6 Adca Training - Part 4 5d7228a93513f
6 Adca Training - Part 4 5d7228a93513f
Part 4
This presentation is only a guideline, that can only be completed by a trained personnel.
(This document’s total or partial use and/or reproduction is only allowed if the reference to the source is kept)
Part 4
▪ Pressure Reduction
▪ Safety Relief Valves and Other Steam Valves
Part 5
▪ Control Valves
▪ Components of Control Valves
▪ Humidification
▪ Industrial fluids are usually distributed from pressurizing stations, boiler houses,
etc, which operate with predefined pressures.
▪ Users not always assume the original pressures, thus it turns out to be
necessary to reduce pressure close to usage points (machinery) or in different
areas of a plant, simply for mechanical or thermodynamic reasons.
▪ High pressures distribution can be convenient namely with compressible fluids,
such as saturated steam, as a mean of decreasing investment through the usage
of smaller section piping and reducing pressure only close to the user. Assuring
not only a stable pressure in usage but also higher latent heat, which represent
less steam consumption and less loss of flash steam from open vents on
condensate tanks, etc.
▪ Therefore, whether for security, functioning or energy saving matters, pressure
reducing valves are a resident member on several fluids systems.
▪ Saturated steam temperature is directly related to its pressure and so, the
pressure control can be also an affective method of temperature control mainly in
those equipments where it is not possible to install a temperature probe in the
right place (i.e. Sterilizers, cooking, contact dryers, ...).
Set Point
Droop
Pressure
Flow
▪ Droop is the deviation of pressure from the set point pressure, that takes place when a pressure regulator moves
from the minimum to the maximum flow.
▪ Higher flow represents more regulating spring relaxing, loosing load force which causes the outlet pressure to drop.
▪ Accumulation is basically the opposite of droop, which increasing flow the set pressure of a pressure sustaining
valve also increases.
▪ Domeloaded regulators with pilot regulators reduces droop or accumulation effect and this can be even optimised
using an external sensing pipe and/or using two stage pressure reduction, where the second one should do the final
control.
▪ Dependency (pressure regulators) if inlet pressure decreases the set pressure rises (opposite way with pressure
sustaining valves).
Balanced valves reduce dependency effect.
Small loads
where accurate
control is not
crucial. Large flows
and main lines
where inlet
pressure do
not have wide
variations.
▪ Clean steam systems also require pressure reducing valves and pressure
sustaining valves.
▪ Mechanical polish or electro polish to 0,5 microns Ra on internal parts are normally
required.
▪ The reduced pressure medium through a controlled
pressure pipe, acts on the underside of the diaphragm of
a pilot which, in turn supplies steam (or gas) at variable
pressure into the upper chamber of the piston operator,
which regulates the main inner valve.
Pilot operated regulators are high performance devices. External sensing pipes are
recommended to reduce droop.
➢ Which valve: Direct acting or Pilot operated?
This is why it is imperative to size and select the valve to the application and
not to existing line size!
▪ Example 1000 kg/h steam at 10 bar g reducing to 2 bar g
DN 50mm
Inlet pipework
S25 Humidity separator Valve selection diameter must be done according to the
DN ½” mains drainage trap set actual flow of steam, liquid or gas passing through the
valve, the minimum inlet pressure and the desired
reduced pressure.
➢ Which Valve and For Which Application?
Gas
Liquid
➢ Which Valve and For Which Application?
P15
PRW25I PRV25/2SS
P20
PRV300SS PRV31SS P7
Steam
PRV30SS Low Pressure P7 PRV25/2SS PRW25I P15/PRV41 PRV30/31 PRV300
Steam (Special)
Gas
Liquid
➢ Which Valve and For Which Application?
PS15
PS31SS
Gas
PS30SS Liquid
PRV25 Series
Advantages Disadvantages
Advantages Disadvantages
Need a water
Low Cost
seal
Possible spring
Reliable
hysteresis
Relative crude
High flow rates
control
PRV47
Advantages Disadvantages
Controlled
More expensive
control
More complex
High flow rates
maintenance
Reliable
➢ Questions to ask
➢ Table of selection
▪ The Kv values should be calculated according to the formulas illustrated in the next page.
▪ The Kv represents the quantity of water , expressed in cubic meters (m3) at 15ºC, that
flows through the valve with a pressure drop of 1 bar , in one hour period.
Operation conditions:
Fluid = Water
P1 (Upstream pressure) = 10bar g (11bar a)
P2 (Downstream pressure) = 6bar g (7bar a)
ΔP = 11-7 =4 bar
Q (Flow rate) = 13 m3/h
d (Density) = 1000 Kg/m3
Required material: Stainless steel
d1
According to the table the formula to be used is Kv Q1
Dp 1000
1000
Kv 13 Kv 6,5m 3 /h
4 1000
Kv 7,8m3 /h
CAPACITIES
Valve Size 40 50
Operation conditions:
Fluid = Compressed air
P1 (Upstream pressure) = 28bar g (29bar a)
P2 (Downstream pressure) = 10bar g (11bar a)
Q (Flow rate) = 220 Nm3/h
d (Density) = 1,293 Kg/m3
t (Temperature) = 20ºC
T (Absolute temperature) = 293 ºK
Required material: Stainless steel
29 Q3
According to the table of formulas since 11 the formula to be used is Kv d2T
2 257 P1
220
Kv 1,293 293 Kv 0,57m3 /h
257 29
Kv 0,68m3 /h
CAPACITIES
Valve Size 15 20
Operation conditions:
Fluid = Saturated steam
P1 (Upstream pressure) = 12bar g
P2 (Downstream pressure) = 5bar g
Q (Flow rate) = 1200 Kg/h
Requested valve material: Steel
With this we can now use the valve selecting table and choose the correct size.
▪ Example 3 – Calculation by Valve Capacity Table: PRV47
Q 1200Kg/h
Valve:
Looking to the capacity table on the
PRV47 datasheet we should consider a
valve PRV47 DN32 for this application.
Regulation spring:
From pressure range spring table, the
black spring (2 to 17 bar) is adequate.
≈ 8 bar
NOTE: Compressor
Non- critical applications
capacity on the limit. PS47
(Closed up to 7 bar)
▪ Pressure in line will decrease in case of overage consumption. When it reaches 7bar pressure
sustaining valve closes, maintaining the available flow to assure functioning of critical
applications.
PS45
PRV47 DN50
Design conditions: Safety set at 2.5 bar g
2500 Kg/h of steam
Inlet 10 barg – Outlet 2 barg
Max.permissible flow
through the valve: 3718 Kg/h
(See capacity table)
In case of PRV failure in open position the safety valve is able to pass the maximum
possible flow rate permitted.