1R.E. Mason Confidential and Proprietary/For internal use only

A Practical Approach To Understanding Steam Systems

Day 4 – Control Valve & Steam Conditioning Applications & Isolation Valve

Applications

Emerson Steam

University

Virtual Series

2

Ticks are small arachnids that bite to fasten themselves onto the skin and feed on blood.

Tick Related Diseases:

• Lyme disease

• Rocky Mountain spotted fever

• Tularemia

• Relapsing fever

• Colorado tick fever

Tick Bite Prevention

• Avoid areas where there is a lot of vegetation or animals that can carry

• Wear clothes and gloves that cover as much skin as possible

• Use bug repellant that protects against ticks

• Check for ticks periodically on your clothes and on your skin

If You Find a Tick on You:

• It is important to remove the tick as quickly as possible

• Use fine tip tweezers to remove the tick

• Make sure the head of the tick is removed with the body

• Save the tick in a zip lock bag or container in case it needs identified later on if disease occurs

Safety

Moment:

Tick Safety

Emerson Steam University Virtual Series

33

• Today’s webinar is scheduled to last 1.25 hrs including Q&A

• All participants will be muted to enable the speakers to

present without interruption

• Questions can be submitted via the GoToWebinar Questions

Panel at any time

• Slides will be emailed 72 hours after the last session in this

series has concluded

– Wednesday, June 2

• Complete polls & surveys to mark attendance for PDH

credits.

– Total PDH credits for today’s session: 1.25 (Live Session ONLY)

• Tell us how we did by completing the survey

– The survey will launch after this sessionEmerson Steam University Virtual Series

Housekeeping

44

Day Topic Length Presenter & Facilitator

1 Introduction to Steam Systems 1 HRKyle Richard

Rick Vance

2 Steam Trap Fundamentals and Testing 1 HRRick Vance

Brett Easterling

3

Pressure Relief for Steam Generation 1 HRDean Barnes

Carl Sitler

Pressure Reduction Applications 30 MINJeff Welch

Carl Sitler

4

Control Valve & Steam Conditioning Applications 30 MINBrad Emry

Kyle Richard

Isolation Valve Applications 30 MINLeif Rickles

Kyle Richard

5

Boiler Feedwater 30 MIN

Tim Dwyer

Rick VanceBoiler Level Monitoring 20 MIN

ARC Valve 10 MIN

Agenda At-A-Glance

55

Session Agenda

1 Control Valve & Steam Conditioning Applications Brad Emry

2 Break

3 Isolation Valve Applications Leif Rickles

4 Q&A

Emerson Steam University Virtual Series

6Emerson Steam University Virtual Series

Speaker

Image

Brad EmryAccount Manager

R.E. Mason

Meet Our

Experts

Brad is an Account Manager for the R.E.

Mason and is based in Charleston, SC. He

has a B.S. in Chemical Engineering from the

University of Nebraska.

Brad worked in applications engineering and

marketing roles for Fisher Controls in

Marshalltown for eight years prior to joining

REM in 1992. In addition to account

responsibilities, he supports the REM Act-

Smart® products and is one of R.E. Mason’s

FIELDVUE Champions.

brad.emry@remason.com

https://www.linkedin.com/in/brad-

emry-836077208/

Valve Applications

in Steam Systems

Brad EmryR.E. Mason

Where Do You Use

Steam?

9

Overview of Steam Applications

• Process Industries

–Pulp & Paper

–Petrochemical, Chemical

–Food & Beverage

–Oil & Gas

• Steam uses vary

–Product Preparation

–Process Heat, Dryers

–Cleaning

–Product Evaporation

Most process plants also have a small power house

10

Steam Applications in Process Industries

• Chemical

– Steam Stripping

• Facilitates separation of components and

pulls unwanted contaminants from a

process fluid

– Fractionation Column

• Carries more volatile products up the tower

to rectifying section

– Pressure Regulation

• Control the partial pressure of a reaction;

increase pressure causing shift reaction

– Vacuum

• Steam ejectors utilized to produce a

vacuum

11

Steam Applications in Process Industries

• Pulp & Paper

– Used to heat the cylinders or air needed for drying paper

– Used to improve the pulping process efficiency and fiber quality

– Must be close to saturation for efficient heat transfer

• Food & Beverage

– Breweries

• Used as a heating media to boil the beer wort

– Sugar Mills

• Used to transform concentrate to liquid via evaporation and provide heat for crystallization

– Used in other food industry applications as a heat source and cleaning media

– Must be close to saturation for efficient heat transfer

12

Steam System Overview

Control Valves:

What Do They Do?

How Do They Get

Specified?

14

What Does a Control Valve Do?

• Simply put – a control valve regulates the area available for flow.

• The area available for flow is expressed as the Cv of the valve –

which is known each valve size and trim combination.

• Geometry around the area available for flow impacts the

efficiency of the flow area at passing fluids depending on phase,

specific gravity, viscosity and other sizing parameters.

15

Typical Cv Information Table

16

Control Valve Components

• Valve Body Assembly

– Pressure retaining shell & packing

– Variable area restriction components

17

Vee-ball Valve

18

Control Valve Components

• Actuator

– Force to move and modulate

valve restriction

– Resistance to process forces

– Provides “fail” condition for loss

of signal / air

19

Control Valve Components

• Positioner (electro-pneumatic)

– Receives analog or digital control signal. Manipulates

air pressure to actuator to position valve from 0-100%

travel.

20

Liquid Applications-Good Control

Cavitation

-Flashing

-Shutoff

Steam-Temperature Control

-Pressure Control

-Noise

-Shutoff

Valve Applications:

What Could Go Wrong?

23

Cavitation & Flashing Potential

P1

P1

P2

PV

PVC

FluidPressure,psia

Upstream Downstream

P2

Cavitation

Process

Recovery

If the pressure drops below the fluid vapor pressure (Pv), then there will be

vapor formation. As the pressure recovers to the outlet pressure (P2), if that

is above the vapor pressure, the vapor will change phase to liquid again,

resulting in cavitation. This is a violent reaction that sounds similar to flowing

rocks through a pipe.

24

Cavitation Potential

P1

P1

P2

PV

PVCUpstream Downstream

P2

Cavitation

Process

Recovery

25

Cavitation Protection Technology

Pressure Staging

• Expanding flow areas stage the pressure drop

• Prevents P2 from falling below the vapor

pressure

Fisher Cavitrol III

trim

Fisher DST trim

26

Other Cavitation and Noise Solutions

For applications that experience cavitation and noise, but with pressure drops that

are not too high, we also offer rotary solutions that will mitigate these two

problems.

NPS 4 and 6: <250 psid

NPS 8, 10, and 12: <200

psid

• Cavitation protection

depends on size and

rotation

• 10 dBa noise reduction

27

Other Noise Solutions

• But how loud is 85dBA? Generally speaking:

• 30dB – Whisper Quite Library at 6’

• 65dB – Normal Conversation at 3’

• 80dB – Telephone Dial Tone

• 85dB – City Traffic (Inside Car)

• 90dB – Train Whistle at 500’

• 95dB – Jackhammer at 50’

• 100 dB – Motorcycle

• 110dB – Power Saw at 3’

Potential Solutions:• Source Solution

• Point Solution

• Piping Modifications

• Insulation

• Burying the Pipe!?!?!

28

Other Noise Solutions

Break up flow to lower noise

29Emerson Confidential 29

Tight Shutoff in Control Valves

Tight shutoff can be crucial to your critical service valves

ANSI Shutoff Classes: II, III, IV, V, & VI

Control Valve

Applications

31

Boiler Feedwater Startup Valve

Boiler Feedwater Regulator Valve

Application

ChallengeSolution

CavitationAnti-cavitation

Trim

Possible

Particulate

Trim to Pass

Particulate

Tight Shutoff CL V Shutoff Trim

High Rangeability Characterized Trim

PurposeProvide smooth transition from startup to

full load operation

32

Boiler Feed Pump Recirculation Valve

Fisher Cavitrol IV

PurposeProtect feed pump by ensuring adequate

flow is passing through the pump at all times

Typical Selection

High pressure globe or angle valve

with trim to prevent cavitation.

Challenge Solution

Extreme

Cavitation

Anti-cavitation

Trim

Possible

Particulate

Trim to Pass

Particulate

33

Condensate Pump Recirculation Valve

Purpose - Protect pumps from overheating and prevent cavitation

Challenge Solution

Moderate CavitationAnti-cavitation Trim

(2-stage)

Possible ParticulateTrim to Pass

Particulate

Tight Shutoff CL V Shutoff Trim

Typical SelectionGlobe valve to meet pressure class requirement with

Cavitrol III, 2-stage trim or DST trim with bore seal to

maintain tight shutoff

34

Deaerator Level Control Valve

Challenge Solution

Moderate Cavitation Anti-cavitation Trim

Possible Particulate Trim to Pass

Particulate

High Rangeability Characterize Trim

Purpose

Maintain consistent deaerator level to

enable the deaerator to perform properly. The

DA provides suction for the BFP’S

Globe valve to meet pressure class requirement with

Cavitrol III trim or DST trim to prevent cavitation.

These trims can be characterized to meet flow

requirements.

35

Steam Pressure Reducing Control Valve

Challenge Solution

High Temperature High Temp Trim &

Packing

Possible Noise Noise Trim

Avoid Cycling Digital Positioner

Purpose

Maintain consistent downstream steam

pressure in spite of changing pressure

demands for steam usage.

Globe valve to meet pressure class requirement with

Whisper trim to prevent noise generation. These trims

can be characterized to meet flow requirements.

Desuperheating

and Steam

Conditioning

37

Why Desuperheat: Unintentional Superheat

Unintentional Superheat Decreases the Heat Transfer

Efficiency of the Steam

38

Desuperheating and Steam Conditioning

• Used to accurately control steam temperature by introducing small quantities of water

– Protect downstream equipment from

thermal fatigue and premature failure over

time.

– Installed upstream of the turbine to ensure

the turbine’s design temperature

limitations are not exceeded (SH Sprays)

– Typical applications include inter-stage

attemperation (high pressure, reheat), final

stage attemperation, terminal reheat steam

Desuperheating

39

Desuperheating and Steam Conditioning

• Uses an upstream pressure reduction valve and downstream desuperheater in conjunction for accurate control of both downstream pressures and temperatures

–Typical applications are:• High Pressure, Hot Reheat and Low Pressure Turbine Bypass

• Condenser Dump

• Steam Letdown

DesuperheatingSteam Conditioning

40

Desuperheating and Steam Conditioning

DesuperheatingSteam Conditioning

41

Challenges in Steam Conditioning Applications

• Optimum Temperature Control–Minimize straight pipe length (SPL) & temperature sensor

length (TSL) without water fallout• Tight Shutoff Requirements

–Class V shutoff capabilities to ensure optimum seat life–Fast stroke speeds & precise control

• Rapid Thermal Cycling–Trim designed to prevent sticking, premature wear, and

fatigue• Easy plant startup, commissioning & maintenance

–Remove particulate from pipe, properly set up equipment, and trim is properly stored until needed

42Emerson Steam University Virtual Series

Key

Takeaways

1Steam System Control Valve

Applications Vary – Use Good

Engineering to Size & Select.

2Control Valves Can Impact

Quality and Cost of

Production.

3 Steam for Indirect Heat

Exchange Needs to be Near

Saturation Temperature.

Emerson Steam University Virtual Series

QuizPlease take a moment to answer

the question about to pop up on

your screen.

Reminder: This also serves as

an attendance requirement for

PDH credits.

Emerson Steam University Virtual Series

Thank you.

Questions?Reminder: Questions can be submitted via the GoToWebinarQuestions Panel

remason.com

brad.emry@remason.com

https://www.linkedin.com/in/brad-emry-

836077208/

4545

Session Agenda

1 Control Valve & Steam Conditioning Applications Brad Emry

2 Break

3 Isolation Valve Applications Leif Rickles

4 Q&A

Emerson Steam University Virtual Series