Desuperheating SolutionsFixed Nozzle, Minicooler Design and Variable Nozzle

Dynamic Temperature Control for your Entire System

Energy Conservation Environment Process Efficiency| | www.forbesmarshall.com

Forbes Marshall Forbes Marshall Arca Forbes Marshall Codel Krohne Marshall Spirax Marshall Forbes Vyncke

For over six decades, Forbes Marshall has been building steam engineering and control instrumentation solutions that work for process industries. Today we have

evolved into a leader in process efficiency and energy conservation through technology tie-ups and focused investments in manufacturing and research. Our joint

ventures with the world's leading names enable us to deliver quality solutions in 18 countries. Forbes Marshall is unique in having extensive expertise in both

steam and control instrumentation. The dual expertise has allowed us to engineer industry specific systems that focus on energy efficiency and utilities

management for diverse sectors such as textiles, food processing, paper, power, mining, oil and gas, and chemicals.

Our teams consist some of the finest engineers and talent. These highly trained professionals have developed innovative solutions to better process efficiencies

and help save millions of dollars for our clients. Our business practices and processes have combined into a singular philosophy of being trusted partners who

provide innovative solutions. It's a philosophy we are proud to live up to.

We have long standing partnerships with some of the best names in the control instrumentation industry such as Spirax, Arca, Codel, Krohne and Shinkawa, to

develop, design and supply innovative solutions for measurement and monitoring of process parameters. With a combination of specialist knowledge and the

latest technology, we provide products and solutions to achieve optimum efficiency. Our products are a unique combination of hardware and software that

make them reliable and accurate.

Steam DesuperheatingForbes Marshall ranks amongst the world's leading suppliers of steam desuperheaters. We specialize in designing and manufacturing such equipment for power,

process and co-generation plants. Forbes Marshall has supplied more than 5000 desuperheaters since 1990. The most practical way of reducing the superheat value

of steam is by the direct injection of water. To achieve temperature stability of the conditioned steam and prevent thermal shock in downstream pipes, cooling water

must be atomized. It is also necessary to have a correct mix of superheated steam and cooling water. To achieve this Forbes Marshall Offers 3 different types of

application based desuperheaters.

Fixed Nozzle Desuperheater - FNDA fixed nozzle desuperheater is essentially a mechanically atomized, back-

pressure-activated desuperheater, with spray nozzles designed for

applications requiring control over moderate load fluctuations. The FND

desuperheater is installed through a flanged connection on the side of a

DN150 (NPS 6”) or larger pipeline and has spray nozzles ranging from a

single nozzle to an array of various nozzles as required as per the line

size.A Forbes Marshall fixed nozzle Desuperheater in conjunction with the

cooling water control valve and temperature loop reduces the superheat

of inlet steam and thereby the temperature.

Features

• Single nozzle Cv as low as 0.019 and as high as 1.872

• Various nozzle combinations available as per pipeline diameter

• For any possible pipe size above 150mm (6")

• Ideal for use in conjunction with water control valve and control system

• Turndown ratio upto 4:1 (depending on water quality)

• Pressure rating upto ANSI #2500

• Can be used up to 540°C (1004°F)

Notes

• Water pressure should be minimum 7 bar (100 psig) more than the

steam pressure

• Maximum recommended pressure difference between steam and water

is 45 bar (653 psig). If it exceeds 45 bar (653 psig) then install pressure

control valve in waterline to reduce water pressure within limits

• Spray water should be very clean (equivalent to boiler feedwater)

• Length of FND insertion will depend upon pipeline size

4 11

10

465

43

8

7

291

AIR SUPPLY

INLET

WATER

(LOOSE SUPPLY)

STUB WITH SORF FLANGES

INLET

STEAM STEAM

OUTLET

AIR SUPPLY

Total Desuperheating system along with control loop

Sr. Kv per Nozzle Cv per Nozzle 'A'

1 0.0162 0.019 100(4”) 25(1”) 200(8”)

2 0.0348 0.041 100(4”) 25(1”) 200(8”)

3 0.0714 0.084 100(4”) 25(1”) 200(8”)

4 0.106 0.124 100(4”) 25(1”) 200(8”)

5 0.138 0.161 100(4”) 25(1”) 200(8”)

6 0.175 0.205 100(4”) 25(1”) 200(8”)

7 0.204 0.239 100(4”) 25(1”) 200(8”)

8 0.233 0.273 100(4”) 25(1”) 200(8”)

9 0.273 0.319 100(4”) 25(1”) 200(8”)

10 0.312 0.365 100(4”) 25(1”) 200(8”)

12 0.864 1.011 150(6”) 50(2”) 300(12”)

13 1.6 1.872 150(6”) 50(2”) 300(12”)

'B' 'C'

Water in

Water Flange

Steam Flange

Nozzles

Typical FND

ABL

RF F

LNG.

BSW

RF F

LNG.

C

D

Pipeline Center

For Nozzle Cv's between0.019 - 0.365

For Nozzle Cv's between1.011 - 1.872

Pipeline 'D’

150-300 (6”-12”) 545 (21.45”)

350-600 (14”-24”) 685 (26.96”)

650-1000 (26”-40”) 885 (34.84”)

Pipeline 'D’

100-125 (4”-5”) 400 (15.74”)

150-300 (6”-12”) 495 (19.48”)

350-600 (14”-24”) 635 (25”)

650-1000 (26”-40”) 835 (32.87”)

Advantages

• Custom made for any size, standard or range

• Simple installation

• Can be used for higher pipe sizes and low steam pressure

• No moving parts

Advantages

• Instantaneous water mixing

• Less straight length requirement

• Absence of moving parts avoids possibility of choking

INLET

INLET

AIR SUPPLY WATER

11 AIR SUPPLY

STEAM

412

3 4

46

5 7

1 8

9

210

OUTLET

STEAM

Sr. Description Sr. Description

1 Dial Thermometer 7 Pid Controller

2 Dial Thermometer 8 Spray Nozzle Insert

3 Non-return Valve 9 Temperature Sensor

4 Stop Valve 10 I / P Convertor

5 Water Flow Control Valve 11 Pipe Work

6 Strainer

Bill of Materials

Minicooler Desuperheater (MCD)

Features:

•

1.872

• Can be used in pipe sizes 25mm (1") - 100mm (4")

• Turndown ratio upto 1:4

• Available upto Pressure rating #1500

• Can be used up to 540°C (1004°F)

Single nozzle Cv as low as 0.019 and as high as

Sr. DESCRIPTION

1 DIAL THERMOMETER

2 DIAL THERMOMETER

3 NON-RETURN VALVE

4 STOP VALVE

5 WATER CONTROL VALVE

6 STRAINER

7 TEMPERATURE CONTROLLER

8 MINI COOLER DESUPERHEATER

9 STEAM PIPELINE

10 TEMPERATURE SENSOR

11 I / P CONVERTOR

12 PIPE WORK

Bill of Materials

Notes

• Water pressure should be minimum 7 bar (100 psig) more than the steam pressure

• Maximum recommended pressure difference between steam and water is 45 bar (653 psig). If it exceeds 45 bar (653 psig) then install pressure control valve in waterline to reduce water pressure within limits

• Ideal for use with Forbes Marshall make water control valve and control system

• Spray water should be very clean (equivalent to boiler feedwater)

Size #300 #600 #900 #1500

25 NB (1”) 197(7.75”) 210(8.26”) 273(10.74”) 273(10.74”)

50 NB (2”) 267(10.5”) 286(11.25”) 375(14.76”) 368.3(14.48”)

80 NB (3”) 317(12.48”) 356(14.01”) 381(15”) 470(18.50”)

100 NB (4”) 369(14.52”) 394(15.51”) 457(17.99”) —

Spray water line:

In operation, spray water is supplied through a water control valve to the desuperheater through a top end connection. A signal from a downstream controller to the control valve positioner actuates the valve to control the amount of spray water flow for cooling. The spray water control valve is a separate valve in the spray water line.

Minicooler Desuperheater is a unique device with a top entry nozzle fitted in an enclosed body. This simple design with a fixed nozzle is extremely efficient as it injects water in an enclosed zone in which the steam flow pattern has the highest turbulence which is excellent for homogenising atomised water with steam.

MCDs are best suited for specific application like ejector gland sealing steam where cooling water injection quantity is low.

WATER IN

25 NB #1500 RF/RTJ

STEAM

IN

25 NB #1500 RF

A± 1.6

1

STEAM

OUTB

Dimension B

Dimension A

Size #

25 NB (1”) 450(17.71”) 460(18.11”) 460(18.11”) 460(18.11”)

50 NB (2”) 465(18.30”) 530(20.86”) 555(21.85”) 555(21.85”)

80 NB (3”) 513(20.19”) 565(22.24”) 565(22.24”) 655(25.78”)

100 NB (4”) 520(20.47”) 645(25.39”) 565(22.24”) —

300 #600 #900 #1500

Sr. Kv Cv

1 0.0162 0.019

2 0.0348 0.041

3 0.0714 0.084

4 0.106 0.124

5 0.138 0.161

6 0.175 0.205

7 0.204 0.239

8 0.233 0.273

9 0.273 0.319

10 0.312 0.365

12 0.864 1.011

13 1.6 1.872

Nozzle Nozzle

Variable Nozzle Desuperheater - VND

Forbes Marshall has incorporated the latest technology in the spray nozzle

design. The Forbes Marshall VND consists of a nozzle head assembly of three

components

A) Spray head B) Nozzle C) Nozzle cap

Each nozzle assembly is served by individual feed holes in the spray cylinder.

Water enters the chamber through these openings. The relatively large volume

of this chamber ensures that water is proportioned evenly through each orifice.

The pressure drop across this spray cylinder head results in an increase in the

fluid velocity.

Water is subsequently rotated in the nozzle chamber before being emitted

through the central hole. The combination of splitting the feed flow,

increasing velocity and rotating effect ensures that water is injected into

the system in a symmetrical hollow cone spray. The high quality surface

finish minimises frictional losses, thereby ensuring that the total pressure

difference between water and steam is available for atomisation of water.

The nozzles are finally assembled with the spray cylinder and are sealed.

The Variable Nozzle Desuperheater may be equipped with a variety of

spray heads. Standard configurations are with either 6 or 9 equally sized

spray nozzles. Special Cv combinations are available for customised VNDs

to suit customers’ specific system requirement.

VND does not require a separate water control valve for its operation as it

regulates the water quantity to be injected by itself.

1) Spray head2) Nozzle3) Nozzle cap

• Spray water must be injected in the direction of the Steam flow.

• To facilitate installation of the water supply line, one of the following four positions have to be indicated before ordering:

SP3 - Along direction of flowSP6 - Transverse right to direction of flowSP9 - Opposite to direction of flowSP12 - Transverse left to direction of flow

NOZZLE POSITIONS

FLOW

STEAM

SP6 SP9SP3 SP12

VND Standard Capacity Range

6A Kv = 0,065 Cv = 0.076 9A Kv = 0,097 Cv = 0.113

6B Kv = 0,137 Cv = 0.160 9B Kv = 0,205 Cv = 0.240

6C Kv = 0,263 Cv = 0.308 9C Kv = 0,395 Cv = 0.462

6D Kv = 0,505 Cv = 0.591 9D Kv = 0,758 Cv = 0.887

6Dx Kv = 1,000 Cv = 1.170 9Dx Kv = 1,500 Cv = 1.755

6E Kv = 1,640 Cv = 1.919 9E Kv = 2,460 Cv = 2.878

6F Kv = 2,450 Cv = 2.867 9F Kv = 3,680 Cv = 4.306

6G Kv = 5,200 Cv = 6.084 9G Kv = 7,800 Cv = 9.126

6H Kv = 8,100 Cv = 9.477 9H Kv = 12,150 Cv = 14.216

6K Kv = 11,570 Cv = 13.537 9K Kv = 17,440 Cv = 20.405

2

3

1

1

2

3

Spray water line:

In operation, spray water is supplied through a water control valve to the desuperheater through a top end connection. A signal from a downstream controller to the control valve positioner actuates the valve to control the amount of spray water flow for cooling. The spray water control valve is a separate valve in the spray water line.

Water Flange Orientation for VND

Features

• Available in 6 and 9 nozzle design

• Compatible with both pneumatic and electric

actuators

• Design as per ANSI B 16.34

• Graphite packing provided for optimal sealing with

stem

• Suitable to fit a variety of yokes. (ideal with - Forbes

Marshall make pneumatic diaphragm actuator)

• Stem - ground, hardened and roller burnished to a

fine finish for optimum performance

• Ensures back-seat sealing due to fine machining and

lapping of the seat after welding

• High performance spray head assembly. Gives fine

atomisation of spray water

• Can be used up to 540°C (1004°F)

WATER INLET

STEAM

OUTLET

STEAM

AIR

SU

PPLY

5

1

6

2

4

3

Schematic Diagram

INLET

Total Desuperheating system along with control loop

Detail ‘X’

X

1

6

16

12

3

2

4

5

7

19

8

9

17

14 15

13

18 11

10

POSITIONER

WATER

ACTUATORAIR TO OPEN

AIR FILTER AND REGULATOR

13.5mm (1/4") NPT(F)

Typical VND

Bill of Materials

Sr. DESCRIPTION

1 DIAL THERMOMETER

2 DIAL THERMOMETER

3 TEMPERATURE SENSOR

4 PID CONTROLLER

5 I / P CONVERTOR

6 AIR FILTER and REGULATOR

Sr. DESCRIPTION

01 SPRAY CYLINDER

02 NOZZLE ASSY.

03 PISTON RING (3)

04 PISTON

05 FASTENER RING

06 SEAT

07 STEM

08 BODY

09 WATER FLANGE

10 SPACER

11 NUT

12 PACKING SET

13 STUD

14 GLAND

15 PLATE

16 NAME PLATE

17 NUT

18 SECURING WASHER

19 BODY FLANGE

AB

CD

E

F

Sr. Pipeline Size Stroke A B C D E F

1 150NB to 300NB (6” to 12”)

90 (3.54”) 66.5 (2.61”) 385(15.15”)

200(7.87”)

120(4.72”)

80(3.14”)

80(3.14”)

55 (2.16”) 60 (2.36”)

2 350NB to 600NB (14” to 24”)

90 (3.54”) 66.5 (2.61”) 528(20.78”)

200(7.87”)

120(4.72”)

80(3.14”)

80(3.14”)

55 (2.16”) 60 (2.36”)

3 650NB to 1000NB (26” to 40”)

90 (3.54”) 66.5 (2.61”) 735(28.93”)

200(7.87”)

120(4.72”)

80(3.14”)

80(3.14”)

55 (2.16”) 60 (2.36”)

4 1050NB to 1200NB (42” to 48”)

90 (3.54”) 66.5 (2.61”) 835(32.87”)

200(7.87”)

120(4.72”)

80(3.14”)

80(3.14”)

55 (2.16”) 60 (2.36”)

Dimensions for Model 38

300(11.81”)

200(7.87”)

100(3.93”)

100(3.93”)

Dimensions for Model 48

Sr. Pipeline Size Stroke A B C D E F

1 150NB to 300NB (6” to 12”)

90 (3.54”) 66.5 (2.61”) 528(20.78”)

300(11.81”)

200(7.87”)

100(3.93”)

100(3.93”)

55 (2.16”) 60 (2.36”)

2 350NB to 600NB (14” to 24”)

90 (3.54”) 66.5 (2.61”) 640(25.19”)

55 (2.16”) 60 (2.36”)

3 650NB to 1000NB(26” to 40”)

90 (3.54”) 66.5 (2.61”) 835(32.87”)

300(11.81”)

200(7.87”)

100(3.93”)

100(3.93”)

55 (2.16”) 60 (2.36”)

4 1050NB to 1200NB(42” to 48”)

90 (3.54”) 66.5 (2.61”) 940(37.00”)

300(11.81”)

200(7.87”)

100(3.93”)

100(3.93”)

55 (2.16”) 60 (2.36”)

mm

(6”)

NOZZLE POSITIONS

FLOW

STEAM

SP6 SP9SP3 SP12

Notes

• Maximum recommended steam pipe size is 1200mm (48”)

• Minimum pipe size required for installation of VND is 150mm (6”)

• VND can be fitted in 100mm (4”) pipe size for nozzle upto 4Dx

• Water pressure should be minimum 5 bar (72.51 psig) more than the steam

pressure

• Maximum recommended pressure difference between steam and water is

45 bar (652.66 psi). If it exceeds 45 bar (652.66 psi) then install pressure

control valve in waterline to reduce water pressure within limit

• Spray water should be very clean (equivalent to boilerfeedwater)

• Model 38 with a maximum water flow capacity of 25 m³/ hr (14.6 cfm) in

continuous service

• Model 48 with a maximum water flow capacity of 50 m³/ hr (29.4 cfm) in

continuous service

• Pressure Rating: Upto ANSI #2500

• Available Forbes Marshall Pneumatic Actuators For Mounting

A. 'A' To 'Dx' Nozzles: UIII-60 n/v

B. 'E' To 'K' Nozzles: UV-100 n/v

• Rangeability

For 6 Nozzle Head: 1:18

For 9 Nozzle Head: 1:27

For Mixed Nozzle Head: More Than 1:27 (as Per Customer's Specifications).

• Custom designed for any size, standard or range

• Simple installation

• VND ensures a fine conical spray that evaporates almost instantaneously,

avoiding pipe impingement

• Eliminates need of a separate coolant valve

• More turndown ratio possible

• Large desuperheating range because of number of available nozzles

Advantages

Typical Applications of Desuperheaters

• Turbine Bypass

• Turbine Exhaust

• Turbine Bleed Steam

• Auxillary Steam

• Process Steam

• Attemperator

• Pressure Reducing Valve Outlet Steam

• Boiler Superheaters

• Boiler Re-heaters

and many more similar applications.

Required Sizing Parameters

Steam Data

Inlet Pressure Bar(g)/psig Inlet Pressure Bar(g)/psig

Inlet Temperature °C/°F Inlet Temperature °C/°F

Outlet Temperature °C/°F

Steam flow (Inlet) kg/hr or lbs/hr (Min/Nor/Max)

General

Pipe Size mm/inches

Pipe Schedule

Turndown Ratio

Water Flange Orientation: SP3 / SP6 / SP9 / SP12

(for detail refer to figure below)

Water Data

Governing Formula for Desuperheater

Mw = Mst x (h1 -h2 )

(h2- hw)

where

Mw = Water Injection mass in kg/hr (Lbs/hr)

Mst = Inlet Steam Mass in kg/hr (Lbs/hr)

h1 = Enthalpy of Inlet Steam in Kcal/kg (Btu/Lb)

h2 = Enthalpy of outlet steam in Kcal/kg (Btu/Lb)

hw = Enthalpy of injection Water in Kcal/kg (Btu/Lb)

Good engineering practices for efficient Desuperheating

• Minimum inlet velocity should be 15m/sec (2952.76 ft/min) for FND and 7m/sec (1377.95 ft/min) for VND

• Minimum straight length downstream beyond the Desuperheater should be 4m (13.2 ft) with minimum possible bends upto temperature sensor

• Optimum distance between water injection point to the temperature sensor mounted downstream should be 12m (39.37 ft)

• It is necessary to keep the steam flow rates (for max. and min conditions) as practical as possible. Else the turndown ratio increases unnecessarily whichnecessitates the selection and use of a combination of nozzles in the same spray cylinder

• Installation of a strainer with a mesh size of approximately 100 µ (3.93 thou) in the water supply line to prevent the nozzles from clogging is essential

• In case the temperature difference between cooling water and steam is above 230ºC (446 deg F) a thermal liner of 4.6m (15 ft) in length must be provided downstream

Environment:

Here at Forbes Marshall we feel responsible for the environment and actively involve is conserving the same. We

not only offer an array of products that help in conserving our environment but we also involve ourselves in

specific manufacturing process to enhance our sustainability.

All our Desuperheaters have asbestos free packing. The gland packing is self-adjustable and self-lubricated which

ensures zero gland leakage. All our water control valves have stainless steel bonnets and sleeves which ensure no

corrosion and thereby no leakage to the atmosphere even in the long run.

Our features How you benefit

High turn down ratio of 1:27 and even more in VND Multiply quantity injection ensures high range of

precision control with faster speeds of operation

No need of water control valves in VND Saves you space and hardware required

MCD design suitable for low steam flow rates Cooling water injection in a contained high turbulence

zone ensuring instantaneous homogenisation

FND customized with a fully fabricated body Customized as per line size and can have multiple

nozzles even for very high line sizes

VND spry profile ensures proper evaporation even at Reduces chances of water accumulation ensuring better

lower steam velocities steam efficiency

Fuel Saving and Process optimization:

Imagine a situation where the controlled outlet temperature is higher than the saturation temperature and the steam is to be

used for heating application. It is absolutely necessary that for such applications the outlet steam temperature should be as close

as possible to its saturation temperature. The sole reason for this is, saturated steam is the best conductor of heat and as the

degree of Superheat increases, the heat transfer reduces. In addition to this the cooling spray water injected homogenizes with

the steam which further adds to the quantity of steam flow which is used for the processes downstream. Both these facts

coupled help to achieve operational optimization lowering fuel costs. This is achieved best with the effective and accurate Forbes

Marshall Desuperheater. Based on these two factors we at Forbes Marshall quantify your fuel cost savings and your pay back on

every equipment we supply.

Our Deuperheaters are accurately designed and function within a maximum tolerance of ±3 deg C (±5ºF). Our ISO 9001 certified manufacturing capabilities guarantee the functioning of our products and we offer a warranty of 1 year on all our products.

All our products are CRN certified.

Ordering Information:

To order any of our desuperheaters, please furnish us the following process parameters and let our engineers offer you a solution best suited for your process:1) Inlet steam Flow Rate2) Inlet steam pressure and temperature3) Required outlet steam temperature4) Available water pressure and temperature5) In case the steam flow rate in not available you may furnish the steam pipeline size.

We are proud to offer ideal solutions, through our tacit and explicit knowledge based on 60 years of experience and expertise to meet customized and complex industry applications. Please call our local representative or Head office as per the contact details given behind for any query or doubt.

Your local Forbes Marshall representative would be happy to provide youwith further information and support.

AMERICA

USAForbes Marshall Inc. USA480,California Avenue,Suite 102,P.O. Box 60670Palo Alto CA 94306California,USATel: +1 650 327 4227/ +1 650 321 4224Fax: +1 650 327 4127/ +1 650 321 4454Email: forbesmarshall@ix.netcom.com

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ASIA PACIFIC

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AFRICA

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MIDDLE EAST ASIA

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