Baker Hughes Masoneilan SteamForm 84003 Series Manual de usuario

Baker Hughes Data Classication : Public

Masoneilan™

84003 Series SteamForm™

Steam Conditioning Control Valve

Installation Guide (Rev. B)

About this Guide

All information contained herein is believed to be accurate at the time of publication and is subject to change without

notice.

Changes to specications, structure, and components used may not lead to the revision of this manual unless such

changes affect the function and performance of the instrument.

In no case does this manual guarantee the merchantability of the hardware or the software or its adaptability to a

specic client needs.

Please report any errors or questions about the information in this manual to your local supplier or visit

valves.bakerhughes.com

Disclaimer

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE

INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE

PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BAKER HUGHES COMPANY (AND ITS

SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC

LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE

REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY

HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN

CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR

REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO

PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION

OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE

WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE

REFERRED TO BAKER HUGHES.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE CUSTOMER/OPERATOR ARE STRICTLY

LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO

ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BAKER HUGHES REGARDING THE EQUIPMENT OR ITS USE

ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,

TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE

REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.

The complete design and manufacture are the intellectual property of Baker Hughes.

All information contained herein is believed to be accurate at the time of publication and is subject to change without

notice.

Document Changes

Version/Date Changes

Rev.A - 05/2015 Original Release

Rev.B - 11/2020 Baker Hughes rebranding

Masoneilan 84003 Series SteamForm Installation Guide | iii

Contents

Masoneilan 84003 Series SteamForm Installation ................................................................................................. 1

Piping system layout............................................................................................................................................... 1

Upstream pipe recommendations .................................................................................................................... 1

Downstream pipe recommendations ............................................................................................................... 2

Straight pipe length .................................................................................................................................... 2

Temperature sensor location ..................................................................................................................... 3

Pressure sensor location ........................................................................................................................... 4

Pipe size and selection .............................................................................................................................. 4

Material break point ................................................................................................................................... 6

Piping material transition recommendations .............................................................................................. 6

Spray water system requirements .......................................................................................................................... 7

Water pressure ................................................................................................................................................ 7

Water temperature ........................................................................................................................................... 8

Strainers .......................................................................................................................................................... 9

Valve installation ..................................................................................................................................................... 9

Valve support ................................................................................................................................................... 9

Actuator support .............................................................................................................................................. 9

Orientation ....................................................................................................................................................... 11

Drains and pipe slopes .................................................................................................................................... 12

Warm-up and preheating steam ...................................................................................................................... 13

Insulation ................................................................................................................................................................ 14

Accessibility ..................................................................................................................................................... 14

Temperature control methods ................................................................................................................................. 14

Temperature – feedback control ...................................................................................................................... 14

Temperature – feedforward control .................................................................................................................. 14

Response time and stroke speed .................................................................................................................... 15

Start-up and commissioning ................................................................................................................................... 15

System blow down and cleaning ..................................................................................................................... 15

Trim Installation Device (TID) .......................................................................................................................... 16

Post weld heat treatment and hydro-testing .................................................................................................... 16

SteamForm assembly ...................................................................................................................................... 16

Commissioning spares .................................................................................................................................... 16

Turbine bypass to condenser applications ............................................................................................................. 16

Bypass system requirements .......................................................................................................................... 16

Process control ................................................................................................................................................ 16

Back-pressure dump tubes .............................................................................................................................. 17

System noise evaluation .................................................................................................................................. 17

Final recommendations .......................................................................................................................................... 17

Table of Figures

Figure 1

Recommended upstream straight pipe length ........................................................................................................ 2

Figure 2

Typical downstream piping installation ................................................................................................................... 3

Figure 3

Recommended pipe length prior to the temperature sensor. ................................................................................. 5

Figure 4

Evaporation process of a water droplet .................................................................................................................. 6

Figure 5

SteamForm water spray control valve Installation .................................................................................................. 10

Figure 6

Recommended orientation of the SteamForm........................................................................................................ 11

Figure 7

Improper orientation of the SteamForm.................................................................................................................. 11

Figure 8

Vertical ow down outlet orientation, should be located at low point downstream ................................................ 12

Figure 9

Drain vertical ow up inlet orientation, drain should be located at low point upstream .......................................... 12

Figure 10

Vertical ow down inlet orientation, drain should be located at low point of SteamForm valve body. .................... 13

Figure 11

Horizontal inlet and horizontal outlet orientation, drain should be located at low point of

SteamForm valve body. .......................................................................................................................................... 13

Figure 12

Start-up trim. ........................................................................................................................................................... 15

Figure 13

Trim Installation Device .......................................................................................................................................... 16

Masoneilan 84003 Series SteamForm Installation Guide | 1

Masoneilan 84003 Series Steamform

Installation

Installation of the Masoneilan 84002 series SteamForm

products requires a thorough understanding of the

surrounding operating environment. Product selection

and evaluation must extend upstream and downstream to

ensure proper design for successful long-term operation.

Baker Hughes’s installation guidelines are intended to

provide recommendations and warnings for the various

design elements of the steam conditioning system.

Enhancements to the overall performance of the system

are tested and documented through years of installed

experience and proven eld-tested methods.

Piping System Layout

The design and layout of the piping system are

important factors for a successful installation of a steam

conditioning valve. Several performance factors are

highly dependent upon the proper arrangement of the

piping system. Without the correct design in place,

the steam conditioning valve becomes ineffective in

achieving temperature control and stability. Additional

Design requirements including selecting pipe size, laying

out upstream and downstream piping, and positioning of

control elements are explained throughout this document.

Upstream Pipe Recommendations

Adjacent pipe bends such as pipe elbows and tee

connections are known to cause high levels of rotational

forces and excessive vibration when installed in close

proximity to a valve body. Long-term exposure to this ow

induced vibration results in problems such as damaged

trim and excessive noise during operation.

To reduce these risks, a uniform and stable ow prole

must be achieved prior to admission of the steam into

the SteamForm valve body. This is accomplished by

supplying a length of straight pipe, L1, upstream of the

valve inlet as shown in Figure 1. A straight pipe section

allows the inlet steam to recover its uniform ow prole

after passing through the turbulent path of an elbow.

In the case of an upstream elbow installation, the

recommended distance of ve pipe diameters of straight

pipe must be mounted upstream of the valve. Longer

lengths of straight pipe are also desirable.

Minimum upstream straight pipe length:

L1 = 5 x Nominal Pipe Diameter

Upstream tee connections involve further consideration,

as higher levels of turbulence are present in these

applications. These systems must supply a longer

length of upstream straight pipe, as higher levels of

instability exist. Consult your local Baker Hughes sales

ofce or factory for the recommended distance for these

applications.

Downstream Pipe Recommendations

Downstream considerations are more complex due to

a larger number of variables that are introduced in the

outlet of the SteamForm. The most signicant of these

variables includes the addition of spray water into the

steam ow and the expansion of steam as the pressure is

reduced. The following sections describe the necessary

features for properly designing the downstream piping

layout.

Straight Pipe Length

To avoid phase separation and downstream problems,

such as erosion or poor process control, it is necessary

to extend the straight pipe length exiting the SteamForm

to allow for water vaporization prior to the installation of a

pipe elbow. This distance ensures that a sufcient mass

of the water droplets is vaporized in order to prevent

water fallout and insufcient mixing. While this length

varies with each set of design conditions, a conservative

design downstream of the valve prior to installation of the

rst pipe elbow is L2, as per the equation below:

Minimum downstream straight pipe length:

L2 = Greater of 10 ft (3m) OR 7 x Nominal Pipe

Diameter

Once a minimum straight distance is obtained, Baker

Hughes recommends installing downstream elbows to

enhance ow turbulence. The downstream elbows assist

in the mixing of spray water within the steam ow and

help achieve an evenly distributed temperature prole. It

is suggested to design the rst pipe bend using a long-

radius, chrome-moly elbow to protect against wear and

erosion. An example installation is shown in Figure 2.

Figure 1: Recommended upstream straight pipe length

Masoneilan 84003 Series SteamForm Installation Guide | 3

Temperature Sensor Recommendations

Baker Hughes recommends a minimum of three (3)

temperature sensors to be mounted at the downstream

of the desuperheater. The sensors should be installed

at 120 degree angle, with 2 out of 3 voting failure, and

average logic.

The temperature sensor must be located at a point far

enough downstream to ensure 100% vaporization of the

water droplets. For control stability, single-phase steam

ow must be achieved. If high-energy water droplets

exist within the steam ow, the temperature element

recognizes sub-saturated conditions and reduces the

capacity of water injection. This misplacement of the

temperature element results in uncontrollable operation

requiring re-engineering to correct the errors of the

improperly designed steam conditioning system.

The proper location of the temperature sensor is

application specic. Benets from a properly designed

downstream pipe system allow for a greatly reduced

distance. Flow induced benets are achieved with the

proper placement of pipe elbows that allow high-energy

turbulence to assist in the mixing of spray water upon

passage through the elbow. For the sensor location

of a specic application, a piping layout along with

operating conditions must be provided to your local Baker

Hughes representative. However, the general direction

for minimum distance required for temperature sensor

location is per the equation below, and shown in Figure 3.

Temperature sensor distance, L3 = Minimum 33 ft

(10m)

Figure 2: Typical downstream piping installation

In some cases, the required distance prior to a

temperature sensor cannot be provided by the plant

due to a lack of real estate or specic application

requirements. In these cases, the use of a feed forward

temperature control algorithm is required for control. See

the temperature control methods that are explained later

in this document for further explanation.

The radial location of the temperature sensor can be

a concern for applications that do not pass through a

pipe bend. Long lengths of straight pipe along with large

quantities of water injection can result in spray water

fallout. Thermal sensors located at or near the lower pipe

wall can measure lower temperatures as water fallout

reduces the temperature of the lower boundary layer at

a faster rate than the pipe core. Temperature sensors

must be placed in the middle to upper portion of the pipe

cross-section to ensure the maximum steam temperature

is observed.

As previously noted, the addition of at least one pipe

elbow within a system is extremely benecial in assisting

with the mixing of spray water with the steam. These

installations must always mount the temperature sensor

downstream of the elbow by at least ve pipe diameters.

Close coupling of the sensor with an elbow can result in

poor temperature control.

Pressure Sensor Recommendations

The pressure sensor must be located at a point

downstream where there is a relatively stable ow prole.

The recommended installation point is ve pipe diameters

downstream of the valve connection and any pipe

elbows. See Figure 3.

Minimum Pressure Sensor location:

L4 = 5 x Nominal Pipe Diameter

Pipe Size and Selection

Prior to laying out the piping system, the appropriate

pipe sizes must rst be determined. This is accomplished

by following velocity limitation guidelines. These

guidelines are usually established by the customer or

by the engineering standards of the design rm. These

guidelines are typically practical for the upstream

design; however, with the addition of spray water some

guidelines become conservative and impractical for the

downstream design of a steam conditioning system.

The ideal environment for water injection is a high

velocity and highly turbulent ow operating between

the ranges of 250 ft./sec and 300 ft./sec. A high velocity

steam jet creates an effect that shears across water

droplets and increases the surface area that is exposed

to steam. By creating more surface area, the diameter

or thickness of the water droplets is decreased. This

drastically decreases the amount of time that is required

for a water droplet to vaporize.

Conversely, a low velocity ow stream does not assist

in breaking down the water droplet. As a result, larger

diameter water droplets are injected into low velocity

applications. Because these larger diameter droplets

carry more mass, it becomes difcult at low velocity for

the steam to suspend the heavier droplet in the ow

stream.

This can result in water fallout and insufcient

evaporation at the temperature sensor location.

Masoneilan 84003 Series SteamForm Installation Guide | 5

It is important to design the pipe around the most

critical operating scenarios. For example, it is common

to design a maximum ow rate scenario that is rarely

ever experienced. For this case, it is benecial to allow

short durations of high velocity (in excess of 300 ft/

sec) to obtain a tradeoff of better performance at lower

ow rates. There is a direct relationship between pipe

size and turndown that must be evaluated for each

installation.

After selecting the pipe size, the next step is to

correctly design the pipe wall thickness and material

to follow the appropriate codes of the country or state

of the installation. The design of the downstream wall

thickness and material depends on the upstream design

temperature as a possible limit. This temperature limit is

set because the water is introduced in the outlet of the

valve, thus, does not effectively cool the steam until a

signicant distance downstream.

Figure 3: Recommended pipe length prior to the temperature sensor

Material Break Point

As previously mentioned, temperature reduction does

not occur immediately at the outlet of the SteamForm.

Spray water injected into the steam must rst heat-up to

the saturation point, and then evaporate into steam for

cooling. This phase change is shown in Figure 4. The

SteamForm valve can be used as a material breakpoint

provided the lower grade material is designed to accept

the full upstream temperature.

Heat-up Time, t1Evaporation Time, t2

Temperature = T water Temperature = T saturation

The material break point, in the case where temperature

reduction is a required design factor, is application

specic and is not possible to advice as a rule of thumb

process. The complexity of this calculation stems from

the fact that the evaporation rate is a function of the

following three variables.

• The enthalpy differential between the water and the

saturation point determines the amount of time required,

t1, for heating the water to its saturation point.

• The droplet diameter, which is a function of nozzle

design and injection velocity, inuences the amount

of time required, t2, to evaporate the water once it

becomes saturated.

• The length for proper evaporation is determined by

multiplying the steam velocity by the sum of t1 and t2.

Multiple variables are presented in the calculation

and are applied through indirect relationships. For

applications where a temperature reduction must take

place prior to the material downgrade, a Baker Hughes

representative should be contacted to provide the best

location for the material transition.

Figure 4: Evaporation process of a water droplet

Warning: Steam exiting the SteamForm valve exhibits high temperature. Complete cooling of the steam

temperature does not occur until the spray water evaporates and mixes with the steam. Therefore, the nal

outlet set point is not achieved until reaching the factory specied temperature sensor location.

Piping Material Transition

Recommendations

SteamForm valves are often manufactured with high alloy

cast material body such as C12A Grade 91, specially for

steam temperatures exceeding 1000°F. The End Users

typically maximize lower grade material piping at the plant

for cost savings. Lower grade materials cannot withstand

the higher temperatures steam conditions. Therefore,

before transitioning piping material from higher grade to

lower grade at downstream of the SteamForm valves,

specic distance guidelines must be followed. Please

contact factory for evaluation and minimum distance

recommendations.

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