VALVE PRODUCTS

Forged Steel
Valves

Gate Valve Globe Valve Check Valve Blow-down

Valve

Cast Steel
Medium
Pressure
Valves
Gate Valve Globe Valve Check Valve Reheating
Isolating Device

Cast Steel
High Pressure
Valves

Gate Valve Globe Valve Check Valve Elbow type

Blow-down Valve
 VALVE PRODUCTS

Quick Closing High Pressure Soot

Non-Return Valve By-pass Valve Blower

Safety Relief Valve Safety Valve Silencer

 VALVE PRODUCTS

Well-Head X-Mas Tree Assembly

Full Bore
Assembly Gate Valve
 TECHNOLOGY BASE
 High Pressure Gate, Globe Toa Valve Co. Ltd., Japan
and Non-Return Valves
 Quick Closing Non-Return Toa Valve Co. Ltd., Japan
valve
 Safety & Safety Relief Valves Dresser Ind. Inc., USA
 Forged Steel Valves Dresser Ind. Inc., USA
 Soot Blowers Copes Vulcan, USA
 HP-LP Bypass Systems SULZER (CCI), Switzerland
 Oil Field Equipments Kvaerner National, USA
What is a Valve

Valves are mechanical devices specially

designed to direct, start, stop, mix or
regulate the flow, pressure, or temperature
of a process fluid, valves can be designed
to handle either liquid or gas applications.
TYPES OF VALVES – FLOW , PRESSURE

FLOW CONTROL :
• GATE, GLOBE & CHECK VALVES

PRESSURE CONTROL :
• PRESSURE RELIEVING VALVES
• CONTROL VALVES
HOW TO SPECIFY A VALVE
What Parameter?
MAIN PARAMETERS TO SPECIFY
1. TYPE OF VALVE
2. SIZE
3. MATERIAL
4. RATING (Pressure & Temperature)
5. END CONNECTION
6. OPERATION
TYPE OF CONVENTIONAL VALVES

1. GATE VALVE
2. GLOBE VALVE
REG. GLOBE

PISTON LIFT
3. CHECK VALVE
SWING CHECK
SIZE
IDENTIFIED BY
NOMINAL PIPE SIZE (NPS)
OF THE PIPING ON WHICH
VALVES ARE MOUNTED.
BHEL MANUFACTURES FROM
0.25” to 36”
 MATERIAL

UPTO 2” 2”
MATERIAL COMPOSITION
TEMP FORGE CAST

425
CARBON STEEL A105 WCB / WCC C-Mn-Si
C
550 ¼ Cr. - ½ Mo
ALLOY STEEL F 22 WC6 / WC9
C 2¼ Cr-1-Mo
550 18 Cr-8 Nl
STAINLESS STEEL F316 CF8 / CF8M
C 16Cr-8Nl-2Mo

A217-C12A DEVELOPED FOR SUPER CRITICAL BOILER APPLICATION

RATING
 MAXIMUM PERMITTED PRESSURE OF MEDIUM
WITH RESPECT TO TEMPERATURE FOR A
MATERIAL GIVEN IN ASME B16.34
 RATINGS DENOTED BY CLASS NUMBERS.

BHEL MANUFACTURES
FORGED VALVE IN
 CLASS 800,1500,2500 & 3000 spl
CAST VALVES IN
 CLASS 150,300,600,1500,2500,3500

ASME CLASS ? ASME CLASS ?

END CONNECTION
VALVE ASSEMBLY MOUNTED
ON PIPELINE BY FOLLOWING MEANS

1. SOCKET WELD ENDS

2. SCREWED ENDS } FOR 2”

3. FLANGED ENDS
4. BUTTWELD ENDS } FOR 2”
OPERATION
 HAND WHEEL OPERATION

 GEAR OPERATION

 MOTOR OPERATION
DESIGN STANDARDS

 API 600 GATE

 API 602 GATE
 ASME B16.34 ALL VALVES
 BS 1414 GATE
 BS 1873 GLOBE
 BS 1868 SWING CHECK
 OTHER STANDARDS

 ASME B16.10 END TO END

 ASME B16.5 FLANGED END
 ASME B16.25 BUTT WELD END
 ASME B16.11 SOCKET/THREADED
 ASME B16.47 LORGE DIA FLANGES
 ASME B1.1 UNIFIED INCH SCREW
 ASME B36.10M STEEL PIPES
 INSPECTION AND TESTING
STANDARD

 API 598 GATE

 BS 6755 PART 1 GATE , GLOBE &SCV
 ASME B16.34 GATE, GLOBE &SCV
 PRODUCT RANGE-GATE
150C 2” TO 36”
 300C 2” TO 20”
 600C 2” TO 12”
 800C 0.25” TO 2”
 900C 4” TO 8”
 1500C 2.5” TO 18”
 2500C 2” TO 18”
 2850C 20”
PRODUCT RANGE-GLOBE
 C 300 2” TO 8”
 C 600 3” TO 4”
 C 800 0.25” TO 2”
 C 1500 2.5” TO 4’
 C 2500 2.5” TO 6”
 C 3000 Spl 0.25” TO 2”
 C 3500 2.5” T0 3”
PRODUCT RANGE-SCV

 C 150 2” TO 8” &24”
 C 300 2” TO 12” &16”
 C 1500 2.5” TO 14”
 C 2500 2.5” TO 18”
PRODUCT RANGE-PLNRV

 C 800 0.25” TO 2”
 C 1500 0.25” TO 2”
 C 2500 0.25” TO 2”
 C 3000 Spl 0.25” TO 2”
Forged Valve : Forged Valve :
Medium Pressure High Pressure
Gate Valves Globe Valves
Globe Valves Check Valves
Check Valves

Cast Steel Bolted High Pressure – Pressure-

Bonnet Valves : Seal Bonnet Valves :
Gate Valves Gate Valves
Globe Valves Globe Valves
Check Valves Check Valves
 Difference between Gate & Globe
GATE VALVE GLOBE VALVE
CONSTRUCT OPEN/CLOSE BY A WEDGE/GATE OPEN/CLOSE BY A PLUG/DISC
USAGE FOR OCCASIONAL OPEN/CLOSE FOR FREQUENT OPERATION
FOR OPEN/CLOSE ONLY REG. GLOBE VALVES USED FOR
REGULATION DUTY
LIFT LIFT IS MORE. LIFT IS LESS(~ D/4)
OPERATING FORCE/TORQUE IS OPERATING FORCE/TORQUE IS
FORCE LESS MORE.
OPERATION OPERATION TIME IS MORE OPERATION TIME IS LESS
PR.DROP PRESSURE DROP IS LESS PRESSURE DROP IS MORE
POPULAR IN ALL SIZES. RESTRICTED TO SMALLER SIZES
SIZES SPECIFICALLY HIGHER SIZES. ONLY.
 SPECIALITIES
• Sealed Gland Arrangement SG
• By-Pass Valve Arrangement BPV
• Pressure Relieving Arrangement PRV
• Limit Switch Arrangement LS
• Balance Hole Arrangement BH
• Locking Arrangement LO
• Indicator Arrangement INDICATOR
• Drain Hole Arrangement DRAIN HOLE
 SPECIALITIES

IN OPERATION
 Chain Wheel Operation CHAIN
 Extension Spindle Operation EXTN
ELECTRICAL ACTUATORS

For

VALVE OPERATION
 Type of actuators

1. Hydraulic actuators
2. Pneumatic actuators
3. Electric actuators

Hydraulic actuators
 Hydraulic actuators are compact, fast acting and
delivers high torque. But these actuators require
complete hydraulic system and cleanliness.
 These are used where there is a requirement of
quick response and compactness.
Pneumatic actuators
 Pneumatic actuators are compact and fast acting.
 But torque developed is very low, sufficient only for small
valves. For other valves need torque amplification system.
 Because of fast action used for control application of small
valves.

Electric Actuators
 Electric Actuators are simple, develop high torque,have
good operating speed.
 With electronic controls these actuators become
robust,easy to install and operate.
 These are also compatible to modern plant control
systems.
 Type actuating movement
 Multi turn Actuators
 Part turn actuators
 Linear Actuators

Multi-Turn actuator
 An actuator which transmits torque to the valve
for one or more revolution.

Part-turn actuator
 An actuator which transmits torque to the valve
for less than one revolution.

Linear Actuator
 An actuator which transmits torque to the valve
With linear motion.
 ELECTRICAL VALVE ACTUATORS
All critical valves in a power plant are operated by an electrical
Actuator from remote control room. These include :
•Main steam stop valves
•Feed discharge valves
•HP heater isolating valves
•Continuous blow down valves
•Emergency blow down valve
•Start up vent valve
•Steam & feed water drain valve
•Extraction line valve
Types of Motor Operated Valves
Motor Operated
Actuators

Actuator without Actuator with

Integral Starter Integral Starter

Actuator with
Electronic
Integral Starter
Actuator with
Smart
Integral Starter
 CONSTRUCTION

Actuator is an electro mechanical equipment consisting

of
•Motor
•Gear box
•Control compartment
•Hand wheel and De-clutch lever
•Thrust base
•Terminal box
 MANUAL OPERATION

For emergency manual operation of valve during power failure

the hand wheel provided in the actuator is coupled to the
output shaft by means of a declutch lever. Once power supply
is restored the hand wheel automatically gets disengaged.
Actuator without Integral starter
For Torque <= 100 Kg M
Actuator without Integral starter
For Torque > 100 Kg M
 SPECIAL FEATURES

•Inbuilt starter
•Explosion proof / frame proof
•Non-intrusive type
•Two wire system
Actuator with & without Integral starter
Integral starter of an actuator
INTEGRAL STARTER
Actuator with integral starter consists of following items.
Reversing contactor
Overload relay
Stop / open / close push button
Local remote selector switch
Monitoring relay
Interposing relays for remote operation
415V / 110V step down transformer
Fuses on primary & secondary circuits.
 ELECTRONIC POSITION TRANSMITTER
(EPT)

Input -> 0 - 100 ohm

Output -> 4-20mA
System -> 2 wire or 4 wire
Supply -> 24V DC
Provided for inching duty regulating valves.
Development / Supply of Two Wire Control
System for Thermal stations.

 Two Wire Control system is being supplied to NTPC-Talcher

(for the first time in power plant environment in India),
comprising the following .
– 60 Channel Master Station with hot standby.
– PakTester
– PakReader
– Non-Intrusive actuators with field control units

 This system enables faster communication with DCS system,

quicker & accurate fault identification apart from enormous
saving in cable cost.
Two Wire Control System
Two Wire Control System
POSITION SEATING
 All GATE valves of size 100mm & above and Pressure rating
1500 C and above shall be set for POSITION SEATING . i.e.,
valve closing shall be by CLOSE POSITION limit switch trip
only.
 The close Torque limit switch to be connected as Back –up /
Parallel connection.
 Valve Opening shall be by OPEN POSITION Limit switch trip.
TORQUE SEATING
 All other GATE,GLOBE and REGULATING valves shall be
set for TORQUE SEATING only. i.e., valve closing shall be by
CLOSE TORQUE limit switch trip only.
 The close position limit should NOT be connected as back –
up / parallel connection.
 Valve Opening shall be by OPEN POSITION Limit switch trip.
 For all Gate valves the during initial 5% opening, of the valve
from its close position, the OPEN TORQUE LIMIT SWITCH
should be bypassed to ensure smooth opening of the valve.
 Thermostat and Over load relay (OLR) should be connected to
the motor control circuit.
 Actuator setting are to be done as per the above
recommendations and set to the recommended opening and
closing torque values ,other wise it can lead to valve jamming.
 For actuator wiring and torque /position limit switch setting
refer wiring diagram 4.V.MISC. 90721 Rev 11 indicated in the
O&M.
At the time of Commissioning:
 All valves gland to be tightened to arrest gland leak.
 Hot tightening of all High pressure valves Bonnet retainer to
arrest Self Sealing Bonnet leak after attaining Max pressure &
temperature.
 Attend to all critical valves involved in Steam Blowing and Acid
cleaning.
- Check for Seat damage and re-lap.
- Replace Gland Packing
- Replace SW Gasket
- Ensure Actuator settings as per recommendation.
At the time of annual over-hauling:
 Replace Gland Packings
 Replace Body-Bonnet joint SW gasket, Hinge pin Gaskets
 Lapping of damaged Seating surfaces in Body,Wedge/Disk.
 Replace Pressure Seal Bonnet Gasket (Soft Iron/ Grafoil)
 Hot tightening of all High pressure valves Bonnet retainer to
arrest Self Sealing Bonnet leak to be ensured after attaining Max
pressure & temperature.
 In Motorised Valves check for settings in the actuator as per
original recommendations.
 All valves are to be attended at least once in TWO years.
1. Gland leakage
 Tightened Gland bolts evenly, as soon as leakage is noticed and arrest it.

 Additional packing shall be added, if necessary (at the next available shut down).
 If leakage persists, packing shall be replaced with new set of packing.

2. Body bonnet joint leakage. (SW gasket)

 Tighten the bolts sequentially. If the leakage still persists, replace the SW gasket.
 Also ensure that the sealing surface is intact.

3. Pressure seal bonnet/ Hinge Pin leak in high pressure valves.

 In pressure seal design, sealing effect is achieved by the medium pressure only.

 TO ensure effective sealing, self sealing bonnet nuts are to be fully tightened in
cold condition and to be retightened after achieving full operating pressure.

 Also bonnet nuts are to be retightened again when maximum operating

temperature is achieved as temperature variations can cause relaxation of
bonnet nuts.
 Contd…
4. VALVE PASSING
 Valve passing is mainly because of damaged sealing surfaces.

 It is due to entrapment of foreign particle between wedge / disc and

body seat.

 It is to be attended by lapping of both the body and wedge / disc seat.

 It is preferable to attend the valves immediately after steam blowing,

in case the valves are involved during steam blowing operation
SPARES DESCRIPTION GV GLV CV CATEGORY

BODY BONNET GASKET COMMISSIONING

GLAND PACKING COMMISSIONING

STEM/SPINDLE MAINTAINENCE

WEDGE/DISC MAINTAINENCE

YOKE BUSH MAINTAINENCE

HINGE PIN GASKET MAINTAINENCE

GV - GATE VALVE GLV - GLOBE VALVE CV - CHECK VALVE

N.A. - NOT APPLICABLE

Thank you
Quick Closing Non-Return
Valve
(QCNRV)
&
Cold Reheat Line
Non-Return Valve
(CRHNRV)
 QUICK CLOSING NON RETURN VALVE

Function:

Quick Closing Non Return Valves are standard non return

valves equipped with power cylinders, ensuring rapid and
positive closing to prevent any reverse flow into the turbine.

Cold Re-Heat Non Return Valve also does the same function but
opens & closes by power cylinder as per the system
requirement.
 QUICK CLOSING NON RETURN VALVE
Application

QCNRVs are used in turbine extraction lines to the heater and

deaerator.

CRH- NRVs are used in cold reheat line from HP turbine to

reheater.

Both QCNRV and CRH-NRVs are closed by power cylinders on

the initiation of turbine trip, when the forward flow ceases.
 RANGE OF VALVES

CLASS RATING
VALVE TYPE SIZE 150 300 600 900
3”
6”
8”
10”
12”
QCNRV 14”
16”
20”
24”
32”

18”
CRH NRV
24”
32”
 BONNET
GASKET

DISC
ARM (STELLITED)

NUT
SEAT
(STELLITED) BODY

AIR/OIL CYLINDER

QUICK CLOSING NON RETURN VALVE

QUICK CLOSING NON RETURN VALVE

OPERATION

Power cylinder energised through oil / air to keep the flap

free to open when there is flow.

Power cylinder de energised to forcibly close the valve by the

spring force.

The flap opening is max. 35 deg. in QCNRV and

85 deg. in CRHNRV.

Position indicators are provided to indicate the valve flap

position.
 QCNRV PHOTO

QUICK CLOSING NON RETURN VALVE

 QUICK CLOSING NON RETURN VALVE

210 MW 500 MW
NB NP QTY NB NP QTY
VALVE mm class Nos mm class Nos

CRH NRV 450 600 1 800 600 1

QCNRV 200 300 2 500 300 4

QCNRV 300 150 2 500 150 2

QCNRV 400 150 2 400 300 2

QCNRV 600 150 2

GO TO
 Maintenance
Maintenance Check: (Recommended per shift)
1. Disc arm assy. swinging freely.
2. On line Test operation of the cylinder.
3. Position transmitter and limit switch function.
4. Steam leakage to be checked at :
• Stuffing box/ gland packing.
• Spiral wound gasket area.

Annual Maintenance
1. The bushes and bearings are to checked. Any abnormality noticed requires
replacement of these components.
2. The claw portion of the Spindle and arm are to checked for any crack.
3. The stellite surface of the spindle to be checked for any abration.
4. Asbestos/Graphite packing area on the spindle are to be checked for any
pitting.
5. In the cylinder all the O’rings, piston rings and packings are to be checked
for leaking .
 QUICK CLOSING NON RETURN VALVE

Recommended Spares

• Gaskets for valves and actuators

• Packings for valves and actuators

• Spiral Wound Gaskets for valves

• O’ rings for actuators

 RECOMMENDED SPARES
SL No. SPARES DESCRIPTION CATEGORY

1 BODY BONNET GASKET COMMISSIONING

2 SIDE BONNET GASKET COMMISSIONING

3 GLAND PACKING COMMISSIONING

4 SPINDLE MAINTAINENCE

5 DISC, ARM MAINTAINENCE

6 BUSH MAINTAINENCE
 SAFETY

AND

SAFETY RELEIF

VALVES
SAFETY VALVES:
A valve, which automatically discharges
fluid to atmosphere so as to prevent a pre-
determined safe pressure being exceeded.
It is generally used for compressible fluids
such as steam and other gases which
demand quick over-pressure relief.
SAFETY & SAFETY RELIEF VALVES

SB

RB

SS

RS
 PRESSURE RELIEF VALVES
CLASSIFICATION OF PRVs :

(A) SV- Safety Valves (1700 & 1811 SERIES)

(B) RV- Relief Valves
(C) SRV - Safety Relief Valves (1900&1990 SERIES)
 Applications of SV, RV & SRV
Safety Valve Relief Valve Safety Relief Valve
Description
(SV) (RV) (SRV)
Compressible Media Incompressible acts as SV in compressible
Applicable Media
Vapors & Gases like medias and acts as RV in
Fluids
steam, air etc All liquids like water incompressible medias
Opening is Pop action in compressible
Pop Action (Sudden proportional to the medias and proportional
Opening
opening) excess pressure opening in incompressible
over the set pressure medias
Code
ASME Sec-I & IBR ASME Sec-VIII ASME Sec-VIII
Requirements

Operating Gap 5% Minimum 10% Minimum 10% Minimum

Blow Down 5% Maximum 15% Maximum 15% Maximum

Petroleum &
Utility & Industrials Fertilizer All applications except
Applications
Boilers boiler drum, SH & RH.
Industries

Over Pressure 3% of set pressure 25% of set pressure 10% of set pressure
CAP

SPG.ADJUSTER

YOKE
SPRING

SPINDLE

LEVER

GUIDE
DISC HOLDER
UP.ADJ.RING

ADJ.RING PINS

LO.ADJ.RING

DISC

BODY
CAP

SPG.ADJUSTER

WASHER

SPRING

SPINDLE

GUIDE

DISC HOLDER

ADJ.RING PIN

ADJ.RING

NOZZLE

BASE
 Typical Number of Valves in Power Boilers.
QUANTITY REQUIRED
LOCATION VALVE MODEL
210 MW 250MW 500 MW
1750 WB 3 1 2
DRUM
1740 WB - 2 4
1739 WD - 2 -
S.H.
1740 WD 1 - 2
1786 WB 1 1 -
C.R.H.
1786 WB-10” - - 4
H.R.H. 1786 WD 3 4 4
ERV-SH 1538 VX-10W 1 2 5
ERV-RH 1525 VX-4 - 2 4
TOTAL 9 14 25
SL COMPONENT PARAMETER EFFECT OF ADJUSTMENTS

01 SPRING SET PRESSURE CLOCKWISE – INCREASE

ADJUSTER COUNTER CLOCKWISE - DECREASE
02 UPPER BLOWDOWN CLOCKWISE / DOWN – INCREASE
ADJUSTING COUNTER CLOCKWISE / UP –
RING DECREASE
LOWER SIMMER / LIFT COUNTER CLOCKWISE – REDUCE SIMMER
03 ADJUSTING AND ENABLE FULL LIFT.
RING

OVERLAP BLOWDOWN CLOCKWISE – TO REDUCE.

04 COLLAR COUNTERCLOCKWISE - INCREASE.

NOTE : ALL ROTATIONS ARE TO BE MADE AS LOOKING FROM

THE TOP OF THE VALVE
COMPONENT NAME SV SRV REQUIREMENTS
DISC COMMISSIONING
ADJ.RING PINS
COMMISSIONING
(Lower & Upper)
ADJUSTING RINGS MAINTENANCE
SPINDLE MAINTENANCE
DISK HOLDER MAINTENANCE
GUIDE MAINTENANCE
OVERLAP COLLAR N.A MAINTENANCE

N.A - Not Applicable

SOOT BLOWERS
&
APPLICATIONS
TYPES OF SOOT BLOWERS APPLICATION

• WALL DESLAGGER - FURNACE WALL ?

* LONG RETACTABLE SOOT - CONVECTION ZONE

BLOWER (SH, RH, LTSH, ECO)

* HALF RETRACTABLE SOOT - CONVECTION ZONE,

BLOWER FLUE GAS < 600 DEG. C

* ROTARY SOOT BLOWERS - CONVECTION ZONE,

INDUSTRIAL BOILERS,
ID FAN (IMPELLER)
BANK TUBES, ECO.
AIR HEATERS

* AIR HEATERS CLEANERS - ROTARY AIR HEATERS.

* TRAVERSING NON- ROTATING - TUBULER AIR HEATERS

 WALL DESLAGGER

DESIGN FEATURES - 2 MOTOR DRIVE

MODEL WBIE
- EASY ACESSIBILITY FOR
MAINTENANCE OF PARTS

- COMPLETE 360 Deg. ROTATION

- FLEXIBILITY TO VARY THE BLOWING TIME

- FLEXIBILITY TO VARY BLOWING ANGLE

- LESS NON - BLOWING TIME

OPERATION
FORWARD TRAVEL -305 MM IN 3 SECS.

ONE ROTATION IN 84 SECS.

RETRACT TRAVEL - 305 MM IN 3 SECS.

TRAVERSE SPEED - 6.1 M / MIN

ROTARY SPEED - 0.7 RPM.

ROTARY GEAR REDUCTION - 2067 : 1

TRAVERSE - 28 : 1
LONG RETACTABLE SOOT BLOWERS

MODELS

SINGLE MOTOR - LRS - I MAX. TRAVEL : 6 MTR.

(CHAIN DRIVEN)

DOUBLE MOTOR - LRD - I E MAX. TRAVEL : 7.6 MTR

( CHAIN DRIVEN ) - LRD - I ER MAX. TRAVEL : 7.6 MTR
- LRD - I A MAX. TRAVEL : 7.6 MTR
- LRD - II E TRAVEL : 7.7 TO 12.2 MTR

GEAR OPERATED - LRS - I ER MAX TRAVEL : 5 MTR

 OPERATION
LANCE MOVEMENT -TRAVERSE & ROTARY

TRAVERSE SPEED -1.63 M/MIN (LRD IE)

ROTARY SPEED -5.2 RPM (LRD IE)

MAX CLEANING RADIUS - 2.5 – 2.7M

GEAR REDUCTION (T) -155:1

GEAR REDUCTION (R) - 28:1

 OPERATION

ROTARY SPEED - 1.2 RPM

NO OF REVOLUTION -1
NO OF NOZZLES - AS MANY COILS
NOZZLE DIAMETER - 6 / 8 / 10 MM
OPERATING TIME - 0.82 MIN
GEAR RATIO - 124 : 1
SOOT BLOWER CHECKS

COMMISSIONING CHECKS:

 LUBRICATING OIL LEVEL.

 INTERLOCKS.
 HAND CRANK AVAILABILITY.
 DIRECTION OF ROTATION OF MOTORS.
 OPERATION OF LIMIT SWITCHES.
 ENSURE STEAM CONDITIONS.
 BLOWING PRESSURE.
 STEAM LEAKAGES.
MAINTENANCE CHECKS

ANNUAL CHECKS

 REPLACE LUBRICATING OILS.

 CHAIN, CHAIN LINKS.

 VALVE STEM ASSY.

 ROTATION OF LANCE ROLLER ASSY.

 BLOWING PRESSURE.

 LANCE / NOZZLE DISTANCE.

GO To
MAINTENANCE CHECKS

SHUT DOWN CHECKS

 REPEAT ANNUAL CHECKS.

 VALVE HEAD SERVICING.

 CHECK FOR BOILER TUBES.

 BLOWER ADJUSTMENT FOR ANY

MISALIGNMENT.

GO TO
Recommended Spares
SL DESCRIP[TION LR WB RB TYPE OF SPARES
01 GEAR BOX ASSY MAINTENANCE
02 MOTOR MAINTENANCE
03 SBV HEAD ASSY MAINTENANCE
04 VALVE STEM MAINTENANCE
05 LIMIT SWITCHES MAINTENANCE
06 BEARINGS MAINTENANCE
07 GLANDS MAINTENANCE
08 OIL SEALS MAINTENANCE
09 LANCE ASSY NA NA MAINTENANCE
10 SWIVEL TUBE ASSY NA NA MAINTENANCE
11 BLOWING ELEMENT NA NA MAINTENANCE
12 PACKINGS COMMISSIONING
13 GASKETS COMMISSIONING
HPLP BYPASS

SYSTEM

VALVES
 HP/LP BYPASS SYSTEM
FUNCTION:

To ensure operation of steam generator by

maintaining a minimum circulation of steam flow ,
when turbine is not in service

ADVANTAGES:

 Quick start up of the unit

 Reheater protection during start - up
 Parallel operation of steam generator & turbine
 House load operation
 Limited safety valve lifting during trip outs
 Dm water saving
 MAINTENANCE CHECKS
• EVERY MONTH
• OIL LEVEL
• OPTICAL PR.DROP INDICATOR (RED BUTTON) IN 3
MICRON FILTER

• EVERY 3 MONTHS

• NITROGEN PRESSURE IN ACCUMULATOR

• SYSTEM PRESSURE
• PRESSURE SWITCH SETTING
• AIR FILTER ELEMENT CHECKING
 MAINTENANCE CHECKS

• EVERY ANNUAL OVER HAUL

• CONDITION OF SEALING SURFACES OF VALVES
• CONDITION OF ACTUATOR SEALS
• CONDITION OF HYDRAULIC OIL
• PUMP SUCTION STRAINER
• DELIVERY FILTER IN OIL SUPPLY UNIT

• ALL OPERATING PRESSURES IN PRESSURE

SWITCH
 HP BYPASS AND SPRAY VALVE SPARES
COMPONENT NAME HPBP SPRAY REQUIREMENT
PACKING RING COMMISSINING
SPIRALWOUND GASKETS COMMISSINING
VALVE SEAT MAINTENANCE
VALVE STEM MAINTENANCE
PRESSURE SEAL PLUG MAINTENANCE
JETCAGE MAINTENANCE
GLAND BUSH MAINTENANCE
GUIDE BUSH MAINTENANCE
N.A: NOT APPLICABLE
 HP BYPASS HYDRAULIC SYSTEM SPARES

COMPONENT NAME REQUIREMENT

FILTER ELEMENTS COMMISSINING
ACTUATOR SEALS & ‘O’RINGS MAINTENANCE
SERVO VALVE SEALS & ‘O’RINGS MAINTENANCE
BLOCKING ELEMENT SEALS & ‘O’RINGS MAINTENANCE
OIL SUPPLY UNIT SEALS & ‘O’RINGS MAINTENANCE
ACCUMULATOR BLADDER MAINTENANCE
FAST OPENING DEVICE SEALS & ‘O’RINGS MAINTENANCE
 DIRECT WATER LEVELGAUGE

To indicate
the visible water level
in pressure containing vessel.

CONSISTS OF
1. GAUGE GLASS ASSEMBLY.
2. TIE BAR ASSEMBLY
3. ILLUMINATOR
4. VIEWING HOODS.
GAUGE ASSY
 REPAIR PORT ASSEMBLY INSTRUCTIONS

• Assy to be done in a clean atmosphere.

• Glass, mica, gasket shall be handled with its

Edges; Faces shall not be touched.

• Incase of leakage, all items (2-5) shall be

changed with new one.
FAST OPENING OF HP BYPASS VALVE UNDER:
1. GENERATOR CIRCUIT BREAKER OPENS
2. TURBINE TRIPS
3. TIRBINE LOAD SHEDDING REALY ACTS.
COMMISSIONING / O&M CHECKS

 Acid cleaning & installation of oil lines

 Setting of oil system pressure
 Flushing with 25micron filter
 Flushing with 3micron filter
 Draining of flushed oil
 Testing of oil for PARAFFIN content
 Line filters should not be used for flushing
 Contamination level to be checked
 Accreditation

 IBR : Well known Tube and Pipe Maker

 ISO 9001 : Quality Systems for Boilers,
Auxiliaries, Valves, Heat Exchangers, Pressure
Vessels and Oil Field Equipment
 ISO 9002 : Quality Systems for Manufacture of
Seamless Steel Tubes.
 Lloyds Register of : Class-I Fusion Welded Pressure
Vessel Shipping Manufacture.
 NABL : National Accreditation Board for
Testing and Calibration laboratory
 VALVES- EXPORT PERFORMANCE

USA MALTA

CYPRUS BANGLADESH JAPAN

SYRIA
GHANA KUWAIT PHILLIPINES
MALAYSIA
INDONESIA

FURTHER PENETRATE into : Middle East, U.S.A., Singapore, Russia(OFE),

Iran, Iraq & Canada for enhanced business volume.
 HAND WHEEL
WEAR WASHERS
STEM WITH DOUBLE ACME THREAD STURDY SWING BOLT

TWO PIECE GLAND

DEEP STUFFING BOX
SPIRAL WOUND GASKET
POSITIVE BACK SEATING
FULLY GUIDED WEDGE

RENEWABLE SEATS.

DESIGN STD. : API-602

TESTING STD. : API-598

GATE VALVE
( FORGED STEEL - MEDIUM PRESSURE )
 THREAD BUSHING

HANDWHEEL STURDY SWING BOLT

TWO-PIECE GLAND DEEP STUFFING BOX

POSITIVE TAPERED BACKSEAT

SPIRAL WOUND GASKET

DISC NUT
GUIDED STEM-DISC
DISC

SCREWED SEAT RING

FOR REG. VALVE

DESIGN STD. : BS-5352

TESTING STD. : BS-6755(1)

GLOBE / REG. VALVE

(FORGED STEEL - MEDIUM PRESSURE )
 HIGH STRENGTH BOLT
TOP ENTRY DESIGN.
CUSHIONED DISC
FORGED BODY & CAP

SPIRAL WOUND GASKET

FLAT SEAT
FULLY GUIDED DISC

RENEWABLE SEAT

DESIGN STD. : BS-5352

TESTING STD. : BS-6755(1)

( FORGED STEEL - MEDIUM PRESSURE )

HAND WHEEL

YOKE BUSH
RISING STEM

GLAND
GREASE NIPPLE

BACK SEAT
EYE BOLTS

STUFFING BOX STEM

SEAT RINGS
WEDGE

BODY END CONNECTIONS

 HAND WHEEL EYE BOLTS

YOKE BUSH
DEEP STUFFING BOX
SELF ALIGNING GLAND
REGULATING DISC

STEM

BACK SEAT
BODY

END CONNECTIONS

DESIGN STANDARD : BS 1873

TESTING STANDARD : BS 6755 Part-I
 BONNET JOINT
HINGE PIN
DISC STOP

HINGE

END CONNECTION

SEAT RING

BODY DISC

DESIGN STANDARD : BS 1868 / API 6D

TESTING STANDARD : BS 6755 Part-I / API 6D
 ALUMINIUM BRONZE BUSHING
YOKE ARM
RUGGED FLANGE
STEM
SPLIT GLAND
STAKE LOCKED DISC NUT
DEEP STUFFING BOX.
DISC PAD

INTEGRAL HARD FACING FULL PENETRATION WELD

FOR REG. VALVE

DESIGN STD. : BS-5352/ANSI-B16.34

TESTING STD.: ANSI-B16.34

GLOBE / REG. VALVE

( FORGED STEEL - HIGH PRESSURE )
SCREWED AND SEAL WELDED COVER SEAL WELD

FULLY GUIDED DISC

FULL PENETRATION WELD

HARD FACING
BODY

DESIGN STD. : BS-5352/ANSI-B16.34

TESTING STD. : ANSI-B16.34

CHECK VALVE
( FORGED STEEL - HIGH PRESSURE )
MECHANICAL
STOPPER

HAND WHEEL

YOKE SLEEVE
YOKE
GREASE NIPPLE
BEARING
RETAINING RING(NI-PLATING)
GLAND FLANGE
SOFT IRON GASKET
GLAND PACKING

STEM
18/8 SS INLAY
YOKE CLAMP
PR. SEAL BONNET
SEAT RING
BACK SEAT
DISC

BODY
 DETAIL OF PRESSURE
SEAL CONSTRUCTION

LIFTING LUG SOFT IRON GASKET

18/8 SS INLAY
RETAINING RING
PRESSURE SEAL
BONNET
CUSHION PLATE
ARM

DISC NUT

SEAT RING BODY

PLUG

BUSHING

SPINDLE
PRESSURE RELEIVING
VALVE ASSEMBLY
BACK
BACK
Thank you