Application Digest - 27-12-07

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APPLICATION DIGEST

March 2008 First Edition

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We Solve Control Valve Problems.

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INDEX

1. History . 5 2. Technology Centers . 7 3. Valve Doctors .. 9 4. CCI in Oil and Gas .. 21 5. CCI in Power 23 6. CCI in Nuclear . 24 7. Product Sheet .. 25 DRAG PRODUCTS 100 DSV spray water valve 100 D choke valve V0 600 ABJ desuperheater 100 DR boiler feed pump recirculation

valve Compressor recycle anti surge valve 800 D Korean valve 100 DLC feed water control valve 100 DPC well head production choke valve

KOREAN PRODUCTS 840 G/H Korean valve 830 T three way valve 840/860 TBS (LLP) Korea

FLUID KINETICS Desuperheaters DAM, DAM-D, DAM-E Silencers Blow off silencer

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Control valve silencer Gas diffuser silencer Compressor silencer Reactive silencer Hydraulic acoustic filter Liquid pulsation dampener SSC/Stabilizer/Separator Steam vent silencer Fluid kinetics in various industries Fluid kinetics in power Fluid kinetics in petrochemical

STI PRODUCTS Actuators SC Series SC/V Series CMV/CML Series APL Series Positioners DE/3M SA/CL-1 SRCCK UP!/R CRP/SS Accessories Position transmitter Air lock device Derivative booster Manual over ride

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Derivative unit

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HISTORY CCI, or Control Component Inc., was created in 1961 by Richard Self, who started the company when he saw a need for valves that could handle very high-pressure liquid hydrogen and oxygen. It was during his research that the right-angle tortuous flow path of CCI DRAG valve trim was conceived. The industry acknowledged this concept as a great leap forward in valve design, and in the 1980s, the Instrument Society of America recognized Richard Self for his contribution to the advancement of flow control technology. In 1971, Self sold CCI to the Babcock and Wilcox Company to finance the rapidly growing company. Later in 1981, British-based IMI, which also saw the growth potential of DRAG in the industry, acquired CCI. Due to the Companys success in the 1980s and 1990s, CCI acquired the Sulzer Companys Thermtec division in 1997 and BTG Valves in 2001. As the worlds leading supplier of severe service controls, CCI strives to expand its outstanding portfolio of products and services. CCI Italy (formerly STI) designs and produces linear pneumatic actuators and accessories for severe service develops accessories for actuators. Furthermore, Fluid Kinetics, which CCI acquired in 2003, extends CCIs leadership by adding more solutions to CCIs resume. Fluid Kinetics is a premier supplier of customized industrial silencers to the power, oil and gas, and industrial gas markets. The combination of Fluid Kinetics in depth silencer expertise and CCIs severe service knowledge and experience positions CCI to provide superior noise solutions to meet customers unique needs. Later in 2003, Herion-Werke KG Gmbh Nuclear Process and Nuclear Process Control products were formally

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transferred from IMI Norgren to CCI. CCI manufactures the Herion solenoid-operated valves, which are extensively used in the Nuclear Power Industry, at its CCI-AG facilities in Winterthur, Switzerland. These synergies support CCIs commitment to meet its customers needs by offering quality products backed by the superior service.

CCI is Solutions: CCI is problem solving CCI is engineering know-how CCI is experience CCI is proven technology CCI is reliability CCI is performance CCI is the leader in severe service control valve solutions. With worldwide manufacturing facilities and a team of expert engineers, we provide you with the custom solution that you need for any application challenge, in any industry, in any part of the world, at any time.

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Our unique Valve Doctor performance experts offer decades of experience and their ongoing commitment to bring a plant to its peak potential always with a focus on safety and reliability. CCI VALVE DOCTOR

Eighty percent of the Valves and controls in the world are healthy or have some minor problems and there are many companies that can take care if these valves. CCI specializes in severe service- the valves and controls that continually cause problems, need protection from difficult environment, or have developed the need for the major replacement. The best severe service valve and control experts in the world are CCIs Valve Doctors. A Valve Doctor is a highly experienced principal valve and control applications expert who provides the detailed solutions for complex applications. This team of specialists provides a unique combination of engineering expertise and global resources with one goal; to prevent or cure customer problem. Customers around the world have saved millions of dollars by using the knowledge and experience of a CCI Valve Doctor.

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TECHNOLOGY CENTERS

CCI-Korea

10F, Sinwon B/D, 210-1, Hangangno-2GA, Yongsan-Gu Seoul, South Korea

Ph : +82 (0)31 980 9960

Fax:

CCI-KK

6-2-2 Takatsukadai, Nishi-ku Kobe City, Hyogo 651-2271 Japan

Ph : +81 78 991 5940

Fax:

CCI-RSM

22591 Avenida Empresa Rancho Santa Margarita, CA 92688 U.S.A.

Ph : +1 949 858 1877

Fax: +1 949 858 1878

CCI-STI

Via G. Pascoli, 10 a-b 24020 Gorle (Bergamo) Italy

Ph : +39 035 2928

Fax: +39 035 2928 247

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CCI-Sweden

Industrigatan 1-3, Box 603 SE-661 29 Saffle Sweden

Ph : +46 533 689 600

Fax: +46 533 689 601

CCI-Switzerland

lm Link 11, P.O. Box 65 8404, Winterthur Switzerland

Ph : +81 78 991 5940

Fax: +41 52 264 95 00

CCI-Vienna

Lembockgasse 63/1 AT-1233 Vienna Austria

Ph : +43 1 869 27 40

Fax: +43 1 865 36 03

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VALVE DOCTORS

Ron Adams Technical Specialist CCI-RSM +1 949-858-1877 [email protected]

Expertise: DRAG

Kiho Ahn Manager-Technical Service CCI-Korea +82 31-980-9930 [email protected]

Expertise: 800 Series

Franz Albrecht Technical Service CCI-Vienna +43 1 869 2740 127 [email protected]

Expertise: BTG, DRAG, Fossil Power

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Sina Alikhani Director-Nuclear Product Dev CCI-RSM +1 949-888-4168 [email protected]

Expertise: DRAG, Nuclear

Peter Baumann Testbed & Actuator Manager CCI-Switzerland [email protected]

Expertise: Sulzer

Urs Blumer Sr Consultant Nuclear Services CCI- Switzerland +41 52 264 9556 [email protected]

Expertise: Sulzer, Nuclear

Peter Borzsony Mktg Mgr Fossil Power CCI-UK +44 (0) 161-655-1688 [email protected]


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Eddie Chau Engineering Manager O&G CCI-RSM +1 949-858-1877 [email protected]

Expertise: DRAG, Oil & Gas

Jay Faramarzi Vice President - R&D CCI-RSM +1 949-888-4190 [email protected]

Expertise: DRAG, Fossil Power, Oil & Gas

Konrad Fluri Sr. Manager CCI- Switzerland +41 52 264 9756 [email protected]

Expertise: Sulzer, Fossil Power

Tord Forslund Chief Engineer CCI-Sweden +46 533 689 671 [email protected] Expertise: BTG, Fossil Power, Pulp & Paper

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Steve Freitas Development Manager, Power CCI-RSM +1 949-858-1877 [email protected]

Expertise: DRAG, Fossil Power

George Friedrichs Manager, Technical Services CCI-RSM +1 949-888-4191 [email protected]


Charlie Hart R&D Lab Manager, RSM CCI-RSM +1 949-858-1877 [email protected]

Expertise: DRAG

Mauro Giovanelli Engineering Manager CCI-STI +39 035 292 8227 maurogiovanelli@stistrumentazione.

Expertise: STI, Actuator Accessories

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Martin Huber Engineering Manager, Power CCI-Vienna +43 1 869 2740 [email protected]


Sven-Ake Jacobsson Development Engineer CCI-Sweden +46 533 689 657 [email protected]

Expertise: BTG, Fossil Power

Ulrich Kaegi Mgr Tech Services CCI- Switzerland +41 52 264 9757 [email protected]

Expertise: Sulzer, DRAG, Fossil Power

Thang Ly Manager- Global Standards CCI-Vienna +43 1 869 2740 * 129 [email protected]

Expertise: DRAG, Oil & Gas

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Brian Metz Program Manager Development CCI-RSM +1 949-888-4314 [email protected]

Expertise: DRAG, Nuclear, Fossil Power

Herb Miller Consultant, Principal Engineer CCI-RSM +1 949-888-4049 [email protected]

Expertise: DRAG

Stan Miller Director of Development, Power CCI-RSM +1 949-858-1877 [email protected]


Tomoaki Miyoshi VP-Operations CCI-KK +81 78 991 5967 [email protected]

Expertise: AB Japan, Fossil Power

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Antonio Negri Operations Manager CCI-STI +39 035 2928228 [email protected]

Expertise: STI, Actuator & Accessories

Steven Oh Operation Manager, China CCI-China +86 21 6518 8455 [email protected]


Shigekazu Nishiyama Engineering Manager CCI-KK +81 78 991 5940 [email protected]


Arvind Patel Principal Engineer CCI-RSM +1 949-888-4006 [email protected]

Expertise: DRAG

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Chris Peterson Engineering Manager Power CCI-RSM +1 949-858-1877 [email protected]


Francesco Rusmini Quality Manager CCI-STI +39 035 2928 262 [email protected]


Dale Schmaeman Chief Engineer CCI-Ventura +1 805-644-5587 [email protected]

Expertise: Fluid Kinetics, Silencers, Fossil Power

Sanjay Sherikar Manager- Tech Development CCI-RSM +1 949-888-4133 [email protected]


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Kouichi Shibata Project Management CCI-KK +81 78 991 5940 [email protected]


Ricardo Simeoni Manager, Factory Sales CCI-Houston +1 713-869-5233 [email protected]

Expertise: DRAG, Oil & Gas, Anti-Surge/Compressor Recycle

Joe Steinke Development Manager, O&G CCI-RSM +1 949-888-4195 [email protected]


Curtis Sterud Consultant, Principal Engineer CCI-RSM +1 949-858-1877 [email protected]


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Larry Stratton Manager, Technical Services CCI-RSM +1 949-888-4136 [email protected]


Sam Sturtevant Project Manager- Development CCI-RSM +1 949-888-4126 [email protected]

Expertise: DRAG

Per Sundberg Upgrades manager EAME CCI-Sweden +46 533 689 734 [email protected]

Expertise: BTG

Flavio Tondolo Engineering Manager CCI-STI +39-035-2928-241 [email protected]


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Tobias Zieger Deputy Director Nuclear D CCI- Switzerland +41 52 264 9759 [email protected]

Expertise: Sulzer

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CCI IN FOSSILE POWER Types of Power Plant are supercritical, combined cycle, conventional drum. CONTROL VALVES IN A POWER PLANT:

1. Condensate pump minimum recirculation valve. 2. Deaerator level control valve (Main condensate

control valve). 3. LP/IP/HP heater drain valves. 4. Deaerator pegging steam valves. 5. Startup feed pump recirculation valve. 6. Boiler feed pump minimum recirculation valve. 7. Feed water control valve. 8. Feed water startup valve. 9. Superheater spray control valve. 10. Superheater spray block valve. 11. Block valve. 12. Soot blower valve. 13. Header drains. 14. APRDS PRV. 15. APRDS spray control valve. 16. Reheater spray control valve. 17. Reheater spray block valve. 18. LP/IP/HP Turbine stop valve. 19. LP//IP/HP Turbine control valve 20. LP/IP/HP Turbine Bypass valve. 21. Turbine drains. 22. LP/IP/HP DSH spray control valve. 23. Cooling water control valve.

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Schematic-showing the Control Valves used in a Power plant.

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CCI IN OIL & GAS Types of Oil and Gas industries are LNG, Oil and Gas extraction, Gas treatment, Petrochemical, Pipe Transportation. CONTROL VALVES IN OIL & GAS: Production chokes Separator level control Gas lift/injection Injection pump recycle Overboard dump Gas regulator Surge relief Hot gas bypass Gas to flare Amine letdown Expander bypass Vent to atmosphere Feed water regulator Feed water pump recirculation Spray water Steam header pressure control.

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CCI IN NUCLEAR Types of Nuclear plants are PWR, BWR, AGR, CANDU. CCI IN CHP Types of CHP are Desalination, Ethylene Plants, Refineries, steel Mills, Aluminum Plants, Chemical Plants, Paper and Pulp, Waste to Energy.

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PRODUCTS DATASHEET

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DRAG TECHNOLOGY Drag is a CCI designed, built and patented technology for control valve. It answers various need for valve capable of handling high-pressure liquids and gases such as water, oil, steam, natural gas, petroleum products and chemicals. DRAG technology is dependent on philosophy of velocity control. High fluid velocity through valve trim is a principal source of system control problems. System control is lost due to valves damaged by the effects of cavitation, erosion, abrasion and vibration, which can quickly destroy a valve and disrupt system operation.

The DRAG trim forces the flow to travel to through paths of turns. Each turn causes a pressure loss to the fluid so the pressure gradually reduces over the turns. This series of multiple pressure drops allows the pressure to reduce without falling below the vapour pressure and so avoids cavitation. High trim exit velocities are commonly responsible for erosion damage in control valves. The velocity control DRAG trim eliminates problems with trim erosion by limiting the trims fluid exit velocities and corresponding kinetic energy.

DRAG 100DSV

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SPRAY WATER VALVE Type: 100DSV

Sizing Tool: Valsiz PowerSiz

Design Loc: CCI-RSM CCI-Vienna CCI-Korea Application: The 100DSV is designed for Spray water Control valves application used in: Superheat; Reheat; Main Steam Bypass to Cold Reheat; and Auxiliary, Export, or Process Steam. These valves regulate steam temperature by controlling the flow of water into desuperheater nozzles. The pressure drop across the valves (P) is dependent upon the size of the desuperheater nozzles. Description: The 100DSV is available in angle and globe configuration and in four trim sizes (3/8, 5/8, 1.0, and 1.5). The same base valve body is used for globe or angle pattern valves. It is designed for up to ASME 2500 rating with a gasket seal design. The trim is an equal-percentage, over the plug flow disk stack design. The standard is a spring diaphragm actuator.

DRAG 100DSV

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Features: DRAG Velocity Control Protects Valve Trim. Up

to 20 stages used to limit trim exit velocity to 100 ft/sec (30 m/sec) or less. Eliminates erosion and cavitation damages.

Improve Heat Rate Efficiencies. The 100DSV minimizes lost energy through leakage and lost production which results in significant cost savings.

Reliable and Repeatable Long Term Shutoff

Eliminates Leakage. Designed with a hard seating surface, DRAG velocity control and actuator sized to 500 PLI, the trim maintains a tight shutoff.

Improve Temperature Control. Equal-percentage

trim characteristic to meet your plant specifications combined with a long stroke and high actuator resolution to improve control.

Reduce Maintenance Costs. Costly and frequent

maintenance procedures are eliminated by DRAG velocity control, actuator sizing and seat ring design. Erosion is eliminated.

Easy to Service Design. Top entry design

minimizes service time, and no welding or inline machining required.

DRAG 100DSV

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Quality Specifications: Valve Specifications:

Body Configuration Globe or Angle Pressure Rating ASME 2500 Max. Inlet Temperature 500 F (260 C) Flow Direction Over-the-Plug

(Flow-to-Close) Rangeability 100:1 Shut-Off Class ANSI/FCI 70.2

Class V Actuator Spring Diaphragm

Positioner (3-15 psig) & Filter Regulator

Failure Mode Fail Close (standard) Fail Open (optional)

Manual Override Optional I/P Transducer Integral (4-20 mA) Position Transmitter Integral (4-20 mA) Limit Switch Optional (DPDT)

DRAG 100DSV

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Trim Specifications:

Trim Btm Labs

Top Labs

1st Disk

Cv MaxGlobe

Cv MaxAngle

0.01 0.02 0.03 3.3% 19% 24% 0.74 0.77

0.01 0.02 0.03 3/8

(10mm) 3.3% 19% 24% 1.06 1.15

0.03 0.06 0.09 3.3% 19% 24% 1.7 1.7

0.03 0.06 0.09 3.3% 19% 24% 2.2 2.3

0.03 0.06 0.09 3.3% 19% 24% 2.7 2.9

0.03 0.06 0.11

5/8 (16mm)

3.3% 19% 24% 3.6 4.1

0.06 0.12 0.21 3.3% 19% 24% 3.0 3.0

0.06 0.12 0.21 3.3% 19% 24% 4.6 4.7

0.06 0.12 0.27 3.3% 19% 24% 6.0 6.3

0.06 0.12 0.27 3.3% 19% 24% 7.8 8.4

0.06 0.12 0.27

1 (25mm)

3.3% 19% 24% 9.9 11.5

0.22 0.37 0.54 2% 12% 17% 8.0 8.1

0.22 0.37 0.54 2% 12% 17% 10.4 10.7

0.22 0.37 0.54 2% 12% 17% 13.3 14.0

0.22 0.37 0.71 2% 12% 17% 17.4 18.9

0.22 0.37 0.71

1.5 (38mm)

2% 12% 17% 23.1 27.0

DRAG 100DSV

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Materials:

Component Item No. Material Of

Construction Body 1 A216WCB/WCC

Bonnet 2 A105 Seat Ring 3 316SS Spindle 4 410 Heat Treat

Disk Stack 5 410 Heat Treat Balance Seal 6 Glass Filled Teflon Stem Packing 7 Glass Filled Teflon

Gasket 8 Flexitallic (Graphite/Stainless Steel)

DRAG 100DSV

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Standard Dimensions:

DRAG 100D

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CHOKE VALVE

Type: 100D Choke

Sizing Tool: Valsiz

Design Loc: CCI-RSM CCI-Vienna Application: Choke valves are almost always

angle valves. Are used to control wellhead

fluids or process fluids. Higher wellhead pressures due to

deeper, more difficult to produce wells.

Higher pressure gas wells, much higher velocities

through choke trim. Increased sand production. Description: The CCI severe service choke uses a combination of proven DRAG velocity control technology and the best upgrades of the tungsten carbide material used in the industry to provide long trim life and precise process control. The DRAG valve concept: CCIs DRAG disk stack controls flowing velocities throughout valve trim by forcing the process fluid to follow a tortuous path of right angle turns. The resistance to the flow provided by these turns limits the trim exits velocity to a safe level, regardless of the pressure drop. The DRAG

DRAG 100D

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choke valve eliminates problems resulting from excessive fluid velocities such as trim and body erosion, noise, vibration and poor process control. The fluid velocities within the trim of CCI choke are typically 1/3 to 1/4 that of conventional single stage chokes. Velocity control protects the trim from erosion and increases the trim life many fold. Features:

Solid Tungsten Carbide Disk Stack

Bolted Bonnet. Easy maintenance.

Pressure Balancing Seals. Reduces actuator/handwheel

force. Provided with dual scrapers to keep solids out of sealing areas.

Solid Tungsten Carbide Plug. Solid tungsten carbide

eliminates galling. Excellent erosion resistance. Large balance holes will not clog.

Solid Tungsten Carbide Disk Stack. Solid tungsten

carbide for erosion resistance. Multi-step letdown to control velocity, erosion and noise. Large flow passages, easily handle solids and dirty fluids.

Solid Tungsten Carbide Venturi Seat. Tungsten carbide

venturi seat in high turbulence zones. Venturi seat transition flows smoothly into valve outlet and piping.

Optional Stellite Insert. Extra erosion resistance.

DRAG 100D

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Valve Specifications:

Body Configuration Angle Pressure Rating ASME 2500

API 10000 Max. Inlet Temperature -40 to 250 F (-40 to 120 C)Flow Direction Over-the-Plug

(Flow-to-Close) Shut-Off Class ANSI/FCI 70.2

Class IV Actuator Pneumatic Actuator Failure Mode Fail Close (standard) Manual Override Optional Positioner Standard or Smart I/P Transducer Integral (4-20 mA) Position Transmitter Integral (4-20 mA) Limit Switch Optional (DPDT)

DRAG 100D

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Materials:

No. Description Standard Optional 1 Body AISI 4130 All ASME, API

materials 2 Bonnet AISI 4130 All ASME, API

materials 3 Disk Stack Tungsten Carbide -- 4 Seat Tungsten Carbide -- 5 Plug Tungsten Carbide -- 6 Stem INC 718 17-4PH, Duplex,

INC625 7 Insert (Optional) Stellite 6 --

AB Japan VO600

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Type: VO600

Sizing Tool:

Design Loc: CCI-KK The VO600 type desuperheater (DSH) puts innovation cooling method into practice, thus it can fully satisfy your demand of strict temperature control of steam. The VO600 is capable of functioning with inlet flow velocities as low as 3m/sec, thus ensuring efficient performance at high turn-downs. It can stabilize superheated steam at a distance of only 6m from the outlet. This is because of the structure of the VO600 which permits very thorough mixing of the steam and cooling water in the upper chamber of the body. Further, the structure is highly simplified since there are no spray nozzles. Principle of Operation: When there is no steam flow, the flow-plug sits on the plug seat, thus automatically shutting the orifice. During operation, the flow-plug is pushed up to a height that is self-determined by its weight and steam flow. The flow-plug changes its position corresponding to the flow rate, but the pressure drop is usually to an extent of 0.034MPa. The cooling water enters the lower chamber when the pressure drop reaches its maximum. Since the plug is supported in the center of the orifice because of the balancing spring, the steam flows uniformly around the plug

AB Japan VO600

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to the upper chamber. As the steam passes the plug, the cooling water is introduced smoothly in one step by the effect of suction created by the pressure difference. A big turbulence is created immediately above the plug, thus mixing the cooling water and the steam rapidly. The vertical installation of the VO600 means that gravitational force ensures that only dry steam flows into the outlet. The cooling water control valve requires a differential of at least 0.3 MPa between the cooling water pressure and the steam pressure for effective operation. The VO600 can achieve a control accuracy of up to 3 C from the set point and superheated steam temperature is possible up to even 6 C above saturated temperature. Features: Easy Maintenance. The VO600 is divided into two

pressure boundary sections and flanged together. The main body is easily removed for installation and inspection.

Limited moving components. The moving portion of

the VO600 is limited to the flow plug and its balancing spring. Less moving parts mean longer lasting trim components.

Maintains Fixed Pressure Drop. The streamlined flow

plug is constantly exposed to high speed steam flow, and due to its own weight and the balancing action of the spring, it maintains a fixed pressure drop regardless of the steam load.

AB Japan VO600

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Quality Specifications:

AB Japan VO600

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Valve Specifications:

Body Configuration Inline, Vertical Pressure Rating JIS, ASME 150-2500 Max. Inlet Temperature < 1100 F (600 C) End Connection JIS, ANSI, JPI Flanges Flow Direction Under-the-Plug

(Flow-to-Open) Pressure Loss 0.034 MPa Rangeability Control is possible up to a

minimum inlet flow velocity of 3 m/sec.

Temperature Control Maintains desuperheater steam at 3 deg C.

Superheated Saturated temperature +6 deg C or higher

Steam Temperature Measurable up to 6 m from outlet side

AB Japan VO600

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No. Description Material Of Construction 1 Housing SCPH2 A216 WCB 2 Manifold Pipe STPT370 STPT370 3 Manifold Flg ASTM A105 ASTM A105 4 Plug Seat SCPH2 A216 WCB 5 Gauge Set - - 6 Distr. Plate SS 400 SS 400 7 Seal Packing Non Asbestos Non Asbestos 8 Cap Screw SNB7 SNB7 9 Screw Lock SUS304 SUS304

10 Flow Plug SCPH21 SCPH21 11 Spring A638.660 A638.660 12 Wear Button SUS420J2 SUS420J2 13 Gasket Non-Asbestos Non-Asbestos 14 Mix Chamber SCPH2 A216 WCB 15 Plug Stop SB410 SB410 16 Stat Bolt SNB7 SNB7 17 Nut S45C S45C 18 Name Plate SUS304 SUS304

AB Japan VO600

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AB Japan VO600

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DRAG Anti-surge valve

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Compressor recycle anti-surge valve Type : Compressor recycle anti-surge valve Sizing Tool: Valsiz

Design Loc: CCI-RSM CCI-Vienna Application: Surge is a powerful disturbance

that can disrupt or trip a process. It can damage equipment, and in catastrophic incidents, may result in the complete destruction of the compressor rotor. Because the consequences of surge are too costly to ignore, surge protection is necessary for all turbo compressors.

The valve capacity must be large enough to prevent surge under all possible operating conditions including start-up and shut down without being oversized. An excessively large valve will provide poor control precision and will drive the compressor into choked flow when fully open.

The CCI anti-surge valve design maximizes control while providing reliable and safe protection from compressor surge

Description: The optimum solution for safety and reliability for this application is given by CCIs compressor recycle and anti-surge valve which combines premium DRAG flow control technology with reliable fast stroking actuation. The result is a complete severe service valve solution designed to maximize the reliability, efficiency and control compressor recycle system.


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Customized DRAG Technology and Actuation systems: CCI custom-designed DRAG trim is ideally suited to minimize noise while providing the capacity and control that is necessary in anti-surge and compressor recycle application. For these applications, the multi-stage DRAG disk stack is in the lower portion of the trim to provide control and maximize noise attenuation. Slotted or drilled-hole-cage trim can be provided in the upper portion of the stack to provide additional capacity for when compressor bypass is required in addition to anti-surge. Features: Accurate control and Reliable Operation For anti-surge and recycle applications, CCIs fast acting pneumatic actuation system can deliver stroke speeds of less than one second while maintaining precise resolution and control. This solution with combine established trim and actuation designs to provide optimal performance and continued valve longevity.

Valve position v/s Time opening


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Tight shutoff These valves are designed with either a soft or hard seat to ensure as ANSI/FCI 70-2 Class V shutoff. This design provides dependable and repeatable shutoff for longer periods of time over very high pressure differentials. It minimizes lost energy through leakage and lost production which results in significant cost savings. Controlled fluid velocity, low noise and additional

capacity

DRAG disk stack with multi-stage tortuous path in the lower portion and slotted cage in the upper portion

DRAG disk stack in the lower portion of the trim provides controlled flow and maximizes noise attenuation and the Drilled hole cage trim in the upper portion provides additional capacity. Quality specifications:


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Valve Applications in compressor recycle service:

Application Differential Pressure

Temperature Inlet/Outlet

Gas production Separation 300-3000 psi

2.1-21 Mpa 100-200F 37-93C

4-12/6-16 100-300 mm/ 150-400 mm

Reinjection 3000 psi 21 Mpa

100-150F 37-65C

4-8/6-8 100-200 mm/ 150-200 mm

Gas Hydrogen 70-300 psi

0.48-2.1 Mpa 100-130F 37-54C

6-12/8-14 150-300 mm/ 200-355mm

Natural gas 100-150 psi 0.69-1 Mpa

100-120F 37-93C

8-24/10-30 200-600 mm/ 255-760 mm

Ammonia 50-100 psi 0.34-0.69 Mpa

100-200F 37-93C

4-8/6-12 100-200 mm/ 150-300 mm

Air 50-700 psi 0.34-4.8 Mpa

100-200F 37-93C

4-16/6-24 100-400 mm/ 150-600 mm

LNG Propane 80-400 psi

0.55-2.7 Mpa -94-248F -70-120C

8-24/10-24 200-600 mm/ 25-600 mm

Material refrigerant

150-700 psi 1-4.8 Mpa

-49-212F -45-100C

12-24/18-32 300-600 mm/ 450-800 mm

Olefins Syngas 300-500 psi

2.1-3.4 Mpa 100-120F 37-49C

4-8/6-10 100-200 mm/ 150-250 mm

Propane 50-150 psi 50-150F 6-16/8-16


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0.34-1 Mpa 10-65C 150-400 mm/ 200-400 mm

Ethylene 100-500 psi 0.69-3.4 Mpa

20-50F -6-10C

4-16/6-10 150-200 mm/ 200-300 mm

Multicomponent

50-300 psi 0.34-2.1 Mpa

100-150F 37-65C

6-8/8-12 150-200 mm/ 200-300 mm

Valve Specifications: Trim Specifications:


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Materials:

No. Description Standard Optional 1 Body A105/WCB A182-F316 2 Bonnet A105 A182-F316 3 Disk Stack 316 SS 316 SS 4 Seat Ring 316 SS 316

SS/Stellite 5 Plug 316 SS 316 SS 6 Stem 17-4 PH 17-4PH 7 Balance Seal Teflon Teflon

Standard dimensions:

DRAG 100DR

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Boiler feed pump recirculation valve Type: 100DR Sizing Tools: Valve Size Design Location: Application: Boiler Feedwater pump recirculation valves are used to provide the minimum flow required for the protection of the boiler feed pump. They reduce water pressure from high pressure to deareator or condenser pressure and maintain tight shut off for long period of time. They may operate as on/off valve or modulate automatically. Description: The 100DR is available in angle and globe configuration and in six trim sizes (1.5, 2, 2.5, 3, 3.5 and 4). It is designed for up to ASME 2500 rating. The trim is an equal-percentage, over the plug flow disk stack design. The standard is a spring fail-open diaphragm actuator Features: Performance Improves plant performance, feed pumps operate without efficiency losses from valve leakage.

DRAG 100DR

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Reduces system cost These Valves do not require unreliable and expensive back pressure or anti flashing devices.

Stops costly Maintenance Cycles These valves are designed specifically to provide longer intervals between maintenance and allow easy access to all components. Quality Specifications: Valve Specifications:

DRAG 100DR

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Material:


DRAG 100DR

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DRAG 800D

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Type: 800D Sizing Tools: Valve Size Design Location: CCI RSM Manufacuturing : Korea Application: The 800D is a pre-designed (standardized) Drag control valve. The product has been targeted for general application in the oil & Gas industry but can be used in Power or other industry with approval of the engineering manager. Description: A short summary of the product range is 1-8 valve size 150-600 ANSI Pressure Class 0 through 8 turns -20 to 500 deg F NACE certification is readily available Standard ANSI Class IV & VI seat leakage

Features: Velocity control prevents cavitation and erosion damage. High shut-off capability Class IV, class V & Class VI

with soft seat. Standard design allows fast turnaround of orders while

maintaining CCIs multistage trim to meet individual operating conditions.

Quality Specifications:

DRAG 800D

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Valve Specifications: Trim Specifications: Material:


DRAG 800D

61

DRAG 100DLC

62

BOILER FEEDWATER CONTROL VALVE Type : 100 DLC.

Sizing Tool: Valsiz

Design Loc: CCI-RSM CCI-Vienna Application: Boiler Feedwater Control Valve has a critical application in power plant operations. It regulates the feedwater level within required limits in a boiler drum. CCIs Feedwater Control Valve is suitable to achieve a smooth start-up and maintain required drum level for safe, reliable and efficient plant operation. Other Severe service applications for CCI DRAG 100DLC Drum Level Control of conventional fossil fired plants (combined and start-up). Start-up Feedwater Regulator valve on large sub critical and supercritical Boilers. Boiler Circulation valves used on supercritical once-through boilers to maintain minimum flow through the boilers. Description: Boiler level control is a crucial factor in a power plant. If the boiler level is too high or too low, the plant may be forced to trip. Most of the plants use two valves for this application, a main feed water regulator and a start-up feed water regulator. The main valve is designed to flow 100% of the Maximum Continuous Rated (MCR) boiler flow with a pressure drop

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of 50-400 psi. Common problems encountered in this case are trim vibration and poor control. The start-up valve controls boiler fill and plant low-load operation. Typical conditions for boiler fill are 5-10% MCR and 2200-3500 psid for low-load operation are 25% MCR and 400-1000 psid. Common problems in this case are trim erosion and poor control. CCIs DRAG Combined solution: Having two control valves for one application, the transition from start-up to main valve can be difficult to control. However, CCI is able to offer a one valve solution with the 100 DLC DRAG valve, which meets both the high and low Cv requirements as an alternative to two valve system. The configuration is only possible due to DRAG high rangeability trim providing excellent controllability at all flows, from start-up through to normal operation. The disk stacks use disks with more pressure let down stages near the seat end of the trim and fewer stages near the full-open end of the trim. This provides critical protection of the seat ring while allowing superior flow control throughout stroke of the valve.

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Comparison between Two valve configuration and Combined DRAG Control Valve Features: Eliminate Cavitation and Erosion with DRAG Combined solution The DRAG trim forces the flow to travel to through paths of turns. Each turn causes a pressure loss to the fluid so the pressure gradually reduces over the turns without falling below the vapour pressure and so avoids cavitation. Also, it eliminates problems with trim erosion by limiting the trims fluid exit velocities and corresponding kinetic energy.

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Reliable long-term shutoff: The DRAG control valve uses hard seat, which resists cutting, and a very high seat loading to provide reliable and repeatable long-term shutoff for very high pressure differentials. The DRAG velocity control trim design owing to control of velocity and high seat force for shut-off protects the seat ring and plug surfaces from cutting or pitting due to the erosion. Reduced Capital and Maintenance costs: By eliminating one valve from the system, associated hardware is eliminated, providing cost savings in the system purchased. Also, with two valve solution there is a potential risk of transferring from the start-up to the main valve too soon. This exposes the main valve to the differential pressures it is not designed for, causing costly damage and contributing significantly to maintenance costs. . Quality specifications: Valve Specifications:

DRAG 100DLC

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DRAG 100DLC

67

Standard dimensions:

DRAG 100DPC

68

Wellhead Production Choke Valve Type : 100DPC

Sizing Tool: Valsiz

Design Loc: CCI- Vienna Application: Field environment with higher wellhead pressures with aggressive fluids with entrained sand and other solid particles requires more than just single stage choke valve. Also to maintain continuous production rates choke repair and replacement is not acceptable. 100 DPC uses DRAG velocity control technology and best grade of tungsten carbide material for long trim life and precise process control. Principle of Operation: . Features:

DRAG 100DPC

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DRAG 100DPC

70

Quality Specifications: Valve Specifications:

Material:


DRAG 100DPC

71

KOREA 840G/H

72

CONVENTIONAL VALVES

Type : 840 G/H.

Sizing Tool: Valsiz.

Design Loc: CCI- Korea. Applications:

840G The 840 G cage-guided valve

is used to control a wide variety of relatively clean liquids and gases at high pressure differentials configured with either flow-to-open or flow-to-close trim.

The valve is well suited for steam, gas or liquids,

where flow-to-close is typically used for liquid service and flow-to-open for steam and gas.

840H The design of 840H (drilled-hole-cage) valve is

primarily used for severe service applications requiring anti-cavitation or low-noise trim. In most cases, high pressure drop process conditions may cause erosion, noise or vibration, which can affect process control. The 840H is a good solution to this severe service.

The valve is well suited for steam, gas or liquids,

where flow-to-close is typically used for liquid service and flow-to-open for steam and gas.

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Description: 840G The 840 G cage-guided valve is specially designed using recent advancements in control valve technology. The valve is flexible, allowing a variety of trim types to be installed in the body. In addition, its cage-guided construction reduces plug vibration and provides stable performance throughout travel. All 840 trims have a quick change design to guarantee convenient repair and easy trim replacement.

Cage-guided design, Balanced Trim, Metal/Soft Seat 840H The 840H Drilled-Holed-Cage trim provides in high pressure drop applications without cavitation, noise, erosion, and vibration common problems associated with general trim design. The Drilled-Holed-Cage trim design is suitable for most pressure drop services except very severe services with very high pressure drop. Cavitation occurs in liquid process when local pressure fluctuations near the liquid vapor pressure result in sudden growth and collapse of vapor bubbles (cavities) in

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downstream liquid. Cavitation often produces high levels of noise and vibration in the system. To avoid this cavitation problem, the right number of multi-stage and multi-path trim design should be adopted. High mass flow and pressure drop in compressible fluids like gas or steam is a major source of noise and accompanies vibration in the system. The right source treatment depends on the right multi-path, multi-stage trim. CCI Drilled-Holed-Cage trim provides noise attenuation in a modular design.

840H Drilled-Holed-Cage trim

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Features: Tight shutoff: A Variety of shutoff classes from ANSI IV through VI are available to meet application requirements. Sour gas/Corrosive fluid capable: The wide choice of body and trim materials allows these valves to be applied to corrosive/sour gas services with full compliance to NACE requirements. Simple to change capacity and characteristics: A simple cage change is all that is required to change between reduced and full-sized capacity trims or between linear and equal percentage characteristics. Easy maintenance: Top-entry design and a cage-retained seat ring allow for quick inspection or trim change. No internal components are screwed or welded into the valve body or bonnet. Quality Specifications: All Series 840 Valves meet the ANSI B16.34 standard

for Valves~Flanged, Threaded and Butt~welding End. This encompasses the dimensions, construction, testing and rating of all valves supplied.

CCI also performs ANSI standard seat leakage and

hydrostatic tests on every valve we build, and operability tests are run on each valve and actuator leaving our factory. Special tests are readily available to meet the specific project needs, including non-destructive testing of valve components and performance testing of actuator controls.

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Valve Specifications: Body Configuration Globe(casting, forging) under/over flow, RF,

BW, SW, RTJ Valve Size 1 through 20 Ratings ANSI Class 150-2500(DIN and JIS

available) End Connections Raised Face Flange, Weld Ends (BW and

SW ) Flow Characterization Linear or equal percentage Seat Leakage Standard ANSI Class IV, Option-ANSI Class

V or VI Trim Quick Change Trim (Single Port, Window-

Cage, Drilled-Hole-Cage) Temperature Range series 840 valves

Bonnet Type Valve Trim

ANSI Class

Seat Type Standard Extended

Seat Leakage

#150 through #900

Soft -30C ~ 230C

-196C ~ 230C

VI ~ 4

#150 through #2500

Metal -30C ~ 300C

-196C ~ 565C

IV, V

#150 through #600

Soft -30C ~ 230C

-196C ~ 230C

VI 6 ~ 20

#150 through #2500

Metal -30C ~ 300C

-196C ~ 565C

IV, V

KOREA 840G/H

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Material:

Contoured Plug 840G Type

Drilled Holed Cage 840H Type

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MATERIAL NO. PART

NAME -26 ~ 260 C

260 ~ 425 C 425 ~ 565 C

1 2

Body Bonnet

A 105 WCB A 216 WCB A 351 CF8M

A 105 WCB A 216 WCB A 351 CF8M

A 217 WC6 A 217 WC9 A217 C 12 A A 182 F11 A 182 F22

3 Plug 410 SS 410 SS A 182 F11(5)

4 Stem 410 SS 410 SS Inconel 718 5

Seat 410 SS 316 SS

410 SS A 182 F11(5)

6 Cage 410 SS 410 SS A 182 F11(6)

7 Packing Gland

316 SS 316 SS

8 Balance Seal Teflon Graphite Graphite

9 Packing Spacer

316 SS 316 SS 316 SS

10 Body/Bonnet Gasket

11 Seat Gasket

TFE(Filler) & SS Or Graphite(Filler) SS



12 Packing Set Teflon Graphite Graphite


KOREA 830T

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830T THREE WAY VALVE

Type : 830 T.

Sizing Tool: Valsiz.

Design Loc: CCI- Korea. Applications: The series 830T three-way valve is designed for

diverting service or mixing service applications. A diverting service valves takes common stream and

splits it into two outlet ports. A mixing service valve combines two fluid streams

and discharges the mixed fluid to a common outlet port.

Description: The 830T three-way valve actually performs the function of two opposite acting standard two-way valves. So the use of one valve instead of two is very economical. Various trim types and end connections of the 830T valves gives the design flexibility that can satisfy the system requirements. The 830T valve is available in size ~ 10 and ANSI 150 and 300 classes.

The M-type configuration features an unbalanced plug for simple maintenance and economical installation. The large size valves are often used with motor operators. Designed with two side and one bottom pipeline connections. The B-type configuration features a balanced plug design, to minimize the actuator forces and provide stable control in large valve sizes, with pneumatic actuators. The quick change trim with the plug accessible from the bonnet

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allows for easy maintenance. Designed with two side and one bottom pipeline connections. The U-type configuration features an unbalanced plug with a Top-Entry Quick Change Trim. Designed with three side pipeline connections, the design simplifies piping installation. Features: Durability: Rugged structure and smooth operation. Guarantee a long maintenance-free service valves. High Capacity: Broad and streamlined fluid passage can pass later amount of fluid than other three-way valves. Stable Operation: Port and top guiding or cage guiding makes the operation of the plug stable regardless of plug travel. . Flexibility: Various body and trim types provide design versatility for your needs. Quality Specifications: All Series 830T Valves meet the ANSI B16.34

standard for Valves~Flanged, Threaded and Butt~welding End. This encompasses the dimensions, construction, testing and rating of all valves supplied.

CCI also performs ANSI standard seat leakage and

hydrostatic tests on every valve we build, and operability tests are run on each valve and actuator

KOREA 830T

81

leaving our factory. Special tests are readily available to meet the specific project needs, including non-destructive testing of valve components and performance testing of actuator controls.

Valve Specifications: Valve Size 3/4 to 10 Ratings ANSI Class 150 and 300. End Connections Flanged end, Welding end. Flow Characterization Linear or equal percentage. Seat Leakage Standard ANSI Class IV. Port sizes Full or reduced. Material:

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Matrix of Standard Material

Fluid Temp. Range Valve Type

Liquid, Steam, Gas -26~260

(Non-corrosive)

3 Way valve Item Material

1. Body 2. Bonnet

A216 WCB / A351 CF8M

3. Bonnet studs A193-B7 / A193-B8M

4. Bonnet nuts A194-2H / A194-8M

5. Seat (Hard) 316SS

6. Plug A351 CF8M or 316SS 7. Cage - 8. Stem 316SS

9. Balance Cylinder -

10. Packing Teflon 11. Bottom

Flange A216 WCB / A351 CF8M

12. Bal. Seal O-Ring Standard Dimensions:

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Type: 840/860 TBS Sizing Tools: Valve Size Design Location: CCI Korea Manufacuturing : CCI Korea Application: This valve is also referred

as Low Low Pressure Valve or LLP valve.

The LLP by CCI is the

leading low pressure turbine bypass valve for combined cycle and process steam plants.

Featuring an integrated spring-loaded spraywater

nozzle desuperheating manifold at the valve outlet, the The LLP minimizes the downstream desuperheating distance, making it extremely compact for all types of low pressure steam conditioning applications including advanced turbine bypass to condenser applications with short pipe runs.

Description: The LLP is designed in both angle and globe body configurations and easily fits into most existing piping arrangements. If the angle configuration is used, the outlet nozzle has been extended to accommodate direct mounting of attemperators. If the globe configuration is used, a pipe exension must be added to the outlet to accommodate desuperheating.

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Four standard sizes have been developed for each configuration of the LLP Valve, an 8 , 10 , 12 and 14 plug size. The pilot plug design is same for 8 and 10 plug valves as in the pilot plug of the 12 and 14 plug valves. The LLP may be installed in any orientation without the need for additional support for the upper structure.

Features: Pressurized seat Trim design to achieve repeatable

Class V shutoff in service and improved plant efficiency through elimination of lost steam.

High-performance, reliable, fast stroking pneumatic

or hydraulic actuation with many years of documented service. Accurate control and resolution to less than one second stroke time with pneumatics.

Small drilled holed cage design reduces noise levels

to below 85 dBA. Low maintenance costs with quick change trim, No

trim parts are welded or screwed into the body. Lightweight, compact and flexible in design, easily

fits into most existing piping arrangements in both globe and angle configurations.

Quality Specifications: The body and bonnet for the LLP valve have a maximum ANSI rating of 600# for the angle configuration and a maximum rating of 300# for the globe valve. The LLP uses the CCI Pressurized Seat Pilot Plug Assembly yo provide repeatable ANSI/FCI 70-2 Class V Shutoff as a standard feature.

KOREA 840/860 TBS

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Valve Specifications: Trim Size 8 10

Low Noise Cage

640 830 Angle Config

Open Port Cage

1030 1410

Low Noise Cage

590 775

Max Capacity (Cv)

Globe Config

Open Port Cage

840 1200

Valve Characterization Linear, Equal % or Modified Equal %

Steam Valve Rangeability Up to 30:1 Desuperheater 50:1 Shutoff Class ANSI/FCI Class V is

Standard Actuator Type and Model Number Spring diaphragm actuator

size 500 Fail Mode Closed Stroke Time Less than 10 sec,

modulating mode Less than 2 sec, trip[ mode standard Less than 1 sec, trip mode optional

Design Pressure Temperature 29 bar/425 C Trim Specifications:

KOREA 840/860 TBS

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Material:

Item no. Component Materials of

construction 1 Body A216-WCB 2 Bonnet A216-WCB 3 Cage 400 Series

Stainless Steel 4 Main plug 400 Series

Stainless Steel 5 Pilot plug 400 Series

Stainless Steel 6 Stem 400 Series

Stainless Steel 7 Seat ring 300 Series

Stainless Steel Standard Dimensions:

KOREA 840/860 TBS

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KOREA 840/860 TBS

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FLUID KINETICS DAM

89

Type: Desuperheater Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: Main steam attemperation is the process whereby sub-

cooled water is injected into superheated steam along the plant main steam line for the purposes of temperature control.

It is typical in both combined cycle and combined heat

power plants. Description: Main steam attemperation consists of a Spring Loaded Water Nozzle(SLSN), spray water enters the nozzle assembly at a pressure greater than the downstream steam, compresses a helical spring which opens the nozzle. As the pressure drop across the nozzle increases, the spring os further compressed and the flow rate of spray water through the nozzle increases. SLSNs are pre-set woth a given loaf on the helical spring. In this configuration, the nozzle will not open until a pre-determined pressure drop, designed the cracking pressure, is achieved across the nozzle. Features: Spray nozzles, connected by a common manifold are mounted circumferentially around a cross steam flow, are the primary components of DAM style desuperheater. The DAM desuperheater can have three basic configurations: DAM, DAM-D and DAM-E.

FLUID KINETICS DAM

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DAM Style Desuperheater The DAM desuperheater consists of a pipe spool, a given quantity of OP nozzles and a manifold. A liner can be added to the assembly for thermal protection or to increase the stem velocity. If a liner is added to a DAM, the liner may only be fixed at one end (the upstream side). The other end must be guided, but free to grow thermally.

(DAM Style Desuperheater)

DAM-D Style Desuperheater The DAM-D desuperheater differs from the DAM in that it includes a Pressure Reducing (or PR) device immediately upstream of the spray injection point. The PR device pressure serves the following functions: Improves spray water mixing by generating a low

pressure zone at the center of the steam flow, drawing a portion of the injected water into the center of the flow.

Generates backpressure to reduce the upstream steam velocity.

Breaks up the high velocity jet flowing through the seat bore into multiple small jets.

Reduces the noise associated with expansion at the outlet of an upstream control valve.

FLUID KINETICS DAM

91

(DAM-D Style Desuperheater)

DAM-E Style Desuperheater The DAM-E Desuperheater incorporates an expander at the outlet which enhances mixing. As the steam/spray water mixture exits the lower diameter pipe region, the sudden expansion will result in an annular wake which will pull a portion of the steam/spray water mixture towards the pipe wall.

(DAM-E Style Desuperheater)

FLUID KINETICS DAM

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Quality Specifications: As a standard practice, the design code ASME Section I

shall be used for the high temperature steam pressure boundary parts.

Design code ASME B31.1 (or EN 13480) for the water piping arrangement.

Maximum pressure class of Standard Manifolds is ASME 1500#. However in special cases it is ASME 2500#.

Thermal stress cycle analysis shall be as per EN 12952.

FLUID KINETICS DAM

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Material:

FLUID KINETICS DAM

94


FLUID KINETICS DAM

95

FLUID KINETICS SILENCERS

96

Type: Blow Off Silencer Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: A blow-off silencer is used to reduce

unwanted noise created by gas or steam flow in a pipeline discharging directly into the atmosphere. This noise can be generated by turbulence around any obstacle in the line that suddenly restricts or changes the direction of flow, such as a valve or an orifice. BOS silencer used at Safety relief valve Start-up valve Blow down valve Compressor station Blow-down

Description: As the gas flow enters the silencer, the inlet diffuser with an array of small diameter holes creates a reflective barrier to noise transmitted from upstream devices. The Fluid Kinetics Blow off Silencer uses a controlled combination of diffuser hole size and spacing to maximize the effectiveness of this barrier. The result is a net decrease in system vent noise, particularly in the low frequency range of the noise spectrum. Final treatment of the noise is achieved through the sound absorbing characteristics of the acoustic pack, combined with the resonant properties of the perforated facing material.


97

Features: Superior acoustic pack Long loomed glass fiber is used for operating upto 1000F. This premium material is selected for its superior acoustic absorptivity, chemical resistance and ability to withstand high grazing velocity without fiber loss and is spooled into the cores, rather than filled from one end. This assures predictable performance by eliminating the risk of voids and varying fill density. Expansion chamber Expansion chamber acts as a transition zone from the high velocity of the diffuser orifice to the reduced velocity appropriate for flow through the acoustic core. Constrains noise generated at the diffuser as well as that created by expansion turbulence. Additional resistance to direct noise radiation through the silencer walls. Diffuser Reduces noise effectively while providing a distributed expansion pattern for the flow into the expansion chamber. Shifts the frequency of the unsilenced noise into higher active bands where the acoustic pack material functions most effectively. Quality Specifications: Standard Dimensions:


98

Type: Control Valve Silencer Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: For stringent silencing requirements Fluid Kinetics has designed a Control Valve Silencer which includes a high performance diffuser and an absorptive section. This combination silencer is capable of providing fluid-borne noise reduction up to 50 dB. Description: Each CVS silencer is custom engineered for the particular installation. The diffuser drilling pattern is selected to provide a reshaped noise spectrum and optimum back pressure for the valve. The packed section is designed so that slot width and length can be varied to provide the correct attenuation of the diffuser noise spectrum.


99

Features: Custom Acoustic Performance: The optimal combination of process conditions, performance requirements, slot width and packed length is used for each application to provide the required noise reduction. Custom Flow Performance Design: The diffuser and packed section are designed to provide the exact amount of pressure drop required for each application. For high pressure and high noise application the diffusers can be designed to efficiently share pressure drop with the control valve. For low pressure drop requirements the silencers can be designed to minimize pressure loss. Triple Layer Pack Protection: The long strand glass fiber acoustic packing material is protected by heavy gauge perforated facing, a layer of fiberglass cloth and a stainless steel screen. This triple protection prevents loss of packing into the gas stream. Annular Core Construction: The packed section consists of a series of annular cores with the long strand fiberglass spooled into place and anchored in a place by the packing support studs. This construction guarantees packing density and prevents shifting of packing. Quality Specifications: Standard Dimensions:


100

Type: Gas Diffuser Silencer Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: High pressure drop across a valve creates excessive noise and deterioration of valve components. The function of the Fluid Kinetics Gas Diffuser Silencer is to share pressure drop with the valve, thereby substantially reducing this noise and wear. BOS silencer used at Safety relief valve Start-up valve Blow down valve Compressor station Blow-down

Description: To accomplish this pressure reduction the diffuser passes the flow through many small holes. Correct hole size and spacing are critical to diffuser performance. It is also important to match the diffuser flow capabilities to the individual system requirements. Fluid Kinetics custom designs each diffuser for the particular valve and piping system it is to be used with. Features:

Can be used in conjunction with any manufacturer's valve

Creates a quieter noise environment Reduces requirements for expensive valve trim


101

Quality Specifications: Standard Dimensions:


102

Type: Compressor Silencer Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: The Fluid Kinetics Model CIS Compressor Silencer is an absorptive type silencer designed for the short acoustic wave lengths produced by centrifugal and axial compressors. CIS is used to silence the inlet or outlet of high speed dynamic compressors handling gas at any pressure. Description: The CIS internal configuration consists of a series of packed annular cores spaced in accordance with the needs of the application. The packing consists of long strand glass fiber which would onto the annular cores, providing a continuous blanket effect. Support studs are welded to the facing at regular intervals to act as anchor points for the packing. Layers of fiber glass cloth and stainless steel screen are applied and enclosed with a heavy perforated metal facing. The triple protection assures against loss of packing into the gas stream.


103

Features: Provides 20 to 40 dB attenuation Heavy, perforated metal facing Custom Engineered Packing: Sound is absorbed by viscous drag in the interstices of the glass fiber packing. It is important to match the packing resistance which creates this drag to the characteristic resistance of the gas handled at its operating condition. To adjust the pack resistance, Fluid Kinetics changes packing density, thickness and fiber diameter. Custom Engineered Slot Width: A high speed dynamic compressor produces a certain noise signature. The silencer must be engineered specifically to handle this frequency spectrum. In the Fluid Kinetics design, the silencer slot width or distance between the annular packed sections is adjusted for each application.


104

Quality Specifications: For pressure applications, the cores contained in a pressure vessel shell built to ANSI 831.3 piping code. ASME section VIII code construction is also available Standard Dimensions:


105

Type: Reactive Silencer/ I/C Engine Diffuser Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: The Model RCS silencer provides high performance flow path pulsation and noise control for compressors or blowers running at constant RPM. The RCS silencer is well suited for use with lobe type blowers and positive displacement compressors that produce high amplitude, low frequency pulsations in critical environments with stringent noise control requirements. Description: The process flow stream enters the silencer through the silencer inlet connection at a tangential orientation to the vessel shell. As the flow stream follows a swirling path along the inside diameter of the vessel, any water that may be entrained in the flow stream is separated by centrifugal force and falls to the bottom of the vessel where it can be piped away to a drainage location The RCS silencer design utilizes a tuned series of reflective internal discontinuities to filter undesirable pressure pulsations from the flow stream. In the most stringent noise requirements, final stage absorptive technology can be applied for further treatment of broadband noise generated by rotating equipment. For blowers that use a liquid injection sealing/cooling system, the RCS silencer can be designed with optional water and mist separating capability. .


106

Features:

The heaviest construction in the industry, designed to eliminate vibration and/or acoustic fatigue failures

Multiple reactive chambers, computer tuned to reduce pulsations a minimum of 95 percent at the blower

fundamental frequency

Special reactive design providing effective pulsation control over the first three harmonics (multiples) of the

fundamental frequency

Pressure drop reducing features to insure maximum performance with minimum blower efficiency impact

Absorptive discharge module with multiple stages to attenuate residual broadband noise

Computer assisted custom designs to match the silencer design to the project/site requirement.



107

Type: Hydraulic Acoustic Filter Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: The Fluid Kinetics Hydraulic Acoustic Filter is designed to reduce by 15 to 20 dB noise and pulsation emanating from high speed hydraulic pumps. It is designed to block fluid-borne noise and pulsation from entering the connected piping. To prevent noise radiation from the pump and motor casing, a commercially available acoustic shroud should be used. This combination treatment is necessary only if there is a requirement to quiet the immediate environment of the hydraulic package. The Hydraulic Acoustic Filter effectively reduces all downstream piping noise. Description: The Hydraulic Acoustic Filter is of all carbon steel construction with no bladder to fill or replace. Working pressure up to 5000 psig are standard. Higher pressures and stainless steel materials are available upon request. The multichambered acoustic filter act analogously to an electrical filter network. It is designed to filter or attenuate the predominate frequency and significant harmonics of the pump. This reactive type of filter does not require resistance or pressure drop to function. However, since there is flow through the filter some pressure drop is imposed. Filter overall size is an inverse function of pressure drop. A computer simulation response curve allows Fluid Kinetics engineers to check the selected AFC performance for each application.


108

Features: Quality Specifications: It offers a simple maintenance-free way to meet existing OSHA workplace standards for hydraulic systems in machine tool, hydraulic press, forging and test stand applications. Standard Dimensions:


109

Type: Liquid Pulsation Dampener Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: All power pumps produce pulsation. Whether or not the pulsation is severe enough to create problems depends upon many system variables. A few of these variables are the fluid handled, the type of pump and the pump speed. As a general guide, Fluid Kinetics engineers recommend using the Liquid Pulsation Dampener on any multi-plunger pump service having a discharge pressure over 500 psig, or on any service, regardless of pressure, whether pulsation problems are expected and a maintenance-free device is required The Fluid Kinetics Liquid Pulsation Dampener reduces discharge pressure pulsation by approximately 75%. Actual performance depends on the type of pump, connected piping system, and liquid handled. Description: The dampener is all steel construction, with no bladders to fill or replace, and virtually no temperature limitation. With nozzles beveled for weld, the unit becomes a part of the piping. Carbon steel construction is standard, but other materials are available Completely liquid filled, with no moving parts, this dampener does away with maintenance and gas charging requirements. The stationary internals guide the incoming flow into a rotating path within the spherical shell. The spinning liquid mass creates a system smoothing effect. Viscous drag on the


110

sphere walls and the capacitance effect of the relatively large volume located next to the pump, further aid to dampen pressure pulsation. Features:

Reduces discharge pressure pulsation by approx. 75% Handles up to 6000 psi Maintenance free - permanently weld in pipeline,

saving flange costs and potential flange leaks. Inline configuration eliminates special support

problems Liquid filled - no moving parts All steel construction Virtually no temperature limitation

Quality Specifications: . Standard Dimensions:


111


112

Type: SSC Stabilizer/ Separator Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: The Fluid Kinetics Stabilizer/Separator is an inline device to eliminate Pulsation, Cavitation and entrained gas in power pump suction lines. It can be used in any system where:

There is an NPSH problem. A gas-rich fluid is being handled. There is other evidence of suction cavitations (i.e.,

excessive vibration or excessive pump maintenance).

Description: Flow enters and leaves the Stabilizer/Separator tangentially, forming a low-velocity vortex. This vortex and the increased path length created by the elevation difference between inlet and outlet stimulates the release of any entrained gas. The freed gas moves through the perforated center tube to the gas or air pocket maintained at the top of the unit. In highly corrosive service, the stabilizer can be supplied with non-corrodible internals and epoxy coating of wetted steel surfaces. Features: The Fluid Kinetics Stabilizer/Separator, close-coupled to the pump suction flange, provides three basic functions necessary for smooth, low-maintenance operation. Volume Effect - Acting as a mini-storage tank, the Stabilizer/Separator provides a full charge of liquid when


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the pump valves open. In systems with marginal available net positive suction head (NPSH), it prevents cavitations. Also, because of its location, it acoustically uncouples the pump from the line eliminating acceleration head consideration. Dampening Effect - The gas charge provides a capacitance or spring effect to absorb pulsation created by the abrupt flow change as the valves open and close. Separation Effect - Entrained gas or vapor is removed before it can enter the pump suction manifold where the sudden pressure changes can cause gas to break out of solution and create partial cavitation. Quality Specifications: . The Stabilizer/Separator is of welded steel construction. Standard models are rated 100 psig in accordance with ANSI B31.3 Code. Inlet and outlet connections are ANSI 150-lb raised face flanges sized to match the pump suction flange. ASME Code construction is available. Standard Dimensions:


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Type: Steam Vent Silencer Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas Application: FKs EVO silencer is used to reduce noise from a gas pipeline discharging directly into the atmosphere through a safety relief valve or a control valve. This noise is generally as a result of high turbulence inside the valve during pressure reduction. The primary release of this noise energy in a safety relief system is via the open stack exit. The EVO silencer is installed either within the stack or at the stack outlet to intercept this noise before it escapes into the environment. Description: Our EVO silencer makes use of the passive silencer design. There are two fundamental noise reduction principles involved in passive silencer design. Dissipative noise reduction: dissipative components made of sound absorbing material provide balanced noise reduction over a broad frequency range. Reactive noise reduction: reactive components using resonant reflections within tuned chambers and passages provide peak noise reduction in a more concentrated frequency band. In addition, the Fluid Kinetics EVO Silencer uses small size passage geometry for shifting frequency and eliminating any shock waves.


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HOW DOES IT WORK? As the gas enters the silencer, the inlet diffuser with an array of small diameter holes acts as a reflective barrier to the noise energy carried within the stream from the safety relief valves. A controlled combination of diffuser hole size and spacing are used to maximize the effectiveness of this barrier. The EVO Silencer uses a QUIETPAK to further break down the jets into smaller sizes thereby increasing the noise frequency and eliminating any potential for shock wave formation from pressure reduction at the inlet diffuser. The result as you can guess is a net decrease in system vent noise! Next, the silencer expansion chamber serves as a reactive volume within the flow path, to further reduce low frequency noise. The resulting expanded flow continues at a much reduced velocity through the annular passages of the acoustic core. Final treatment of the noise is achieved through the sound absorbing characteristics of the acoustic pack, combined with the resonant properties of the perforated facing material Features: These vent silencers are a combination of our field-proven, time-tested diffusers and our QUIETPAK. These EVO silencers provide dramatic improvements in acoustic performance and offer significant reductions in overall silencer height and weight. Furthermore the design incorporates minimal pressure drop to the system. Quality Specifications: Standard Dimensions:


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POWER

Boilers/HRSG

Safety Relief Valve Silencers

EVO ( Steam Vent / Gas blow down ) BOS ( Blow-off Silencer ) HPS ( Vent Silencer )

Control/Start-up Valve Silencer

EVO ( Steam Vent / Gas blow down ) BOS ( Blow-off Silencer ) GDS ( Steam / Gas Diffuser Silencer )

Blow-down Valve Silencers

BOS ( Blow-off Silencer ) HRSG Stack

CTS ( Gas turbine / HRSG exhaust ) Engine Exhaust Silencers

EES ( Combustion Engine Silencer )


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PETROCHEMICAL

Safety Relief Valve Silencers

EVO ( Steam Vent / Gas blow down ) BOS ( Blow-off Silencer ) HPS ( Vent Silencer )

Control Valve

GDS ( Steam / Gas Diffuser Silencer )

Blow-down Valve Silencers

BOS ( Blow-off Silencer ) EVO ( Steam Vent / Gas blow down )

HRSG Stack

CTS ( Gas turbine / HRSG exhaust ) Engines

EES ( Combustion Engine Silencer ) CTS ( Gas turbine / HRSG exhaust ) RCS ( Positive displacement Compressor / Blower

Silencer )

Compressor Station Blow-down EVO ( Steam Vent / Gas blow down ) BOS ( Blow-off Silencer )

Compressor CIS ( Compressor Inline Silencer )

Liquid Pulsation Dampener PDS (Pulsation Dampener )

Hydraulic Acoustic Filter


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AFC ( Hydraulic Acoustic Filter ) Suction Separator / Stabilizer SSC ( Suction Stabilizer )

STI ACTUATORS

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Type: SC Series Sizing Tools: Valsiz Design Location: STI, Italy Manufacuturing : STI, Italy Application & Description: The SC actuators are available in eight different sizes, from diameter 63 mm to 420 mm, and are therefore able to satisfy small to high thrust requirements. Manufactured with fabricated steel cylinder (except for the sizes 63 and 100 which are made of corrosion resistant aluminum alloy), they are suitable for service in harsh environment such as desert areas, power stations, petrochemical plants and steel industries. Their light and functional design assures an easy installation. Furthermore, due to the built in lubrication system, typical of all STI actuators, they are virtually Maintenance free. SC actuators are integrated by a complete line of pneumatic and electro-pneumatic positioner and accessories to meet the most various service requirements. Technical Data: Thrust 1400 to 68,000 N Standard Sizes Diameter

63,100,125,160,200,260,330,420 mm

Stroke 150 to 450 mm Operating temperature -20 to +80o C Supply Pressure max1,000 kPa Standard Pressure NPT F (1/2 NPT F for sizes

330 and 420)

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Actuator size mm Strokemm

Unit WeightKg

150 4 63 200 4.5 150 8 200 9.5 250 11 100

300 12.5 150 13 200 14 250 15 125

300 16 200 24.5

250 25.5 160 300 27.5 200 27.5 200 300 32

300 45 260 400 55

330 400 155 420 450 278

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Materials: Component Material Of Construction

Cylinder Aluminium alloy for 63 to 100 Carbon steel for 125 to 420

Cover Aluminium alloy for 63 to 260 Carbon steel for 330 to 420

Piston Aluminium alloy for 63 to 100 Carbon steel for 125 to 420 Shaft Chromium plated alloy steel.

Tie rod and Clevis Tropicalized zinc-plated carbon steel.

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Type: SC/V Series Sizing Tools: Valsiz Design Location: STI, Italy Manufacuturing : STI, Italy Application & Description: The SC/V actuators, double acting or spring return type, deliver small, medium to high thrusts and are designed to satisfy the most common applications. The small-medium thrust actuators are manufactured with corrosion resistant cast aluminium body, they are suitable for service in harsh environments such as desert areas, power stations, petrochemical plants and steel industries. Their light, compact and functional design assures an easy installation. The high thrust actuators are made of fabricated steel cylinder therefore suitable for heavy duty applications. Several sizes, from diameter 260 mm to 850 mm and over are available to meet specific force requirements. The SC/V range actuators have built in lubrication system, which are virtually maintenance free. A Complete line of pneumatic and electro-pneumatic positioners and accessories is available in connection with the actuators. The shaft as well as the connection flange to the valve can be manufactured according to the various applications to meet all te customers specific needs.

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For several applications, where safety is the main concern, SC/V actuators are required to drive the valve to a defined position (either close ot open) even in the event of air supply failure. This can be accomplished by an air-lock system or by a mechanical spring. Spring Features: Quality Specifications: Materials:

Actuator Material Part Small-med thrust High thrust

Cylinder Aluminium alloy Carbon steel Cover Aluminium alloy Carbon steel Piston Aluminium alloy Carbon steel Shaft Stainless steel Stainless steel Standard Dimensions: Technical data:

Actuator Type Specifications Small-med thrust High thrust

Thrust 880-4000 daN 2600-30000 daN Standard Sizes 150, 200, 250, 300

mm 260, 330, 420, 520, 600, 650, 800, 850 mm

Stroke 40-150 mm 100-400 mm Operating temperature

-26C to 80C -26C to 80C

Supply Pressure Max 1000 KPa Max 1000 KPa Supply Media Dry instrument air

or Clean gas Dry instrument air or Clean gas

Standard Connections

NPTF NPTF

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Type: CML/CMV Series Sizing Tools: Valsiz Design Location: STI, Italy Manufacuturing : STI, Italy Application: The increase of the unit capacity of modern power stations requires for the control of final elements (dampers, hydraulic converters, ect.) the use of high power actuators able to develop torque up to 20000 Nm (14,760 lb.ft). CMV actuators meet these requirements as they can guarantee properly sized actuators. Actuator Selection: The selection of the actuator is possible by referring to table (a) which shows the torque values referred to the supply pressure of 100 Psig and operating times (without load) relating to the positioner SA/CL-1 ND or ND . The torque values are referred to an operating angle of 70o which is the standard operating angle of the lever in the CMV series. This angle of 70 o is considered as the most suitable for an efficient control of dampers, butterfly valves and other final control elements. It is therefore recommendable, when performing the coupling to the final control device, not to amplify this angle. Only for ON-OFF actuators, it is suggested to use for the final control devices a larger operating angle corresponding to about 80/90o.

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Actuator type

Min. torque (1)

Max. torque (1) Operating time (2)with positioner

Weight

Angle 70 90

70 angle 90 SA/CL1

SA/CL1

CMV1 125/250

140daNm 99 1033lb.ft.727

171daNm 139 1265lb.ft.1030

2.5 - Kg153 Lb337

CMV1 160/200

185daNm 130 1363lb.ft.961

226daNm 184 1668lb.ft.1360

3 - Kg163 Lb359

CMV1* 200/200

188daNm 132 1386lb.ft.976

230daNm 187 1699lb.ft.1380

5.5 - Kg183 Lb403

CMV2 160/300

277daNm 195 2045lb.ft.1443

340daNm 278 2510lb.ft 2040

4.5 sec 2 sec Kg260 Lb574

CMV2 200/300

438daNm309 3234lb.ft.2278

537daNm 436 39625lb.ft.3221

7 sec 3.5 sec Kg280 Lb618

CMV2 260/300

745daNm 525 5496lb.ft.3873

913daNm 742 6736lb.ft.5476

12 sec 6 sec Kg305 Lb673

CMV3 260/400

993daNm 700 7330lb.ft.5163

1217daNm989 8983lb.ft.7302

16 sec 8 sec Kg520 Lb1148

CMV3 330/400

1627daNm114610206lb.ft.8454

1993daNm162014707lb.ft.11955

27 sec 13 sec Kg620 Lb1363

CMV4 420/450

3026daNm211340997lb.ft.28627

3695daNm299650061lb.ft.40590

65 sec 27 sec Kg1600Lb7100

Description: Features: Quality Specifications:

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Materials of Construction: Bearing Frame Carbon steel Housing Carbon steel Shaft Alloy steel 38 NiCrMo4

heat treated Lever Carbon steel Shaft Support Bronze fro CMV2 and

CMV3; Spherical joints for CMV1 and CMV4

Manual Control Screw Alloy steel 38 NiCrMo4 heat treated

Standard Connections Brass fittings and copper tubing

Painting Epoxydic Standard Dimensions: Technical data: Torque 100 to 34000 Nm Sizes 63 to 520 mm Angles 90 for CML Series and

70 for CMV Series Air supply Dry instrument air 35/100 Psig Operating temperature

-25 C to 80 C

Control Signal Standard 3 to 15 Psig

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Type: APL Series Sizing Tools: Valsiz Design Location: STI, Italy Manufacuturing : STI, Italy Application & Description: This type of pneumatic, double-acting control actuator for small to medium forces is normally equipped with a handwheel. The unit consists mainly of a piston-type doubleacting actuator of the SCV series, the stem of which transmits its movement to a hinged lever arm with an operating angle of 45o.The actuator is characterized by simple, functional design and grease ease of installation. This makes it a very competitive control component for butterfly valves, louvers, dampers, speed variators, void hydraulic couplings, etc. APL series actuators are therefore suitable for service in harsh environments such as desert zones, cement works, power stations and the steel industry. The installation is easy.The actuators are fastened to a horizontal or vertical support by four bolts that fix the base plate .

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Features: 3 Sizes (APL 150/200/250) available in torque ratings

from 490 to 3000 Nm Piston with permanent built-in-fabrication system Lever arm with regularly spaced holes for linkage

flexibility Integrated positioner with custom-shaped control cam,

force-balance type, insensitive to vibrations and supply air pressure variations

Excellent response times without use of boosters Hand wheel manual control with enclosed gear

elements, suitable also for stroke limitation. Quality Specifications: Materials of Construction: Cover Aluminium alloy Sleeve and Piston Aluminium alloy Stem Stainless steel Lever Carbon steel Stand (Yoke) Aluminium alloy Tubes Copper Fittings Brass Lubrication Mineral grease Sealing Buna N TM

Paint Epoxy

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Standard Dimensions: Technical data: Torque 250 to 3000 Nm Sizes 150 to 250 mm Angles 45 to 90 Supply Pressure 200 to 665 KPa Supply Air Dried and oil-less air Temperature -25 C to 80 C Connections NPTF

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Positioner DE/3M DE/3M is a series of liner positioner purposely designed by STI to control small to medium size SC actuators and usable for strokes from 60 to 300mm. it can be supplied either with a pneumatic or an electro-pneumatic inlet signal. The positioner is normally provided with low flow spool valve bit a special suitable for high flow service is also available on option. The DE/3M assures am easy installation and maintenance like all STI positioners.

Operating Principle:

The operation of the DE/3M positioners is based on the force-balance principle. The force generated by an increase of the control electric signal to the Electro-Pneumatic converter (1) produces an increase of the signal pressure on the diaphragm (2) which stretches the feedback spring (3) and cause a displacement of the spool valve. (4) The increase of the air pressure in chamber A allows the actuator shaft and consequently the feedback spring (3) Connected through the rod (5) to extend. The actuator shaft reaches a stable position only when the spool valve (4) is in equilibrium; that means when the load on the feed back spring equals the force produced by the signal pressure on

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the diaphragm.

Air Features: Air quality according

Application Digest - 27-12-07

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Transcript of Application Digest - 27-12-07