hi-fluidic parallel slide gate valves design features & user benefits – model kmp-100 fluid...

Hi-Fluidic Parallel Slide Gate Valves Design Features & User Benefits – Model kmp-100

Fluid Flow & Valve SpecialistKey Valve Technologies

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SPL Parallel Slide Gate Valve(PSGV) - Design Features



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Two piece Parallel Discs Gate SPL(Spring Pack Loaded) Sliding Discs & Arrangements Flow Throttle-ability Seat Ring Design(Downstream) Advantages of Sliding Seating Stellite Hardfacing & Super Hardness CrN Coating on Discs Back Seating & Pressure Sealed Bonnet Design Design consideration for in-line Maintenance Positive Flexibility Seating under irregular Thermal Expansio

n(Structural Discontinuity in Valve Body) Qualified by CE-PED, Testing & References

KVT Parallel Slide Gate Valves -



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Design Features – SPL Sliding Disc Design Concepts

Wide Flat Seat – Longer Life

Independent Flat Discs – Free Rotating & Tilting in Thermal Expansion



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Design Features – SPL Sliding Disc & Coil Spring

Coil Spring

KVTSPL Disc Spring

• Less Flatness – Possible tilted seating

• Less Precise Stiffness Spring – no good for low pressure service

• Longer length than Disc spring – Thick disc trim

• Hard to control the Spring Stiffness

• Hard to alignment for two separated disc

• Fine Flatness

• Most Precise Stiffness Spring

• Easy to control the Spring Stiffness

• Can be assembled with multi-Spring Pack

• Maintain leak tight seating even sliding



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Design Features – Two Piece Parallel Discs Gate

• The two identical parallel discs are separate, independent and constantly loaded by high spring rated disc springs, allowing maximum freedom for each to adjust to any angular distortion of the body seats.

• Design with independent discs, wide flat seats(at least 2.5~3 times than wedge type), variable numbers of spring pack to be allowed proper sealing forces and sharp shaped edge on the discs.

• SPL two piece gate design minimizes the overall seat-to-seat dimension of the gate trim assembly due to eliminating the wedge forcing effects in the gate.

• Provides tighter and more dependable sealing under power station pressure & temperature service condition compare wedge gate valves.

• Provides freedom from sticking and binding result from thermal effects associated with wedge gate valves.

• Provides minimizing the effects of minor damager to the surface as sealing occurs over the entire seating surfaces.

• Provides higher flow capacity for given seat port diameter by reducing flow interruption and resulting turbulence in the gap wedge and seat ring( ζ value – 4 times more lower than wedge gate).



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Design Features – Conventional Wedge Gate vs. Parallel Slide Gate

• Narrow Seating Area(High Contacting Stress)

• Stiff for Thermal Flexibility of Disc

• Stem Forcing – Torque to Compress to Seat

• Torque to Seating – Transient Wedging Effets

• Normally Damage on lower wedge edge

• Wide Seating Area(lower Contacting Stress)

• Flexible in Thermal Expansion in Valve Body

• Stem Forcing – Thrust to Slide

• Torque to Seating – Stable & Smooth

• Longer Life Time of Discs & Seats Surfaces

Parallel Slide Gate Valve is forON-OFF & Flow Throttling both



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PSGVFlow Throttling Control

• V-Port Design (Downstream port)

• Linear / =% Flow Characteristics Possible

• Much Higher Flow Capacity(Cv) values

• Can achieve Leakage Class VI

• Photos – for Blow Down Control

Hi-Fluidic PSGV Control Valve

Korea Atomic Energy Research Inst.

2”x2500#RTJ, CF8M



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Design Features – Arrangement of Spring Pack

Variable numbers of Spring pack per Size

Guides & holds the discs by pin and Spring(For 24” & bigger sizes, install spring pack)

Disc

Arrange. of Spring Cartridge in DiscArrange. of Spring Cartridge in Disc

upto 1.5”(DN40) 1Ea(*1)

2.0”(DN50)-4”(DN100) 1Ea(*2)

5”(DN125)-8”(DN200) 3-4Ea

10”(DN250)-32”(DN800) 6-16Ea

*1 : Smaller Size Disc Springs*2 : larger Size Disc Springs



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Design Features – Two Piece Parallel Discs Gate & Discs guide

• Disc holder in the two piece gate design is threaded into stem larger than DN 65 and all sizes of power operated.

(Disc & stem precisely assembled into seat rings)

• Disc holder grips two SPL discs and pinned DN 50 and smaller size in manual valves.

• SPL PSGV is fully guided through out its travel in sliding seat. Travel stop is on back seat in open position and is on yoke stop in full closed position.

• Disc holder design relatively high reduces the overall height of the valve body and reducing the valve weight Compact & art design of Hi-Fluidic PSGV.

• Wide flat seat is smoothly guided in the full travel without departing from seat ring in full open position. In wedge gate valve, the wedge must have positioning guides on its sides to keep it in line while closing under full flow condition. These guides are usually made of any hard material, and tend to wear, and eventually may cause jamming. As discs are guided only by its full Stellited* and fine lapping sealing surface, SPL PSGV never occurs such as jamming even horizontal installation the valve in vertical piping.

* Trade mark “Stellite” is a hardfacing material.



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Design Features – Arrangement of PSGV Trim Set

Disc Guide

Disc Holder

Spring PackDisc(STL.#6 HF)



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Design Features – Seat Ring Design for PSGV Control Valve

Linear EQ% Let Down

KVT offer a reliable control solutions to maintain the zero leaks of the control valves.

We had referenced these PSGV control valves to be main feed water minimum flow control function ( P=140bar) in POSCOs’ 100MW class thermal power plants. ∆

Operation for all the valves are perfect and never leaks in the valve seat.



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Design Features – Brief Outlines the PSGV

• Full compliance with ASME B16.34 design requirement

• State of art design (aesthetics design)

• Structural integrity for pressure retaining parts – Body, Bonnet, Bolts

• TSSA approval design of Canada BV&P

• Very easy disassembly structure : No welding

• Low torque & smooth operation

• Provision of bypass piping & pressure relieving device



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Design Features – Spring Pack Loaded(SPL) Parallel Slide Disc, Sliding Sealing

• Sealing is obtained by sliding, not by compression according to wedging effects.

• No need for final surge of torque to make the seating leak tight.

• No additional power is required for the first effort in unseating the discs. Unseating torque for SPL PSGV are ten times more lower than a wedge gate.

• Actuator size can be much smaller (at least 1~2 size) than for the wedge gate.

• Achieving smaller stem diameter brings much reliable packing sealing results & long life.

• Denting local stress & fatigue on the seating surface due to impurities are much less on SPL PSGV, which results in longer lifetime and reliable leak tight.

Wedging Effects

(Compression)

Sliding (Only Friction

Force)



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• No tendency to mark, notch, local strain hardening, or indents the sealing surface due to cumulate impurities on seating surfaces better tightness & longer maintenance free lifetime.

• The exact position of the stem is not critical when the valve is closed. As a result, there are no problems with differences in thermal expansion coefficient of material. Also the motor actuators can be stopped with general position switches.


Tilt-able & Rotate-able

Laterally Flexible

Sliding Up/Downward



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Design Features – Stellite Hardfacing & Super Ceramic Coating

Stellite Hardfacing by weld deposit(KVT use only Deloro® welding rods)

• Disc : Stellite #6 (AWS R CoCr-B) Hardness HRc 39~43 1.15C, 27.75Cr, 4.5W

• Seat Ring : Stellite #12(AWS R CoCr-A) Hardness HRc 47~51 1.40C, 39.50Cr, 8.25W

• CrN Ceramic Coating ( Hv 2100, 700℃) by Cathodic Arc Evaporation Process, Super resistance against corrosion

• Stellite is a time proven hard-facing material which is erosion & corrosion resistant and which retains high temperature hardness to minimize galling and surface degradation.

• Different hardness between seat & disc is good for anti-galling. KVT PSGV have HRc 5~7 hardness different.

• In case of quick open/closing or frequently operating PSGV, KVT strongly recommend the use of CrN Coating disc. This is a proven coating material by Korea Atomic Energy Research Institute (KAERI).



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Design Features – Back Seating & Pressure Seal Design



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Design Features – Back Seating & Pressure Seal Design

• Back seat is of integral and cone-on-cone design

• The time proven Delta type pressure seal design seals more effectively as pressure increases because the pressure forces the sealing elements into closer contact. Sealing effectiveness is thus unaffected by high temperature relaxation of materials and pressure cycles.

The pressure seal gasket has an optimum angular relationship with body and bonnet to provide a high elastic & resilient sealing force as it yields initially under bolting (screwed) pre-loads and then under line pressure. The gasket is shaped a delta form and made pure graphite of very high resilient properties.

• KVT’s narrow cone-on-cone design withstands over-torquing better than other design

• In comparison with other pressure seal design, KVT design is unique and simple for the sizes (even small size) and effective sealing area provided, and for ease of maintenance after long years service.

• In order to disassemble a KVT Hi-Fluidic pressure seal bonnet, line pressure must be relieved and cooled – This is important safety feature of the KVT design.



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Design Features – Bypass & Over Pressurization Protection Design

Flow Direction

• Bypass Valve is used to reduce the traversing differential pressure across the valve seat.

• Also provide a convenient means for the initial warming through of pipe line

• Equalizing device is used to relieve the fluid trapped between the seat faces



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Design Features – In-Line Maintenance & Others

• Stem Packing – Packing stays resilient to maintain long term sealing-ability. KVT use the stem packing of something special.

• Stem Bushing - An Aluminum Bronze alloy bushing with two paired needle thrust bearing eliminates galling of the stem and provide smoother operation, reduce torque , longer life.

• Four windows bar type yoke – to promote air cooling of the packing chamber area, ease access to the pressure seal bonnet and ease disassemble the whole valve as in-line condition.

All KVT Hi-Fluidic Valves have been designed for ease of in-line maintenance, KVT also offers a variety of portable field tools - and the services of KVT trained specialists – to provide in-line repair and refinishing or replacement of internal parts.



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• Torque test results, kgf-cm• Sealing is obtained by sliding, not by compression according to wedging effects.

• Test results of the valve thermal binding.

- Compare with wedge gate valve

- Test specimen : DN 40, ANSI 1500#

- Room temperature & 400℃ hot temp.

- Heating in open position and closed, and then re-open the valve after cooling.

Solid Wedge

SPL PSGV

Close

Open

Close

Open

Normal 404 185 405 184

Heating/

cooled412 997 406 86

• Result show that wedge gate seating tend to jam & binding as a result of body contraction after cooled. Like these malfunction problems often occur of a wedge gate valve if they are closed while hot, and cooled afterwards. SPL PSGV never occur.



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• Longer maintenance free lifetime on sealing surfaces Sealing integrity endurance test

• Test Conditions

- Size : DN40, ANSI 1500#, A105

- Actuator : Spring return(RA), Piston

- Fluid : rusted water

- Open/Closing time : below 10 seconds

Test Results

Number of cycles

Result of valve seat leaks

Specimen 1

Specimen 2

10,000 No leak No leak



40,000 ~ No leak No leak1. Stop at 40,000 cycles due to limited test times.

2. Test duration : 24days

We can guarantee the best quality of seating integrity of a power operated PSGV when introducing CrN super ceramic coating t

o the discs.



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Design Features – FEA Design for Structural Integrity & Thermal

Wedge Gate Valve (open-closed)

PSGV (open-closed)

Wedge Gate – Thermal Stress

PSGV – Thermal Stress

No Good !

Good !



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Design Features – FEA Design for Structural Integrity & Thermal

SPL PSGV General Wedge Gate

Temp.

Appl. Press.

Max. Stres

s

Max. Strain

℃ barg barg mm

OpenPositio

n

40 188 1431 0.031

150 188 3900 0.113

300 188 9673 0.272

ClosePositio

n

40 188 1568 0.030

150 188 3508 0.132

300 188 9359 0.317

Temp.

Appl. Press.

Max. Stres

s

Max. Strain

℃ barg barg mm

OpenPositio

n

40 188 1343 0.039

150 188 6254 0.114

300 1881607

30.235

ClosePositio

n

40 188 1646 0.032

150 188 5214 0.156

300 1881048

60.328



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Design Features – Fluid Flow Analysis by CFD in PSGV Control Valve - example

CFD Model of PSGV Control

100% 80% 60% 40%

Flow Pathlines per Opening %

100% 80%

60% 40%

Strain Rate per Open Rate

100% 80%

60% 40%Achieve good sealing but high fluid

induced strain. So, PSGV control valve should be designed with more stuff trim structural integrity.



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Key Min posed at his PSGVs which are for power station. DN200-ANSI 2500# BW, Bypass & Pressure relieving device, Motor & Manual operated, Total 12 sets

• Pressure sealed bonnet using high density pure graphite gasket (Delta formed)

• To protect bonnet over pressure introducing pressure relieving device

• Bypass piping

• SPL Parallel sliding discs

• Wide flat seats

• Travel stop on Yoke

• Non-revolving stem by stopper

• Different hardfacing on seatings Different hardness ( ~ 5 HRc) on seating surface : Discs – Stl #12, Seat – Stl #6

• Integral back seat in bonnet – conical type

• Flow is directional

• Two thrust bearings and Al-Bronze bushing




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Design Features – Gate Control Valve SPL PSGV

• High Spring Rate of Disc Spring (INCONEL 718) yield a good Sealing

Force• Design of the Outer Edge of Disc is

based on Life Liability Cycle Test (Actual Operation Condition, 172barg-342℃ at KAERI Test Lab)

• Design by FEA, specific for Thermal Effects

• No stopper inside of valve

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Fast Acting Pneumatic PSGVFast Acting Pneumatic PSGV* * – Proto Type Model Testing– Proto Type Model Testing in in hot test loophot test loop

Korea Atomic Energy Research Institute(KAERI)

Thermal Hydraulic Testing Lab

Valve Size : 2”(50mm)

Valve Pressure Class : 2500# RTJ

Opening Time : 0.3 Second

Closing Time : 0.7 Second

Valve Stroke : 50mm

Valve Stroking Speed : 100 mm/sec

(* MOVs Stroking Speed 5mm/sec.)

Testing Cond. : 172barg, 342deg.C

Differential Pressure : 172bar

Fluid Medium : Steam

Test Purpose : Seating Integrity and CrN Coating Endurance Test in Hot Cond.



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Seating Mechanism Advantages Dis-advantages

Solid Wedge1. Increasing stem torque increasing seating force(positive seating)2. Simple 3. By-directional flow

1.Possible seat leaks under hot service due to piping reaction forces such as thermal

2. Possible thermal binding 3. Low flexibility

Split Wedge1. Strong against piping reaction loads2. Increasing stem torque increasing seat force

1. Possible pressure locking 2. Possible seating unstability

Flexible Wedge

1. Low flexibility against piping reaction & thermal

2. Increasing stem torque increasing seat force

1. Possible pressure locking & disc jamming

2. High torque when unseating after cooled

Parallel Slide Double Flat Seat

1. High flexibility to the piping reaction & thermal

2. Constant stem force in open/closing3. Long life seating integrity & easy

maintenance4. Fast acting operation using pneumatic

actuator

1. Possible pressure locking2. Wide flat seat area required

Parallel Expanding

1. Increasing stem torque increasing seat force

2. Positive seating 3. Easy maintenance

1. Possible pressure locking2. Lack of flexibility to piping reaction3. High torque when unseating after

cooled

Knife Gate1. Low pressure service. 2. Good for dirt

fluid3. Low weight

1. Leaks in seat2. No good for high temp. service

Advantages of each type Seating Figuration in a Gate Valve



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Application

Power Generation• Feed Water Heater Isolation• Main Steam Stop & Isolation• Boiler Blow-off • Main Steam Drains• Heater Drains• Turbine Drains• Soot Blower Steam Isolation• Safety Valve Isolation• Blow-down• Reheater Isolation• Boiler Recirculation Pump Isolation• High Energy System Isolation

Others

1. Raw Water (River) Stop Valves

2. Process Steam Stop Valves

3. Quick Open/Close Stop Valves

4. Fast Acting Stop Valves

5. High differential Press. Control Valves such as Blow-down Control

6. Steam Dump Valve



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Quick Opening PSGV

12”, 600# RF, Pneumatic Piston

< Operation Condition >

- Pressure : 60barg

- Temp : 70°F

- Differential Press. : 60bar

- Opening Time : 1.0 second

KAERI Line Breaking Research Work



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Standard Material Construction – Pressure Sealed Bonnet

Part NameCarbon Steel Alloy Steel Stainless

A216-WCB/A105

A217-WC6/F11

A217-WC9/F22A217-C12A/

F91A351-CF8M/

SS316

Body WCB/A105 WC6/F11 WC9/F22 C12A/F91 CF8M/SS316

Bonnet WCB/A105 WC6/F11 WC9/F22 C12A/F91 CF8M/SS316

DiscSS410/

A105+HFF11+HF F22+HF F91+HF SS316+HF

Stem SS410 SS410SS410/SS431

SS316

Seat RingSS410/1020+

HFF11+HF F22+HF F91+HF SS316+HF

GasketMOLD

GRAPHITE

Packing GRAPHITE

Packing Gland SS410 SS316

Bonnet Bolt A193-B7A193-B7/

B16A193-B7/

B16A193-B16 A193-B8

Bonnet Clamp 1045 1045 1045 1045 SS304

Gasket retainer SS410 SS316

Gasket Ring SS410 SS316



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Conventional Valve Problems

Lack of high temperature strength Thermal fatigue cracking. Heavy weights. Crack detection on fabrication welds of forged valve bodies. Welding Dissimilar metals.

9%Cr Alloy Steel Solution(C12A)

Modified 9%Cr typically has twice the hot strength of the usual Chrome Moly and CMV steels. Greater resistance to thermal cracking. Half the weight(could be used with down pressure class)

KVT Valve Developments For Thermal Cycling Plant



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Key Design Constitution of PSGV according to ANSI B16.34

Intermediate Pressure Class and its Wall thickness

Prd = Pr1 +{ (Pd – P1) / (P2-P1) } x (Pr2 – Pr1)

Prd : Intermediate Pressure Class P1 & P2 are ratings corresponding to pressure class Pr1 & Pr2 Pr1 : Low designated pressure class, Pr2 : next designated class of Pr1

tm = t1 + { (Prd – Pr1) / (Pr2 – Pr1) } x (t2 – t1)

t1 & t2 are wall thickness corresponding to pressure class & nominal size of Pr1 & Pr2

KVT design & manufacture the Intermediate Class Valves as per customer requests and/or KVT engineering efforts.

KVT Technology of Fluid Flow ProductDesign Features & User Benefits, Hi-Fluidic®


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KVT - Overall Product Ranges

• Engineering Service related with Valve Technology Valve Engineering supported by CFD & FEA tools

Examples : Reverse Engineering(Design) for anti-cavitation trims of severe service control valve such as CAVITROL-II,III,WHISPER,HUSH,INTROL,etc

• Orifice Technology, Only for Restriction of Fluid Flow Multi-Stage Multi-Hole Cone Type Orifice.

Examples : Boiler Minimum Flow(Recirculation) Line Control Flow Patterner (Flow Conditioner), etc.

• Blowdown Control Valves Orifice Technology

• Control Valves for Severe Service Only Custom Designed, Special

• Turbine Bypass Valve & Desuperheaters Only Custom Designed , Special

• Parallel Slide Gate Valve Pressure Sealed Bonnet, High Class



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Valve Engineering Service

Valve Engineering Tools & Test Facility

• Hardware

- Flow Test Loop upto DN 100, Pressure 60 barg

- Hydrostatic Test Loop, DN 8 through DN 600, Pressure up to ANSI 2500/4500#

- Air Leaks Test, 8barg

• Software

- Computational Fluid Dynamics (CFD), FLUENT

- Fluid Flow, Flowmaster

- Finite Element Analsis(Structural Analysis – Linear, Thermal, Dynamics), ANSYS

- Orifice & Valve Sizing Programs



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Experience & References

• CFD Analysis for Nozzle Design, Korea NPP – Reactor Building Spray

• CFD Design of Moisture Separator (Hydrogen Recombinder) – KNPP

• Re-design the main feed water stop valve(26”-1500#) to reduce pressure drop using CFD Technology

• Vaporizing study in severe cavitating valves of high energy service.

• Pressure drop phenomena study according to check valve types

• System improvement program study introducing proper valve selection



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Control Valves – based on an innovative & reverse engineered design • KCG Control Valves – 3/8”~12”, ANSI Class

150#~2500# General Globe Style Control Valve

• KCG Micro-Flow Laboratory Control Valve Customer-Oriented Specialization

• Special Valves

Ultra low Pressure Control Valve

Hi-Cavitating, Severe Duty Control Valve

Emergency Shut-off Control Valve

• Major Customers

POSCO, KEPCO(KOSPO), KAERI



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Blowdown Control Valves

• Type ABD Angle Type, Most good for high blowdown

• Type SBD Straight Type, Cascade pressure control, can be fine control blowdown (turn down ratio ~ 120:1), mitigate blowdown

• Type TBD 2~4 angle valves combined, Share the pressure drop

• Type PBD Parallel Slide Gate Type, restriction orifices in valve down-stream, can be remote control, heater/main steam drain system

ABD SBD & ABD

Type PBDSpring powered SBD



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Restriction Orifices

• Boiler Minimum Flow Line

On-Off Valve + High Restriction Orifice

• Descaling Line of Steel Woks

Quick Open/Close Valve + Dump to Reservoir

• Heater Drain Lines to Condenser

To avoid erosion of valve body due to severe flashing

• Noise Control Gas/Steam Dump

Use a labyrinth velocity profile orifices

Multi Hole-Multi Stage Orifice

(500MWe TPP, Boiler Mini. Flow Line)



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Desuperheaters, Pressure & Temperature Conditioning Valve (PTCV)

•SAMO : Spring Assist Multiple Orifice Desuperheater

Supplied to POSCO Thermal Power Plant, DN100/ANSI 2500#, 6 Nozzles Orifice

•MNSD : Multi Nozzle Spray Desuperheater– No need spray water control valve

Supplied to POSCO Thermal Power Plant, DN80/ANSI 900#, 6 Nozzles

•PTCV – Turbine Bypass Valves, under construction (deliver to POSCO in April 20)

6”(DN150) x 14”(DN350), WC9, 2500#, Angle Type, Piston Actuator(RA), 2250kgf

Steam Inlet Steam Outlet Cooling WaterParamet

erUnit

127 28.3 155 Pressure barg

538 330 158.2 Temp. (℃)

132,000 152,363 20,363 Flow rate Kgf/hr

Design Parameters of PTCV



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Mo = Ms + Mw

Where, Mo = Flow rate of outlet,

Ms = Inlet flow rate,

Mw = Spray water flow rate

(Ei – Eo)

(Eo – Ew)Mw = Mi

Where, Mi=Ms,

Ei=Inlet steam enthalpy,

Eo=Outlet steam enthalpy,

Ew=Spray water enthalpy,

* Enthalpy is the function of temperature

Mw, EwMs(Mi), Ei

Mo, Eo



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CFD Analysis for Design the Turbine Bypass Valve of Severe Service Duty

Temp.

Pressure

Velocity

Velocity



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Control Valves, Severe Duty Service – Refurbishment Program for the Trim

Based on Reverse Engineering & Field

Experiences• Fisher CAVITROL II, III

Anti-Cavitation Trim

• Fisher WHISPER, WHISPER FLO

Anti –Noise Trim

• COPES-VULCAN HUSH Trims

• CASCADE Trims

• Multi-Stage Restriction Orifice Type Trim

CAVITROL-III Trim Model & Velocity Profile

CAVITROL-III Trim 상단부 케비테이션 예측

Experiences in Korea1. Modification of CAVITROL-III Trim (Reduced Cv

value by 40% - CFD Analysis & redesign, revamping the trim for KEPCO)

2. Introducing a HUSH like trim(multi-hole, multi-cylinder) into PTCV(HP turbine bypass valve) for POSCO

3. Other small jobs



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High Pressure Turbine Bypass Valve, DN150xDN350, 2500#, WC9



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Parallel Slide Gate Valve, KMP-100, DN300-2500#, WC9



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All the products of KVT are based on engineering experience, which are also for valuable

customer satisfaction.

KVT is an ever growing idea company in the valves of high

energy industry.

Epilogue

hi-fluidic parallel slide gate valves design features & user benefits – model kmp-100 fluid...

Documents

piece gate design

design features spl

wedge gate valves

valve body

identical parallel discs

gate trim assembly

spring stiffness hard

thermal expansion slide