ISSUE NUMBER 1
SPRING 1992
N
DRAG Meets
Feedpump
Recirculation
Demands
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Page 2
Pressurized
Seat Trim
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Page 2
E
W
S
Turbine Bypass
System
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Page 3
Nuclear Renewals
Approved
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Page 6
Special Materials
Compose Oil
Platform Valves
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Page 4
Adviser
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Page 7
VBJ Actuator
Exchange
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Page 5
Retrofits Solve Tough
installation and related piping changes.
CCI’s successful record of retrofitting includes
Valve Problems
more than 70 recently
completed valve retrofits
If the control valves in your facility are performing below
expectation – experiencing poor flow controllability, vibration,
in nuclear and fossil
control deficiencies or seat leakage – the high price you may be
power, and non-power
paying for maintenance isn’t the only expense consuming your
applications in facilities
budget. For example, seat leakage can erode valve trim, as well
throughout the world.
as result in costly energy loss to your operation. In plants where
For more information
other major control valve suppliers have tried unsuccessfully to
on CCI’s retrofit
provide relief, Control Components has implemented long-
capabilities, or for a
term solutions through retrofit. Using cutting-edge technology
retrofit suitability
and 30 years’ engineering experience in the design and
analysis of your valves,
manufacture of severe service control valves, CCI’s velocity
contact CCI’s Inside
control DRAG® trim is packaged into other manufacturers’ cage-
Sales Department,
guided control valve bodies. During this simple maintenance
or your local sales
procedure the body remains in line while the valve’s original
representative.
trim is removed and replaced. Performance is improved
Before
immediately, without the expense associated with new valve
1
After
DRAG Meets Feedpump
Recirculation Demands
In a boiler feedpump recirculation application the
Pressurized Seat Trim
In boiler feedpump recirculation applications
differential pressures across the valve in both the
where the differential pressures are extremely
closed and open positions are almost equal to the full
high, CCI recommends and supplies a
discharge pressure capabilities of the feedpump: many
pressurized seat trim. This trim combines
at 4000psi(28Kg/cm2). The valve must reduce the high
precise engineering and quality manufacturing
feedpump pressure to the low downstream pressure
to provide superior, block valve type shut off
without generating excessive velocities that would
(better than Class V) as required by the
create destructive cavitation or highly erosive flashing.
application without the need for a large actuator.
The valve must also have a tight shut off, and
maintain this shut off over a long period of time to
CCI’s pressurized seat trim effectively uses
prevent rapid seat and plug erosion failure through
upstream pressure applied to the top of the plug
leakage. Should the valve leak, even the smallest
to increase the seating load of the valve. The
amount of flashing water would cut the setting surface
inlet pressure is allowed to pressurize the
and in a short time the shut-off capability of the valve
bonnet cavity through a controlled bypass path
is lost. Excessive leakage reduces the efficiency of the
while the valve is in the closed position. When
plant through direct energy losses and because of loss
the valve must be opened, a pilot
of capacity to the boiler. In some cases, entire power
plug is opened by the actuator
plants have shut down because of a single leaking valve.
and the bonnet cavity pressure
Through velocity control with CCI’s custom-
drops to the downstream
designed trim, and in-house and on-site plant
pressure so that the main
testing, DRAG valves have been developed that:
plug can be moved.
•
Achieve the highest reliability in critical service
for improved availability of the plant.
•
Provide excellent shut off (equal to block
valves) to improve the plant’s heat rates by
eliminating leakage through the valve.
•
Eliminate cavitation, noise and vibration during
throttling to give longer trim life and lower
maintenance costs.
•
Allow for ease of maintenance when required.
CCI’s pressurized
seat recirculation
valve design.
Trim is not screwed into the body and special
tools are not required.
2
Turbine Bypass System
Canadian Power Station To Use DRAG-Based Systems
These valves are equipped with CCI pneumatic
piston operators that meet Class V shut-off
requirements and have a quick opening stroke speed
of less than one second.
HP System
Earlier this year, Control
Components was awarded the
design and manufacture of
6” x 12” (150mm x 300mm) DRAG Pressure-reducing Valve
3” x 3” (75mm x 75mm) DRAG Spray Water Valve
12” (300mm) Desuperheater
high pressure (HP) and low
pressure (LP) turbine bypass
LP System
systems for Nova Scotia
16” x 18” (400mm x 450mm) DRAG Pressure-reducing Valve
Power’s new Point Aconi
4” x 4” (100mm x 100mm) DRAG Spray Water Valve
Station Unit 1 in Nova Scotia,
18” (450mm) Desuperheater
Canada. The 160MW coal-fired
➣
facility is equipped with a drum
DRAG pressurized
seat turbine bypass
This project uses a separate steam pressure-
boiler with a fluidized bed.
reducing DRAG valve for the desuperheater to
The HP bypass system
avoid problems that occur in traditional steam
features one pressure
conditioning valves. Desuperheating in the
controlled HP bypass valve
bypass valve can limit the valve’s ability to
which directs excess steam into the cold reheat line.
achieve the correct pressure drop, resulting in
When main steam is bypassed to the cold reheat
thermal stress caused by water injection, and
line, it is desuperheated by spraying water supplied
possible body cracking.
by the boiler feedpump through the spray water
The desuperheater element, independent
downstream, employs special spray nozzles to atomize
valve in a temperature controlled mode.
The LP bypass system controls the hot reheat steam
the water into fine droplets for quicker evaporation
pressure by opening the LP bypass valve in the event of
and cooling of the steam. The no-maintenance
a pressure increase, directing the excess hot reheat
design consists of three basic components: the body,
steam into the condenser after it has been
spray shield and nozzle assembly.
desuperheated with spray water. The LP desuperheating
All valves are custom-designed and engineered to
spraywater is supplied by the boiler feedpump and is
support the plant’s specific needs with regard to inlet
controlled by the LP bypass desuperheating valve in a
pressure and temperature, and required outlet
temperature controlled mode. At low load, hot reheat
pressure and temperature. Pressure-reducing DRAG
pressure is controlled at a constant minimum value;
trim is used in the main bypass valves to prevent
the set point can be adjusted for unit start-up operation.
high fluid velocities, which, uncontrolled, can result
Scope of supply for each system includes a
pressure-reducing bypass valve, spray water injection
in erosion, mechanical vibration and noise.
A similar system installed in Suralaya, Indonesia,
has performed without problems since 1984.
control valve and desuperheater.
3
Special Materials Compose
Oil Platform Valves
The corrosive nature of the fluids being handled,
combined with exposure to ocean elements, dictated
“CCI will deliver
defect-free
that the valves be constructed of corrosion-resistant
products and
Super Austenitic Stainless Steel (254 SMO). When
services on time
noise severe duty valves for Woodside offshore
processed through a procedure called Hot Isostatic
to our customers’
Petroleum’s Goodwyn “A” Platform being constructed
Pressing (HIP), a workable material was produced
for the North West Shelf Project in Australia.
combining the best features of a forging and casting.
Control Components recently shipped several low
DRAG technology was chosen for this project to
requirements,
with an emphasis
on prevention
Valve bodies constructed using the HIP process have
methods and the
control noise, without the use of diffusers or
the uniform grain microstructure of a forging and the
attitude of doing it
downstream pressure-breakdown orifices, and to
pre-formed shape of a casting, which lessens the
right the first time.”
keep equipment weight to a minimum.
extent of machining required.
DRAG 6” x 10”
DRAG 16” x 16”
DRAG 6” x 6”
(150mm x 250mm)
(400mm x 400mm)
(150mm x 150mm)
HIP’ed angle test
HIP’ed anglefire
HIP’ed globe
separator pressure
water pump
condensate cooler
control valve with
discharge control
termerature
Destec flange
valve with raised
control valve with
connections for
face flange and
raised face flange
ease of installation
connections
end connections
4
VBJ Actuator Exchange
•
The customer provides CCI with the serial
number of the valve. From this, the exact model
configuration of the actuator, size and stroke, can be
Long recognized as the mainstay of the boiler
determined from the original data sheet for the
industry, the Bailey line of control valves has served
application. Needed parts are identified and, upon
reliably in utility, pulp & paper and chemical plants
request, a cost guarantee is provided for the work.
for more than 50 years. Thousands of these robust
•
An actuator is then assembled and tested to
the same exacting standards as a new one and
valves remain in service today.
delivered to the plant site prior to the scheduled
outage, usually within 48 hours. (In some cases, a
customer may prefer to have their own original
actuator rebuilt. Turnaround time for these actuators
is normally one week.)
•
After the replacement actuator is installed, the
customer returns the old actuator to CCI in the same
shipping container. The company’s account is
credited for return of the core unit. Cost is about
one-third that of new equipment.
Old actuator
Rebuilt actuator
Ten years ago, CCI acquired the Bailey line of
CCI’s technical experts are factory trained, with
valves from Bailey Controls Company. Since that
access to engineering support, to make sure rebuilds
time, CCI has stood behind these valves as the
are done right the first time.
authorized OEM, to improve and expand services
to Bailey valve customers.
One such service is the VBJ Actuator Exchange
Rebuild it
yourself ? The
large number of
Program, which offers a way of correcting
existing actuator problems and providing
parts involved is
preventative maintenance, by incorporating the
formidable and
latest design improvements, parts and materials
the process
in the replacement unit.
difficult without
experience.
By taking advantage of this service at regular
intervals, many plants have benefited from
improved valve performance. The mechanics of
the program are simple.
Skilled CCI technicians
reassemble a VBJ actuator
5
Nuclear Renewals Approved
Control Components’ N-stamp and NPT-stamp
certification renewals were approved recently
following an on-site audit and inspection. The twoday review process was conducted by representatives
from The American Society of Mechanical Engineers,
National Board of Boiler and Pressure Vessel
Inspection, Hartford Steam Boiler Inspection and
Insurance Company, Tennessee Valley Authority and
The State of California.
Certification renewal authorizes CCI to supply
ASME Class I, II, and III valves, valve parts and
appurtenances, and piping subassemblies through
1994. CCI has been supplying valves and parts to
Critical parts
the nuclear industry since 1971.
undergo liquid
penetrant
“DRAG” Defined
RAPID Link Complete
The question has often been raised, “What is DRAG?”
CCI has linked up with NUS Corporation’s RAPID
To set the record straight, DRAG is not an
(Readily Accessible Parts Information Directory)
acronym. It doesn’t refer to popular slang, such as a
database, to supply spare parts availability
street or “main drag”, a puff on a cigarette, or one
information 24 hours a day, seven days a week via
that is obnoxiously tiresome or a bore. Nor does
computer and modem.
DRAG refer to the clothing characteristic of one sex
when worn by a member of the opposite sex.
Contrary to the colorful alternatives, DRAG is
Utility members of NOMIS (Nuclear
Operations & Maintenance Information Service),
FOMIS (Fossil Operations & Maintenance
a description of the velocity control capabilities of
Information Service) and other industry affiliates
the tortuous path trim invented by Control
have access to this service.
Components’ founder, Richard E. Self, in 1967. The
term, used typically in aerodynamics, means the
For more information, contact Malcolm
Holdroyd, CCI Spare Parts Manager.
retarding force exerted on a moving body by a fluid
medium. More simply, DRAG defined means
something that slows motion or controls velocity.
6
inspection.
Adviser
A:
CCI’s customer service engineers are
based in California, New Jersey, Texas, and Holland.
Q:
A technician can usually be at a plant site anywhere
I’ve got a valve body with a scratched
metal seal surface. What can be done to repair it?
A:
Repair procedures vary depending on
several factors including the depth of the gouge and
its location, the seal’s material composition, and a
in the world within 24 hours.
Q:
In case of an emergency during non-
business hours, who can I contact for help?
A:
Regular business hours are 8 a.m. to 5
facility’s on-site machining and welding capabilities.
p.m. PST, although staff are usually on site between
CCI’s Field Service Department can provide repair
the hours of 6 a.m. and 6 p.m. During off hours,
guidelines over the phone or, upon request, dispatch
contact the following:
a technician to provide hands-on assistance.
Ron Adams
Field Service Manager
California, U.S.
(714) 855-1346 (residence)
Daniel Bourgeois
Regional Service Office Manager
Texas, U.S.
(713) 855-0953 (residence)
Loek Smit
Regional Service Office Manager
Gouda, Holland
011 31 10 451-3524 (residence)
Need maintenance tips? Want information about
how your valves work? We welcome your questions.
➣
Send inquiries to:
A DRAG 24” x 24”
(600mm x 600mm)
main seawater
return valve is
prepared for
shipment
Q:
Can CCI modify an existing valve to meet
CCI Adviser
Marketing Communications Department
22591 Avenida Empresa
Rancho Santa Margarita, CA 92688 U.S.A.
changed flow conditions?
A:
Yes. After new conditions are identified,
an engineering review is completed to determine
what hardware changes are necessary to meet the
new requirements.
Q:
If I need maintenance or valve repair, how
CCI’s World Headquarters and main
manufacturing facility in Southern California
quickly can a technician be dispatched?
7
“We Solve Control Valve Problems”
CCI World Headquarters - California
Telephone: (949) 858-1877
Fax: (949) 858-1878
22591 Avenida Empresa
Rancho Santa Margarita,
California 92688 USA
CCI Switzerland
formerly Sulzer Thermtec
Telephone: 41 52 262 11 66
Fax: 41 52 262 01 65
P.O. Box Hegifeldstrasse 10
CH-8408 Winterthur, Switzerland
CCI Korea
Telephone: 82 341 85 9430
Fax: 82 341 85 0552
26-17, Pungmu-Ri
Kimpo-Eup, Kimpo Gun
Kyunggi-Do, South Korea
238
CCI Japan
Telephone: 81 726 41 7197
Fax: 81 726 41 7198
194-2, Shukunosho
Ibaraki-City, Osaka 567
Japan
8