_TECpress

STEAM CONDITIONING- &

TURBINE BYPASS VALVES

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TECartec GmbH * Am Heidering 7a * D-16515 Oranienburg * +493301/2032-60 * [email protected]
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What is an HP Turbine Bypass Valve?

It routes high pressure and high temperature steam around the HP Turbine, from the main steam line
typically to the cold reheat line. In doing so, the HP turbine bypass valve must perform both, pressure
reduction of the life steam as well as temperature control.
Pressure reduction is accomplished by a multi-stage low-noise trim within the valve body. The inlet
pressure is controlled by an upstream pressure controller, signaling the valve to modulate to maintain
the pressure at the required set point. Alternatively the valve can accept a digital signal to quickly
modulate and control the pressure.
Temperature control is accomplished through the addition of cooling water to the steam flow to reduce
the specific enthalpy of the steam (a process called desuperheating). A separate water control valve
supplies the correct amount of spray water to the desuperheating mechanism within the steam
conditioning valve. A downstream temperature transmitter typically operates by applying a feed-
forward algorithm within the DCS to dictate the amount of water injected into the steam.
TECpress with steam-assisted water injection and TECpress HT with up to 40 individually controlled
spray nozzles in the outlet section. Note: the outlet section can be substantially larger in diameter than
the inlet. This is typically the case for LP Turbine Bypass Valves.

Typical Applications for HRSG HT-Desuperheaters and TECpress Turbine Bypass Valves in a CCPP

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Combined Pressure Reduction and Desuperheating ensure Maximum Performance and Reliability
The TECpress range of valves is primarily used in utility power plants for Steam Turbine Bypass to Cold
Reheat but it also can be utilized for similar desuperheating applications in Process Applications.
- As reliability and accurate performance are paramount to the operation and safety of the plant,
the selection of the TECpress for turbine bypass applications is highly beneficial. By utilizing the
energy of high velocity steam in a Laval nozzle to mix with small cooling water droplets, an
efficient temperature control can be assured.
- Alternatively, for very large spray water amount requirements and extremely high steam
temperatures the TECpress can be equipped with a ring injection system (TECtemp HT R). This
system with no moving parts in the heat affected zone is used in supercritical and ultra-
supercritical power plants.
- The inlet steam pressure reduction takes place independently of the water injection. This avoids
potential excessively high thermal stresses caused by temperature differentials between the
cooling water and superheated steam.
This guarantees a long life time of all control elements and avoids costly downtimes.

TECpress

TECtemp TECsteam TECtemp HT R

multi nozzle desuperheater Steam-assisted desuperheater multi nozzle radial desuperheater

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Requirements for a reliable high performance Turbine Bypass System

Resistance to Thermal Shock and Fatigue
- The Bypass Valve will repeatedly be subject to severe thermal stresses and very frequent cycling
of the plant during its lifetime.
- TECartec is using only forged, and fully machined high temperature-resistant alloys for the
pressure containment, and no crack-sensitive castings.
- The valve body is contoured without any abrupt changes in wall thickness, therefore minimizing
thermal stresses.
- Valve body and trim are both designed to assure reliable and safe operation.

Maximizing Power Output of Plant and reduced Valve Maintenance

- Longtime seat tightness is provided to prevent steam leakage.
- Severe seat leakage results in excessive maintenance, costly plant shutdowns and financial
losses.

Must handle severe Pressure Drops

The Bypass Valve will control pressure drops of greater than 100 bar. The valve trim has sufficient
pressure reduction stages to prevent erosive wear, excessive vibration and noise. We can install up to 8
pressure reduction stages in our cage design.
Depending on the application our pressure reducing stages are built in different ways:

Stacked cages Stacked disc design with cage

Advantages of the TECartec pressure reduction design:

- Easy maintenance due to threaded design
- No welded-in seats
- No special tools required
- Rugged and reliable design
- Max. SPL<=85dBA (1m distance)

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Bonnet Executions for Steam Conditioning and Turbine Bypass Valves

Standard Bolted Bonnet

The simple bolted bonnet cover (used for lower
pressure class…….) can easily be removed. It
represents the second most important boundary
of a pressurized valve.

TECartec’s bonnet is made of forged material, and

is fully machined.

For the sealing we use a special graphite ring,

tightened down by alloyed high temperature
resistant stretch bolts.

Figure 4. Standard bolted bonnet (cover)

Pressure Seal Bonnet (UHDE Bretschneider)

Pressure seal bonnets are self–sealing (once they

are pre-stressed at a defined torque) and have
successfully been used in high-pressure and high
temperature environments in power and process
plants for many years. After asbestos gaskets were
banned from usage the industry adopted
successfully highly compressed graphite cap seals.
These special rings have proven their viability since
many years and are available in several special
versions, for example with metal reinforcement or
with stainless steel caps for certain special
applications. This bonnet concept stands out mainly by its reliability, high p&T-rating, ease of
use, safety aspects and its service friendliness.

TECartec VSS

This is a pressure seal bonnet design which has

been developed for excessively high pressures and
temperatures. We use this patented design for
supercritical and ultra-supercritical conditions in
process and power plants.

The gasket is located in the direct flow of force.

Changing pressures inside of the valve have no
impact on the special gasket. Typically we use a
specially coated metal C-ring. This ring doesn’t
undergo oxidation due to the hot gas as this
would be the case for common graphite rings.

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TECpress with integral water injection (Standard)

Steam Conditioning Valve or Turbine Bypass System(HP, IP, LP)

Main Characteristics of our Standard Execution

The TECpress Steam Conditioning Valve is capable of controlling pressure and temperature
simultaneously.

Due to an intricate pressure reducing arrangement the steam pressure is reduced subcritical at all load
levels.

Silencers are used to keep sound pressure levels below the typically specified level of 85dBA with an
insulation thickness of 100mm (4”) of heavy density Rockwool.

Water doesn’t get injected in areas where high temperature differentials (water/steam) could damage
the mechanical components.

Seat tightness is at least ANSI Class V.

Specifics

- design according to PED, DIN, EN 12952, ASME B16.34

- safety function according to TRD421, AD2000 A2
- angle valve design execution
- globe valve design execution
- forged, fully machined and welded body design (we do not use castings for these severe service
conditions)
- subcritical pressure reduction over the entire control range
- desuperheating takes place immediately after the pressure reduction, with either…
o a steam-assisted nozzle, or
o a number of individually controlled nozzles (up to 40 pcs. for a TBV) in the outlet of the
valve, and with minimal flow disturbance and pressure loss in the steam line. See
TECpress HT picture further down.
o very fine and uniform distribution of spray droplets across the entire pipe section,
resulting in short droplet evaporation time and distance
o drastically reduced droplet impingement risk compared to conventional systems
- connections:
o Flanges acc. DIN, ANSI, JIS
o BWE
- actuation:
o Pneumatic
o Electrical
o Hydraulic (incl. hydraulic actuator, power supply unit, and electronic controls)

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TECpress HT R TECtemp HT Spray Water Control Unit

This HP/IP Turbine Bypass Valve comes with the patented TECtemp HT Cooler Unit installed immediately
after the steam pressure reduction. It is specifically designed for Supercritical and Ultra-supercritical
installations with large spray water amounts, and medium to very large steam outlet pipelines, and
where controlled water-injection and atomization resulting in short evaporation lengths are required.

TECartec offers different desuperheating solutions (probe-style, ring-style, ring-style with ventury spray
body), all with absolutely no moving parts in the heat-affected zone, and depending on the particular
design with up to 40 individually controlled spray nozzles of different size and spraying pattern/capacity.
The pressure loss in the steam line due to these nozzles is max. 0.1bar, way less than with conventional
probe-style desuperheaters.

This design allows to generate the finest cooling water droplet size spectrum and allows to evaporate
the spray water over the shortest possible distance, without impinging on the very sensitive pipe wall.

Turbine bypass valve TECpress HT with TECtemp HT desuperheater

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Main Parts and Materials (x : recommended Spare Parts)

Parts and Materials

ITEM
PART MATERIAL

1 Body Carbon Steel, Chrome - Moly

2 Concentric Reducer Carbon Steel, Chrome - Moly
3 Desuperheated Steam Outlet Carbon Steel, Chrome - Moly
4 Bonnet Carbon Steel, Chrome - Moly
5 Gland Flange Stainless Steel
6 Gland Bushing - x Stainless Steel
7 Stem - x Stainless Steel, Inconel®
8 Perforated Cage – x Stainless Steel with Chrome Plating and Nitriding
9 Pressure Reduction Cages - x Stainless Steel with Chrome Plating and Nitriding
10 Perforated Disc Stainless Steel with Chrome Plating and Nitriding
Desuperheating Unit
11 (Nozzle Body, Nozzle Housing, Carbon Steel, Chrome - Moly
Cooling Water Inlet)
12 Base Ring Alloyed Special Steel
13 Gasket - x Pure Graphite 99,85% (1,2;1,4;1,6)
14 Graphite Seal Rings - x Pure Graphite 99,85% (1,2;1,4;1,6)
15 Graphite Seal Rings - x Pure Graphite 99,85% (1,2;1,4;1,6)
Pure Graphite 99,85% (1,2;1,4;1,6) with
16 Seal ring with insert - x
Stainless Steel Ring
17 Studbolt - x Alloyed Special Steel
18 Hexnut - x Alloyed Special Steel
19 Studbolt - x Alloyed Special Steel
20 Hexnut - x Alloyed Special Steel
21 Cagenut Alloyed Special Steel
*Common materials: typically 13CrMo44, 10CrMo910, F91, F92 (other materials on request)

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Dimensions

Body Size Stem & Seat Packing Seal Stroke

Inlet Outlet Seat Stem Plug Stem Inner Outer
E H G C
No. F I A B D Diameter Diameter
[mm] [mm] [mm] [mm]
DN/ASME DN/ASME [mm] [mm] [mm] [mm] [mm]
12 20 18 18 38
14 20 18 18 38
25 / 1" 40 / 1 ½" 17 20 18 18 38
32 / 1 ¼" 50 / 2"
1 150 60 70 20 23 18 18 38 30
40 / 1 ½" 65 / -
50 / 2" 80 / 3" 22 25 18 18 38
25 28 20 20 32
27 30 20 20 32
32 35 20 20 32
50 / 2" 80 / 3" 37 40 25 25 41
65 / - 100 / 4" 42 45 25 25 41
2 250 140 110 70
80 / 3" 150 / 6" 47 50 40 40 60
100 / 4" 200 / 8" 57 60 40 40 60
67 70 40 40 60
77 80 50 50 70
150 / 6" 87 90 50 50 70
100 / 4"
200 / 8"
3 400 200 150 150 / 6" 97 100 50 50 70 120
250 / 10"
200 / 8" 106 110 60 60 80
300 / 12"
116 120 60 60 80
126 130 70 70 90
250 / 10" 136 140 70 70 90
200 / 8"
4 500 380 200 300 / 12" 170
250 / 10" 146 150 70 70 90
350 / 14"
156 160 70 70 90
350 / 14" 166 170 70 70 90
300 / 12"
5 530 420 215 400 / 16" 176 180 80 80 100 190
350 / 14"
450 / 18" 186 190 80 80 100
400 / 16" 196 200 80 80 100
300 / 12"
6 560 470 230 450 / 18" 206 210 80 80 100 200
350 / 14"
500 / 20" 216 220 80 80 100
350 / 14" 450 / 18" 226 230 100 100 100
7 600 490 250 400 / 16" 500 / 20" 236 240 100 100 120 200
450 / 18" 600 / 24" 246 250 100 100 120

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_TECpress

SCV/TBV/DSH Product Selection

APPLICATION Service TECartec Product Remarks

Process Steam Pressure & Temp. Control TECpress
Low- int.med. Temp. Contr. TECtemp
Elevated Temp. Controls TECtemp Boiler Environment
Super- and Boiler Interstage
Ultrasupercritical TECtemp HT L, HT R Attemperation
Temp. contr. close to
Steam-assisted DSH TECsteam Saturation

HP, Super- and TECpress, TECpress HT

Turbine Bypass Ultrasupercritical R
TECpress, TECpress HT
IP/LP R/HT L
Hydr. Power Unit & Depending on
Controls Application Contact TECartec

TECpress (and
Condenser Dump Low to high Loads Dumptube)

Spraywater Control Contact TECartec

Spraywater Isolation Contact TECartec
Filter Contact TECartec

Water Valves and Auxiliary Steam Applications

TECartec manufactures a considerable selection of special high pressure control valves for liquids (
mainly for water), steam, oil and gas. This also includes special coated metal-seated ball valves, gate
valves, and severe service control valves. They are used for spray water control (in conjunction with DSH,
SCV and TBV), drain service (including two-phase flow) and many other applications in power and
process plants, as for example…

- Feedwater control
- Spraywater control for superheater and reheater applications
- Pegging steam in deaerators
- Deaerator level control
- Extraction applications
- Boiler level control and blow-down valves
- Heater drain control valves
- Etc.

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Engineering, R&D

TECartec’s advanced and unique designs display a significant degree of innovation and originality,
incorporating several decades of valve know-how and practical experience in the power and process
industries. Our field service team shares their long experience (based on our own and other makers’
valves) with the R&D group and feeds important inputs from our customers to develop solutions
which provide an optimum performance, reliability, and best possible return of investment to the users
of our products. Many of our unique designs have been awarded patents.

FEA of forged Valve Body CAD and DDS Designing

Example 1: The TECtemp HT multi nozzle turbine bypass design for temperatures above 520C has no
moving parts at all in the hot area and is good up to 720C.
The spray characteristics of the TECtemp HT design is substantially better than what for example
commonly used spring-loaded nozzles are capable to achieve under best conditions.

Below picture: Uniform Temp. Distribution around the Pipe Periphery, with cooler sections rapidly
moving towards the center of the pipe (blue). Notice: Cold Water Droplets don’t impinge on the pipe
wall.

Large Pipe DN: Temperature Distribution shortly after Injection Droplet -Path and -Velocity

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Example 2: Exhaust Gas Cooling in HRSG

Arrangement of several patented
Desuperheaters TECtemp HT after a
Gasturbine, at the inlet to the HRSG.
Notice the Dropletsize-Reduction after a
very short Distance. No Impingement on
the HRSG walls!

Example 3: Waterinjection pipes (spray cooling) with Thermal Liners (TECartec / MHI-Hitachi) in a
Supercritical Power Plant. Replacement of a competitive desuperheater design. This DSH can also be
used in conjunction with the Turbine Bypass TECpress.

Example 4: Interstage Attemperation with TECtemp HT Desuperheaters in a Supercritical HRSG. This

DSH with no moving parts in the heat-affected zone is good for up to 750C, and can solve many of the
current problems the industry experiences with conventional DSHs.

HRSG TECtemp HT L

Patented High Temp. DSH for HRSG interstage attemperation

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Manufacturing / Stock

We are equipped with state-of-the-art CNC machines to manufacture, weld, assemble and test all of our
products in-house.

We also keep a sizable inventory of all potential spare parts, and raw materials in various high temperature
grades.

All welding work and PWHT is done internally

Machining of all components in our factory in Oranienburg near Berlin

In-house programming on CNC machines

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TECpress Installations

Safety Function Test Equipment acc. TRD421

for Turbine Bypass System

TECpress Turbine Bypass during start-up phase

Hydraulic Power Supply Unit for Turbine Bypass

HT Desuperheater / TBV

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TECtemp HT Desuperheater installation examples

Nozzle Head for Turbine Bypass Valve (min. 3 pcs. in a pipe)

No

Multi Nozzle Venturi Desuperheater TECtemp HT V

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TEC artec GmbH

Am Heidering 7a | D-16515 Oranienburg | [email protected]
P. +49 (0)3301 20 32-60 | F. +49 (0)3301 20 32-70 | www.tec-artec.de
GPS: 52.773151°, 13.262119°

AVK Valves Korea Co., Ltd. Korea World Valve B.V.

fon: +82 51 664 8808 fon: +31 5353 81 295
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fon: +966 2637 1570 fon: +98 21 220 53 563-4 Ext.: 105
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fon: + 27 1265 38 313 fon: +43 2231 67390
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