damage, erosion and unstable actuator downstream of the valve.
2ote; $l'a!s o&en t(e steam valve slig(tl! before t(e 'ater valve and close t(e
'ater valve slig(tl! before t(e steam valve. To minimi4e t(e ris)s< it
s(ould be (ard'ired to t(e s!stem so t(at s&ra! 'ater valve s(ould not
be able to o&en before t(e steam valve. 0(en t(e eAui&ment reac(es
minimum s&ecified flo'< t(e steam valve and t(e s&ra! 'ater valve s(all
close simultaneousl! and Auic)l!.
0hen steam atomi,ed no,,les are used in combination with spring-loaded variable area
no,,les two separate water valves must be used. #or steam atomi,ed no,,les a separate
on5off valve is used to supply atomi,ing steam that must be interloc/ed to open only
after the steam valve has opened. 0ater valve associated with steam atomi,ed
desuperheating system must open after atomi,ing steam valve.
<emember that water hammer can destroy all /inds of piping and valves and opening or
closing should therefore never be faster than what the process re%uires. ! spray water
valve may never open %uic/er than a bypass valve.
Ine$actness is normally a by-product of too short actuating times and incorrect "I
settings.


Steam Conditioning Valves
Installation
Guidelines

4 II500.00/7en



0$12I2G

S!stems 'it( lo' degree of su&er(eat< es&eciall! at lo' &ressure<
do often reAuire ent(al&!*based feed for'ard control to be able to
o&erate correctl!.


<ecommended distance to temperature sensors is based on a well tuned "I loop.
The instrumentation is often the wea/est point for e$act control and must also be
discussed with the factory for applications with large pipes, low pressure and high
rangeability.
2ote; "istance to a tem&erature sensor must be enoug( to allo' not onl! for com&lete
eva&oration at stead! state conditions< but also for transients '(en a steam
valve o&ens or closes Auic)l! and t(erefore causes a Auic) c(ange in reAuired
'ater inCection.
1.15 (ressure control
The pressure control system is normally %uite uncomplicated and causes very few
problems. "ressure control is always a closed loop system with feedbac/.

To be considered
=alve stro/e time.
System response time
Start-up condition
Stability, especially in the actuator
Foosters because they can create instability
<esponse on small signal variations
1.1 ,emperature control
! successful temperature control system is a result of several considerations:
! closed loop control system shall be used, only when the downstream
temperature can be accurately measured and used for feedbac/.
egree of superheat. The higher degree of superheat, the easier the control.
! feed forward control system shall be used when accurate temperature
measurements cannot be made. #eed forward systems re%uire more e$act
instruments and also correct flow measurement over the full range especially at
the water side.
2ote; 0it( feed for'ard control s!stem 'e (ere mean t(e control s!stem for t(e
s&ra! 'ater control. It s(all not be mi%ed u& 'it( our descri&tion of
feed for'ard control in ot(er CCI literature< e.g. for steam conditioning
valve t!&e VST =mec(anical lin) bet'een steam and 'ater flo'>.

Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

,5


Temperature measurements must only be made at a location where all in.ected
water has evaporated, and the steam is absolutely dry.
he temperature at the measuring point shall be at least $ C 5 D #
abo"e saturation temperature to guarantee that the steam is dry. This can be
achieved under steady state conditions with very careful instrumentation,
installation and control and must be discussed prior to order.
Turndown re%uirement and capability of steam conditioning and spray water
valves.
!vailable spray water pressure and temperature.
The piping arrangement must allow for re%uired straight run and distance to the
temperature sensor.
"iping arrangement must allow for proper draining in case of malfunction of the
temperature control system.
!n interloc/ shall be used, and the spray water valve will therefore automatically
close if and when the steam conditioning valve closes.
If possible ( a"oid a separate pressure reducing valve upstream of the spray
water valve. If you must use it ( ta/e great care in designing the control system
and consider the response times in different control loops. This often leads to
pressure transients far above specified inlet pressure, resulting in increased
maintenance and wear of the last spray water valve. This is a design that always
should be avoided if possible, since there today are e$cellent water valves that
can ta/e the full pressure drop.
"revent particles in the water from damaging the valve or no,,les by installing a
strainer upstream of the spray water control valve in the spray water supply line.
Spray water valves must always be Class = tight to prevent water from being
collected in the system, thus causing others problems.
2ote; 9a% acce&table &article si4e is 100 * ,00 microns< de&ending on t!&e of
s&ra! 'ater no44le used.

Steam Conditioning Valves
Installation
Guidelines

# II500.00/7en

To achieve good performance the control loop itself must also be analy,ed to find out, within
which e$actness the water flow can be controlled by the complete control loop. The most
important parameters are the following:
Sensor response time
Controller response time and e$actness
"ositioner e$actness
=alve e$actness
=alve characteristic
=alve position e$actness
ead band
Ba$imum transients
!ctuator e$actness and stiffness
This analysis also provides the answer regarding si,ing of the drainage system
downstream of a desuperheater or steam conditioning valve.























#ig. ,1 #eed for'ard control @ e%am&le.

The algorithm is based on the dump device used as a flow meter and a heat
balance using inlet pressure and temperature

,/
//
Steam
Spra. 'ater
,/
$CS
0/
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

,7






#ig. ,, #eedbac) control @ e%am&le





















#ig. , #eed for'ard '(en a dum& device cannot be used as a flo' meter. $lgorit(m based on
valve &osition 'it( com&ensation for variations in inlet &ressure and tem&erature. +
in

and T
in
are also used in t(e (eat balance

,/
//
Steam
Spra. 'ater
$CS
0/
,S


$CS or ,;C 'it! !eat
&alancing a&ilit.

Steam Conditioning Valves
Installation
Guidelines

( II500.00/7en




















#ig. ,5 D!&ass to condenser. 1ecommended installation
























#ig. ,5 0(en t(e valve is ver! large< t(e belo' installation (el&s sim&lif!ing maintenance
Steam Isolation Valve
7Cuic= Closing8
$ump /u&e Condenser
$esuper!eater
$ump /u&e Condenser

Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

,7


1.1! Special for feed forward with dump to condenser

2ote; Dends do'nstream can onl! be used if t(e ent(al&! of t(e mi%ture is at
least 10EC / 1:E# above saturation in t(e inlet of t(e dum& device since all
bends create se&aration bet'een steam and 'ater.

#eed forward control is superior to temperature control since all transients that may damage the
pipe and condenser are avoided. amages to valve outlet, piping, dump device, condenser, etc.
are very rare. *very year there are damages reported where the temperature control is used
especially when there is a long distance &more than -2 m 5 9: ft' between water in.ection to
condenser.

! recommended set point for this application is to have appro$ -2?C 5 +9?# superheat after the
dump tube to avoid the ris/ of having free water after the dump tube. !n enthalpy of -9:2
K.5/g is normally recommended for most applications.

#or this application a water flow meter must be used in the water line for each water valve in
case of more than one water valve. There should also be a pressure sensor upstream and
downstream of the water valve to allow for good estimation of the water flow below the
effective range of the water flow meters. Those pressure sensors can also be used for bac/ up
of the flow meter if it fails and as preventive maintenance measurement since deviations from
calculated values indicate the true cause of the problem before conse%uences as damages etc.
can occur.
1.1" #ctuation
!ctuator type is very important for the performance, especially for a control which re%uires
stable temperature close to saturation since wet steam hitting the temperature sensor during
transients are heavily amplified if the actuator ma/es any overshoot.

*lectrical, hydraulic or double-acting piston actuators with a high performance smart positioner
must be used.

To avoid problems the actuator must be slower than the steam valve as stability is much more
important than speed.


Steam Conditioning Valves
Installation
Guidelines

30 II500.00/7en

1.1$ (reheating arrangement of upstream piping
1pstream piping must be done in such a way that poc/ets of condensate always are
drained away.
2ote; It is absolutel! necessar! in all conditions to (ave su&er(eated steam in
t(e inlet of t(e do'nstream valve.
2ote; $dditional &re(eating of CCI valves is not reAuired.
!rrange for preheating, in those cases when the control valve normally is closed under
operation ( e.g. in a turbine bypass application.
"reheating of the piping upstream of the valve is not necessary when the valve is located
above the live steam line and the pipe slopes down to the main steam line.
0hen the valve has to be installed lower than the live steam header there are a number
of solutions for the preheating arrangement. The main ob.ectives, when selecting the
arrangements are to:
Create an effective system so that the piping will be sufficiently preheated and
drained.
Binimi,e the energy losses due to preheating steam.
#igures )6 ( -2 show a few arrangements that can be used. The piping layout will
determine the preheating arrangement that will be the most effective for a specific
application.
2ote; CCI can give advice on t(e best solutions for different t!&es of &lantsF
suc( as conventional re(eaters< combined c!cle< cogeneration &lants and
ot(ers.
Typical pipe dimensions for the preheating line is in the range of -: to :2 mm 5 ) to -
inches. The preheating line must be e%uipped with an isolation valve, which also can be
used for manual flow control of the steam flow for preheating.
he preheating si%ing is based on&
- Eength of pipe between valve and main line
- t between surface temperature outside the insulation and the environment.
- Indoor or outdoor installation
! heat balance based on this information will provide the necessary preheating flow.

'dditional preheating o! CCI "al"es is not required.

Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

1














#ig. ,6 +re(eating arrangement utili4ing t(e natural &ressure dro& in t(e steam &i&e

The method above is the most energy effective, but it also re%uires a suitable system
design.
0hen the steam flows from &)' to &-' there will be a pressure drop p in the line. 0ith
proper si,ing of the preheater piping, &)' to &+' it is possible to have a sufficiently large
flow to /eep the piping &+' to &-' free of water. (arning) Required pressure drop is
o!ten practically di!!icult to achie"e and requires o!ten both a big pre-warming
pipe and restriction in the main line. Reasonable pressure drop is *.2-*.$ bar.
























,re!eati ng %lo'
,re!eating line
Steam condition valve
>.pass line
*ain steam line
1
,

+
>
!ypass line
Preheatin" flow

Steam Conditioning Valves
Installation
Guidelines

3 II500.00/7en

#ig. ,7a/,/ +re(eating arrangement b!&assing t(e control valve






#ig. ,7b +re(eating arrangement b!&assing t(e control valve












+
>
!ypass line
Preheatin" flow
TIC TT
PT To DCS
Set from
DCS
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

!ypass
line
Preheatin" flow
TIC TT
PT To DCS
Set from
DCS
in #$% m
>
+



#ig. ,7c +re(eating arrangement b!&assing t(e control valve


The method shown in fig. -> is the easiest and most common way of preheating upstream
piping &valve'. Here you simply connect the inlet with the outlet and use a restriction to limit
the steam flow.
The steam flow used for preheating shall be moderated according to re%uired pipe 5 valve
temperature, to reduce energy loss. In most cases normal Apreheating flow is :2--22 /g5h 5
)+8-:+: lb5h.
This preheating with connecting inlet to outlet can cause very high temperature downstream
and special springs made of Limonic or similar must be used. The factory must also be
informed prior to manufacturing if this method is used. Lormally the downstream connecting
point must be used after the valve to prevent hotspots that may cause deformation of the valve
outlet.


Steam Conditioning Valves
Installation
Guidelines

34 II500.00/7en

























#ig. ,: +re(eating arrangement utili4ing a (ig(er &ressure level
t(an t(e valve inlet &ressure


The solution shown in above figure is energy effective but can sometimes re%uire a long
preheating line.

,re!eati ng %lo'
,re!eati ng line
>.pass line
*ain steam line
5ot re!eat line

Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

5

, #i% &oints and su&&orts
The piping system must be so designed that the valve&s' will not be used as a fi$ point.
Supports are often re%uired for au$iliary e%uipment and valves, and must be properly
designed. See figs. below for e$amples.























#ig. ,7 Vertical installation




Steam
Inlet
$ump
/u&e
$uct
Crane
%or l i%ting
Do66le
;
1
;

,lat%orm


Steam Conditioning Valves
Installation
Guidelines

3# II500.00/7en

















Inlet pipe !rom abo"e Inlet pipe !rom below














Inlet pipe !rom below Inlet pipe !rom abo"e

#ig. 0 8ori4ontal installation


Spring
!anger

Spring
!anger

Vi&ration
a&sor&er
Sliding
support

Sliding
support
Vi&ration
a&sor&er
Installation
Guidelines
Steam Conditioning Valves

II500.00/7en

7


2.1 !ctuators with springs must always supported due to the weight to avoid e$cessive
forces on yo/e and mounting details. *specially when the actuator is mounted
hori,ontally this must be considered and spring hangers are always recommended.

Steam Conditioning Valves
Installation
Guidelines

3( II500.00/7en

3 #ccessibilit)
Space must be provided for service and maintenance of the valve. If the valve is
installed in a pipe rac/ or any other location which is difficult to reach, you need to
provide a platform around the valve as well as a safe route to it. The platform shall be
sufficiently large to accept a minimum of two persons and temporary storage of valve
internals.

2ote; Consider also trans&ortation of (eav! s&are &arts.
! brac/et or other arrangement for a lifting device shall also be available. The capacity
shall be at least : tonnes.
To facilitate maintenance within scheduled time, lifting e%uipment as well as a wor/ing
platform must be provided.
"lanning for future maintenance is a very good investment and should always be ta/en
into consideration.





















CCI reserves the right to ma/e technical improvements.