CCI DRAG DA-90DSV Attemperator

DA-90DSV Attemperator application discussion

1100

50

1000

40

Minimizes Leakage Handles High Thermal Stresses Enhances Controllability 800 Prevents Cavitation Damage
700 50 Meets Common Face-to-face Dimensions 900

With each new operating season, the limits of inter-stage attemperators in Heat Recovery Steam Generators (HRSGs) are being tested. As plants search for the most economical operation, be it cycling daily or operating at reduced loads for extended hours, reliability and operability of the
20 superheat (SH) and reheat (RH) inter-stage attemperators consistently 30

come into question. Whether it is a constantly leaking attemperator that must be repaired or replaced every outage, or a more catastrophic 10 failure like a boiler tube leak or a ruptured steam line, the headaches and frustrations associated with inter-stage attemperation are becoming all
15 20 25 30 0 too familiar to plant managers, operators, and maintenance personnel.

Lowers Maintenance 0 5

600

40 Costs 10

Time, minutes Reduces Erosion Damage30

Spraywater flow, kpph

Economizer Boiler

Final steam

Flash Vessel

Spraywater flow
Steam Generator

Spraywater flow, kpph

Temperature, deg F

From HP Turbine Exhaust

Reheater Superheater Spraywater DA-90 DSV SH-Interstage Attemperator Reheater Superheater

Spraywater

10

0 10 15 20 25 30

DA-90DSV RH-Interstage Attemperator IP/LP Turbine HP Turbine

Time, minutes
SH2 inlet Final steam Spraywater flow

HRSG

Figure 1: Typical HRSG schematic

Symptoms of Faulty Attemperators

CCI DRAG DA-90DSV Attemperator

Some of the first signs of trouble start with uncontrolled spraywater flow and leakage. Scheduled inspections often reveal: n Damaged spray nozzles n Cracked attemperator housings n Damaged seals n Cracked steam pipes and boiler tubes n Cracked/broken thermal liner The root cause of most inter-stage attemperator problems can be traced to four main system/installation parameters: n High pressure drop through the spraywater control portion of the attemperator n High thermal stresses caused by large temperature differences between the steam and the cooling water
Figure 2: Illustrations of damage due to thermal cycling, often caused by poor attemperator performance
50

n Poor atomization of the cooling water leading to large amounts of unevaporated water in the steam line n Poor installation with short distances to downstream elbows, temperature sensors, or HRSG reentry points

40

30

flow, kpph

DRAG DA-90DSV Attemperator

Faulty Attemperator Design Many of the common interstage attemperator systems overlook several or all of the root causes of failure listed on the previous page. Such designs will lead to problems in your plant, its only a matter of time! Consider the following: Single Stage Pressure Drop Problem When using fixed speed pumps, the pressure drop in some inter-stage attemperator spraywater systems can reach levels greater than 2000 psi (133 bar). This high pressure drop will severely damage and prematurely wear a single stage control element causing wire draw, leakage, and cavitation damage (See Figure 3). The key to eliminating this root cause of failure is to incorporate multiple stages of pressure drop in a control valve trim. CCIs DRAG Velocity Control Trim can easily package up to 20 stages of pressure drop in attemperator systems to handle the large pressure drop of the spraywater system. Valve Trim in the Steam Flow Problem As allowable operating temperatures increase, inter-stage attemperators can see steam to spraywater temperature differences near 700F (390C). This high temperature difference in conventional attemperator designs will lead to high thermal stresses. An attemperator design, such as the one shown in Figure 4, that locates tight clearance control elements (i.e. valve trim) in an environment that sees these drastic temperature swings will fail. Common failures such as cracked attemperator bodies, cracked attemperator welds, cracked attemperator nozzles, stuck or seized plug and stem elements, and even packing leaks can all be attributed to a design that neglects to account for the high temperature difference in this application. To avoid these problems, location is the key. Tight clearance valve trim components should be moved out of the steam pipe and away from the hot steam temperatures. Pressure Boundary and Tack Welds Problem Due to the nature of the application and the operation of todays HRSGs, interstage attemperators will always be exposed to thermal cycling. Welds, and the heat affected zones around them, are vulnerable to cracking when put through thermal cycles while also being exposed to high pressure loads and bending stresses. A properly designed interstage attemperator eliminates all welds by using a one-piece Chrome Moly forging, thus removing the risk of cracking in the attemperator body. Solution Use multiple stages of pressure drop in a DRAG Velocity Control Trim Move the valve trim to a safer environment outside of the steam pipe and away from harsh thermal stresses Eliminate all welds by using a one-piece Chrome Moly forging

Figure 3: Cavitation damage on plug

CCI DRAG DA-90DSV Attemperator

Figure 4: Section view of a conventional attemperator design

Problems High pressure drop in a single stage Expose attemperator to high thermal stresses by locating trim components in the hot steam pipe Use pressure boundary welds and tack welds

DRAG DA-90DSV Attemperator features

Multi-stage DRAG Disk Stack Technologies Limits fluid velocities, controls vibration and erosion. Multiple Cv disks throughout disk stack allow for characterized design with optimum control throughout all operating conditions Stem Packing Graphite packing is standard for high temperature service

Class V Shut-off A metal seat is standard, with a 500 PLI (9 kg/mm) loading force to achieve tight shut-off

Water Inlet

Disk Stack Labyrinth Grooves This section of the disk stack has no flow passages; in their place labyrinth grooves break up clearance flow, preventing seat ring damage

Customer Connections

CCI DRAG DA-90DSV Attemperator

Benefits

DRAG DA-90DSV

Competition

n n n

Provides the Valve Doctor Solution. CCI works with plant operators to improve plant performance, reliability and output. Prevents Cavitation Damage. CCI works in accordance with ISA guidelines to ensure cavitation is avoided. Eliminates Erosion Damage. By controlling fluid velocities, erosion is eliminated.

Use check list to evaluate the benefits of CCIs DRAG DA-90DSV Attemperator

Forged Design A fully forged one-piece Chrome Moly design eliminates the need for welding, and eliminates the risk of welds failing due to the high thermal cycling and stress of the surrounding environment

Spray Nozzle The variable orifice spray nozzle used in the DA-90DSV provides excellent primary atomization and high rangeability. The design is proven through decades of installation in high temperature steam applications. Multiple nozzle designs (as pictured) are available for high capacity installations

Tapered Profile The attemperator is designed with a tapered profile to minimize any vibrations caused by harmonic frequencies associated with vortex shedding. This becomes especially important as pipe sizes increase and the length of the attemperator increases Low Flow

No Trim in Steam Flow Many probe designs place valve trims in the steam flow, exposing them to high steam temperatures and very large thermal stresses. The DA-90DSV moves all tight clearance trim components out of the steam flow and out of the harmful thermal environment High Flow

CCI DRAG DA-90DSV Attemperator

Benefits

DRAG DA-90DSV

Competition

n n n n

Thermal Stress Analysis. CCI accounts for all thermal stresses in the attemperator design. Stops Costly Maintenance Cycles. CCI valves are designed and sized to provide longer intervals between maintenance and allow easy access to all components. Eliminate Thermal Damage to the Trim. Control element is located outside of the hot steam flow. Proven Desuperheating Experience.

DA-90DSV Attemperator Solutions

Multiple Inlet Flow Channels

Eliminate Cavitation with DRAG DRAG trim forces the fluid to travel through a torturous path of turns (Figure 5). Each turn causes a pressure loss in the fluid, and the pressure gradually reduces as the fluid flows through the multiple turns. This series of multiple pressure drops controls the fluid velocity and allows the pressure to reduce without falling below the vapor pressure, thus avoiding cavitation and the destruction to the valve and trim that can come with it. The DRAG multistage pressure drop trim provides a clear benefit in terms of performance and maintenance costs when cavitation is a concern. Accurate Control and Reliable Operation at all Flow Conditions with the CCI DRAG Disk Stack DRAG disk stacks can be customized to provide the required Cv throughout the valve stroke. This is accomplished by configuring disks with various numbers of turns within the stack (Figure 6). Thus, the DRAG control valve disk stack can be designed for many different flow characteristics, i.e. linear, equal percentage, or modified equal percentage (Figure 6). The disks at the bottom of the disk stack, close to the valve seat, are equipped with a higher number of pressure letdown stages (up to 20 stages or more) to provide critical protection of the seating surfaces on the plug and seat ring. As the valve strokes open, fewer pressure letdown stages are used for more capacity as the process requires, providing good control over the entire range of flow conditions. Independent and isolated flow paths are used to eliminate short circuits between flow paths and provide the best result in pressure letdown. Reliable Long Term Shutoff

Pressure Equalizing Ring (PER) Grooves

Figure 5: Each turn in the DRAG trim is a single stage of pressure drop, eliminating potentially harmful kinetic energy

CCI DRAG DA-90DSV Attemperator

% Flow
100 90 80 70 60 50 40 30 20 10 0 0 10

Linear Modified Linear Modified Equal %

The DRAG control valve uses a hard seat material and a very high seat loading to provide reliable and repeatable long term shutoff in very high pressure differential applications. The actuator is sized to provide a minimum seating load of 500 lb/in (9 kg/mm) of seat ring circumference, as recommended by ISA guidelines. The DRAG velocity control trim design, combined with the high seating force for shut-off, protects the seating surfaces from cutting and pitting due to erosion or wire draw. Benefits of DRAG Velocity Control Trim n n

Prevents Cavitation Damage Improves Plant Performance Eliminates Erosion Damage Lowers Operating Costs Reduces Maintenance Costs Reduces System Complexity Avoids Plant Shutdowns Provides Accurate Temperature Control

% Stroke

Figure 6: Characterized Equal Percentage DRAG disk stack trim

n n n n n n

Technical Specifications

6 (153mm) MIN
10 8 9 5
MIN BORE, D

4 3 1 7 6 5
11 12

HEIGHT

No 1 2 3
WATER INLET B

Name Body Bonnet Spindle Guide Bushing Gaskets Seat Disk Stack Packing, Stem Packing, Spacer Yoke Nozzle Housing Spray Nozzle

Material ASME-SA217-WC9/C12A ASME-SA182-F22/F91 INCONEL 718 300 SS Graphite/300 SS 300 SS INCONEL 718 Graphite Carbon Carbon Steel ASME-SA182-F22/F91 ANSI 616

4 5 6 7 8 Length
(see note 3 & 6)

STEAM CONNECTION

Nom. Pipe Dia. 10-14(250-350) 16-20(400-500) >20 (>500)

9 10 11 12

14.12(358.6) 17.75(450.8) 21.25 (539.8)

CCI DRAG DA-90DSV Attemperator

Trim Size

Water Flange 1.5 RF (40) 2.5 RF (65)

Steam Flange 3.0 RF (80) 4.0 RF (100)

ANSI 600-1500 2500 600-2500

A 9.0 (229) 9.5 (241) 12.25 (311.2)

B 6.0 (152) 7.0 (178) 12.25 (276.4)

Dia. D(4) 2.9 (73.7) 3.81 (96.8)

Height (2)

Weight

3/8 5/8 1 , , (10, 15, 25) 1.5 (40)

19.7 (500)

34 (865) 51 (1295)

~300 lbs (140 kg) ~500 lbs (230 kg)

Notes: 1. Contact factory for other sizes 2. Given is maximum; add 15 (380 mm) for manual override 3. Customer flange height will vary to center nozzle(s) in steam pipe 4. Customer supplied flanged connection 5. Numbers in brackets give dimensions in millimeters 6. Custom probe lengths available for retrofit projects

Throughout the world, companies rely on CCI to solve their severe service control valve problems. CCI has provided custom solutions for these and other industry applications for nearly half a century.
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DRAG is a registered trademark of CCI. 2007 CCI 880 05/11/07