CONTROL VALVE

SOURCEBOOK
PULP & PAPER
Copyright 2011 Fisher Controls International LLC
All Rights Reserved.
Fisher, ENVIRO-SEAL, Whisper Trim, Cavitrol, WhisperFlo, VeeBall, ControlDisk, NotchFlo, easye and FIELDVUE are marks
owned by Fisher Controls International LLC, a business of Emerson Process Management. The Emerson logo is a trademark and
service mark of Emerson Electric Co. All other marks are the property of their respective owners.
This publication may not be reproduced, stored in a retrieval system, or transmitted in whole or in part, in any form or by any means,
electronic, mechanical, photocopying, recording or otherwise, without the written permission of Fisher Controls International LLC.
Printed in U.S.A., First Edition
iii
Table of Contents
Introduction v
Chapter 1 Control Valve Selection 1-1
Chapter 2 Actuator Selection 2-1
Chapter 3 Liquid Valve Sizing 3-1
Chapter 4 Cavitation & Flashing 4-1
Chapter 5 Gas Valve Sizing 5-1
Chapter 6 Control Valve Noise 6-1
Chapter 7 Steam Conditioning 7-1
Chapter 8 Process Overview 8-1
Chapter 9 Pulping 9-1
Chapter 10A Batch Digesters 10A-1
Chapter 10B Continuous Digesters 10B-1
Chapter 11 Black Liquor Evaporators/Concentrators 11-1
Chapter 12 Kraft Recovery Boiler 12-1
Chapter 13 Recausticizing & Lime Recovery 13-1
Chapter 14 Bleaching & Brightening 14-1
Chapter 15 Stock Preparation 15-1
Chapter 16 Wet End Chemistry 16-1
Chapter 17 Paper Machine 17-1
Chapter 18 Power & Recovery Boiler 18-1
iv
v
Pulp and Paper Control Valves
Introduction
This sourcebooks intent is to introduce a pulp
and paper mills processes, as well as the use of
control valves in many of the processes found in
the mill. It is intended to help you:
D Understand pulp and paper processes
D Learn where control valves are typically
located within each process
D Identify valves commonly used for specific
applications
D Identify troublesome/problem valves within
the process
The information provided will follow a standard
format of:
D Description of the process
D Functional drawing of the process
D Fisher
R
valves to be considered in each
process and their associated function
D Impacts and/or considerations for
troublesome/problem valves
Valve Selection
The information presented in this sourcebook is
intended to assist in understanding the control
valve requirements of general pulp and paper
mills processes.
Since every mill is different in technology and
layout, the control valve requirements and
recommendations presented by this sourcebook
should be considered as general guidelines.
Under no circumstances should this information
alone be used to select a control valve without
ensuring the proper valve construction is identified
for the application and process conditions.
All valve considerations should be reviewed by the
local business representative as part of any valve
selection or specification activity.
Control Valves
Valves described within a chapter are labeled
and numbered corresponding to the identification
used in the process flow chart for that chapter.
Their valve function is described, and a
specification section gives added information on
process conditions, names of Fisher valves that
may be considered, process impact of the valve,
and any special considerations for the process
and valve(s) of choice.
Process Drawings
The process drawings within each chapter show
major equipment items, their typical placement
within the processing system, and process flow
direction. Utilities and pumps are not shown
unless otherwise stated.
Many original equipment manufacturers (OEMs)
provide equipment to the pulp and paper
industry, each with their own processes and
proprietary information. Process drawings are
based on general equipment configurations
unless otherwise stated.
Problem Valves
Often there are references to valve-caused
problems or difficulties. The list of problems
include valve erosion from process media,
stickiness caused by excessive friction (stiction),
excessive play in valve to actuator linkages
(typically found in rotary valves) that causes
deadband, excessive valve stem packing
leakage, and valve materials that are
incompatible with the flowing medium. Any one,
or a combination of these difficulties, may affect
process quality and throughput with a resulting
negative impact on mill profitability.
Many of these problems can be avoided or
minimized through proper valve selection.
Consideration should be given to valve style and
size, actuator capabilities, analog versus digital
instrumentation, materials of construction, etc.
Although not being all-inclusive, the information
found in this sourcebook should facilitate the
valve selection process.

vi
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Chapter 1
Control Valve Selection
In the past, a customer simply requested a control
valve and the manufacturer offered the product
best-suited for the job. The choices among the
manufacturers were always dependent upon
obvious matters such as cost, delivery, vendor
relationships, and user preference. However,
accurate control valve selection can be
considerably more complex, especially for
engineers with limited experience or those who
have not kept up with changes in the control valve
industry.
An assortment of sliding-stem and rotary valve
styles are available for many applications. Some
are touted as universal valves for almost any
size and service, while others are claimed to be
optimum solutions for narrowly defined needs.
Even the most knowledgeable user may wonder
whether they are really getting the most for their
money in the control valves they have specified.
Like most decisions, selection of a control valve
involves a great number of variables; the everyday
selection process tends to overlook a number of
these important variables. The following
discussion includes categorization of available
valve types and a set of criteria to be considered in
the selection process.
What Is A Control Valve?
Process plants consist of hundreds, or even
thousands, of control loops all networked together
to produce a product to be offered for sale. Each
of these control loops is designed to control a
critical process variable such as pressure, flow,
level, temperature, etc., within a required operating
range to ensure the quality of the end-product.
These loops receive, and internally create,
disturbances that detrimentally affect the process
variable. Interaction from other loops in the
network provides disturbances that influence the
process variable. To reduce the effect of these
load disturbances, sensors and transmitters collect
information regarding the process variable and its
relationship to a desired set point. A controller then
processes this information and decides what must
occur in order to get the process variable back to
where it should be after a load disturbance occurs.
When all measuring, comparing, and calculating
are complete, the strategy selected by the
controller is implemented via some type of final
control element. The most common final control
element in the process control industries is the
control valve.
A control valve manipulates a flowing fluid such as
gas, steam, water, or chemical compounds to
compensate for the load disturbance and keep the
regulated process variable as close as possible to
the desired set point.
Many people who speak of control valves are
actually referring to control valve assemblies.
The control valve assembly typically consists of
the valve body, the internal trim parts, an actuator
to provide the motive power to operate the valve,
and a variety of additional valve accessories,
which may include positioners, transducers, supply
pressure regulators, manual operators, snubbers,
or limit switches.
It is best to think of a control loop as an
instrumentation chain. Like any other chain, the
entire chain is only as good as its weakest link. It
is important to ensure that the control valve is not
the weakest link.
12
Valve Types and Characteristics
The control valve regulates the rate of fluid flow as
the position of the valve plug or disk is changed by
force from the actuator. To do this, the valve must:
D Contain the fluid without external leakage.
D Have adequate capacity for the intended
service.
D Be capable of withstanding the erosive,
corrosive, and temperature influences of the
process.
D Incorporate appropriate end connections to
mate with adjacent pipelines and actuator
attachment means to permit transmission of
actuator thrust to the valve plug stem or rotary
shaft.
Many styles of control valve bodies have been
developed. Some can be used effectively in a
number of applications while others meet specific
service demands or conditions and are used less
frequently. The subsequent text describes popular
control valve body styles utilized today.
Globe Valves
Single-Port Valve Bodies
Single-port is the most common valve body style
and is simple in construction. Single-port valves
are available in various forms, such as globe,
angle, bar stock, forged, and split constructions.
Generally, single-port valves are specified for
applications with stringent shutoff requirements.
They use metal-to-metal seating surfaces or
soft-seating with PTFE or other composition
materials forming the seal.
Single-port valves can handle most service
requirements. Because high pressure fluid is
normally loading the entire area of the port, the
unbalance force created must be considered when
selecting actuators for single-port control valve
bodies. Although most popular in the smaller
sizes, single-port valves can often be used in NPS
4 to 8 with high thrust actuators.
Many modern single-seated valve bodies use cage
or retainer-style construction to retain the seat ring
cage, provide valve plug guiding, and provide a
means for establishing particular valve flow
Figure 1-1. Single-Ported Globe-Style Valve
Body
W7027-1
characteristics. Retainer-style trim also offers ease
of maintenance with flow characteristics altered by
changing the plug. Cage or retainer-style
single-seated valve bodies can also be easily
modified by a change of trim parts to provide
reduced-capacity flow, noise attenuation, or
cavitation eliminating or reducing trim (see
chapter 4).
Figure 1-1 shows one of the more popular styles of
single-ported or single-seated globe valve bodies.
They are widely used in process control
applications, particularly in sizes NPS 1 through
NPS 4. Normal flow direction is most often flow-up
through the seat ring.
Angle valves are nearly always single ported, as
shown in figure 1-2. This valve has cage-style trim
construction. Others might have screwed-in seat
rings, expanded outlet connections, restricted trim,
and outlet liners for reduction of erosion damage.
Bar stock valve bodies are often specified for
corrosive applications in the chemical industry
(figure 1-3), but may also be requested in other
low flow corrosive applications. They can be
machined from any metallic bar-stock material and
from some plastics. When exotic metal alloys are
required for corrosion resistance, a bar-stock valve
body is normally less expensive than a valve body
produced from a casting.
High pressure single-ported globe valves are often
found in power plants due to high pressure steam
(figure 1-4). Variations available include
13
Figure 1-2. Flanged Angle-Style
Control Valve Body
W0971
Figure 1-3. Bar Stock Valve Body
W9756
cage-guided trim, bolted body-to-bonnet
connection, and others. Flanged versions are
available with ratings to Class 2500.
Balanced-Plug Cage-Style Valve
Bodies
This popular valve body style, single-ported in the
sense that only one seat ring is used, provides the
advantages of a balanced valve plug often
Figure 1-4. High Pressure Globe-Style
Control Valve Body
W0540
Figure 1-5. Valve Body with Cage-Style Trim,
Balanced Valve Plug, and Soft Seat
W0992-4
associated only with double-ported valve bodies
(figure 1-5). Cage-style trim provides valve plug
guiding, seat ring retention, and flow
characterization. In addition, a sliding piston
ring-type seal between the upper portion of the
valve plug and the wall of the cage cylinder
virtually eliminates leakage of the upstream high
pressure fluid into the lower pressure downstream
system.
14
Figure 1-6. High Capacity Valve Body with
Cage-Style Noise Abatement Trim
W0997
Downstream pressure acts upon both the top and
bottom sides of the valve plug, thereby nullifying
most of the static unbalance force. Reduced
unbalance permits operation of the valve with
smaller actuators than those necessary for
conventional single-ported valve bodies.
Interchangeability of trim permits the choice of
several flow characteristics or of noise attenuation
or anticavitation components. For most available
trim designs, the standard direction of flow is in
through the cage openings and down through the
seat ring. These are available in various material
combinations, sizes through NPS 20, and pressure
ratings to Class 2500.
High Capacity, Cage-Guided Valve
Bodies
This adaptation of the cage-guided bodies
mentioned above was designed for noise
applications, such as high pressure power plants,
where sonic steam velocities are often
encountered at the outlet of conventional valve
bodies (figure 1-6).
The design incorporates oversized end
connections with a streamlined flow path and the
ease of trim maintenance inherent with cage-style
constructions. Use of noise abatement trim
reduces overall noise levels by as much as 35
decibels. The design is also available in cageless
versions with a bolted seat ring, end connection
sizes through NPS 20, Class 600, and versions for
liquid service. The flow direction depends upon the
intended service and trim selection, with
unbalanced constructions normally flow-up and
balanced constructions normally flow-down.
Port-Guided Single-Port Valve Bodies
D Usually limited to 150 psi (10 bar) maximum
pressure drop.
D Susceptible to velocity-induced vibration.
D Typically provided with screwed in seat rings
which might be difficult to remove after use.
Three-Way Valve Bodies
D Provide general converging (flow-mixing) or
diverging (flow-splitting) service.
D Best designs use cage-style trim for positive
valve plug guiding and ease of maintenance.
D Variations include trim materials selected for
high temperature service. Standard end
connections (flanged, screwed, butt weld, etc.) can
be specified to mate with most any piping scheme.
D Actuator selection demands careful
consideration, particularly for constructions with
unbalanced valve plug.
A balanced valve plug style three-way valve body
is shown with the cylindrical valve plug in the down
position (figure 1-7). This position opens the
bottom common port to the right-hand port and
shuts off the left-hand port. The construction can
be used for throttling mid-travel position control of
either converging or diverging fluids.
Rotary Valves
Traditional Butterfly Valve
Standard butterfly valves are available in sizes
through NPS 72 for miscellaneous control valve
applications. Smaller sizes can use versions of
traditional diaphragm or piston pneumatic
actuators, including the modern rotary actuator
styles. Larger sizes might require high output
electric or long-stroke pneumatic cylinder
actuators.
Butterfly valves exhibit an approximately equal
percentage flow characteristic. They can be used
15
Figure 1-7. Three Way Valve with
Balanced Valve Plug
W9045-1
Figure 1-8. High-Performance Butterfly
Control Valve
W4641
for throttling service or for on-off control. Soft-seat
constructions can be obtained by utilizing a liner or
by including an adjustable soft ring in the body or
on the face of the disk.
D Require minimum space for installation
(figure 1-8).
D Provide high capacity with low pressure loss
through the valves.
Figure 1-9. Eccentric-Disk Rotary-Shaft
Control Valve
W8380
D Offer an economic advantage, particularly in
larger sizes and in terms of flow capacity per dollar
investment.
D Mate with standard raised-face pipeline
flanges.
D Depending on size, might require high output
or oversized actuators due to valve size valves or
large operating torques from large pressure drops.
D Standard liner can provide precise shutoff
and quality corrosion protection with nitrile or
PTFE liner.
Eccentric-Disk Control Valve
Eccentric disk rotary control valves are intended
for general service applications not requiring
precision throttling control. They are frequently
applied in applications requiring large sizes and
high temperatures due to their lower cost relative
to other styles of control valves. The control range
for this style of valve is approximately one third as
large as a ball or globe-style valves.
Consequently, additional care is required in sizing
and applying this style of valve to eliminate control
problems associated with process load changes.
They are well-suited for constant process load
applications.
D Provide effective throttling control.
D Linear flow characteristic through 90 degrees
of disk rotation (figure 1-9).
D Eccentric mounting of disk pulls it away from
the seal after it begins to open, minimizing seal
wear.
16
Figure 1-10. Fisher Control-Disk Valve with 2052 Actuator and FIELDVUE DVC6200 Digital Valve Controller
W9425 W9418
WAFER STYLE SINGLE FLANGE STYLE
D Bodies are available in sizes through NPS 24
compatible with standard ASME flanges.
D Utilize standard pneumatic diaphragm or
piston rotary actuators.
D Standard flow direction is dependent upon
seal design; reverse flow results in reduced
capacity.
Control-Disk Valve
The Control-Diskt valve (figure 1-10) offers
excellent throttling performance, while maintaining
the size (face-to-face) of a traditional butterfly
valve. The Control-Disk valve is first in class in
controllability, rangeability, and tight shutoff, and it
is designed to meet worldwide standards.
D Utilizes a contoured edge and unique
patented disk to provide an improved control range
of 15 - 70% of valve travel. Traditional butterfly
valves are typically limited to 25% - 50% control
range.
D Includes a tested valve sealing design,
available in both metal and soft seats, to provide
an unmatched cycle life while still maintaining
excellent shutoff
D Spring loaded shaft positions disk against the
inboard bearing nearest the actuator allowing for
the disk to close in the same position in the seal,
and allows for either horizontal or vertical
mounting.
D Complimenting actuator comes in three,
compact sizes, has nested springs and a patented
Figure 1-11. Rotary-Shaft Control Valve
with V-Notch Ball
W8172-2
lever design to increase torque range within each
actuator size.
V-notch Ball Control Valve
This construction is similar to a conventional ball
valve, but with patented, contoured V-notch in the
ball (figure 1-11). The V-notch produces an
equal-percentage flow characteristic. These
control valves provide precise rangeability, control,
and tight shutoff.
D Straight-through flow design produces little
pressure drop.
D Bodies are suited to provide control of
erosive or viscous fluids, paper stock, or other
slurries containing entrained solids or fibers.
17
Figure 1-12. Sectional of Eccentric-Plug
Control Valve Body
W4170-4
D They utilize standard diaphragm or piston
rotary actuators.
D Ball remains in contact with seal during
rotation, which produces a shearing effect as the
ball closes and minimizes clogging.
D Bodies are available with either heavy-duty or
PTFE-filled composition ball seal ring to provide
excellent rangeability in excess of 300:1.
D Bodies are available in flangeless or
flanged-body end connections. Both flanged and
flangeless valves mate with Class 150, 300, or 600
flanges or DIN flanges.
D Valves are capable of energy absorbing
special attenuating trim to provide improved
performance for demanding applications.
Eccentric-Plug Control Valve
D Valve assembly combats erosion. The
rugged body and trim design handle temperatures
to 800F (427C) and shutoff pressure drops to
1500 psi (103 bar).
D Path of eccentric plug minimizes contact with
the seat ring when opening, thus reducing seat
wear and friction, prolonging seat life, and
improving throttling performance (figure 1-12).
D Self-centering seat ring and rugged plug
allow forward or reverse-flow with tight shutoff in
either direction. Plug, seat ring, and retainer are
available in hardened materials, including
ceramics, for selection of erosion resistance.
D Designs offering a segmented V-notch ball in
place of the plug for higher capacity requirements
are available.
This style of rotary control valve is well-suited for
control of erosive, coking, and other
hard-to-handle fluids, providing either throttling or
on-off operation. The flanged or flangeless valves
feature streamlined flow passages and rugged
metal-trim components for dependable service in
slurry applications.
Control Valve End Connections
The three common methods of installing control
valves in pipelines are by means of:
D Screwed pipe threads
D Bolted gasketed flanges
D Welded end connections
Screwed Pipe Threads
Screwed end connections, popular in small control
valves, are typically more economical than flanged
ends. The threads usually specified are tapered
female National Pipe Thread (NPT) on the valve
body. They form a metal-to-metal seal by wedging
over the mating male threads on the pipeline ends.
This connection style, usually limited to valves not
larger than NPS 2, is not recommended for
elevated temperature service. Valve maintenance
might be complicated by screwed end connections
if it is necessary to take the body out of the
pipeline. This is because the valve cannot be
removed without breaking a flanged joint or union
connection to permit unscrewing the valve body
from the pipeline.
Bolted Gasketed Flanges
Flanged end valves are easily removed from the
piping and are suitable for use through the range
of working pressures for which most control valves
are manufactured (figure 1-13). Flanged end
connections can be used in a temperature range
from absolute zero to approximately 1500F
(815C). They are used on all valve sizes. The
most common flanged end connections include
flat-face, raised-face, and ring-type joint.
The flat face variety allows the matching flanges to
be in full-face contact with the gasket clamped
between them. This construction is commonly
used in low pressure, cast iron, and brass valves,
and minimizes flange stresses caused by initial
bolting-up force.
The raised-face flange features a circular
raised-face with the inside diameter the same as
the valve opening, and the outside diameter less
than the bolt circle diameter. The raised-face is
18
Figure 1-13. Popular Varieties of
Bolted Flange Connections
A7098
Figure 1-14. Common Welded End Connections
A7099
finished with concentric circular grooves for
precise sealing and resistance to gasket blowout.
This kind of flange is used with a variety of gasket
materials and flange materials for pressures
through the 6000 psig (414 bar) pressure range
and for temperatures through 1500F (815C).
This style of flanging is normally standard on Class
250 cast iron bodies and all steel and alloy steel
bodies.
The ring-type joint flange is similar in looks to the
raised-face flange except that a U-shaped groove
is cut in the raised-face concentric with the valve
opening. The gasket consists of a metal ring with
either an elliptical or octagonal cross-section.
When the flange bolts are tightened, the gasket is
wedged into the groove of the mating flange and a
tight seal is made. The gasket is generally soft iron
or Monelt, but is available in almost any metal.
This makes an excellent joint at high pressures
and is used up to 15,000 psig (1034 bar),
however, it is generally not used at high
temperatures. It is furnished only on steel and
alloy valve bodies when specified.
Welding End Connections
Welding ends on control valves (figure 1-14) are
leak-tight at all pressures and temperatures, and
are economical in first cost. Welding end valves
are more difficult to take from the line and are
limited to weldable materials. Welding ends come
in two styles:
D Socket welding
D Buttwelding
The socket welding ends are prepared by boring in
a socket at each end of the valve with an inside
diameter slightly larger than the pipe outside
diameter. The pipe slips into the socket where it
butts against a shoulder and then joins to the valve
with a fillet weld. Socket welding ends in a given
size are dimensionally the same regardless of pipe
schedule. They are usually furnished in sizes
through NPS 2.
The buttwelding ends are prepared by beveling
each end of the valve to match a similar bevel on
the pipe. The two ends are then butted to the
pipeline and joined with a full penetration weld.
This type of joint is used on all valve styles and the
end preparation must be different for each
schedule of pipe. These are generally furnished for
control valves in NPS 2-1/2 and larger. Care must
be exercised when welding valve bodies in the
pipeline to prevent excessive heat transmitted to
valve trim parts. Trims with low-temperature
composition materials must be removed before
welding.
Valve Body Bonnets
The bonnet of a control valve is the part of the
body assembly through which the valve plug stem
or rotary shaft moves. On globe or angle bodies, it
is the pressure retaining component for one end of
the valve body. The bonnet normally provides a
means of mounting the actuator to the body and
houses the packing box. Generally, rotary valves
do not have bonnets. (On some rotary-shaft
valves, the packing is housed within an extension
of the valve body itself, or the packing box is a
separate component bolted between the valve
body and bonnet.)
19
Figure 1-15. Typical Bonnet, Flange,
and Stud Bolts
W0989
On a typical globe-style control valve body, the
bonnet is made of the same material as the valve
body or is an equivalent forged material because it
is a pressure-containing member subject to the
same temperature and corrosion effects as the
body. Several styles of valve body-to-bonnet
connections are illustrated. The most common is
the bolted flange type shown in figure 1-15. A
bonnet with an integral flange is also illustrated in
figure 1-15. Figure 1-3 illustrates a bonnet with a
separable, slip-on flange held in place with a split
ring. The bonnet used on the high pressure globe
valve body illustrated in figure 1-4, is screwed into
the valve body. Figure 1-8 illustrates a rotary-shaft
control valve in which the packing is housed within
the valve body and a bonnet is not used. The
actuator linkage housing is not a pressure-
containing part and is intended to enclose the
linkage for safety and environmental protection.
On control valve bodies with cage- or retainer-style
trim, the bonnet furnishes loading force to prevent
leakage between the bonnet flange and the valve
body, and also between the seat ring and the
valve body. The tightening of the body-bonnet
bolting compresses a flat sheet gasket to seal the
body-bonnet joint, compresses a spiral-wound
gasket on top of the cage, and compresses an
additional flat sheet gasket below the seat ring to
provide the seat ring-body seal. The bonnet also
provides alignment for the cage, which, in turn,
guides the valve plug to ensure proper valve plug
stem alignment with the packing.
As mentioned previously, the conventional bonnet
on a globe-type control valve houses the packing.
The packing is most often retained by a packing
follower held in place by a flange on the yoke boss
area of the bonnet (figure 1-15). An alternate
packing retention means is where the packing
follower is held in place by a screwed gland (figure
1-3). This alternate is compact, thus, it is often
used on small control valves, however, the user
cannot always be sure of thread engagement.
Therefore, caution should be used if adjusting the
packing compression when the control valve is in
service.
Most bolted-flange bonnets have an area on the
side of the packing box which can be drilled and
tapped. This opening is closed with a standard
pipe plug unless one of the following conditions
exists:
D It is necessary to purge the valve body and
bonnet of process fluid, in which case the opening
can be used as a purge connection.
D The bonnet opening is being used to detect
leakage from the first set of packing or from a
failed bellows seal.
Extension Bonnets
Extension bonnets are used for either high or low
temperature service to protect valve stem packing
from extreme process temperatures. Standard
PTFE valve stem packing is useful for most
applications up to 450F (232C). However, it is
susceptible to damage at low process
temperatures if frost forms on the valve stem. The
frost crystals can cut grooves in the PTFE, thus,
forming leakage paths for process fluid along the
stem. Extension bonnets remove the packing box
of the bonnet far enough from the extreme
temperature of the process that the packing
temperature remains within the recommended
range.
Extension bonnets are either cast (figure 1-16) or
fabricated (figure 1-17). Cast extensions offer
better high temperature service because of greater
heat emissivity, which provides better cooling
effect. Conversely, smooth surfaces that can be
fabricated from stainless steel tubing are preferred
for cold service because heat influx is usually the
major concern. In either case, extension wall
thickness should be minimized to cut down heat
transfer. Stainless steel is usually preferable to
110
Figure 1-16. Extension Bonnet
W0667-2
Figure 1-17. Valve Body with
Fabricated Extension Bonnet
W1416
carbon steel because of its lower coefficient of
thermal conductivity. On cold service applications,
insulation can be added around the extension to
protect further against heat influx.
Figure 1-18. ENVIRO-SEALt Bellows
Seal Bonnet
W6434
Bellows Seal Bonnets
Bellows seal bonnets (figure 1-18) are used when
no leakage (less than 1x106 cc/sec of helium)
along the stem can be tolerated. They are often
used when the process fluid is toxic, volatile,
radioactive, or highly expensive. This special
bonnet construction protects both the stem and the
valve packing from contact with the process fluid.
Standard or environmental packing box
constructions above the bellows seal unit will
prevent catastrophic failure in case of rupture or
failure of the bellows.
As with other control valve pressure/ temperature
limitations, these pressure ratings decrease with
increasing temperature. Selection of a bellows
seal design should be carefully considered, and
particular attention should be paid to proper
inspection and maintenance after installation. The
bellows material should be carefully considered to
ensure the maximum cycle life.
Two types of bellows seal designs are used for
control valves:
D Mechanically formed as shown in figure 1-19
D Welded leaf bellows as shown in figure 1-20
The welded-leaf design offers a shorter total
package height. Due to its method of manufacture
and inherent design, service life may be limited.
111
Figure 1-21. Comprehensive Packing Material Arrangements
for Globe-Style Valve Bodies
B2565
Figure 1-19. Mechanically Formed Bellows
A5954
Figure 1-20. Welded Leaf Bellows
A5955
The mechanically formed bellows is taller in
comparison and is produced with a more
repeatable manufacturing process.
Control Valve Packing
Most control valves use packing boxes with the
packing retained and adjusted by a flange and
stud bolts (figure 1-27). Several packing materials
can be used depending upon the service
conditions expected and whether the application
requires compliance to environmental regulations.
Brief descriptions and service condition guidelines
for several popular materials and typical packing
material arrangements are shown in figure 1-21.
PTFE V-Ring
D Plastic material with inherent ability to
minimize friction.
D Molded in V-shaped rings that are spring
loaded and self-adjusting in the packing box.
Packing lubrication not required.
D Resistant to most known chemicals except
molten alkali metals.
D Requires extremely smooth (2 to 4
micro-inches RMS) stem finish to seal properly.
Will leak if stem or packing surface is damaged.
D Recommended temperature limits: 40F to
+450F (40C to +232C)
D Not suitable for nuclear service because
PTFE is easily destroyed by radiation.
112
Figure 1-22. Measurement Frequency for Valves
Controlling Volatile Organic Chemicals (VOC)
B2566
Laminated and Filament Graphite
D Suitable for high temperature nuclear service
or where low chloride content is desirable (Grade
GTN).
D Provides leak-free operation, high thermal
conductivity, and long service life, but produces
high stem friction and resultant hysteresis.
D Impervious to most hard-to-handle fluids and
high radiation.
D Suitable temperature range: Cryogenic
temperatures to 1200F (649C).
D Lubrication not required, but an extension
bonnet or steel yoke should be used when packing
box temperature exceeds 800F (427C).
USA Regulatory Requirements for
Fugitive Emissions
Fugitive emissions are non-point source volatile
organic emissions that result from process
equipment leaks. Equipment leaks in the United
States have been estimated at over 400 million
pounds per year. Strict government regulations,
developed by the US, dictate Leak Detection and
Repair (LDAR) programs. Valves and pumps have
been identified as key sources of fugitive
emissions. In the case of valves, this is the
leakage to atmosphere due to packing seal or
gasket failures.
The LDAR programs require industry to monitor all
valves (control and noncontrol) at an interval that
is determined by the percentage of valves found to
be leaking above a threshold level of 500 ppmv
(some cities use a 100 ppmv criteria). This
leakage level is so slight you cannot see or hear it.
The use of sophisticated portable monitoring
equipment is required for detection. Detection
occurs by sniffing the valve packing area for
leakage using an Environmental Protection
Agency (EPA) protocol. This is a costly and
burdensome process for industry.
The regulations do allow for the extension of the
monitoring period for up to one year if the facility
can demonstrate an extremely low ongoing
percentage of leaking valves (less than 0.5% of
the total valve population). The opportunity to
extend the measurement frequency is shown in
figure 1-22.
Packing systems designed for extremely low
leakage requirements also extend packing seal life
and performance to support an annual monitoring
objective. The ENVIRO-SEALt packing system is
one example. Its enhanced seals incorporate four
key design principles including:
D Containment of the pliable seal material
through an anti-extrusion component.
113
D Proper alignment of the valve stem or shaft
within the bonnet bore.
D Applying a constant packing stress through
Belleville springs.
D Minimizing the number of seal rings to reduce
consolidation, friction, and thermal expansion.
The traditional valve selection process meant
choosing a valve design based upon its pressure
and temperature capabilities as well as its flow
characteristics and material compatibility. Valve
stem packing used in the valve was determined
primarily by the operating temperature in the
packing box area. The available material choices
included PTFE for temperatures below 93C
(200F) and graphite for higher temperature
applications.
Today, choosing a valve packing system has
become much more complex due to the number of
considerations one must take into account. For
example, emissions control requirements, such as
those imposed by the Clean Air Act within the
United States and by other regulatory bodies,
place tighter restrictions on sealing performance.
Constant demands for improved process output
mean that the valve packing system must not
hinder valve performance. Also, todays trend
toward extended maintenance schedules dictates
that valve packing systems provide the required
sealing over longer periods.
In addition, end user specifications that have
become de facto standards, as well as standards
organizations specifications, are used by
customers to place stringent fugitive emissions
leakage requirements and testing guidelines on
process control equipment vendors. Emerson
Process Management and its observance of
limiting fugitive emissions is evident by its reliable
valve sealing (packing and gasket) technologies,
global emissions testing procedures, and
emissions compliance approvals.
Given the wide variety of valve applications and
service conditions within industry, these variables
(sealing ability, operating friction levels, operating
life) are difficult to quantify and compare. A proper
understanding requires a clarification of trade
names.
Figure 1-23. Single PTFE V-Ring Packing
A6161-1
Single PTFE V-Ring Packing (Fig.
1-23)
The single PTFE V-ring arrangement uses a coil
spring between the packing and packing follower.
It meets the 100 ppmv criteria, assuming that the
pressure does not exceed 20.7 bar (300 psi) and
the temperature is between 18C and 93C (0F
and 200F). It offers excellent sealing performance
with the lowest operating friction.
ENVIRO-SEAL PTFE Packing
(Fig. 1-24)
The ENVIRO-SEAL PTFE packing system is an
advanced packing method that utilizes a compact,
live-load spring design suited to environmental
applications up to 51.7 bar and 232C (750 psi
and 450F). While it most typically is thought of as
an emission-reducing packing system,
ENVIRO-SEAL PTFE packing is, also, well-suited
for non-environmental applications involving high
temperatures and pressures, yielding the benefit of
longer, ongoing service life.
ENVIRO-SEAL Duplex Packing
(Fig. 1-25)
This special packing system provides the
capabilities of both PTFE and graphite
components to yield a low friction, low emission,
fire-tested solution (API Standard 589) for
applications with process temperatures up to
232C (450F).
114
Figure 1-24. ENVIRO-SEAL PTFE Packing System
A6163
Figure 1-25. ENVIRO-SEAL Duplex (PTFE and
Graphite) Packing System
KALREZt Valve Stem Packing (KVSP)
systems
The KVSP pressure and temperature limits
referenced are for Fisher valve applications only.
KVSP with PTFE is suited to environmental use up
to 24.1 bar and 204C (350 psi and 400F) and, to
some non-environmental services up to 103 bar
(1500 psi). KVSP with ZYMAXXt, which is a
Figure 1-26. ENVIRO-SEAL Graphite
ULF Packing System
39B4612-A
carbon fiber reinforced TFE, is suited to 260C
(500F) service.
ENVIRO-SEAL Graphite Ultra Low
Friction (ULF) Packing (Fig. 1-26)
This packing system is designed primarily for
environmental applications at temperatures in
excess of 232C (450F). The patented ULF
packing system incorporates thin PTFE layers
inside the packing rings and thin PTFE washers on
each side of the packing rings. This strategic
115
Figure 1-27. ENVIRO-SEAL Graphite
Packing System for Rotary Valves
W6125-1
placement of PTFE minimizes control problems,
reduces friction, promotes sealing, and extends
the cycle life of the packing set.
HIGH-SEAL Graphite ULF Packing
Identical to the ENVIRO-SEAL graphite ULF
packing system below the packing follower, the
HIGH-SEAL system utilizes heavy-duty, large
diameter Belleville springs. These springs provide
additional follower travel and can be calibrated
with a load scale for a visual indication of packing
load and wear.
ENVIRO-SEAL Graphite Packing for
Rotary Valves (Fig. 1-27)
ENVIRO-SEAL graphite packing is designed for
environmental applications from 6C to 316C
(20F to 600F) or for those applications where fire
safety is a concern. It can be used with pressures
to 103 bar (1500 psi) and still satisfy the 500 ppmv
EPA leakage criteria.
Graphite Ribbon Packing for Rotary
Valves
Graphite ribbon packing is designed for
non-environmental applications that span a wide
temperature range from 198C to 538C (325F
to 1000F).
The following table provides a comparison of
various sliding-stem packing selections and a
relative ranking of seal performance, service life,
and packing friction for environmental applications.
Braided graphite filament and double PTFE are
not acceptable environmental sealing solutions.
The following applies to rotary valves. In the case
of rotary valves, single PTFE and graphite ribbon
packing arrangements do not perform well as
fugitive emission sealing solutions.
The control of valve fugitive emissions and a
reduction in industrys cost of regulatory
compliance can be achieved through these stem
sealing technologies.
While ENVIRO-SEAL packing systems have been
designed specifically for fugitive emission
applications, these technologies should also be
considered for any application where seal
performance and seal life have been an ongoing
concern or maintenance cost issue.
Characterization of Cage-Guided
Valve Bodies
In valve bodies with cage-guided trim, the shape of
the flow openings or windows in the wall of the
cylindrical cage determines flow characterization.
As the valve plug is moved away from the seat
ring, the cage windows are opened to permit flow
through the valve. Standard cages have been
designed to produce linear, equal-percentage, and
quick-opening inherent flow characteristics. Note
the differences in the shapes of the cage windows
shown in figure 1-28. The flow rate/travel
relationship provided by valves utilizing these
cages is equivalent to the linear, quick-opening,
and equal-percentage curves shown for contoured
valve plugs (figure 1-29).
Cage-guided trim in a control valve provides a
distinct advantage over conventional valve body
assemblies in that maintenance and replacement
of internal parts is simplified. The inherent flow
characteristic of the valve can easily be changed
by installing a different cage. Interchange of cages
to provide a different inherent flow characteristic
does not require changing the valve plug or seat
ring. The standard cages shown can be used with
either balanced or unbalanced trim constructions.
Soft seating, when required, is available as a
retained insert in the seat ring and is independent
of cage or valve plug selection.
Cage interchangeability can be extended to
specialized cage designs that provide noise
attenuation or combat cavitation. These cages
furnish a modified linear inherent flow
characteristic, but require flow to be in a specific
116
Figure 1-28. Characterized Cages for Globe-Style Valve Bodies
W0958 W0959 W0957
QUICK OPENING LINEAR EQUAL PERCENTAGE
Figure 1-29. Inherent Flow
Characteristics Curves
direction through the cage openings. Therefore, it
could be necessary to reverse the valve body in
the pipeline to obtain proper flow direction.
Characterized Valve Plugs
The valve plug, the movable part of a globe-style
control valve assembly, provides a variable
restriction to fluid flow. Valve plug styles are each
designed to:
D Provide a specific flow characteristic.
D Permit a specified manner of guiding or
alignment with the seat ring.
D Have a particular shutoff or
damage-resistance capability.
Valve plugs are designed for either two-position or
throttling control. In two-position applications, the
valve plug is positioned by the actuator at either of
two points within the travel range of the assembly.
In throttling control, the valve plug can be
positioned at any point within the travel range as
dictated by the process requirements.
The contour of the valve plug surface next to the
seat ring is instrumental in determining the
inherent flow characteristic of a conventional
globe-style control valve. As the actuator moves
the valve plug through its travel range, the
unobstructed flow area changes in size and shape
depending upon the contour of the valve plug.
When a constant pressure differential is
maintained across the valve, the changing
relationship between percentage of maximum flow
capacity and percentage of total travel range can
be portrayed (figure 1-29), and is designated as
the inherent flow characteristic of the valve.
Commonly specified inherent flow characteristics
include:
Linear Flow
D A valve with an ideal linear inherent flow
characteristic produces a flow rate directly
proportional to the amount of valve plug travel
throughout the travel range. For instance, at 50%
of rated travel, flow rate is 50% of maximum flow;
at 80% of rated travel, flow rate is 80% of
maximum; etc. Change of flow rate is constant
with respect to valve plug travel. Valves with a
linear characteristic are often specified for liquid
level control and for flow control applications
requiring constant gain.
Equal-Percentage Flow
D Ideally, for equal increments of valve plug
travel, the change in flow rate regarding travel may
be expressed as a constant percent of the flow
117
Figure 1-30. Typical Construction to Provide
Quick-Opening Flow Characteristic
A7100
rate at the time of the change. The change in flow
rate observed regarding travel will be relatively
small when the valve plug is near its seat, and
relatively high when the valve plug is nearly wide
open. Therefore, a valve with an inherent
equal-percentage flow characteristic provides
precise throttling control through the lower portion
of the travel range and rapidly increasing capacity
as the valve plug nears the wide-open position.
Valves with equal-percentage flow characteristics
are used on pressure control applications, on
applications where a large percentage of the
pressure drop is normally absorbed by the system
itself with only a relatively small percentage
available at the control valve, and on applications
where highly varying pressure drop conditions can
be expected. In most physical systems, the inlet
pressure decreases as the rate of flow increases,
and an equal percentage characteristic is
appropriate. For this reason, equal percentage
flow is the most common valve characteristic.
Quick-Opening Flow
D A valve with a quick opening flow
characteristic provides a maximum change in flow
rate at low travels. The curve is essentially linear
through the first 40 percent of valve plug travel,
then flattens out noticeably to indicate little
increase in flow rate as travel approaches the
wide-open position. Control valves with
quick-opening flow characteristics are often used
for on/off applications where significant flow rate
must be established quickly as the valve begins to
open. As a result, they are often utilized in relief
valve applications. Quick-opening valves can also
be selected for many of the same applications for
which linear flow characteristics are
recommended. This is because the quick-opening
characteristic is linear up to about 70 percent of
maximum flow rate. Linearity decreases
significantly after flow area generated by valve
plug travel equals the flow area of the port. For a
typical quick-opening valve (figure 1-30), this
occurs when valve plug travel equals one-fourth of
port diameter.
Valve Plug Guiding
Accurate guiding of the valve plug is necessary for
proper alignment with the seat ring and efficient
control of the process fluid. The common methods
used are listed below.
D Cage Guiding: The outside diameter of the
valve plug is close to the inside wall surface of the
cylindrical cage throughout the travel range. Since
the bonnet, cage, and seat ring are self-aligning
upon assembly, the correct valve plug and seat
ring alignment is assured when the valve closes
(figure 1-15).
D Top Guiding: The valve plug is aligned by a
single guide bushing in the bonnet, valve body
(figure 1-4), or by packing arrangement.
D Stem Guiding: The valve plug is aligned with
the seat ring by a guide bushing in the bonnet that
acts upon the valve plug stem (figure 1-3, left
view).
D Top-and-Bottom Guiding: The valve plug is
aligned by guide bushings in the bonnet and
bottom flange.
D Port Guiding: The valve plug is aligned by the
valve body port. This construction is typical for
control valves utilizing small-diameter valve plugs
with fluted skirt projections to control low flow rates
(figure 1-3, right view).
Restricted-Capacity Control Valve
Trim
Most control valve manufacturers can provide
valves with reduced- or restricted- capacity trim
parts. The reduced flow rate might be desirable for
any of the following reasons:
D Restricted capacity trim may make it possible
to select a valve body large enough for increased
future flow requirements, but with trim capacity
properly sized for present needs.
D Valves can be selected for adequate
structural strength, yet retain reasonable
travel/capacity relationship.
D Large bodies with restricted capacity trim can
be used to reduce inlet and outlet fluid velocities.
D Purchase of expensive pipeline reducers can
be avoided.
D Over-sizing errors can be corrected by use of
restricted capacity trim parts.
118
Conventional globe-style valve bodies can be fitted
with seat rings with smaller port size than normal
and valve plugs sized to fit those smaller ports.
Valves with cage-guided trim often achieve the
reduced capacity effect by utilizing valve plug,
cage, and seat ring parts from a smaller valve size
of similar construction and adapter pieces above
the cage and below the seat ring to mate those
smaller parts with the valve body (figure 1-28).
Because reduced capacity service is not unusual,
leading manufacturers provide readily available
trim part combinations to perform the required
function. Many restricted capacity trim
combinations are designed to furnish
approximately 40% of full-size trim capacity.
General Selection Criteria
Most of the considerations that guide the selection
of valve type and brand are rather basic. However,
there are some matters that may be overlooked by
users whose familiarity is mainly limited to just one
or a few valve types. Table 1-1 below provides a
checklist of important criteria; each is discussed at
length following the table.
Table 1-1. Suggested General Criteria for Selecting Type
and Brand of Control Valve
Body pressure rating
High and low temperature limits
Material compatibility and durability
Inherent flow characteristic and rangeability
Maximum pressure drop (shutoff and flowing)
Noise and cavitation
End connections
Shutoff leakage
Capacity versus cost
Nature of flowing media
Dynamic performance
Pressure Ratings
Body pressure ratings ordinarily are considered
according to ANSI pressure classes the most
common ones for steel and stainless steel being
Classes 150, 300 and 600. (Source documents
are ASME/ANSI Standards B16.34, Steel
Valves, and ANSI B16.1, Cast Iron Pipe
Flanges and Flanged Fittings.) For a given body
material, each NSI Class corresponds to a
prescribed profile of maximum pressures that
decrease with temperature according to the
strength of the material. Each material also has a
minimum and maximum service temperature
based upon loss of ductility or loss of strength. For
most applications, the required pressure rating is
dictated by the application. However, because all
products are not available for all ANSI Classes, it
is an important consideration for selection.
Temperature Considerations
Required temperature capabilities are also a
foregone conclusion, but one that is likely to
narrow valve selection possibilities. The
considerations include the strength or ductility of
the body material, as well as relative thermal
expansion of various parts.
Temperature limits also may be imposed due to
disintegration of soft parts at high temperatures or
loss of resiliency at low temperatures. The soft
materials under consideration include various
elastomers, plastics, and PTFE. They may be
found in parts such as seat rings, seal or piston
rings, packing, rotary shaft bearings and butterfly
valve liners. Typical upper temperature limits for
elastomers are in the 200 - 350F range, and the
general limit for PTFE is 450F.
Temperature affects valve selection by excluding
certain valves that do not have high or low
temperature options. It also may have some affect
on the valves performance. For instance, going
from PTFE to metal seals for high temperatures
generally increases the shutoff leakage flow.
Similarly, high temperature metal bearing sleeves
in rotary valves impose more friction upon the
shaft than do PTFE bearings, so that the shaft
cannot withstand as high a pressure-drop load at
shutoff. Selection of the valve packing is also
based largely upon service temperature.
Material Selection
The third criterion in table 1-1, material
compatibility and durability, is a more complex
consideration. Variables may include corrosion by
the process fluid, erosion by abrasive material,
flashing, cavitation or pressure and temperature
requirements. The piping material usually indicates
the body material. However, because the velocity
is higher in valves, other factors must be
considered. When these variables are included,
often valve and piping materials will differ. The trim
materials, in turn, are usually a function of the
body material, temperature range and qualities of
the fluid. When a body material other than carbon,
alloy, or stainless steel is required, use of an
alternate valve type, such as lined or bar stock,
should be considered.
119
Flow Characteristic
The next selection criterion, inherent flow
characteristic, refers to the pattern in which the
flow at constant pressure drop changes according
to valve position. Typical characteristics are
quick-opening, linear, and equal-percentage. The
choice of characteristic may have a strong
influence upon the stability or controllability of the
process (see table 1-3), as it represents the
change of valve gain relative to travel.
Most control valves are carefully characterized
by means of contours on a plug, cage, or ball
element. Some valves are available in a variety of
characteristics to suit the application, while others
offer little or no choice. To quantitatively determine
the best flow characteristic for a given application,
a dynamic analysis of the control loop can be
performed. In most cases, however, this is
unnecessary; reference to established rules of
thumb will suffice.
The accompanying drawing illustrates typical flow
characteristic curves (figure 1-29). The quick
opening flow characteristic provides for maximum
change in flow rate at low valve travels with a fairly
linear relationship. Additional increases in valve
travel give sharply reduced changes in flow rate,
and when the valve plug nears the wide open
position, the change in flow rate approaches zero.
In a control valve, the quick opening valve plug is
used primarily for on-off service; but it is also
suitable for many applications where a linear valve
plug would normally be specified.
Rangeability
Another aspect of a valves flow characteristic is its
rangeability, which is the ratio of its maximum and
minimum controllable flow rates. Exceptionally
wide rangeability may be required for certain
applications to handle wide load swings or a
combination of start-up, normal and maximum
working conditions. Generally speaking, rotary
valvesespecially partial ball valveshave
greater rangeability than sliding-stem varieties.
Use of Positioners
A positioner is an instrument that helps improve
control by accurately positioning a control valve
actuator in response to a control signal. They are
useful in many applications and are required with
certain actuator styles in order to match actuator
and instrument pressure signals, or to provide
operating stability. To a certain extent, a valve with
one inherent flow characteristic can also be made
to perform as though it had a different
characteristic by utilizing a nonlinear (i.e.,
characterized) positioner-actuator combination.
The limitation of this approach lies in the
positioners frequency response and phase lag
compared to the characteristic frequency of the
process. Although it is common practice to utilize a
positioner on every valve application, each
application should be reviewed carefully. There
are certain examples of high gain processes
where a positioner can hinder valve performance.
Pressure Drop
The maximum pressure drop a valve can tolerate
at shutoff, or when partially or fully open, is an
important selection criteria. Sliding-stem valves
are generally superior in both regards because of
the rugged nature of their moving parts. Many
rotary valves are limited to pressure drops well
below the body pressure rating, especially under
flowing conditions, due to dynamic stresses that
high velocity flow imposes on the disk or ball
segment.
Noise and Cavitation
Noise and cavitation are two considerations that
often are grouped together because both result
from high pressure drops and large flow rates.
They are treated by special modifications to
standard valves. Chapter four discusses the
cavitation phenomenon and its impact and
treatment, while chapter six discusses noise
generation and abatement.
End Connections
The three common methods of installing control
valves in pipelines are by means of screwed pipe
threads, bolted flanges, and welded end
connections. At some point in the selection
process, the valves end connections must be
considered with the question simply being whether
the desired connection style is available in the
valve being considered.
In some situations, this matter can limit the
selection rather narrowly. For instance, if a piping
specification calls for welded connections only, the
choice usually is limited to sliding-stem valves.
Screwed end connections, popular in small control
valves, offer more economy than flanged ends.
120
The threads usually specified are tapered female
NPT on the valve body. They form a
metal-to-metal seal by wedging over the mating
male threads on the pipeline ends. This
connection style is usually limited to valves not
larger than NPS 2, and is not recommended for
elevated temperature service.
Valve maintenance might be complicated by
screwed end connections if it is necessary to take
the body out of the pipeline. Screwed connections
require breaking a flanged joint or union
connection to permit unscrewing the valve body
from the pipeline.
Flanged end valves are easily removed from the
piping and are suitable for use through the range
of working pressures that most control valves are
manufactured (figure 1-13).
Flanged end connections can be utilized in a
temperature range from absolute zero (273F) to
approximately 1500F (815C). They are utilized
on all valve sizes. The most common flanged end
connections include flat face, raised face, and ring
type joint.
Welded ends on control valves are leak-tight at all
pressures and temperatures and are economical
in initial cost (figure 1-14). Welded end valves are
more difficult to remove from the line and are
limited to weldable materials. Welded ends come
in two styles, socket weld and buttweld.
Shutoff Capability
Some consideration must be given to a valves
shutoff capability, which is usually rated in terms of
classes specified in ANSI/FCI70-2 (table 1-4). In
service, shutoff leakage depends upon many
factors, including but not limited to, pressure drop,
temperature, and the condition of the sealing
surfaces. Because shutoff ratings are based upon
standard test conditions that can be different from
service conditions, service leakage cannot be
predicted accurately. However, the shutoff class
provides a good basis for comparison among
valves of similar configuration. It is not uncommon
for valve users to overestimate the shutoff class
required.
Because tight shutoff valves generally cost more
both in initial cost, as well as in later maintenance
expense, serious consideration is warranted. Tight
shutoff is particularly critical in high pressure
valves, considering that leakage in these
applications can lead to the ultimate destruction of
the trim. Special precautions in seat material
selection, seat preparation and seat load are
necessary to ensure success.
Flow Capacity
Finally, the criterion of capacity or size can be an
overriding constraint on selection. For extremely
large lines, sliding-stem valves are more
expensive than rotary types. On the other hand,
for extremely small flows, a suitable rotary valve
may not be available. If future plans call for
significantly larger flow, then a sliding-stem valve
with replaceable restricted trim may be the
answer. The trim can be changed to full size trim
to accommodate higher flow rates at less cost than
replacing the entire valve body assembly.
Rotary style products generally have much higher
maximum capacity than sliding-stem valves for a
given body size. This fact makes rotary products
attractive in applications where the pressure drop
available is rather small. However, it is of little or
no advantage in high pressure drop applications
such as pressure regulation or letdown.
Conclusion
For most general applications, it makes sense
both economically, as well as technically, to use
sliding-stem valves for lower flow ranges, ball
valves for intermediate capacities, and high
performance butterfly valves for the very largest
required flows. However, there are numerous
other factors in selecting control valves, and
general selection principles are not always the
best choice.
Selecting a control valve is more of and art than a
science. Process conditions, physical fluid
phenomena, customer preference, customer
experience, supplier experience, among numerous
other criteria must be considered in order to obtain
the best possible solution. Many applications are
beyond that of general service, and as chapter 4
will present, there are of number of selection
criteria that must be considered when dealing with
these sometimes severe flows.
Special considerations may require out-of-the-
ordinary valve solutions; there are valve designs
and special trims available to handle high noise
applications, flashing, cavitation, high pressure,
high temperature and combinations of these
conditions.
121
After going through all the criteria for a given
application, the selection process may point to
several types of valves. From there on, selection
becomes a matter of price versus capability,
coupled with the inevitable personal and
institutional preferences. As no single control valve
package is cost-effective over the full range of
applications, it is important to keep an open mind
to alternative choices.
Table 1-2. Major Categories and Subcategories of Control Valves with Typical General Characteristics
Valve Style
Main
Characteristics
Typical Size
Range,
inches
Typical
Standard Body
Materials
Typical Standard
End Connection
Typical
Pressure
Ratings
Relative Flow
Capacity
Relative
Shutoff
Capability
Regular
Sliding-stem
Heavy Duty
Versatile
1 to 24
Carbon Steel
Cast Iron
Stainless
ANSI Flanged
Welded
Screwed
To ANSI 2500 Moderate Excellent
Bar Stock
Machined from Bar
Stock
to 3 Variety of Alloys
Flangeless
Screwed
To ANSI 600 Low Excellent
Economy
Sliding-stem
Light Duty
Inexpensive
to 2
Bronze
Cast Iron
Carbon Steel
Screwed To ANSI 125 Moderate Good
Thru-Bore
Ball
On-Of f Service 1 to 24
Carbon Steel
Stainless
Flangeless To ANSI 900 High Excellent
Partial Ball
Characterized for
Throttling
1 to 24
Carbon Steel
Stainless
Flangeless
Flanged
To ANSI 600 High Excellent
Eccentric Plug Erosion Resistance 1 to 8
Carbon Steel
Stainless
Flanged To ANSI 600 Moderate Excellent
Swing-Thru
Butterfly
No Seal 2 to 96
Carbon Steel
Cast Iron
Stainless
Flangeless
Lugged
Welded
To ANSI 2500 High Poor
Lined Butterfly
Elastomer or
TFE Liner
2 to 96
Carbon Steel
Cast Iron
Stainless
Flangeless
Lugged
To ANSI 300 High Good
High
Performance
Butterfly
Offset Disk
General Service
2 to 72
Carbon Steel
Stainless
Flangeless
Lugged
To ANSI 600 High Excellent
122
Table 1-3. Control Valve Characteristic Recommendations
Liquid Level Systems
Control Valve Pressure Drop
Best Inherent
Characteristic
Constant P Linear
Decreasing P with increasing load, P at maximum load > 20% of minimum load P Linear
Decreasing P with increasing load, P at maximum load < 20% of minimum load P Equal-percentage
Increasing P with increasing load, P at maximum load < 200% of minimum load P Linear
Increasing P with increasing load, P at maximum load > 200% of minimum load P Quick Opening
Pressure Control Systems
Application
Best Inherent
Characteristic
Liquid Process Equal-Percentage
Gas Process, Large Volume (Process has a receiver, Distribution System or Transmission Line Exceeding 100 ft. of
Nominal Pipe Volume), Decreasing P with Increasing Load, P at Maximum Load > 20% of Minimum Load P Linear
Gas Process, Large Volume, Decreasing P with Increasing Load, P at Maximum Load < 20% of Minimum Load P Equal-Percentage
Gas Process, Small Volume, Less than 10 ft. of Pipe between Control Valve and Load Valve Equal-Percentage
Flow Control Processes
Application Best Inherent Characteristic
Flow Measurement Signal to
Controller
Location of Control Valve in Relation
to Measuring Element
Wide Range of Flow Set Point
Small Range of Flow but
Large P Change at Valve
with Increasing Load
Proportional to Flow In Series Linear Equal-Percentage
In Bypass* Linear Equal-Percentage
Proportional to Flow Squared In Series Linear Equal-Percentage
In Bypass* Equal-Percentage Equal-Percentage
*When control valve closes, flow rate increases in measuring element.
123
Table 1-4. Control Valve Leakage Standards
ANSI
B16.104-1976
Maximum Leakage Test Medium Pressure and Temperature
Class II 0.5% valve capacity at full travel Air
Service P or 50 psid (3.4 bar differential),
whichever is lower, at 50_ or 125_F (10_ to 52_C)
Class III 0.1% valve capacity at full travel Air
Service P or 50 psid (3.4 bar differential),
whichever is lower, at 50_ or 125_F (10_ to 52_C)
Class IV 0.01% valve capacity at full travel Air
Service P or 50 psid (3.4 bar differential),
whichever is lower, at 50_ or 125_F (10_ to 52_C)
Class V
5 x 10
- 4
mL/min/psid/inch port dia. (5
x 10
- 12
m
3
/sec/bar/mm port dia)
Water Service P at 50_ or 125_F (10_ to 52_C)
Class VI
Nominal Port
Diameter
Bubbles per
Minute
mL per Minute
Test
Medium
Pressure and Temperature
In
1
1-1/2
2
2-1/2
3
4
6
8
mm
25
38
51
64
76
102
152
203
1
2
3
4
6
11
27
45
0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75
Air
Service P or 50 psid (3.4 bar
differential), whichever is lower, at 50_
or 125_F (10_ to 52_C)
Copyright 1976 Fluid Controls Institute, Inc. Reprinted with permission.
124
www.Fisher.com
Chapter 2
Actuator Selection
The actuator is the distinguishing element that
differentiates control valves from other types of
valves. The first actuated valves were designed in
the late 19th century. Today, they would be better
described as regulators since they operated
directly from the process fluid. These automatic
valves were the mainstay of industry through the
early 1930s.
It was at this time that the first pneumatic
controllers were used. Development of valve
controllers and the adaptation of standardized
control signals stimulated design of the first, true,
control valve actuators.
The control valve industry has evolved to fill a
variety of needs and desires. Actuators are
available with an array of designs, power sources
and capabilities. Proper selection involves process
knowledge, valve knowledge, and actuator
knowledge.
A control valve can perform its function only as
well as the actuator can handle the static and
dynamic loads placed on it by the valve.
Therefore, proper selection and sizing are very
important. Since the actuator can represent a
significant portion of the total control valve price,
careful selection of actuator and accessory options
can lead to significant dollar savings.
The range of actuator types and sizes on the
market today is so great that it seems the selection
process might be highly complex. With a few rules
in mind and knowledge of fundamental needs, the
selection process can be simple.
The following parameters are key as they quickly
narrow the actuator choices:
D Power source availability
D Fail-safe requirements
D Torque or thrust requirements
D Control functions
Power Source Availability
The power source available at the location of a
valve can often point directly to what type of
actuator to choose. Typically, valve actuators are
powered either by compressed air or by electricity.
However, in some cases water pressure, hydraulic
fluid, or even pipeline pressure can be used.
Since most plants have both electricity and
compressed air readily available, the selection
depends upon the ease and cost of furnishing
either power source to the actuator location.
Reliability and maintenance requirements of the
power system must also be considered.
Consideration should also be given to providing
backup operating power to critical plant loops.
Fail-safe Requirements
The overall reliability of power sources is quite
high. However, many loops demand specific valve
action should the power source ever fail. Desired
action upon a signal failure may be required for
safety reasons or for protection of equipment.
Fail-safe systems store energy, either
mechanically in springs, pneumatically in volume
tanks, or in hydraulic accumulators. When power
fails, the fail-safe systems are triggered to drive
the valves to the required position and to then
maintain this position until returned to normal
operation. In many cases, the process pressure is
used to ensure or enhance this action.
22
Actuator designs are available with a choice of
failure mode between failing open, failing closed,
or holding in the last position. Many actuator
systems incorporate failure modes at no extra
cost. For example, spring-and-diaphragm
actuators are inherently fail open or closed, while
electric operators typically hold their last position.
Torque or Thrust Requirements
An actuator must have sufficient thrust or torque
for the prescribed application. In some cases this
requirement can dictate actuator type as well as
power supply requirements.
For instance, large valves requiring a high thrust
may be limited to only electric or electro-hydraulic
actuators due to a lack of pneumatic actuators with
sufficient thrust capability. Conversely,
electro-hydraulic actuators would be a poor choice
for valves with very low thrust requirements.
The matching of actuator capability with valve
body requirements is best left to the control valve
manufacturer as there are considerable
differences in frictional and fluid forces from valve
to valve.
Control Functions
Knowledge of the required actuator functions will
most clearly define the options available for
selection. These functions include the actuator
signal (pneumatic, electric, etc.), signal range,
ambient temperatures, vibration levels, operating
speed, frequency, and quality of control that is
required.
Signal types are typically grouped as such:
D Two-position (on-off)
D Analog (throttling)
D Digital
Two-position electric, electro-pneumatic, or
pneumatic switches control on-off actuators. This
is the simplest type of automatic control and the
least restrictive in terms of selection.
Throttling actuators have considerably higher
demands put on them from both a compatibility
and performance standpoint. A throttling actuator
receives its input from an electronic or pneumatic
instrument that measures the controlled process
variable. The actuator must then move the final
control element in response to the instrument
signal in an accurate and timely fashion to ensure
effective control. The two primary additional
requirements for throttling actuators include:
D Compatibility with instrument signal
D Better static and dynamic performance to
ensure loop stability
Compatibility with instrument signals is inherent in
many actuator types, or it can be obtained with
add-on equipment. But, the high-performance
characteristics required of a good throttling
actuator cannot be bolted on; instead, low
hysteresis and minimal deadband must be
designed into actuators.
Stroking speed, vibration, and temperature
resistance must also be considered if critical to the
application. For example, on liquid loops
fast-stroking speeds can be detrimental due to the
possibility of water hammer.
Vibration or mounting position can be a potential
problem. The actuator weight, combined with the
weight of the valve, may necessitate bracing.
It is essential to determine the ambient
temperature and humidity that the actuator will
experience. Many actuators contain either
elastomeric or electronic components that can be
subject to degradation by high humidity or
temperature.
Economics
Evaluation of economics in actuator selection is a
combination of the following:
D Cost
D Maintenance
D Reliability
A simple actuator, such as a
spring-and-diaphragm, has few moving parts and
is easy to service. Its initial cost is low, and
maintenance personnel understand and are
comfortable working with them.
23
An actuator made specifically for a control valve
eliminates the chance for a costly performance
mismatch. An actuator manufactured by the valve
vendor and shipped with the valve will eliminate
separate mounting charges and ensure easier
coordination of spare parts procurement.
Interchangeable parts among varied actuators are
also important to minimize spare-parts inventory.
Actuator Designs
There are many types of actuators on the market,
most of which fall into five general categories:
D Spring-and-diaphragm
D Pneumatic piston
D Rack and Pinion
D Electric motor
D Electro-hydraulic
Each actuator design has weaknesses, strong
points and optimum uses. Most actuator designs
are available for either sliding stem or rotary valve
bodies. They differ only by linkages or motion
translators; the basic power sources are identical.
Most rotary actuators employ linkages, gears, or
crank arms to convert direct linear motion of a
diaphragm or piston into the 90-degree output
rotation required by rotary valves. The most
important consideration for control valve actuators
is the requirement for a design that limits the
amount of lost motion between internal linkage
and valve coupling.
Rotary actuators are now available that employ
tilting pistons or diaphragms. These designs
eliminate most linkage points (and resultant lost
motion) and provide a safe, accurate and enclosed
package.
When considering an actuator design, it is also
necessary to consider the method by which it is
coupled to the drive shaft of the control valve.
Slotted connectors mated to milled shaft flats are
generally not satisfactory if any degree of
performance is required. Pinned connections, if
solidly constructed, are suitable for nominal torque
applications. A splined connector that mates to a
splined shaft end and then is rigidly clamped to the
shaft eliminates lost motion, is easy to
disassemble, and is capable of high torque.
Sliding stem actuators are rigidly fixed to valve
stems by threaded and clamped connections.
Because they dont have any linkage points, and
their connections are rigid, they exhibit no lost
motion and have excellent inherent control
characteristics.
Spring-and-Diaphragm Actuators
The most popular and widely used control valve
actuator is the pneumatic spring-and-diaphragm
style. These actuators are extremely simple and
offer low cost and high reliability. They normally
operate over the standard signal ranges of 3 to 15
psi or 6 to 30 psi, and therefore, are often suitable
for throttling service using instrument signals
directly.
Many spring-and-diaphragm designs offer either
adjustable springs and/or wide spring selections to
allow the actuator to be tailored to the particular
application. Because they have few moving parts
that may contribute to failure, they are extremely
reliable. Should they ever fail, maintenance is
extremely simple. Improved designs now include
mechanisms to control the release of spring
compression, eliminating possible personnel injury
during actuator disassembly.
Use of a positioner or booster with a
spring-and-diaphragm actuator can improve
control, but when improperly applied, can result in
poor control. Follow the simple guidelines
available for positioner applications and look for:
D Rugged, vibration-resistant construction
D Calibration ease
D Simple, positive feedback linkages
The overwhelming advantage of the
spring-and-diaphragm actuator is the inherent
provision for fail-safe action. As air is loaded on
the actuator casing, the diaphragm moves the
valve and compresses the spring. The stored
energy in the spring acts to move the valve back to
its original position as air is released from the
casing. Should there be a loss of signal pressure
to the instrument or the actuator, the spring can
move the valve to its initial (fail-safe) position.
24
DIAPHRAGM
DIAPHRAGM CASING
DIAPHRAGM
PLATE
ACTUATOR SPRING
ACTUATOR STEM
SPRING SEAT
SPRING ADJUSTOR
STEM CONNECTOR
YOKE
TRAVEL INDICATOR DISK
INDICATOR SCALE
W0363-1
LOWER DIAPHRAGM CASING
W0364-1
Figure 2-1. Spring-and-diaphragm actuators offer an excellent first choice for most control valves.
They are inexpensive, simple and have built-in, fail-safe action. Pictured above are cutaways of the popular
Fisher 667 (left) and Fisher 657 (right) actuators.
Figure 2-2. Spring-and-diaphragm actuators
can be supplied with a top-mounted handwheel.
The handwheel allows manual operation and also
acts as a travel stop or means of emergency
operation.
W0368-2
Actuators are available for either fail-open or
fail-closed action. The only drawback to the
spring-and-diaphragm actuator is a relatively
limited output capability. Much of the thrust
created by the diaphragm is taken up by the spring
and thus does not result in output to the valve.
Therefore, the spring-and-diaphragm actuator is
used infrequently for high force requirements. It is
not economical to build and use very large
spring-and-diaphragm actuators because the size,
weight and cost grow exponentially with each
increase in output force capability.
Piston Actuators
Piston actuators are generally more compact and
provide higher torque or force outputs than
spring-and-diaphragm actuators. Fisher piston
styles normally work with supply pressures
between 50 and 150 psi and can be equipped with
spring returns (however, this construction has
limited application).
Piston actuators used for throttling service must be
furnished with double-acting positioners that
simultaneously load and unload opposite sides of
the piston. The pressure differential created across
the piston causes travel toward the lower pressure
side. The positioner senses the motion, and when
the required position is reached, the positioner
equalizes the pressure on both sides of the piston.
The pneumatic piston actuator is an excellent
choice when a compact unit is required to produce
high torque or force. It is also easily adapted to
25
Figure 2-3. The Fisher 2052 spring-and-
diaphragm actuator has many features to provide
precise control. The splined actuator connection
features a clamped lever and single-joint linkage
to help eliminate lost motion.
W9589-1 W9588-1
Figure 2-4. Double-acting piston actuators such
as the Fisher 1061 rotary actuator are a good
choice when thrust requirements exceed the
capability of spring-and-diaphragm actuators.
Piston actuators require a higher supply pressure,
but have benefits such as high stiffness and small
size. The 1061 actuator is typically used for
throttling service.
W38271
services where high ambient temperatures are a
concern.
The main disadvantages of piston actuators are
the high supply pressures required for positioners
when used in throttling service and the lack of
fail-safe systems.
Figure 2-5. Spring fail-safe is present in this
piston design. The Fisher 585C is an example of
a spring-bias piston actuator. Process pressure
can aid fail-safe action, or the actuator can be
configured for full spring-fail closure.
W7447
Figure 2-6. Since the requirements for accuracy
and minimal lost motion are unnecessary for
on-off service, cost savings can be achieved by
simplifying the actuator design. The Fisher
1066SR incorporates spring-return capability.
W4102
There are two types of spring-return piston
actuators available. The variations are subtle, but
significant. It is possible to add a spring to a piston
26
actuator and operate it much like a spring-and-
diaphragm. These designs use a single-acting
positioner that loads the piston chamber to move
the actuator and compress the spring. As air is
unloaded, the spring forces the piston back. These
designs use large, high output springs that are
capable of overcoming the fluid forces in the valve.
The alternative design uses a much smaller spring
and relies on valve fluid forces to help provide the
fail-safe action. In normal operation they act like a
double action piston. In a fail-safe situation the
spring initiates movement and is helped by
unbalance forces on the valve plug. These
actuators can be sized and set up to provide full
spring closure action without process assistance.
An alternative to springs is a pneumatic trip
system which often proves to be complex in
design, difficult to maintain and costly. While a trip
system is completely safe, any fail-safe
requirement consideration should be given first to
spring-and-diaphragm operators if they are
feasible.
Special care should be given during the selection
of throttling piston actuators to specify a design
that has minimal hysteresis and deadband. As the
number of linkage points in the actuator increases,
so does the deadband. As the number of sliding
parts increases, so does the hysteresis. An
actuator with high hysteresis and deadband can
be quite suitable for on-off service; however,
caution is necessary when attempting to adapt this
actuator to throttling service by merely bolting on a
positioner.
The cost of a spring-and-diaphragm actuator is
generally less than a comparable piston actuator.
Part of this cost saving is a result of the ability to
use instrument output air directly, thereby
eliminating the need for a positioner. The inherent
provision for fail-safe action in the spring-and-
diaphragm actuator is also a consideration.
Rack and Pinion Actuators
Rack and pinion actuators may come in a
double-acting design, or spring return, and are a
compact and economical solution for rotary shaft
valves. They provide high torque outputs and are
typically used for on-off applications with high
cycle life. They may also be used in processes
where higher variability is not a concern.
Figure 2-7. The FieldQt actuator is a quarter
turn pneumatic rack and pinion actuator. It comes
with an integrated module combining the solenoid
and switchbox into a low profile, compact
package.
W9479
Electric Actuators
Electric actuators can be applied successfully in
many situations. Most electric operators consist of
motors and gear trains and are available in a wide
range of torque outputs, travels, and capabilities.
They are suited for remote mounting where no
other power source is available, for use where
there are specialized thrust or stiffness
requirements, or when highly precise control is
required.
Electric operators are economical versus
pneumatic actuators for applications in small size
ranges only. Larger units operate slowly and weigh
considerably more than pneumatic equivalents.
Available fail action is typically lock in last position.
One key consideration in choosing an electric
actuator is its capability for continuous closed-loop
control. In applications where frequent changes
are made in control-valve position, the electric
actuator must have a suitable duty cycle.
High performance electric actuators using
continuous rated DC motors and ball screw output
devices are capable of precise control and 100%
duty cycles.
Compared to other actuator designs, the electric
actuator generally provides the highest output
27
available within a given package size. Additionally,
electric actuators are stiff, that is, resistant to valve
forces. This makes them an excellent choice for
good throttling control of large, high-pressure
valves.
Actuator Sizing
The last step in the selection process is to
determine the required actuator size.
Fundamentally, the process of sizing is to match
as closely as possible the actuator capabilities to
the valve requirements.
In practice, the mating of actuator and valve
requires the consideration of many factors. Valve
forces must be evaluated at the critical positions of
valve travel (usually open and closed) and
compared to actuator output. Valve force
calculation varies considerably between valve
styles and manufacturers. In most cases it is
necessary to consider a complex summation of
forces including:
D Static fluid forces
D Dynamic fluid forces and force gradients
D Friction of seals, bearings, and packing
D Seat loading
Although actuator sizing is not difficult, the great
variety of designs on the market and the ready
availability of vendor expertise (normally at no
cost) make detailed knowledge of the procedures
unnecessary.
Actuator Spring for Globe Valves
The force required to operate a globe valve
includes:
A. Force to overcome static unbalance of the
valve plug
B. Force to provide a seat load
C. Force to overcome packing friction
D. Additional forces required for certain specific
applications or constructions
Total force required = A + B + C + D
A. Unbalance Force
The unbalance force is that resulting from fluid
pressure at shutoff, and in the most general sense
can be expressed as:
Unbalance force = net pressure differential X net
unbalance area
Frequent practice is to take the maximum
upstream gauge pressure as the net pressure
differential unless the process design always
ensures a back pressure at the maximum inlet
pressure. Net unbalance area is the port area on a
single seated flow up design. Unbalance area may
have to take into account the stem area depending
on configuration. For balanced valves there is still
a small unbalance area. This data can be obtained
from the manufacturer. Typical port areas for
balanced valves flow up and unbalanced valves in
a flow down configuration are listed in table 2-1.
Table 2-1. Typical Unbalance Areas of Control Valves
Port Diameter,
Inches
Unbalance Area
Single-Seated
Unbalanced
Valves, In
2
Unbalance Area
Balanced Valves,
In
2
1/4 0.049
3/8 0.110
1/2 0.196
3/4 0.441
1 0.785
1 5/16 1.35 0.04
1 7/8 2.76 0.062
2 5/16 4.20 0.27
3 7/16 9.28 0.118
4 3/8 15.03 0.154
7 38.48 0.81
8 50.24 0.86
B. Force to Provide Seat Load
Seat load, usually expressed in pounds per lineal
inch or port circumference, is determined by
shutoff requirements. Use the guidelines in table
2-2 to determine the seat load required to meet
the factory acceptance tests for ANSI/FCI 70-2
and IEC 534-4 leak Classes II through VI.
Because of differences in the severity of service
conditions, do not construe these leak
classifications and corresponding leakage rates as
indicators of field performance. To prolong seat life
and shutoff capabilities, use a higher than
recommended seat load. If tight shutoff is not a
prime consideration, use a lower leak class.
28
Table 2-2. Recommended Seat Load Per Leak Class for
Control Valves
Class I As required by customer
specification, no factory leak test
required
Class II 20 pounds per lineal inch of port
circumference
Class III 40 pounds per lineal inch of port
circumference
Class IV Standard (Lower) Seat only40
pounds per lineal inch of port
circumference (up through a
43/8 inch diameter port)
Standard (Lower) Seat only80
pounds per lineal inch of port
circumference (larger than 43/8
inch diameter port)
Class V Metal Seatdetermine pounds
per lineal inch of port
circumference from figure 2-9
C. Packing Friction
Packing friction is determined by stem size,
packing type, and the amount of compressive load
placed on the packing by the process or the
bolting. Packing friction is not 100% repeatable in
its friction characteristics. Newer live loaded
packing designs can have significant friction forces
especially if graphite packing is used. Table 2-3
lists typical packing friction values.
D. Additional Forces
Additional forces to consider may include bellows
stiffness, unusual frictional forces resulting from
seals or special seating forces for soft metal seals.
The manufacturer should either supply this
information or take it into account when sizing an
actuator.
Actuator Force Calculations
Pneumatic spring-and-diaphragm actuators
provide a net force with the additional air pressure
after compressing the spring in air-to-close, or with
the net pre-compression of the spring in
air-to-open. This may be calculated in pounds per
square inch of pressure differential.
For example, suppose 275 pound-force (lbf) is
required to close the valve as calculated per the
process described earlier. An air-to-open actuator
with 100 square inches of diaphragm area and a
bench set of 6 to 15 psig is one available option.
The expected operating range is 3 to 15 psig. The
Figure 2-8. Recommended Seat Load
A22224/IL
pre-compression can be calculated as the
difference between the lower end of the bench set
(6 psig) and the beginning of the operating range
(3 psig). This 3 psig is used to overcome the
pre-compression so the net pre-compression force
must be:
3 psig X 100 sq. in. = 300 lbf.
This exceeds the force required and is an
adequate selection.
Piston actuators with springs are sized in the same
manner. The thrust from piston actuators without
springs can be calculated as:
Piston area X minimum supply pressure =
minimum available thrust
(maintain compatibility of units)
In some circumstances an actuator could supply
too much force and cause the stem to buckle, to
bend sufficiently to cause a leak, or to damage
valve internals.
The manufacturer normally takes responsibility for
actuator sizing and should have methods
documented to check for maximum stem loads.
Manufacturers also publish data on actuator
thrusts, effective diaphragm areas, and spring
data.
29
Table 2-3. Typical Packing Friction Values (Lb)
Stem Size
(Inches)
ANSI
Class
PTFE Packing Graphite
Ribbon/
Filament
Single Double
5/16 All 20 30
3/8 125
150
250
300
38 56
125

190
600
900
1500
250
320
380
1/2 125
150
250
300
50 75
180

230
600
900
1500
2500
320
410
500
590
5/8 125
150
250
300
600
63 95
218

290
400
3/4 125
150
250
300
75 112.5
350

440
600
900
1500
2500
660
880
1100
1320
1 300
600
900
1500
2500
100 150 610
850
1060
1300
1540
11/4 300
600
900
1500
2500
120 180 800
1100
1400
1700
2040
2 300
600
900
1500
2500
200 300 1225
1725
2250
2750
3245
Values shown are frictional forces typically encountered when using standard
packing flange bolt-torquing procedures.
Actuator Sizing for Rotary Valves
In selecting the most economical actuator for a
rotary valve, the determining factors are the torque
required to open and close the valve and the
torque output of the actuator.
This method assumes the valve has been properly
sized for the application and the application does
not exceed pressure limitations for the valve.
Torque Equations
Rotary valve torque equals the sum of a number of
torque components. To avoid confusion, a number
of these have been combined, and a number of
calculations have been performed in advance.
Thus, the torque required for each valve type can
be represented with two simple and practical
equations.
Breakout Torque
T
B
=A(DP
shutoff
)+B
Dynamic Torque
T
D
=C(DP
eff
)
Specific A, B, and C factors, for example, rotary
valve designs are included in tables 2-4 and 2-5.
Maximum Rotation
Maximum rotation is defined as the angle of valve
disk or ball in the fully open position.
Normally, maximum rotation is 90 degrees. The
ball or disk rotates 90 degrees from the closed
position to the wide-open position.
Some of the pneumatic spring-return piston and
pneumatic spring-and-diaphragm actuators are
limited to 60 or 75 degrees rotation.
For pneumatic spring-and-diaphragm actuators,
limiting maximum rotation allows for higher initial
spring compression, resulting in more actuator
breakout torque. Additionally, the effective length
of each actuator lever changes with valve rotation.
Published torque values, particularly for pneumatic
piston actuators, reflect this changing lever length.
The Selection Process
In choosing an actuator type, the fundamental
requirement is to know your application. Control
signal, operating mode, power source available,
thrust/torque required, and fail-safe position can
make many decisions for you. Keep in mind
simplicity, maintainability and lifetime costs.
Safety is another consideration that must never be
overlooked. Enclosed linkages and controlled
compression springs available in some designs
are important for safety reasons. Table 2-6 lists
the pros and cons of the various actuator styles.
210
Table 2-4. Typical Rotary Shaft Valve Torque Factors V-Notch Ball Valve with Composition Seal
Fisher TCMt Plus Ball Seal
Valve Size,
NPS
Valve Shaft
Diameter,
Inches
A
B
C
Maximum T
D
,
LbfSIn.
Composition Bearings
(1)
60 Degrees 70 Degrees
1
1-1/2
2
3
4
6
8
1/2
5/8
5/8
3/4
3/4
1
1-1/4
0.07
0.12
0.19
0.10
0.10
1.80
1.80
50
100
175
280
380
500
750
0.38
1.10
1.30
0.15
1.10
1.10
3.80
0.48
1.10
2.40
3.80
18.0
36.0
60.0
515
1225
1225
2120
2120
4140
9820
10
12
14
16
16
20
1-1/4
1-1/2
1-3/4
2
2-1/8
2-1/2
1.80
4.00
42
60
60
97
1250
3000
2400
2800
2800
5200
3.80
11.0
75
105
105
190
125
143
413
578
578
1044
9820
12,000
23,525
23,525
55,762
55,762
1. PEEK/PTFE or metal/PTFE bearings.
Table 2-5. Typical High Performance Butterfly Torque Factors for Valve with Composition Seal
PEEK/PTFE Bearings with PTFE Seal
Valve Size Shaft Diameter
A B
C Maximum Allowable Torque
ANGLE OF OPENING S17400 H1075 S20910
NPS Inch 60_ (K) 90_ (q) lbfSin lbfSin
2 1/2 0.30 100 1.05 2.45 515 515
3 5/8 0.56 150 3.59 10.8 1087 1028
4 3/4 0.99 232 7.65 21.2 1640 1551
6 1 2.30 438 17.5 46.7 4140 4140
8 1-1/4 4.80 705 33.4 223 7988 7552
10 1-1/4 8.10 1056 82.2 358 9792 9258
12 1-1/2 12.5 1470 106 626 12000 12000
Table 2-6. Actuator Feature Comparison
Actuator Type Advantages Disadvantages
Spring-and-Diaphragm Lowest cost
Ability to throttle without positioner
Simplicity
Inherent fail-safe action
Low supply pressure requirement
Adjustable to varying conditions
Ease of maintenance
Limited output capability
Larger size and weight
Pneumatic Piston High thrust capability
Compact
Lightweight
Adaptable to high ambient temperatures
Fast stroking speed
Relatively high actuator stiffness
Higher cost
Fail-safe requires accessories or
addition of a spring
Positioner required for throttling
High supply pressure requirement
Electric Motor Compactness
Very high stiffness
High output capability
High cost
Lack of fail-safe action
Limited duty cycle
Slow stroking speed
Electro-Hydraulic High output capability
High actuator stiffness
Excellent throttling ability
Fast stroking speed
High cost
Complexity and maintenance difficulty
Large size and weight
Fail-safe action only with accessories
211
Actuator Selection Summary
D Actuator selection must be based upon a
balance of process requirements, valve
requirements and cost.
D Simple designs such as the spring-and-
diaphragm are simpler, less expensive and easier
to maintain. Consider them first in most situations.
D Piston actuators offer many of the
advantages of pneumatic actuators with higher
thrust capability than spring-and-diaphragm styles.
They are especially useful where compactness is
desired or long travel is required.
D Electric and electro-hydraulic actuators
provide excellent performance. They are, however,
much more complex and difficult to maintain.
D Actuator sizing is not difficult, but the wide
variety of actuators and valves make it difficult to
master. Vendor expertise is widely available.
D Systems such as control valves are best
purchased, assembled and tested by one source.
Figure 2-9. The FIELDVUE Digital Valve Controller
brings increased control accuracy and flexibility.
When utilized with AMS ValveLinkt software,
FIELDVUE instruments provide valuable diagnostic
data that helps to avoid maintenance problems.
W9915
Use of actuators and accessories of the same
manufacturer will eliminate many problems.
212
www.Fisher.com
*Some information in this introductory material has been extracted from ANSI/ISA
S75.01 standard with the permission of the publisher, the ISA.
{All terms are defined in the nomenclature section.
Chapter 3
Liquid Valve Sizing
Valves are selected and sized to perform a
specific function within a process system. Failure
to perform that given function in controlling a
process variable results in higher process costs.
Thus, valve sizing becomes a critical step to
successful process operation. The following
sections focus on correctly sizing valves for liquid
service: the liquid sizing equation is examined, the
nomenclature and procedures are explained, and
sample problems are solved to illustrate their
use.2-
Valve Sizing Background
Standardization activities for control valve sizing
can be traced back to the early 1960s when a
trade association, the Fluids Control Institute,
published sizing equations for use with both
compressible and incompressible fluids. The
range of service conditions that could be
accommodated accurately by these equations was
quite narrow, and the standard did not achieve a
high degree of acceptance.
In 1967, the International Society of America
(ISAt) established a committee to develop and
publish standard equations. The efforts of this
committee culminated in a valve sizing procedure
that has achieved the status of American National
Standards Institute (ANSI). Later, a committee of
the International Electrotechnical Commission
(IEC) used the ISA works as a basis to formulate
international standards for sizing control valves.*
Except for some slight differences in nomenclature
and procedures, the ISA and IEC standards have
been harmonized. ANSI/ISA Standard S75.01 is
harmonized with IEC Standards 534-2-1 and
534-2-2 (IEC Publications 534-2, Sections One
and Two for incompressible and compressible
fluids, respectively).
Liquid Sizing Equation Background
This section presents the technical substance of
the liquid sizing equations. The value of this lies in
not only a better understanding of the sizing
equations, but also in knowledge of their intrinsic
limitations and relationship to other flow equations
and conditions.
The flow equations used for sizing have their roots
in the fundamental equations, which describe the
behavior of fluid motion. The two principle
equations include the:
D Energy equation
D Continuity equation
The energy equation is equivalent to a
mathematical statement of the first law of
thermodynamics. It accounts for the energy
transfer and content of the fluid. For an
incompressible fluid (e.g. a liquid) in steady flow,
this equation can be written as:

V
2
2g
c
)
P

) gZ *w )q )U + constant (1)
The three terms{ in parenthesis are all
mechanical, or available, energy terms and carry a
special significance. These quantities are all
capable of directly doing work. Under certain
conditions more thoroughly described later, this
quantity may also remain constant:
V
2
2g
c
)
P

) gZ + constant (2)
This equation can be derived from purely
kinematic methods (as opposed to thermodynamic
methods) and is known as Bernoullis equation.
The other fundamental equation, which plays a
vital role in the sizing equation, is the continuity
32
Figure 3-1. Liquid Critical Pressure Ratio Factor for Water
equation. This is the mathematical statement of
conservation of the fluid mass. For steady flow
conditions (one-dimensional) this equation is
written as follows:
VA + constant (3)
Using these fundamental equations, we can
examine the flow through a simple, fixed
restriction such as that shown in figure 3-1. We
will assume the following for the present:
1. The fluid is incompressible (a liquid)
2. The flow is steady
3. The flow is one-dimensional
4. The flow can be treated as inviscid (having no
viscosity)
5. No change of fluid phase occurs
As seen in figure 3-1, the flow stream must
contract to pass through the reduced flow area.
The point along the flow stream of minimum cross
sectional flow area is the vena contracta. The flow
processes upstream of this point and downstream
of this point differ substantially, thus it is
convenient to consider them separately.
The process from a point several pipe diameters
upstream of the restriction to the vena contracta is
very nearly ideal for practical intents and purposes
(thermodynamically isentropic, thus having
constant entropy). Under this constraint,
Bernoullis equation applies and we see that no
mechanical energy is lost it merely changes
from one form to the other. Furthermore, changes
in elevation are negligible since the flow stream
centerline changes very little, if at all. Thus,
energy contained in the fluid simply changes from
pressure to kinetic. This is quantified when
considering the continuity equation. As the
flowstream passes through the restriction, the
velocity must increase inversely proportional to the
change in area. For example, from equation 4
below:
V
VC
+
(constant)
A
VC
(4)
Using upstream conditions as a reference, this
becomes:
V
VC
+ V
1

A
1
A
VC
(5)
Thus, as the fluid passes through the restriction,
the velocity increases. Below, equation 2 has been
33
applied and elevation changes have been
neglected (again using upstream conditions as a
reference):
V
1

2
2g
c
) P
1
+
V
VC

2
2g
c
)P
VC
(6)
In the equation below, equation 5 has been
inserted and rearranged:
P
VC
+ P
1
*
V
1

2
2g
c

A
1
A
VC

2
* 1 (7)
Thus, at the point of minimum cross sectional
area, we see that fluid velocity is at a maximum
(from equation 5 above) and fluid pressure is at a
minimum (from equation 6 above).
The process from the vena contracta point to a
point several diameters downstream is not ideal,
and equation 2 no longer applies. By arguments
similar to the above, it can be reasoned (from the
continuity equation) that, as the original cross
sectional area is restored, the original velocity is
also restored. Because of the non-idealities of this
process, however, the total mechanical energy is
not restored. A portion of it is converted into heat
that is either absorbed by the fluid itself, or
dissipated to the environment.
Let us consider equation 1 applied from several
diameters upstream of the restriction to several
diameters downstream of the restriction:
U
1
)
V
1

2
2g
c
)
P
1

)
gZ
1
g
C
)q +
U
2
)
V
2

2
2g
c
)
P
2

)
gZ
2
g
C
)w
(8)
No work is done across the restriction, thus the
work term drops out. The elevation changes are
negligible and as a result, the respective terms
cancel each other. We can combine the thermal
terms into a single term, H
I
:
V
1

2
2g
c
) P
1
+
V
2

2
2g
c
)P
2
)H
I
(9)
The velocity was restored to its original value so
that equation 9 reduces to:
P
1
+ P
2
)H
I
(10)
Consequently, the pressure decreases across the
restriction, and the thermal terms (internal energy
and heat lost to the surroundings) increase.
Losses of this type are generally proportional to
the square of the velocity (references one and
two), so it is convenient to represent them by the
following equation:
H
I
+ K
I

V
2
2
(11)
In this equation, the constant of proportionality, K
I
,
is called the available head loss coefficient, and is
determined by experiment.
From equations 10 and 11, it can be seen that the
velocity (at location two) is proportional to the
square root of the pressure drop. Volume flow rate
can be determined knowing the velocity and
corresponding area at any given point so that:
Q + V
2
A
2

2 (P
1
* P
2
)
K
I

A
2
(12)
Now, letting:
+ G
W
and, defining:
C
V
+ A
2

W
K
I
(13)
Where G is the liquid specific gravity, equation 12
may be rewritten as:
Q + C
V

P
1
* P
2
G

(14)
Equation 14 constitutes the basic sizing equation
used by the control valve industry, and provides a
measure of flow in gallons per minute (GPM)
when pressure in pounds per square inch (PSI) is
used. At times, it may be desirable to work with
other units of flow or independent flow variables
(pressure, density, etc). The equation
fundamentals are the same for such cases, and
only constants are different.
Determination of Flow Coefficients
Rather than experimentally measure K
I
and
calculate C
v
, it is more straightforward to measure
C
v
directly.
34
Figure 3-2. Liquid Critical Pressure Ratio Factor for Liquids Other Than Water
A2738-1
In order to assure uniformity and accuracy, the
procedures for both measuring flow parameters
and use in sizing are addressed by industrial
standards. The currently accepted standards are
sponsored by the ISA.
The basic test system configuration is shown in
figure 3-2. Specifications, accuracies, and
tolerances are given for all hardware installation
and data measurements such that coefficients can
be calculated to an accuracy of approximately 5%.
Fresh water at approximately 68F is circulated
through the test valve at specified pressure
differentials and inlet pressures. Flow rate, fluid
temperature, inlet and differential pressure, valve
travel, and barometric pressure are all measured
and recorded. This yields sufficient information to
calculate the following sizing parameters:
D Flow coefficient (C
v
)
D Pressure recovery coefficient (F
L
)
D Piping correction factor (F
p
)
D Reynolds number factor (F
R
)
In general, each of these parameters depends on
the valve style and size, so multiple tests must be
performed accordingly. These values are then
published by the valve manufacturer for use in
sizing.
Basic Sizing Procedure Overview
The procedure by which valves are sized for
normal, incompressible flow is straightforward.
Again, to ensure uniformity and consistency, a
standard exists that delineates the equations and
correction factors to be employed for a given
application.
The simplest case of liquid flow application
involves the basic equation developed earlier.
Rearranging equation thirteen so that all of the
fluid and process related variables are on the right
side of the equation, we arrive at an expression for
the valve C
v
required for the particular application:
C
v
+
Q
P
1
*P
2
G

(15)
It is important to realize that valve size is only one
aspect of selecting a valve for a given application.
Other considerations include valve style and trim
characteristic. Discussion of these features can be
referenced in chapter 2, chapter 4, and other
thorough resources.
Once a valve has been selected and C
v
is known,
the flow rate for a given pressure drop, or the
pressure drop for a given flow rate, can be
predicted by substituting the appropriate quantities
into equation 16.
* The ability to recognize which terms are appropriate for a specific sizing
procedure can only be acquired through experience with different valve sizing
problems. If any of the above terms appears to be new or unfamiliar, refer to
the Abbreviations and Terminology Table (table 3-1) for a complete definition.
35
Many applications fall outside the bounds of the
basic liquid flow applications just considered.
Rather than develop special flow equations for all
of the possible deviations, it is possible (and
preferred) to account for different behavior with
the use of simple correction factors. These
factors, when incorporated, change the form of
equation 14 to the following:
Q + (N
1
F
P
F
R
) C
V

P
1
* P
2
G

(16)
All of the additional factors in this equation are
explained in the following sections.
Sizing Valves for Liquids
Following is a step-by-step procedure for the
sizing of control valves for liquid flow using the
IEC procedure. Each of these steps is important
and must be considered during any valve sizing
procedure. Steps three and four concern the
determination of certain sizing factors that may, or
may not, be required in the sizing equation
depending upon the service conditions of the
sizing problem. If one, two, or all three of these
sizing factors are to be included in the equation for
a particular sizing problem, please refer to the
appropriate factor determination section(s) located
in the text proceeding step six.
1. Specify the variables required to size the valve
as follows:
D Desired design
D Process fluid (water, oil, etc.)
D Appropriate service conditions Q or w, P
1
, P
2
or P, T
1
, G
f
, P
v
, P
c
, and *
2. Determine the equation constant, N.
N is a numerical constant contained in each of the
flow equations to provide a means for using
different systems of units. Values for these various
constants and their applicable units are given in
the Equation Constants Table (table 3-2).
Use N
1
if sizing the valve for a flow rate in
volumetric units (gpm or m
3
/h).
Use N
6
if sizing the valve for a flow rate in mass
units (lb/h or kg/h).
3. Determine F
p
, the piping geometry factor.
F
p
is a correction factor that accounts for pressure
losses due to piping fittings such as reducers,
elbows, or tees that might be attached directly to
the inlet and outlet connections of the control
valve to be sized. If such fittings are attached to
the valve, the F
p
factor must be considered in the
sizing procedure. If, however, no fittings are
attached to the valve, F
p
has a value of 1.0 and
simply drops out of the sizing equation.
For rotary valves with reducers (swaged
installations), and other valve designs and fitting
styles, determine the F
p
factors by using the
procedure for determining F
p
, the piping geometry
factor.
4. Determine q
max
(the maximum flow rate at
given upstream conditions) or P
max
(the
allowable sizing pressure drop).
The maximum or limiting flow rate (q
max
),
commonly called choked flow, is manifested by no
additional increase in flow rate with increasing
pressure differential with fixed upstream
conditions. In liquids, choking occurs as a result of
vaporization of the liquid when the static pressure
within the valve drops below the vapor pressure of
the liquid.
The IEC standard requires the calculation of an
allowable sizing pressure drop (P
max
) to account
for the possibility of choked flow conditions within
the valve. The calculated P
max
value is
compared with the actual pressure drop specified
in the service conditions, and the lesser of these
two values is used in the sizing equation. If it is
desired to use P
max
to account for the possibility
of choked flow conditions it can be calculated
using the procedure for determining q
max
, the
maximum flow rate, or P
max
, the allowable sizing
pressure drop. If it can be recognized that choked
flow conditions will not develop within the valve
P
max
need not be calculated.
36
Table 3-1. Abbreviations and Terminology
Symbol Symbol
C
v
Valve sizing coefficient P
1
Upstream absolute static pressure
d Nominal valve size P
2
Downstream absolute static
pressure
D Internal diameter of the piping P
c
Absolute thermodynamic critical
pressure
F
d
Valve style modifier,
dimensionless
P
v
Vapor pressure absolute of liquid at
inlet temperature
F
F
Liquid critical pressure ratio factor,
dimensionless
P Pressure drop (P
1
-P
2
) across the
valve
F
k
Ratio of specific heats factor,
dimensionless
P
max(L)
Maximum allowable liquid sizing
pressure drop
F
L
Rated liquid pressure recovery
factor, dimensionless
P
max(LP)
Maximum allowable sizing pressure
drop with attached fittings
F
LP
Combined liquid pressure recovery
factor and piping geometry factor
of valve with attached fittings
(when there are no attached
fittings, F
LP
equals F
L
),
dimensionless
q Volume rate of flow
F
P
Piping geometry factor,
dimensionless
q
max
Maximum flow rate (choked flow
conditions) at given upstream
conditions
G
f
Liquid specific gravity (ratio of
density of liquid at flowing
temperature to density of water at
60_F), dimensionless
T
1
Absolute upstream temperature
(degree K or degree R)
G
g
Gas specific gravity (ratio of
density of flowing gas to density of
air with both at standard
conditions
(1)
, i.e., ratio of
molecular weight of gas to
molecular weight of air),
dimensionless
w Mass rate of flow
k Ratio of specific heats,
dimensionless
x Ratio of pressure drop to upstream
absolute static pressure (P/P
1
),
dimensionless
K Head loss coefficient of a device,
dimensionless
x
T
Rated pressure drop ratio factor,
dimensionless
M Molecular weight, dimensionless Y Expansion factor (ratio of flow
coefficient for a gas to that for a
liquid at the same Reynolds
number), dimensionless
N Numerical constant Z Compressibility factor,
dimensionless
1
Specific weight at inlet conditions
Kinematic viscosity, centistokes
1. Standard conditions are defined as 60_F (15.5_C) and 14.7 psia (101.3kPa).
37
Table 3-2. Equation Constants
(1)
N w q p
(2)
g T d, D
N
1
0.0865
0.865
1.00
- - -
- - -
- - -
m
3
/h
m
3
/h
gpm
kPa
bar
psia
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
N
2
0.00214
890
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
mm
inch
N
5
0.00241
1000
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
mm
inch
N
6
2.73
27.3
63.3
kg/h
kg/h
lb/h
- - -
- - -
- - -
kPa
bar
psia
kg/m
3
kg/m
3
lb/ft
3
- - -
- - -
- - -
- - -
- - -
- - -
N
7
(3)
Normal Conditions
T
N
= 0_C
3.94
394
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
T
s
= 15.5_C
4.17
417
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
T
s
= 60_F
1360 - - - scfh psia - - - deg R - - -
N
8
0.948
94.8
19.3
kg/h
kg/h
lb/h
- - -
- - -
- - -
kPa
bar
psia
- - -
- - -
- - -
deg K
deg K
deg R
- - -
- - -
- - -
N
9
(3)
Normal Conditions
T
N
= 0_C
21.2
2120
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
Ts = 15.5_C
22.4
2240
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
T
S
= 60_F
7320 - - - scfh psia - - - deg R - - -
1. Many of the equations used in these sizing procedures contain a numerical constant, N, along with a numerical
subscript. These numerical constants provide a means for using different units in the equations. Values for the
various constants and the applicable units are given in the above table. For example, if the flow rate is given in U.S.
gpm and the pressures are psia, N
1
has a value of 1.00. If the flow rate is m
3
/hr and the pressures are kPa, the N
1
constant becomes 0.0865.
2. All pressures are absolute.
3. Pressure base is 101.3 kPa (1.013 bar)(14.7 psia).
5. Solve for required C
v
, using the appropriate
equation.
For volumetric flow rate units:
C
v
+
q
N
1
F
P

P
1
*P
2
G
f

(17)
For mass flow rate units:
C
v
+
w
N
6
F
P
(P
1
* P
2
) g

(18)
In addition to C
v
, two other flow coefficients, K
v
and A
v
, are used, particularly outside of North
America. The following relationships exist:
K
V
+ (0.865)(C
V
)
A
V
+ (2.40 10
*5
)(C
V
)
6. Select the valve size using the appropriate flow
coefficient table and the calculated C
v
value.
Determining Piping Geometry Factor
(F
p
)
Determine an F
p
factor if any fittings such as
reducers, elbows, or tees will be directly attached
to the inlet and outlet connections of the control
valve that is to be sized. When possible, it is
recommended that F
p
factors be determined
experimentally by using the specified valve in
actual tests.
Calculate the F
p
factor using the following
equation:
F
p
+1 )
SK
N
2

C
v
d
2

*12
(19)
where,
N
2
= Numerical constant found in the Equation
Constants table
d = Assumed nominal valve size
C
v
= Valve sizing coefficient at 100% travel for the
assumed valve size
38
In the above equation, the K term is the
algebraic sum of the velocity head loss
coefficients of all of the fittings that are attached to
the control valve.
SK + K
1
)K
2
)K
B1
*K
B2
(20)
where,
K
1
= Resistance coefficient of upstream fittings
K
2
= Resistance coefficient of downstream fittings
K
B1
= Inlet Bernoulli coefficient
K
B2
= Outlet Bernoulli coefficient
The Bernoulli coefficients, K
B1
and K
B2
, are used
only when the diameter of the piping approaching
the valve is different from the diameter of the
piping leaving the valve, whereby:
K
B1
orK
B2
+ 1 *

d
D

4
(21)
where,
d = Nominal valve size
D = Internal diameter of piping
If the inlet and outlet piping are of equal size, then
the Bernoulli coefficients are also equal, K
B1
=
K
B2
, and therefore they are dropped from the
equation.
The most commonly utilized fitting in control valve
installations is the short-length concentric reducer.
The equations for this fitting are as follows:
For an inlet reducer:
K
1
+ 0.5

1 *
d
2
D
2

2
(22)
For an outlet reducer:
K
2
+ 1.0

1 *
d
2
D
2

2
(23)
For a valve installed between identical reducers:
K
1
)K
2
+ 1.5

1 *
d
2
D
2

2
(24)
Determining Maximum Flow Rate
(q
max
)
Determine either q
max
or P
max
if it is possible for
choked flow to develop within the control valve
that is to be sized. The values can be determined
by using the following procedures:
q
max
+ N
1
F
L
C
v

P
1
* F
F
P
v
G
f
(25)
Values for F
F
, the liquid critical pressure ratio
factor, can be obtained from figure 3-3, or from the
following equation:
F
F
+ 0.96 * 0.28
P
v
P
c
(26)
Values of F
L
, the recovery factor for rotary valves
installed without fittings attached, can be found in
published coefficient tables. If the given valve is to
be installed with fittings such as reducer attached
to it, F
L
in the equation must be replaced by the
quotient F
LP
/F
p
, where:
F
LP
+
K
1
N
2

C
v
d
2

2
)
1
F
L

*12
(27)
and
K
1
= K
1
+ K
B1
where,
K
1
= Resistance coefficient of upstream fittings
K
B1
= Inlet Bernoulli coefficient
Note: See the procedure for determining F
p
, the
piping geometry factor, for definitions of the other
constants and coefficients used in the above
equations.)
Determining Allowable Sizing Pressure
Drop (DP
max
)
P
max
(the allowable sizing pressure drop) can be
determined from the following relationships:
For valves installed without fittings:
DP
max(L)
+ F
L

P
1
*F
F
P
v

(28)
39
Figure 3-3. Liquid Critical Pressure Ratio Factor for Water
For valves installed with fittings attached:
DP
max(LP)
+
F
LP
F
P

P
1
*F
F
P
V

(29)
where,
P
1
= Upstream absolute static pressure
P
2
= Downstream absolute static pressure
P
v
= Absolute vapor pressure at inlet temperature
Values of F
F
, the liquid critical pressure ratio
factor, can be obtained from figure 3-3 or from the
following equation:
F
F
+ 0.96 * 0.28
P
v
P
c
(30)
An explanation of how to calculate values of F
LP
,
the recovery factor for valves installed with fittings
attached, is presented in the preceding procedure
determining q
max
(the maximum flow rate).
Once the P
max
value has been obtained from the
appropriate equation, it should be compared with
the actual service pressure differential (P = P
1

P
2
). If P
max
is less than P, this is an indication
that choked flow conditions will exist under the
service conditions specified. If choked flow
conditions do exist (P
max
< P
1
P
2
), then step
five of the procedure for sizing valves for liquids
must be modified by replacing the actual service
pressure differential (P
1
P
2
) in the appropriate
valve sizing equation with the calculated P
max
value.
Note: Once it is known that choked flow conditions
will develop within the specified valve design
(P
max
is calculated to be less than P), a further
distinction can be made to determine whether the
choked flow is caused by cavitation or flashing.
The choked flow conditions are caused by flashing
if the outlet pressure of the given valve is less than
the vapor pressure of the flowing liquid. The
choked flow conditions are caused by cavitation if
the outlet pressure of the valve is greater than the
vapor pressure of the flowing liquid.
Liquid Sizing Sample Problem
Assume an installation that, at initial plant start-up,
will not be operating at maximum design
capability. The lines are sized for the ultimate
system capacity, but there is a desire to install a
control valve now which is sized only for currently
310
anticipated requirements. The line size is 8-inches,
and an ANSI Class 300 globe valve with an equal
percentage cage has been specified. Standard
concentric reducers will be used to install the valve
into the line. Determine the appropriate valve size.
1. Specify the necessary variables required to
size the valve:
D Desired valve design is an ANSI Class 300
globe valve with equal percentage cage and an
assumed valve NPS 3.
D Process fluid is liquid propane
D Service conditions are q = 800 gpm
P
1
= 300 psig = 314.7 psia
P
2
= 275 psig = 289.7 psia
P = 25 psi
T
1
= 70F
G
f
= 0.50
P
v
= 124.3 psia
P
c
= 616.3 psia
2. Use an N
1
value of 1.0 from the Equation
Constants table.
3. Determine F
p
, the piping geometry factor.
Because it is proposed to install a NPS 3 valve in
an 8-inch line, it will be necessary to determine the
piping geometry factor, F
p
, which corrects for
losses caused by fittings attached to the valve.
From Equation 19,
Fp +1 )
SK
N
2

C
v
d
2

*12
where,
N
2
= 890, from the Equation Constants Table
d = 3 inches, from step one
C
v
= 121, from the flow coefficient table for an
ANSI Class 300, NPS 3 globe valve with equal
percentage cage.
To compute K for a valve installed between
identical concentric reducers:
SK + K
1
)K
2
+ 1.5

1 *
d
2
D
2

2
+ 1.5 1 *
(3)
2
(8)
2

2
+ 1.11
where,
D = 8 inches, the internal diameter of the piping
so,
F
p
+1 )
1.11
890

121
3
2

*12
+ 0.90
4. Determine P
max
(the allowable sizing
pressure drop)
Based upon the small required pressure drop, the
flow will not be choked (P
max
> P).
5. Solve for C
v
, using equation 17.
C
v
+
q
N
1
F
P
P
1
*P
2

G
f
+
800
(1.0)(0.90)
25
0.5

+ 125.7
6. Select the valve size using the flow coefficient
table and the calculated C
v
value.
The required C
v
of 125.7 exceeds the capacity of
the assumed valve, which has a C
v
of 121.
Although, for this example, it may be obvious that
the next larger size (NPS 4) would be the correct
valve size, this may not always be true, and a
repeat of the above procedure should be carried
out. This is assuming that a NPS 4 valve, C
v
=
203. This value was determined from the flow
coefficient table for an ANSI Class 300, NPS 4
globe valve with an equal percentage cage.
Recalculate the required C
v
using an assumed C
v
value of 203 in the F
p
calculation.
311
where,
SK + K
1
)K
2
+ 1.5

1 *
d
2
D
2

2
+ 1.5

1 *
16
64

2
+ 0.84
and
F
p
+1 )
SK
N
2

C
v
d
2

*12
+1 )
0.84
890

203
4
2

*12
+ 0.93
and
C
v
+
q
N
1
F
p
P
1
*P
2
G
f

+
800
(1.0)(0.93)
25
0.5

+ 121.7
This solution indicates only that the NPS 4 valve is
large enough to satisfy the service conditions
given. There may be cases, however, where a
more accurate prediction of the C
v
is required. In
such cases, the required C
v
should be determined
again using a new F
p
value based on the C
v
value
obtained above. In this example, C
v
is 121.7,
which leads to the following result:
F
p
+1 )
SK
N
2

C
v
d
2

*12
+1 )
0.84
890

121.7
4
2

*12
+ 0.97
The required C
v
then becomes:
C
v
+
q
N
1
F
p
P
1
*P
2
G
f

+
800
(1.0)(0.97)
25
0.5

+ 116.2
Because this newly determined C
v
is close to the
C
v
used initially for this recalculation (116.2 versus
121.7), the valve sizing procedure is complete,
and the conclusion is that a NPS 4 valve opened
to about 75% of total travel should be adequate for
the required specifications.
Sizing for Pulp Stock
The behavior of flowing pulp stock is different from
water or viscous Newtonian fluids. It is necessary
to account for this behavior when determining the
required valve size. Methods have been
developed to aid in determining correct valve size
for these types of applications.
The pulp stock sizing calculation uses the
following modified form of the basic liquid sizing
equation (equation thirteen, above):
Q + C
v
K
p
DP

where,
P = sizing pressure drop, psid
C
v
= valve flow coefficient
K
p
= pulp stock correction factor
Q = volumetric flow rate, gpm
The root of this calculation is the pulp stock
correction factor, K
p
. This factor is the ratio of the
pulp stock flow rate to water flow rate under the
same flowing conditions. It, therefore, modifies the
relationship between Q, C
v
, and P to account for
the effects of the pulp stock relative to that for
water. The value of this parameter, in theory,
depends on many factors such as pulp stock type,
consistency, freeness, fiber length, valve type and
pressure drop. However, in practice, it appears
that the dominant effects are due to three primary
factors: pulp type, consistency and pressure
differential. Values of K
p
for three different pulp
stock types are shown in figure 3-4 through 3-6.
312
Once the value of the pulp stock correction factor
is known, determining the required flow coefficient
or flow rate is equivalent to basic liquid sizing. For
example, consider the following:
Q = 1000 gpm of 8% consistency Kraft pulp stock
P = 16 psid
P
1
= 150 psia
K
p
= 0.83 from figure 3-5
therefore, C
v
+
Q
K
p
DP

+
1000
0.83 16

+ 301
Figure 3-4. Pulp Stock Correction Factors for Kraft Pulp
E1377
313
Figure 3-5. Pulp Stock Correction Factors for Mechanical Pulp
E1378
Figure 3-6. Pulp Stock Correction Factors for Recycled Pulp
E1379
314
www.Fisher.com
Chapter 4
Cavitation and Flashing
Severe Liquid Flow Sizing
Proper control valve sizing is important to
successful plant operation. However, sizing is not
always straightforward. At times, it involves
considering phenomena beyond that of general
service. Selecting the appropriate control valve
can be extremely critical to the complete process
loop. Liquid sizing for severe flow service,
including events involving cavitation or flashing,
must be closely examined in order to obtain
successful plant operation.
Sizing for severe flow service applications can be
explained by expanding upon base liquid sizing
knowledge. The following sections will build upon
the basic liquid sizing equations presented in
chapter 3 in order to study liquid fluid behaviors
involved with choked flow, cavitation, flashing,
viscous flow, and sizing for pulp stock. In addition,
discussion of considerations in selecting the
appropriate control valves for cavitating and
flashing services will take place.
Choked Flow
The equation illustrated below (chapter 3, equation
14) would imply that, for a given valve, flow could
be continually increased to infinity by simply
increasing the pressure differential across the
valve.
Q + C
v
P
1
* P
2
G

(31)
In reality, the relationship given by this equation
holds for only a limited range. As the pressure
differential is increased a point is reached where
the realized mass flow increase is less than
expected. This phenomenon continues until no
additional mass flow increase occurs in spite of
Figure 4-1. Typical Flow Curve Showing Relationship
Between Flow Rate Q and Imposed Pressure
Differential DP
A3442 / IL
increasing the pressure differential (figure 4-1).
This condition of limited maximum mass flow is
known as choked flow. To understand more about
what is occurring, and how to correct it when
sizing valves, it is necessary to revisit some of the
fluid flow basics discussed in chapter 3.
Recall that, as a liquid passes through a reduced
cross-sectional area, velocity increases to a
maximum and pressure decreases to a minimum.
As the flow exits, velocity is restored to its original
value while the pressure is only partially restored
thus creating a pressure differential across the
device. As this pressure differential is increased,
the velocity through the restriction increases
(increasing flow) and the vena contracta pressure
decreases. If a sufficiently large pressure
differential is imposed upon the device, the
minimum pressure may decrease to, or below, the
vapor pressure of the liquid under these
conditions. When this occurs the liquid becomes
thermodynamically unstable and partially
vaporizes. The fluid now consists of a liquid and
vapor mixture that is no longer incompressible.
42
While the exact mechanisms of liquid choking are
not fully confirmed, there are parallels between
this and critical flow in gas applications. In gas
flows, the flow becomes critical (choked) when the
fluid velocity is equal to the acoustic wave speed
at that point in the fluid. Pure incompressible fluids
have high wave speeds and, practically speaking,
they do not choke. Liquid-to-gas or liquid-to-vapor
mixtures, however, typically have low acoustic
wave speeds (actually lower than that for a pure
gas or vapor), so it is possible for the mixture
velocity to equal the sonic velocity and choke the
flow.
Another way of viewing this phenomenon is to
consider the density of the mixture at the vena
contracta. As the pressure decreases, so does the
density of the vapor phase, hence, the density of
the mixture decreases. Eventually, this decrease
in density of the fluid offsets any increase in the
velocity of the mixture to the point where no
additional mass flow is realized.
It is necessary to account for the occurrence of
choked flow during the sizing process so that
undersizing of a valve does not occur. In other
words, knowing the maximum flow rate a valve
can handle under a given set of conditions is
necessary. To this end, a procedure was
developed which combines the control valve
pressure recovery characteristics with the
thermodynamic properties of the fluid to predict
the maximum usable pressure differential, i.e. the
pressure differential at which the flow chokes.
A pressure recovery coefficient can be defined as:
K
m
+
P
1
* P
2
P
1
* P
vc
(32)
Under choked flow conditions, it is established
that:
P
vc
+ r
c
P
v
(33)
The vapor pressure, P
v
, is determined at inlet
temperature because the temperature of the liquid
does not change appreciably between the inlet
and the vena contracta. The term r
c
is known as
the critical pressure ratio, and is another
thermodynamic property of the fluid. While it is
actually a function of each fluid and the prevailing
conditions, it has been established that data for a
variety of fluids can be generalized, according to
figure 4-2 or the following equation, without
significantly compromising overall accuracy:
Figure 4-2. Generalized r
c
Curve
A3443 / IL
r
c
+ F
F
+ 0.96 * 0.28
P
vc
P
c

(34)
The value of K
m
is determined individually by test
for each valve style and accounts for the pressure
recovery characteristics of the valve.
By rearranging equation sixteen, the pressure
differential at which the flow chokes can be
determined is known as the allowable pressure
differential:
(P
1
* P
2
)
allowable
+ K
m
(P
1
* r
c
P
v
)
(35)
When this allowable pressure differential is used in
the equation below (equation 14 from chapter 3),
the choked flow rate for the given valve will result.
Q + C
v
P
1
* P
2
G

If this flow rate is less than the required service

flow rate, the valve is undersized. It is then
necessary to select a larger valve, and repeat the
calculations using the new values for C
v
and K
m
.
The equations supplied in the sizing standard are,
in essence, the same as those presented in this
chapter, except the nomenclature has been
changed. In this case:
Q
max
+ N
1
F
L
C
v
P
1
* F
F
P
v
G

(36)
43
Figure 4-3. Typical Cavitation Damage
W1350
where:
F
L
= K
m

F
F
= rc
N
1
= units factor
Cavitation
Closely associated with the phenomenon of
choked flow is the occurrence of cavitation. Simply
stated, cavitation is the formation and collapse of
cavities in the flowing liquid. It is of special
concern when sizing control valves because if left
unchecked, it can produce unwanted noise,
vibration, and material damage.
As discussed earlier, vapor can form in the vicinity
of the vena contracta when the local pressure falls
below the vapor pressure of the liquid. If the outlet
pressure of the mixture is greater than the vapor
pressure as it exits the valve, the vapor phase will
be thermodynamically unstable and will revert to a
liquid. The entire liquid-to-vapor-to-liquid phase
change process is known as cavitation, although
it is the vapor-to-liquid phase change that is the
primary source of the damage. During this phase
change a mechanical attack occurs on the
material surface in the form of high velocity
micro-jets and shock waves. Given sufficient
intensity, proximity, and time, this attack can
remove material to the point where the valve no
longer retains its functional or structural integrity.
figure 4-3 shows an example of such damage.
Cavitation and the damage it causes are complex
processes and accurate prediction of key events
such as damage, noise, and vibration level is
difficult. Consequently, sizing valves for cavitation
conditions requires special considerations.
Figure 4-4. Comparison of High and Low Recovery Valves
A3444
The concept of pressure recovery plays a key role
in characterizing a valves suitability for cavitation
service. A valve that recovers a significant
percentage of the pressure differential from the
inlet to the vena contracta is appropriately termed
a high recovery valve. Conversely, if only a small
percent is recovered, it is classified as a low
recovery valve. These two are contrasted in figure
4-4. If identical pressure differentials are imposed
upon a high recovery valve and a low recovery
valve, all other things being equal, the high
recovery valve will have a relatively low vena
contracta pressure. Thus, under the same
conditions, the high recovery valve is more likely
to cavitate. On the other hand, if flow through
each valve is such that the inlet and vena
contracta pressures are equal, the low recovery
valve will have the lower collapse potential
(P
2
P
vc
), and cavitation intensity will generally be
less.
Therefore, it is apparent that the lower pressure
recovery devices are more suited for cavitation
service.
The possibility of cavitation occurring in any liquid
flow application should be investigated by
checking for the following two conditions:
1. The service pressure differential is
approximately equal to the allowable pressure
differential.
2. The outlet pressure is greater than the vapor
pressure of the fluid.
44
Figure 4-5. Pressure Profiles for Flashing
and Cavitating Flows
A3445
If both of these conditions are met, the possibility
exists that cavitation will occur. Because of the
potentially damaging nature of cavitation, sizing a
valve in this region is not recommended. Special
purpose trims and products to control cavitation
should be considered. Because of the great
diversity in the design of this equipment, it is not
possible to offer general guidelines for sizing
valves with those specialized trims. Please refer to
specific product literature for additional
information.
Cavitation in Pulp Stock
Cavitation behavior in low consistency pulp stock
(less than 4%) is treated as equivalent to that of
water. Generally, pulp stock consistency greater
than 4% is not known to be problematic, as the
stock itself absorbs the majority of the energy
produced by the cavitating microjets.
Flashing
Flashing shares some common features with
choked flow and cavitation in that the process
begins with vaporization of the liquid in the vicinity
of the vena contracta. However, in flashing
applications, the pressure downstream of this
point never recovers to a value that exceeds the
vapor pressure of the fluid. Thus, the fluid remains
in the vapor phase. Schematic pressure profiles
for flashing and cavitating flow are contrasted in
figure 4-5.
Flashing is of concern not only because of its
ability to limit flow through the valve, but also
because of the highly erosive nature of the
liquid-vapor mixture. Typical flashing damage is
smooth and polished in appearance (figure 4-6) in
Figure 4-6. Typical Flashing Damage
W2842
stark contrast to the rough, cinder-like appearance
of cavitation (figure 4-3).
If P
2
< P
v
, or there are other service conditions to
indicate flashing, the standard sizing procedure
should be augmented with a check for choked
flow. Furthermore, suitability of the particular valve
style for flashing service should be established
with the valve manufacturer. Selection guidelines
will be discussed later in the chapter.
Viscous Flow
One of the assumptions implicit in the sizing
procedures presented to this point is that of fully
developed, turbulent flow. Turbulent flow and
laminar flow are flow regimes that characterize the
behavior of flow. In laminar flow, all fluid particles
move parallel to one another in an orderly fashion
and with no mixing of the fluid. Conversely,
turbulent flow is highly random in terms of local
velocity direction and magnitude. While there is
certainly net flow in a particular direction,
instantaneous velocity components in all directions
are superimposed on this net flow. Significant fluid
mixing occurs in turbulent flow. As is true of many
physical phenomena, there is no distinct line of
demarcation between these two regimes. Thus, a
third regime of transition flow is sometimes
recognized.
The physical quantities which govern this flow
regime are the viscous and inertial forces; this
ratio is known as the Reynolds number. When the
viscous forces dominate (a Reynolds number
below 2,000) the flow is laminar, or viscous. If the
inertial forces dominate (a Reynolds number
above 3,000) the flow is turbulent, or inviscid.
Consideration of these flow regimes is critical
because the macroscopic behavior of the flow
changes when the flow regime changes. The
primary behavior characteristic of concern in sizing
is the nature of the available energy losses. In
earlier discussion it was asserted that, under the
assumption of inviscid flow, the available energy
45
Figure 4-7. Viscous Flow Correction Factors
A3446
losses were proportional to the square of the
velocity.
In the laminar flow regime, these same losses are
linearly proportional to the velocity; in the
transitional regime, these losses tend to vary.
Thus, for equivalent flow rates, the pressure
differential through a conduit or across a
restriction will be different for each flow regime.
To compensate for this effect (the change in
resistance to flow) in sizing valves, a correction
factor was developed. The required C
v
can be
determined from the following equation:
C
v
reqd
+ F
R
C
v
rated
(37)
The factor F
R
is a function of the Reynolds
number and can be determined from a simple
nomograph procedure, or by calculating the
Reynolds number for a control valve from the
following equation and determining F
R
from figure
4-7.
Re
v
+
N
4
F
d
Q
nF
L
12C
v
12

1
N
2
(F
L
)
2

C
v
d
2

2
) 1
14
(38)
To predict flow rate, or resulting pressure
differential, the required flow coefficient is used in
place of the rated flow coefficient in the
appropriate equation.
When a valve is installed in a field piping
configuration which is different than the specified
test section, it is necessary to account for the
effect of the altered piping on flow through the
valve. (Recall that the standard test section
consists of a prescribed length of straight pipe up
and downstream of the valve.) Field installation
may require elbows, reducers, and tees, which will
induce additional losses immediately adjacent to
the valve. To correct for this situation, two factors
are introduced:
D F
p
D F
lp
Factor F
p
is used to correct the flow equation
when used in the incompressible range, while
factor F
lp
is used in the choked flow range. The
expressions for these factors are:
F
p
+
SK
N
2

C
v
d
2

2
) 1
*12
(39)
F
Ip
+ F
L

F
L

2
K
I
N
2

C
v
d
2

2
) 1
*12
(40)
The term K in equation 39 is the sum of all loss
coefficients of all devices attached to the valve
and the inlet and outlet Bernoulli coefficients.
Bernoulli coefficients account for changes in the
kinetic energy as a result of a cross-sectional flow
area change. They are calculated from the
following equations.
K
B
inlet
+ 1 * (dD)
4
(41a)
K
B
outlet
+ (dD)
4
* 1
(41b)
Thus, if reducers of identical size are used at the
inlet and outlet, these terms cancel out.
The term K
I
in equation 40 includes the loss
coefficients and Bernoulli coefficient on the inlet
side only.
In the absence of test data or knowledge of loss
coefficients, loss coefficients may be estimated
from information contained in other resources.
The factors F
p
and F
I
would appear in flow
equations 31 and 36 respectively as follows:
For incompressible flow:
Q + F
p
C
v
P
1
* P
2
G

(42)
46
Figure 4-8. The implosion of cavitation vapor cavities is rapid, asymmetric and very energetic. The mechanics of
collapse give rise to high velocity liquid jets, which impinge on metallic surfaces. Ultimately, the metal fatigues and
breaks away in small pieces.
E0111
For choked flow:
Q
max
+ F
I
C
v
P
1
* F
F
P
v
G

(43)
Valve Material Damage
Cavitation damage is usually the most
troublesome side effect plaguing the control valve
industry. It does not take many examples of such
damage to fully demonstrate the destructive
capabilities of cavitation.
Typically, cavitation damage is characterized by
an irregular, rough surface. The phrase
cinder-like appearance is used frequently to
describe cavitation damage. It is discernible from
other types of flow damage such as erosion and
flashing damage which are usually smooth and
shiny in appearance. This next section will deal
with cavitation damage, although most of the
comments can also apply to flashing damage. A
comparison of figures 4-3 and 4-6 illustrates these
differences.
While the results of cavitation damage are all too
familiar, the events and mechanisms of the
cavitation damage process are not known or
understood completely in spite of extensive study
over the years. There is general agreement,
however, on a number of aspects of the process
and consistency in certain observations.
Cavitation damage has been observed to be
associated with the collapse stage of the bubble
dynamics. Furthermore, this damage consists of
two primary events or phases:
1. An attack on a material surface as a result of
cavitation in the liquid.
2. The response or reaction of the material to the
attack.
Any factor that influences either of these events
will have some sort of final effect on the overall
damage characteristics.
The attack stage of the damage process has been
attributed to various mechanisms, but none of
them account for all the observed results. It
appears that this attack involves two factors that
interact in a reinforcing manner:
1. Mechanical attack
2. Chemical attack
There is evidence indicating the almost universal
presence of a mechanical attack component which
can occur in either of two forms:
1. Erosion resulting from high-velocity microjets
impinging upon the material surface.
2. Material deformation and failure resulting from
shock waves impinging upon the material surface.
In the first type of mechanical attack a small,
high-velocity liquid jet is formed during the
asymmetrical collapse of a vapor bubble. If
orientation and proximity of the jets is proper, a
damaging attack occurs on the metal surface as
shown in figure 4-8. This is the most probable
form of mechanical attack. High-speed
cinematography, liquid drop impingement
comparisons, and various analytical studies
support its presence.
The second type of mechanical attack, shock
wave impingement, does not appear to be as
47
dominant. Analytical estimations of vapor bubble
collapse pressures do not suggest that the shock
waves are on a damaging order of magnitude
at least during the initial collapse. Experimental
studies bear this out. They also reveal that
resulting collapse pressures increase in magnitude
with subsequent rebound collapses and become
potentially damaging.
The other primary component of attack, chemical
attack, is perhaps more significant because it
interacts with the mechanical component rather
than acting by itself. After a period of mechanical
attack, many of the protective coatings of a
material (films, oxides, etc.) are physically
removed, making the base material more
vulnerable to chemical attack.
Just as a number of variables have an affect on
the behavior of individual cavities, a number of
variables influence the degree and extent of
material damage. The principal variables that
influence cavitation damage include air content,
pressure, velocity and temperature.
Air content impacts cavitation damage primarily
through its effect on cavity mechanics. Again, two
opposing trends are evident on increasing the
amount of air. Adding air supplies more entrained
air nuclei which, in turn, produce more cavities
that can increase the total damage. After a point,
however, continued increases in air content
disrupt the mechanical attack component and
effectively reduce the total damage.
Pressure effects also exhibit two opposing trends.
Given a fixed inlet pressure P
1
, decreasing the
backpressure P
2
tends to increase the number of
cavities formed, which creates a worse situation.
However, a lower backpressure also creates a
lower collapse pressure differential (P
2
P
v
),
resulting in a decrease in the intensity of the
cavitation.
An additional pressure effect, unrelated to the
above, concerns the location of damage. As the
backpressure is changed, the pressure required to
collapse the cavities moves upstream or
downstream depending upon whether the
pressure is increased or decreased, respectively.
In addition to a change in the severity of the total
damage, there may be an accompanying change
in the physical location of the damage when
pressure conditions are altered.
It should now be apparent that the cavitation and
flashing damage process is a complex function of:
1. Intensity and degree of cavitation (cavitation
attack)
2. Material of construction (material response)
3. Time of exposure
While the above-mentioned influences have been
observed, they remain to be quantified. Often,
experience is the best teacher when it comes to
trying to quantify cavitation damage.
Noise
Although the noise associated with a cavitating
liquid can be quite high, it is usually of secondary
concern when compared to the material damage
that can exist. Therefore, high intensity cavitation
should be prevented to decrease the chance of
material damage. If cavitation is prevented, the
noise associated with the liquid flow will be less
than 90 dBA.
For a flashing liquid, studies and experience have
shown that the noise level associated with the
valve will be less than 85 dBA, regardless of the
pressure drop involved to create the flashing.
Cavitation / Flashing Damage
Coefficients and Product Selection
Cavitation in control valves can be an application
challenge. It is important to understand the
guidelines when selecting an appropriate valve
and trim. Experience, knowledge of where
cavitation problems begin, and the effect of valve
size and type, are all useful in deciding which
valve and trim can be used.
Terminology
F
L
: Pressure recovery coefficient. A valve
parameter used to predict choked flow.
P
max
: Allowable sizing pressure drop. The
limiting pressure drop beyond which any increase
in pressure drop brought about by decreasing P
2
will not generate additional flow through the valve.
Therefore the valve is choked. Per equation 28
of chapter 3:
DP
max(L)
+ F
L
2
(P
1
* F
F
P
v
)
where,
P
1
= Upstream absolute static pressure
P
v
= Absolute vapor pressure at inlet temperature
48
F
F
= the liquid critical pressure ratio factor. Can be
obtained from the following equation:
F
F
+ 0.96 * 0.28
P
v
P
c

K
c
: Cavitation coefficient. A valve parameter
dependent upon valve style and trim. It predicts
the beginning of cavitation related damage and
vibration problems for a particular valve/trim style.
DP
Cavitation
+ K
c
(P
1
* P
v
)
A
r
: Application ratio. A cavitation index which is
dependent upon the actual service conditions. It
indicates the presence of flashing or potentially
cavitating services.
A
r
+ (DP
Flow
) (P
1
* P
v
)
K
i
: Incipient cavitation coefficient. A valve
parameter which predicts the point of initial
generation and collapse of vapor bubbles.
(Specific values of K
i
are generally not available).
DP
Incipient Cav.
+ K
i
(P
1
* P
v
)
Valve Selection Coefficient Criteria and
Selection Procedure
1. Determine P
Flowing
(P
Flow
)
2. Calculate A
r
a. If A
r
1.0, the service is flashing.
b. If A
r
1.0, the service is potentially
cavitating.
3. Use P
Flow
and A
r
in conjunction with the K
c
values of valve trim P limits and K
c
indices, as
well as other valve selection criteria (P
1
, temp.,
style, etc.), to make a valve selection.
The cavitation coefficient (K
c
) is based upon valve
type and pressure drop limit. Select a valve/trim
that has a P limit higher than the service P
Flow
and a K
c
higher that the service A
r
.
Application Guidelines
Guidelines (including A
r
and K
c
ratios) were
developed to help select the proper valve
construction when cavitation is present. These
guidelines are intended to provide valve selections
free of cavitation related material and vibration
damage over the long term. The guidelines do not
indicate an absence of cavitation. Thus, noise due
to cavitation may still be present. If noise is a
concern, use hydrodynamic noise prediction to
assist in selecting a valve.
The following restrictions apply to these
guidelines:
D Water only
D Customer requirements that may require use
of different guidelines
Examples:
D Long maintenance intervals
D Very low noise requirements
D Different fluids
D Corrosive an/or erosive environment
D Installation limitations
D Valve usage rate
These guidelines will aid in selecting a valve and
trim designed to help prevent cavitation damage
and thus offer long term valve life in potentially
cavitating services.
For detailed cavitating service valve selection
guidelines, please contact your local sales office.
Additional Guidelines
D For all valve styles and sizes, applying
backpressure to the valve can eliminate cavitation.
This solution is most effective when the service
conditions do not vary widely.
D Fluids information:
Cold water is the most common problem
fluid.
Pure component fluids, similar to water,
can also cause problems.
Fluid mixtures, like that of pulp stock, can
be less damaging even when the numbers
indicate cavitation is present. Experience is
most useful here.
These guidelines have been constructed from a
broad base of experience. There are undoubtedly
exceptions to these guidelines and, as always,
49
recent experience should be used to select the
best valve for specific applications.
Hardware Choices for Flashing
Applications
It was stated previously that flashing is a liquid
flow phenomenon that is defined by the system,
and not by the valve design. Therefore, since
flashing cannot be prevented by the control valve,
all that can be done is to prevent flashing damage.
There are three main factors that affect the
amount of flashing damage in a control valve:
1. Valve design
2. Materials of construction
3. System design
Valve Design
While valve design has no bearing upon whether
flashing does or does not occur, it can have a
large impact on the intensity of flashing damage.
Generally, there are two valve designs that are
more resistant to flashing damage.
An angle valve with standard trim in the flow down
direction and with a downstream liner is perhaps
the best solution to preventing flashing damage.
figure 4-9 shows a typical angle valve for flashing
service.
This construction is an excellent choice because
flashing damage occurs when high velocity vapor
bubbles impinge on the surface of a valve. An
angle valve reduces the impingement by directing
flow into the center of the downstream pipe, not
into the valve body. If damage does occur, the
downstream liner can be replaced much more
economically than the valve body.
A rotary plug style of valve is also an excellent
choice for medium to low pressure flashing
applications. This valve can be installed with the
plug facing the downstream side of the body
(figure 4-10) so when flashing occurs, it does so
downstream of the valve. In some cases, a spool
piece of sacrificial pipe is used to absorb the
flashing damage.
Materials of Construction
There are several factors that determine the
performance of a given material in a particular
flashing and/or cavitating situation including the
materials toughness, hardness, and its corrosion
Figure 4-9. Fisher EAS valve with outlet liner is
used for flashing service. The liner resists
erosion and protects the body.
W0970
RESTRICTED-TRIM
ADAPTOR
LINER
resistance in the application environment. Within a
given material family (e.g. the 400-series stainless
steels), hardness is a fairly accurate method for
ranking materials. However, when comparing
materials from different families, hardness does
not correlate with overall resistance to damage.
For example, cobalt-chromium-tungsten based
alloy 6 has much more resistance to cavitation
and flashing than either hardened type 410 or 17-4
stainless steels, even though they all exhibit
roughly the same hardness. In fact, alloy 6 equals
or exceeds the performance of many materials
with a hardness of 60 HRC and higher. The
superior performance of alloy 6 is attributed to a
built-in energy-absorbing mechanism shared by
a number of cobalt-base alloys.
Materials commonly used for flashing and
cavitating services are alloy 6 (solid and overlays),
nickel-chromium-boron alloys (solid and overlays),
hardened 440C stainless steel, hardened 17-4
stainless steel, and hardened 410/416 stainless
steel.
Because the standard materials used in valve
bodies are relatively soft, selection for cavitation and
flashing resistance must rely upon factors other than
hardness. In general, as the chromium and
molybdenum contents increase, the resistance to
damage by both cavitation and flashing increase.
Thus, the chromium-molybdenum alloy steels have
410
Figure 4-10. Rotary plug valves, such as the V500 Vee-Ball valve(reverse flow trim direction, trim level 3) have excellent
erosion resistance and perform well in flashing service
W8359
better resistance than the carbon steels, and the
stainless steels have even better resistance than the
chromium-molybdenum alloy steels.
In the past, ASME SA217 grade C5 was the most
commonly specified chromium-molybdenum alloy
steel. However, because of the poor casting,
welding, and manufacturing characteristics of C5,
ASME SA217 grade WC9 has become a more
popular alternative. Experience indicates that WC9
performs on par with C5 in cavitation and flashing
services despite its lower chromium content
(2-1/4% vs. 5%). This is apparently because its
higher molybdenum content (1% vs. 1/2%) makes
up for the lower chromium content.
ASTM A217 grade C12A is becoming more
common in the power industry. This material has
excellent high temperature properties, and is
typically used at temperatures exceeding 1000F
(538C). Its higher chromium and molybdenum
contents (9% Cr, 1% Mo) would indicate excellent
cavitation resistance.
While angle bodies are a better choice for flashing
applications than globe bodies, they are also a
more economical choice in most cases. This is
because carbon steel bodies can be used in an
angle valve with an optional hardened downstream
liner (17-4PH SST or alloy 6) because only the
downstream portion of the valve will experience
the flashing liquid (see figure 4-9). If a globe valve
is used, it is better to use a
chromium-molybdenum alloy steel body because
the flashing will occur within the body itself.
Figure 4-11. Location of a control valve can often
be changed to lengthen its life or allow use of less
expensive products. Mounting a heater drain valve
near the condenser is a good example.
E0864
System Design
This section discusses system design where it is
assumed flashing will occur. The optimum position
of the valve in a flashing service can have a great
impact on the success of that valve installation.
Figure 4-11 shows the same application with the
exception of the location of the control valve.
These figures are fairly representative of a valve
that controls flow to a condenser. In the top
illustration, the flashing will occur in the
downstream pipe between the control valve and
the tank. Any damage that occurs will do so in that
downstream piping area. In the bottom illustration,
the flashing will occur downstream of the valve
within the tank.
Because the tank has a much larger volume
compared to the pipe, high velocity fluid
411
impingement on a material surface will not occur
as there is essentially no material surface. This
system design will help prevent flashing damage.
Hardware Choices for Cavitating
Applications
The design of a control valve greatly affects the
ability of a valve to control cavitation. This section
discusses the theories behind each type of trim
design that is used for cavitation control and also
reviews each type of Fisher trim used to control
cavitation.
The design theories or ideas behind the various
trim designs include:
D Tortuous path
D Pressure drop staging
D Expanding flow area
D Drilled hole design
D Characterized cage
D Separation of seating and throttling locations
D Cavitation control in lieu of prevention
Tortuous Path
Providing a tortuous path for the fluid through the
trim is one way to lower the amount of pressure
recovery of that trim. Although this tortuous path
can be in the form of drilled holes, axial flow
passages or radial flow passages, the effect of
each design is essentially the same. The use of a
tortuous path design concept is used in virtually
every cavitation control style of hardware.
Pressure Drop Staging
This approach to damage control routes flow
through several restrictions in series, as opposed
to a single restriction. Each restriction dissipates a
certain amount of available energy and presents a
lower inlet pressure to the next stage.
A well-designed pressure-staging device will be
able to take a large pressure differential while
maintaining the vena contracta pressure above the
vapor pressure of the liquid, which prevents the
liquid from cavitating.
Figure 4-12. In Cavitrol trim, the pressure drop is
staged in two or more unequal steps. Staging is
accomplished by increasing the flow area from
stage to stage. This stepped reduction allows full
pressure drop without the vena contracta pressure
falling below the vapor pressure of the liquid.
A2149-1
For the same pressure differential then, the vena
contracta pressure in conventional trim will be
lower than for the staged trim, and the liquid will
be more prone to cavitate.
Trims that dissipate available energy have an
additional advantage. If the design pressure
differential is exceeded and cavitation does occur,
the intensity will be less. This is because the
pressure that causes the collapse of cavities (i.e.,
the recovered pressure) will be less.
Expanding Flow Areas
The expanding flow area concept of damage
control is closely related to the pressure drop
staging concept. Figure 4-12 shows a pressure
versus distance curve for flow through a series of
fixed restrictions where the area of each
succeeding restriction is larger than the previous.
Notice that the first restriction takes the bulk of the
pressure drop, and the pressure drop through
successive sections decreases.
412
Figure 4-13. By combining the geometric effects of
thick plates and thin plates, it is possible to design
a flow passage that optimizes capacity and
recovery coefficient values. These carefully
designed passages are used exclusively in
Cavitrol cages.
E01131
In the last restriction, where cavitation is most
likely to occur, the pressure drop is only a small
percentage of the total drop, and the pressure
recovery is substantially lowered.
The expanding flow area concept requires fewer
pressure drop stages to provide the same
cavitation protection as the equal area concept.
Because the pressure drop of the last stage is
rather low compared to the total pressure drop, if
cavitation does occur, the intensity and cavitation
damage will be much less.
Drilled Hole Design
Drilled hole cages are used in the Fisher Cavitrolt
cavitation control trim line to provide a tortuous
path, pressure drop staging, and expanding flow
area. The design of each particular drilled hole has
a significant impact on the overall pressure
recovery of the valve design.
Figure 4-13 illustrates a cross section of three
types of drilled holes that could be used in a
cavitation control cage. The thin plate design is an
inefficient flow device, but it does provide a high
F
L
2
and, therefore, a low pressure recovery. The
thick plate design provides an efficient design, but
also provides a high pressure recovery as denoted
by a low F
L
2
value.
The Cavitrol trim hole design is a balance between
the thick plate and the thin plate hole designs. It
provides relatively high flow efficiency while
maintaining a high F
L
2
, which results in a low
pressure recovery. This design represents the
optimal choice between capacity and cavitation
control.
Another benefit of this type of drilled hole design is
that the vena contracta point is further from the
exit of the hole when compared to a straight
through drilled hole. Consequently, if pressure
recovery above the vapor pressure occurs
(cavitation), it will do so further away from the
external wall of the cage, and the amount of
damage will be smaller.
One disadvantage of cavitation control trims is the
potential for flow passages to become plugged
with sand, dirt or other debris. Particulate laden
flow is common to water injection applications.
The flowing media often times contains small
particulate that can plug the passages, restricting
or totally stopping flow through the valve. If this
potential exists, the particles must be removed
from the flow stream, usually by filtration or an
alternative approach to cavitation should be taken.
An alternative is to use a trim that is designed to
allow the particulate to pass, but still control
cavitation. The Fisher Dirty Service Trim (DST)
has been designed to allow particles up to 3/4 to
be passed and to control cavitation up to pressure
drops of 4000 psi. This trim has been used
extensively in produced water injection, water
injection pump recirculation, and other liquid flow,
particulate containing, high pressure drop
applications.
Characterized Cage
The characterized cage design theory has evolved
from the fact that capacity is inversely related to a
designs ability to prevent cavitation. In those
applications where the pressure drop decreases
as the flow rate increases, characterized cages
can be used to optimize cavitation prevention and
capacity.
For a Cavitrol III trim design, as the travel
increases, the cage design changes. It begins as
a pressure-staging design and then develops into
a straight-through hole design. Consequently, the
cavitation control ability of this trim design is
greatest at low travels and decreases with
increasing valve plug travel.
Care should be taken to employ characterized
cages only in applications where the pressure
drop decreases as travel increases.
413
Figure 4-14. Cavitrol IV trim provides cavitation
protection at pressures to 6500 psi. It uses
expanding flow areas to affect a four-stage
pressure drop. All significant pressure drop is
taken downstream of the shutoff seating surface.
W36681
Separate Seating and Throttling
Locations
In a modern power plant, most cavitating
applications require a control valve to not only
provide cavitation control, but also provide tight
shutoff. The best way to accomplish this is to
separate the throttling location from the seating
location as shown in figure 4-14. The seating
surface of the plug is upstream of the throttling
location, and the upper cage is designed such that
it takes very little pressure drop. The seating
surface experiences relatively low flow velocities
as velocity is inversely related to pressure. A
recent technological advancement has been to
implement the use of a softer seating material
relative to the material of the plug. This allows for
a slight deformation of the seating material, which
provides much better plug/seat contact and, as a
result, greatly enhanced shutoff capability. Valves
utilizing this soft seating material are capable of
providing Class VI shutoff.
Cavitation Control Hardware
Alternatives
In the previous sections, theories behind modern
types of cavitation control hardware were
discussed. This section presents alternatives to
the, sometimes, costly cavitation hardware.
Guidelines are also presented to help determine
when cavitation control hardware is required or
when other alternatives can be employed.
System Design
Correct liquid system design is the most
economical way to prevent the damaging effects
caused by cavitation without applying cavitation
prevention control valves. Unfortunately, even the
best system design is likely to need cavitation type
control valves, but by applying certain design
features, the complexity of these control valves
may be simplified.
The most common and oldest method of
designing a liquid flow system where large
pressure drops must occur is to use a standard
trim control valve with a downstream
backpressure device. Although these devices
come in various sizes, shapes, and designs, they
all perform the same function of lowering the
pressure drop across the control valve by raising
its downstream pressure.
Because the downstream pressure of the valve is
increased, the vena contracta pressure is
increased. If the backpressure device is sized
correctly, the vena contract pressure will not fall
below the vapor pressure, and cavitation will not
occur.
While this is a simple and cost-effective way to
prevent cavitation damage in the control valve,
there are several serious considerations to look at
before using a downstream backpressure device.
D A larger valve may be required to pass the
required flow as the pressure drop is lowered.
D Although cavitation may not occur at the
control valve, it may occur at the backpressure
device.
D The backpressure device can only be sized
for one condition. If other conditions exist, the
414
backpressure provided may allow cavitation to
occur.
D If the backpressure device becomes worn,
the backpressure will decrease and cavitation in
the valve may occur.
Another disadvantage that is rarely mentioned
occurs when a valve is opened against a high
upstream pressure. Until the flow reaches the
backpressure device and stabilizes, the valve will
experience the entire pressure drop of the system.
Although this may only occur for a short period of
time, the potential for damage exists.
In the instance of rotary valves, air injection
(known as aspiration) also can be used to
minimize the effects of cavitation in a system. With
this method, air is injected upstream of the vena
contracta. The dispersed air acts as a buffer when
the vapor bubbles implode so that the intensity of
the cavitation is lowered. Unfortunately, the
location of the vena contracta, the amount of air to
be injected, etc. are hard to quantify.
Because air is being injected into the system, this
method of cavitation control is usually used on
large valves dumping to a tank or pond or where
solids in the system prevent the use of other
cavitation control devices.
Cavitation is an interesting but destructive
phenomenon. Preventing cavitation is the most
acceptable way of limiting potential for damage.
Proper application of available products, based
upon sizing equations and field experience, will
provide long term success.
Summary
The past two chapters have indicated that a
fundamental relationship exists between key
variables (P
1
, P
2
, P
v
, G, C
v
, Q) for flow through a
device such as a control valve. Knowledge of any
four of these allows the fifth to be calculated or
predicted. Furthermore, adjustments to this basic
relationship are necessary to account for special
considerations such as installed piping
configuration, cavitation, flashing, choked flow,
and viscous flow behavior. Adherence to these
guidelines will ensure correct sizing and optimum
performance.
It is important to understand that pulp stock flow
exhibits characterizations that closely resemble
those of water. Guidelines for hindering the effects
of cavitation are based upon process testing using
water. One must consider that a pulp stock
multi-phase flow may result in less severe damage
when compared to that of water for flashing,
cavitation, or turbulent flow. However, it must be
noted that pulp stock can lead to other issues
such as erosion and corrosion, depending on
process make-up and the materials used in the
process. Therefore, it is important to understand
the process media, as well as firm process
conditions, in order to ensure the correct valve is
properly sized and selected for the given severe
service application.
As noted throughout the chapter, it is evident that
severe flow phenomena through a control valve
can occur under the proper conditions. In general,
the most common liquid severe service
applications involve either cavitation or flashing. It
is important to have a basic understanding of both
liquid service incidents as presented in this
chapter.
www.Fisher.com
Chapter 5
Gas Sizing
This chapter addresses the six-step procedure for
sizing control valves for compressible flow using
the standardized ISA procedure. All six steps are
outlined below, and must be accounted for when
sizing a valve for compressible flow. Steps three
and four are involved in determining specific sizing
factors that may or may not be required in the
sizing equation depending on the service
conditions of the application. When steps three
and/or four are required, refer to the appropriate
section of the book referenced below.
Standardized ISA Procedure
1. Specify the necessary variables required to
size the valve as follows:
D Desired valve design (globe, butterfly, ball)
D Process fluid (air, natural gas, steam, etc.)
D Appropriate service conditions (q, or w, P
1
,
P
2
or DP, T
1
, G
g
, M, k, Z, and g
1
)
The ability to recognize the appropriate terms for a
specific valve sizing application is gained through
experience sizing valves for different applications.
Refer to the notations table in chapter three for
any new or unfamiliar terms.
2. Determine the equation constant, N.
N is a numerical constant contained in each of the
flow equations to provide a means for using
different systems of units. Values for these various
constants and their applicable units are given in
the equation constants table 5-2 at the end of this
chapter.
Use N
7
or N
9
when sizing a valve with a specified
flow rate in volumetric units (scfh or m
3
/h).
Selecting the appropriate constant depends upon
the specified service conditions. N
7
is used only
when specific gravity, G
g
, has been specified
along with the other required service conditions.
N
9
is used only when the molecular weight, M, of
the gas has been specified.
Use N
6
or N
8
when sizing a valve with a specified
flow rate in mass units (lb/h or kg/h). In this case,
N
6
is used only when specific weight, g
1
, has been
specified along with the other required service
conditions. N
8
is used only when the molecular
weight, M, of the gas has been specified.
3. Determine F
p
, the piping geometry factor.
F
p
is a correction factor that accounts for any
pressure losses due to piping fittings such as
reducers, elbows, or tees that might be attached
directly to the inlet and outlet connections of the
control valve. If such fittings are attached to the
valve, the F
p
factor must be considered in the
sizing procedure. If no fittings are attached to the
valve, F
p
has a value of one and drops out of the
sizing equation.
For rotary valves with reducers, other valve
designs and fitting styles refer to the determining
piping geometry section of chapter three to
determine the appropriate F
p
value.
4. Determine Y, the expansion factor.
Y + 1 *
x
3F
k
x
T
where,
F
k
= k/1.4, the ratio of specific heats factor
k = Ratio of specific heats
x = DP/P
1
x
T
= The pressure drop ratio factor for valves
installed without attached fittings. More
definitively, x
T
is the pressure drop ratio required
52
to produce critical, or maximum, flow through the
valve when F
k
= 1.0
When the control valve to be installed has fittings,
such as reducers or elbows attached to it, their
effect is accounted for in the expansion factor
equation by replacing the x
T
term with a new
factor x
TP
. A procedure for determining the x
TP
factor is described in the following section:
Determining x
TP
, the Pressure Drop Ratio Factor.
Note: Conditions of critical pressure
drop are realized when the value of x
becomes equal to or exceeds the
appropriate value of the product of
either F
k
*x
T
or F
k
*x
TP
at which
point::
y + 1 *
x
3F
k
x
T
+ 1 * 13 + 0.667
In actual service, pressure drop ratios can, and
often will exceed the indicated critical values. At
this point, critical flow conditions develop. Thus,
for a constant P
1
, decreasing P
2
(i.e., increasing
DP) will not result in an increase in the flow rate
through the valve. Therefore, the values of x
greater than the product of either F
k
*x
T
or F
k
*x
TP
must never be substituted in the expression for Y.
This means that Y can never be less than 0.667.
This same limit on values of x also applies to the
flow equations introduced in the next section.
5. Solve for the required C
V
using the appropriate
equation.
For volumetric flow rate units
D when specific gravity, G
g
, of the gas has
been specified:
C
v
+
q
N
7
F
p
P
1
Y
x
G
g
T
1
Z

D when molecular weight, M, of the gas has

been specified:
C
v
+
q
N
9
F
p
P
1
Y
x
M T
1
Z

For mass flow rate units

D when specific weight, g
1
, of the gas has been
specified:
C
v
+
w
N
6
F
p
Y x P
1
g
1

D when molecular weight, M, of the gas has

been specified:
C
v
+
M
N
8
F
p
P
1
Y
x M
T
1
Z

6. Select the valve size using the appropriate flow

coefficient table using the calculated C
V
value.
Determining x
TP
, the Pressure Drop
Ratio Factor
When the control valve is to be installed with
attached fittings such as reducers or elbows, their
affect is accounted for in the expansion factor
equation by replacing the x
T
term with a new
factor, x
TP
.
x
TP
+
x
T
F
p

2
1 )
x
T
K
i
N
5

C
v
d
2

*1
where,
N
5
= numerical constant found in the equation
constants table
d = assumed nominal valve size
C
V
= valve sizing coefficient from flow
coefficient table at 100% travel for the assumed
valve size
F
p
= piping geometry factor
x
T
= pressure drop ratio for valves installed
without fittings attached. x
T
values are included
in the flow coefficient tables.
In the above equation, K
i
is the inlet head loss
coefficient, which is defined as:
K
i
+ K
1
) K
B1
where,
K
1
= resistance coefficient of upstream fittings
(see the procedure: Determining F
p
, the Piping
Geometry Factor, which is contained in Chapter
3: Liquid Valve Sizing
K
B1
= Inlet Bernoulli coefficient (see the
procedure: Determining F
p
, the Piping
Geometry Factor, which is contained in chapter
three: Liquid Valve Sizing
Compressible Fluid Sizing Sample
Problem No. 1
Assume steam is to be supplied to a process
designed to operate at 250 psig. The supply
53
source is a header maintained at 500 psig and
500_F. A 6-inch line from the steam main to the
process is being planned. Also, make the
assumption that if the required valve size is less
than 6 inches, it will be installed using concentric
reducers. Determine the appropriate ED valve with
a linear cage.
1. Specify the necessary variables required to
size the valve.
D Desired valve designANSI Class 300 ED
valve with a linear cage. Assume valve size is 4
inches.
D Process fluidsuperheated steam
D Service conditions
w = 125,000 lb/h
P
1
= 500 psig = 514.7 psia
P
2
= 250 psig = 264.7 psia
DP = 250 psi
x = DP/P
1
= 250/514.7 = 0.49
T
1
= 500_F
g1
= 1.0434 lb/ft
3
(from properties of
saturated steam table)
k= 1.28 (from properties of saturated steam
table)
2. Determine the appropriate equation constant,
N, from the equation constants table 3-2 in
chapter three.
Because the specified flow rate is in mass units,
(lb/h), and the specific weight of the steam is also
specified, the only sizing equation that can be
used is that which contains the N
6
constant.
Therefore, N
6
= 63.3
3. Determine F
p
, the piping geometry factor.
F
p
+1 )
SK
N
2

C
v
d
2

*12
where,
N
2
= 890, determined from the equation
constants table
d = 4 in.
C
v
= 236, which is the value listed in the flow
coefficient table 4-2 for a NPS 4 ED valve at
100% total travel.
and
SK + K
1
) K
2
+ 1.5

1 *
d
2
D
2

2
+ 1.5

1 *
4
2
6
2

2
+ 0.463
Finally:
F
p
+

1 )
0.463
890

(1.0)(236)
(4)
2

2

*12
+ 0.95
4. Determine Y, the expansion factor.
Y + 1 *
x
3F
k
x
TP
where,
F
k
+
k
1.40
+
1.28
1.40
+ 0.91
x + 0.49(Ascalculatedinstep1.)
Because the size 4 valve is to be installed in a
6-inch line, the x
T
term must be replaced by x
TP
.
x
TP
+
x
T
F
p

2
1 )
x
T
K
i
N
5

C
v
d
2

*1
where,
N
5
= 1000, from the equation constants table
d = 4 inches
F
p
= 0.95, determined in step three
x
T
= 0.688, a value determined from the
appropriate listing in the flow coefficient
table
54
C
v
= 236, from step three
and
K
i
+ K
1
) K
B1
+ 0.51 *
d
2
D
2

2
)1 *
d
D

+ 0.51 *
4
2
6
2

2
)1 *
4
6

+ 0.96
where D = 6 inches
so:
X
TP
+
0.69
0.95
2
1 )
(0.69)(0.96)
1000

236
4
2

*1
+ 0.67
Finally:
Y + 1 *
x
3 F
k
x
TP
+ 1 *
0.49
(3) (0.91) (0.67)
+ 0.73
55
Table 5-1. Abbreviations and Terminology
Symbol Symbol
C
v
Valve sizing coefficient P
1
Upstream absolute static pressure
d Nominal valve size P
2
Downstream absolute static
pressure
D Internal diameter of the piping P
c
Absolute thermodynamic critical
pressure
F
d
Valve style modifier,
dimensionless
P
v
Vapor pressure absolute of liquid at
inlet temperature
F
F
Liquid critical pressure ratio factor,
dimensionless
P Pressure drop (P
1
-P
2
) across the
valve
F
k
Ratio of specific heats factor,
dimensionless
P
max(L)
Maximum allowable liquid sizing
pressure drop
F
L
Rated liquid pressure recovery
factor, dimensionless
P
max(LP)
Maximum allowable sizing pressure
drop with attached fittings
F
LP
Combined liquid pressure recovery
factor and piping geometry factor
of valve with attached fittings
(when there are no attached
fittings, F
LP
equals F
L
),
dimensionless
q Volume rate of flow
F
P
Piping geometry factor,
dimensionless
q
max
Maximum flow rate (choked flow
conditions) at given upstream
conditions
G
f
Liquid specific gravity (ratio of
density of liquid at flowing
temperature to density of water at
60_F), dimensionless
T
1
Absolute upstream temperature
(degree K or degree R)
G
g
Gas specific gravity (ratio of
density of flowing gas to density of
air with both at standard
conditions
(1)
, i.e., ratio of
molecular weight of gas to
molecular weight of air),
dimensionless
w Mass rate of flow
k Ratio of specific heats,
dimensionless
x Ratio of pressure drop to upstream
absolute static pressure (P/P
1
),
dimensionless
K Head loss coefficient of a device,
dimensionless
x
T
Rated pressure drop ratio factor,
dimensionless
M Molecular weight, dimensionless Y Expansion factor (ratio of flow
coefficient for a gas to that for a
liquid at the same Reynolds
number), dimensionless
N Numerical constant Z Compressibility factor,
dimensionless
1
Specific weight at inlet conditions
Kinematic viscosity, centistokes
1. Standard conditions are defined as 60_F (15.5_C) and 14.7 psia (101.3kPa).
56
Table 5-2. Equation Constants
(1)
N w q p
(2)
g T d, D
N
1
0.0865
0.865
1.00
- - -
- - -
- - -
m
3
/h
m
3
/h
gpm
kPa
bar
psia
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
N
2
0.00214
890
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
mm
inch
N
5
0.00241
1000
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
mm
inch
N
6
2.73
27.3
63.3
kg/h
kg/h
lb/h
- - -
- - -
- - -
kPa
bar
psia
kg/m
3
kg/m
3
lb/ft
3
- - -
- - -
- - -
- - -
- - -
- - -
N
7
(3)
Normal Conditions
T
N
= 0_C
3.94
394
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
T
s
= 15.5_C
4.17
417
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
T
s
= 60_F
1360 - - - scfh psia - - - deg R - - -
N
8
0.948
94.8
19.3
kg/h
kg/h
lb/h
- - -
- - -
- - -
kPa
bar
psia
- - -
- - -
- - -
deg K
deg K
deg R
- - -
- - -
- - -
N
9
(3)
Normal Conditions
T
N
= 0_C
21.2
2120
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
Ts = 15.5_C
22.4
2240
- - -
- - -
m
3
/h
m
3
/h
kPa
bar
- - -
- - -
deg K
deg K
- - -
- - -
Standard Conditions
T
S
= 60_F
7320 - - - scfh psia - - - deg R - - -
1. Many of the equations used in these sizing procedures contain a numerical constant, N, along with a numerical
subscript. These numerical constants provide a means for using different units in the equations. Values for the
various constants and the applicable units are given in the above table. For example, if the flow rate is given in U.S.
gpm and the pressures are psia, N
1
has a value of 1.00. If the flow rate is m
3
/hr and the pressures are kPa, the N
1
constant becomes 0.0865.
2. All pressures are absolute.
3. Pressure base is 101.3 kPa (1.013 bar)(14.7 psia).
57
Table 5-3. Flow Coefficient Table
Gas or Liquid Flow
Modified Equal
Percentage Characteristic
Valve
Size,
Inches
Minimum
Throttling
C
V
(1)
Coefficient
s
Valve Rotation, Degrees
10 20 30 40 50 60 70 80 90
8 86.7
C
v
47.3 126 236 382 604 972 1600 3000 4960
K
V
40.9 109 204 330 522 841 1380 2600 4290
F
L
0.79 0.87 0.91 0.91 0.85 0.81 0.73 0.63 0.63
F
d
0.37 0.64 0.78 0.88 0.94 0.97 0.98 0.99 1.00
X
T
0.44 0.64 0.77 0.77 0.67 0.51 0.38 0.20 0.13
10 136
C
v
74.1 197 369 598 946 1520 2510 4700 7770
K
V
64.1 171 320 517 818 1320 2170 4060 6720
F
L
0.79 0.87 0.91 0.91 0.85 0.81 0.73 0.63 0.63
F
d
0.37 0.64 0.78 0.87 0.94 0.97 0.99 0.99 1.00
X
T
0.44 0.64 0.77 0.77 0.67 0.51 0.38 0.20 0.13
12 196
C
v
107 284 532 861 1360 2190 3610 6760 11 200
K
V
92.2 246 460 745 1180 1890 3120 5850 9670
F
L
0.79 0.87 0.91 0.91 0.85 0.81 0.73 0.63 0.63
F
d
0.39 0.67 0.79 0.87 0.93 0.97 0.99 1.00 1.00
X
T
0.44 0.64 0.77 0.77 0.67 0.51 0.38 0.20 0.13
16 347
C
v
189 505 945 1530 2420 3890 6410 12 000 19 900
K
V
164 437 818 1320 2090 3370 5540 10 400 17 200
F
d
0.38 0.64 0.79 0.87 0.93 0.97 0.99 0.99 1.00
F
L
0.79 0.87 0.91 0.91 0.85 0.81 0.73 0.63 0.63
X
T
0.44 0.64 0.77 0.77 0.67 0.51 0.38 0.20 0.13
20 542
C
v
296 788 1480 2390 3780 6080 10 000 18 800 31 000
K
V
256 681 1280 2070 3270 5260 8660 16 200 26 800
F
d
0.42 0.66 0.79 0.87 0.93 0.97 0.99 1.00 1.00
F
L
0.79 0.87 0.91 0.91 0.85 0.81 0.73 0.63 0.63
X
T
0.44 0.63 0.76 0.76 0.66 0.50 0.38 0.20 0.13
1. Valves should not be required to throttle at a Cv less than the minimum throttling Cv.
58
Table 5-4. Representative Sizing Coefficients for ED Single-Ported Globe Style Valve Bodies
Valve Size
(inches)
Valve Plug Style Flow Characteristic
Port Dia.
(in.)
Rated
Travel
(in.)
C
V
F
L
X
T
F
D
1/2 Post Guided Equal Percentage 0.38 0.50 2.41 0.90 0.54 0.61
3/4 Post Guided Equal Percentage 0.56 0.50 5.92 0.84 0.61 0.61
1
Micro Form
Cage Guided
Equal Percentage
Linear
Equal Percentage
3/8
1/2
3/4
1 5/16
1 5/16
3/4
3/4
3/4
3/4
3/4
3.07
4.91
8.84
20.6
17.2
0.89
0.93
0.97
0.84
0.88
0.66
0.80
0.92
0.64
0.67
0.72
0.67
0.62
0.34
0.38
1 1/2
Micro-Form
Cage Guided
Equal Percentage
Linear
Equal Percentage
3/8
1/2
3/4
1 7/8
1 7/8
3/4
3/4
3/4
3/4
3/4
3.20
5.18
10.2
39.2
35.8
0.84
0.91
0.92
0.82
0.84
0.65
0.71
0.80
0.66
0.68
0.72
0.67
0.62
0.34
0.38
2
Cage Guided Linear
Equal Percentage
2 5/16
2 5/16
1 1/8
1 1/8
72.9
59.7
0.77
0.85
0.64
0.69
0.33
0.31
3
Cage Guided Linear
Equal Percentage
3 7/16 1 1/2 148
136
0.82
0.82
0.62
0.68
0.30
0.32
4
Cage Guided Linear
Equal Percentage
4 3/8 2 236
224
0.82
0.82
0.69
0.72
0.28
0.28
6
Cage Guided Linear
Equal Percentage
7 2 433
394
0.84
0.85
0.74
0.78
0.28
0.26
8
Cage Guided Linear
Equal Percentage
8 3 846
818
0.87
0.86
0.81
0.81
0.31
0.26
www.Fisher.com
Chapter 6
Control Valve Noise
Noise has always been present in control valves.
It is a natural side effect of the turbulence and
energy absorption inherent in control valves. This
chapter will address how noise is created, why it
can be a problem, and methods to attenuate noise
created in control valves.
The major problem with industrial noise is its affect
on humans. Companies usually build town border
stations on sites remote from residential
developments. Isolation, however, is not always
possible, and noise prevention is a must.
The U.S. Occupational Safety and Health Act
(OSHA) establishes maximum permissible noise
levels for all industries whose business affects
interstate commerce. These standards relate
allowable noise levels to the permissible exposure
time. Notice in table 6-1 that the maximum
permissible levels depend upon the duration of
exposure. For example, the maximum sound level
a person should be exposed to for an eight hour
day is 90 dBA. These maximum sound levels have
become the accepted noise exposure standard for
most regulatory agencies. Thus, they have
become the standard by which much noise
generating equipment has been specified and
measured.
Table 6-1. Maximum Permissible Noise Levels
Duration of Exposure
(Hours)
Maximum Sound Pressure
(dBA)
16 85
8 90
4 95
2 100
1 105
1/2 110
1/4 115
Decibels (dB) are a measure to give an indication
of loudness. The A added to the term indicates
the correction accounting for the response of the
human ear. The sensitivity of our ears to sound
varies at different frequencies. Applying this A
correction is called weighting, and the corrected
noise level is given in dBA.
The A-weighting factor at any frequency is
determined by how loud noise sounds to the
human ear at that particular frequency compared
to the apparent loudness of sound at 1000 hertz.
At 1000 hertz the A-weighting factor is zero, so if
the sound pressure level is 105 dB, we say it
sounds like 105 dB.
On the other hand, if we listen to a sound at 200
hertz with a sound pressure level of 115 dB, it
sounds more like 105 dB. Therefore, we say that
the A-weighted loudness of the noise with a sound
pressure level of 115 dB is 105 dBA.
Essentially, if two or more sounds with different
sound pressure levels and frequencies sound like
the same loudness, they have the same dBA,
regardless of what their individual, unweighted
sound pressure levels may be.
The effect of A-weighting on control valve noise
depends upon the flowing medium since each
develops its own characteristic spectrum. Noise
levels for hydrodynamic noise, or liquid flow noise,
have appreciable energy at frequencies below 600
hertz. When the levels are A-weighted, it makes
the low frequency terms more meaningful and the
government standards somewhat more difficult to
meet.
On the other hand, aerodynamic noise levels
produced by steam or gas flow are the same in
either dB or dBA. This is because aerodynamic
noise occurs primarily in the 1000 to 8000 hertz
frequency range. The human ear has a fairly flat
response in the frequency range of 600 to 10,000
62
hertz, and the A-weighting factor is essentially
zero in this range. Thus, there is negligible
difference between the dB and dBA ratings.
Sound Characteristics
Analyzing noise, in the context of piping and
control valves, requires consideration of its origin.
This indicates how the noise will propagate.
Generally speaking, noise originates from either a
line source or a point source.
A sound level meter is used to determine sound
pressure levels. Readings for line source noise
levels are normally measured one meter from the
pipes surface and at a point one meter
downstream from the valve outlet. Measurements
should be made in an unobstructed free field area
with no sound reflecting surfaces nearby.
Line source noise levels are radiated from the
piping in the form of an imaginary cylinder, the
pipe centerline as the axis. As you move away
from the pipeline, the sound pressure level
decreases inversely to the changes in surface
area of the imaginary cylinder. The following
equation defines the sound pressure level (L
p
A) at
distances other than one meter from the pipeline
surface:
L
p
A +F )10 log
1 )r
R )r
where,
L
p
A = sound pressure level
F = noise level at one meter from the pipe
surface
r = pipe radius in meters based on the
pipe outside diameter
R = distance in meters from the pipe
surface
What this equation tells us is that the sound
pressure level decreases dramatically as the
distance from the pipeline increases. Keep in mind
that this equation determines the noise level
radiated only by the pipeline. Other noise sources
could combine with the pipeline noise source to
produce greater overall sound pressure level.
The other type of noise source needed to be
discussed is point source. Point source noise
measurements are taken at a three meter distance
in the horizontal plane through the source. Vent
applications are typical examples of point source
noise. Point source noise levels are radiated in the
form of an imaginary sphere with the source at the
center of the sphere. As you move away from a
point source, the sound pressure level decreases
inversely in proportion to the changes in the
surface area of the imaginary sphere. The
equation that defines the sound pressure level at
distances other than three meters from the point
source and below a horizontal plane through the
point source is:
L
p
A +F )20 log
3
R
where,
L
p
A = the sound pressure level
F = the noise level at three meters from
the source
R = the distance in meters from the
source
This procedure determines the noise level radiated
only by the point source. Other noise sources
could combine with the point source noise to
produce a greater overall sound pressure level.
Combining Noise Sources
The noise level in a certain area is the result of
combining all of the noise generated by every
noise source in the vicinity. The methodology of
combining sources is important to prediction and
actually lies at the root of noise abatement
technology.
To determine the resultant noise level of two noise
sources, it is necessary to combine two sources of
energy. The energy, or power, of two sources
combines directly by addition. The power levels
must be calculated separately and then
logarithmically combined as one overall noise
source. The sources can be line, point, or a
combination of both. Table 6-2 simplifies the
process of combining two known noise levels.
63
Table 6-2. Combined Noise Corrections
dBA
1
- dBA
2
dBA Adder to Loudest Noise Source
0 3.01
1 2.54
2 2.12
3 1.76
4 1.46
5 1.2
6 <1
To use table 6-2:
1. Determine the noise level of each source at the point where you want to
determine the combined noise level.
2. Determine the arithmetic dB difference between the two sources at the
location of interest.
3. Find the difference between the two sources in the table.
4. Read across the table to find the dB factor to be used. Add this factor to the
louder of the two sources. This value is the combined dB of the two sources.
Lets put this table to work to illustrate how noise
sources combine. Two interesting examples help
illustrate how sound levels combine:
1. When two noise sources with equal sound
pressure levels of 90 dB are combined, the
correction factor is 3.01. Therefore, the resultant
combined noise level is 93 dB.
2. If two sources have considerably different
noise levels, say 95 dB and 65 dB, the correction
factor is nearly zero. Therefore, the combined
noise level is essentially the same as the louder of
the two sources, that is, 95 dB. This leads us to
the first rule of noise control: Preventing or
controlling the loudest noise sources first.
While this appears obvious, in practice it is not the
easiest path.
Sources of Valve Noise
Control valves have long been recognized as a
contributor to excessive noise levels in many fluid
process and transmission systems. The major
sources of control valve noise are mechanical
vibration noise, aerodynamic noise, and
hydrodynamic noise.
Mechanical noise generally results from valve plug
vibration. Vibration of valve components is a result
of random pressure fluctuations within the valve
body and/or fluid impingement upon the movable
or flexible parts. The most prevalent source of
noise resulting from mechanical vibration is the
lateral movement of the valve plug relative to the
guiding surfaces. The sound produced by this type
of vibration normally has a frequency less than
1500 hertz and is often described as a metallic
rattling. In these situations, the physical damage
incurred by the valve plug and associated guiding
surfaces is generally of more concern than the
noise emitted.
Another source of mechanical vibration noise is
resonant vibration, which occurs when a valve
component resonates at its natural frequency.
Resonant vibration produces a single-pitched tone
normally having a frequency between 3000 and
7000 hertz. This type of vibration produces high
levels of mechanical stress that may produce
fatigue failure of the vibrating part. Valve
components susceptible to natural frequency
vibration include contoured valve plugs with hollow
skirts and flexible seals.
The noise caused by the vibration of valve
components is usually of secondary concern, and,
ironically, may even be beneficial because it gives
warning when conditions exist that could produce
valve failure. Noise resulting from mechanical
vibration has for the most part been eliminated by
improved valve design. Most modern control
valves employ cage guiding and more precise
bearings to eliminate vibration problems. Testing
helps isolate and eliminate resonant frequency
problems before installation.
The second type of noise is hydrodynamic noise.
Hydrodynamic noise results from liquid flow and is
caused by the implosion of vapor bubbles formed
in the cavitation process. Vapor bubble formation
occurs in valves controlling liquids when the
service conditions are such that the local static
pressure, at some point within the valve, is less
than or equal to the liquid vapor pressure.
Localized areas of low static pressures within the
valve are a result of the pressure-to-velocity-head
interchange that occurs at the valve vena
contracta. When the vapor bubbles move
downstream, they encounter pressures higher
than the vapor pressure and collapse. The rapid
implosion can result in severe damage to adjacent
valve or pipeline surfaces, and generate high
noise levels.
Hydrodynamic noise sounds similar to that of
gravel flowing through a pipe. Intense cavitation
can cause noise levels as high as 115 dBA, but
such cavitation would not be tolerated because
cavitation damage would drastically shorten the
operating life of the installation. Therefore, control
valve damage is normally of more concern than
the noise produced in cavitating services.
Aerodynamic noise is generated by the turbulence
associated with control of gas, steam, or vapors.
While generally thought of as accompanying high
capacity, high pressure systems, damaging noise
64
levels can be produced in a two-inch line with as
little as a 200 psi pressure drop. Major sources of
aerodynamic noise are the stresses or shear
forces present in turbulent flow.
Some of the sources of turbulence in gas
transmission lines are obstructions in the flow
path, rapid expansion or deceleration of
high-velocity gas, and directional changes in the
fluid stream. Specific areas that are inherently
noisy include headers, pressure regulators, line
size expansions, and pipe elbows.
Aerodynamic noise is generally considered the
primary source of control valve noise. There are
several reasons for this:
D This type of noise has its highest energy
components at the same frequencies where the
human ear is most sensitive - between 1000 and
8000 hertz.
D Large amounts of energy can be converted
to aerodynamic noise without damaging the valve.
In the past, the noise was considered a nuisance,
but as long as the valve did its job, it was not of
major concern. Today, with increasing focus on
environmental issues, including noise, there are
guidelines on the amount of noise a valve can emit
in a given workplace. Research has also shown
that sustained noise levels above 110 decibels
can produce mechanical damage to control
valves.
High noise levels are an issue primarily because
of OSHAs standards for permissible noise limits
and the potential for control valve damage above
110 dBA. Additionally, loud hydrodynamic noise is
symptomatic of the more dangerous and
destructive phenomenon known as cavitation.
Noise Prediction
Industry leaders use the International
Electrotechnical Commission standard IEC
534-8-3. This method consists of a mix of
thermodynamic and aerodynamic theory and
empirical information. This method allows noise
prediction for a valve to be based only upon the
measurable geometry of the valve and the service
conditions applied to the valve. There is no need
for specific empirical data for each valve design
and size. Because of this pure analytical approach
to valve noise prediction, the IEC method allows
an objective evaluation of alternatives.
The method defines five basic steps to noise
prediction:
1. Calculate the total stream power in the process
at the vena contracta.
The noise of interest is generated by the valve in
and downstream of the vena contracta. If the total
power dissipated by throttling at the vena
contracta can be calculated, then the fraction that
is noise power can be determined. Because power
is the time rate of energy, a form of the familiar
equation for calculating kinetic energy can be
used. The kinetic energy equation is:
E
k
+12mv
2
where,
m = mass
v = velocity
If the mass flow rate is substituted for the mass
term, then the equation calculates the power. The
velocity is the vena contracta velocity and is
calculated with the energy equation of the first law
of thermodynamics.
2. Determine the fraction of total power that is
acoustic power.
This method considers the process conditions
applied across the valve to determine the
particular noise generating mechanism in the
valve. There are five defined regimes dependent
upon the relationship of the vena contracta
pressure and the downstream pressure. For each
of these regimes an acoustic efficiency is defined
and calculated. This acoustic efficiency
establishes the fraction of the total stream power,
as calculated in step one, which is noise power. In
designing a quiet valve, lower acoustic efficiency
is one of the goals.
3. Convert acoustic power to sound pressure.
The final goal of the IEC prediction method is to
determine the sound pressure level at a reference
point outside the valve where human hearing is a
concern. Step two delivers acoustic power, which
is not directly measurable. Acoustic or sound
pressure is measurable and, therefore, has
become the default expression for noise in most
situations. Converting from acoustic power to the
sound pressure uses basic acoustic theory.
4. Account for the transmission loss of the pipe
wall and restate the sound pressure at the outside
surface of the pipe.
Steps one and three are involved with the noise
generation process inside the pipe. There are
65
times when this is the area of interest, but the
noise levels on the outside of that pipe are the
prime requirement. This method must account for
the change in the noise as the reference location
moves from inside the pipe to outside the pipe.
The pipe wall has physical characteristics, due to
its material, size, and, shape, that define how well
the noise will transmit through the pipe. The
fluid-borne noise inside the pipe interacts with the
inside pipe wall causing the pipe wall to vibrate,
then the vibration transmits through the pipe wall
to the outside pipe wall, and there the outside pipe
wall interacts with the atmosphere to generate
sound waves. These three steps of noise
transmission are dependent upon the noise
frequency. The method represents the frequency
of the valve noise by determining the peak
frequency of the valve noise spectrum. It also
determines the pipe transmission loss as a
function of frequency. The method then compares
the internal noise spectrum to determine how
much the external sound pressure will be
attenuated by the pipe wall.
5. Account for distance and calculate the sound
pressure level at the observers location.
Step four delivers the external sound pressure
level at the outside surface of the pipe wall.
Again, basic acoustic theory is applied to calculate
the sound pressure level at the observers
location. Sound power is constant for any given
situation, but the associated sound pressure level
varies with the area of distributed power. As the
observer moves farther away from the pipe wall,
the total area of distributed sound power
increases. This causes the sound pressure level
to decrease.
Methods to Attenuate Noise
With increasing interest in the environmental
impact of all aspects of industry, there are
increasing demands for noise abatement
procedures and equipment.
In a closed system, (not vented to the
atmosphere) noise becomes airborne only by
transmission through the valves and adjacent
piping that contains the flowstream. The sound
field in the flowstream forces these solid
boundaries to vibrate, causing disturbances in the
surrounding air to propagate as sound waves.
Figure 6-1. Whisper Trim I cage used for reducing
aerodynamic noise
W1257/IL
Noise control techniques fall into one of two basic
categories:
D Source treatment
D Path treatment
While preventing noise at the source is the
preferred approach to noise control, it is
sometimes economically or physically impractical
due to particular application requirements. Path
treatment is then a reasonable approach. There
are also instances when source treatment alone
does not provide sufficient noise reduction; path
treatment is then used as a supplement.
In any event, the decision to use source
treatment, path treatment, or a combination of
both should be made only after the application
requirements and alternative approaches have
been thoroughly analyzed.
Source Treatment
The Fisher Whisper Trimt I cage, illustrated in
figure 6-1 , is interchangeable with standard trim in
many globe valves. It uses many narrow parallel
slots designed to minimize turbulence and provide
a favorable velocity distribution in the expansion
area of the valve. It provides a multitude of low
noise flowpaths, which combine to produce less
overall noise than standard cages. A Whisper Trim
I cage is most efficient when the ratio of pressure
drop to inlet pressure is equal to or less than 0.65
(that is, P/P
1
is less than or equal to 0.65). In
addition, this approach is most effective when the
maximum downstream velocity of the fluid is equal
to or less than half the sonic velocity of that fluid.
This style of cage will provide up to 18 dBA
attenuation versus a standard cage with little
sacrifice in flow capacity.
66
Figure 6-2. Valve with Whisper Trim I and Inline Diffuser Combination
W2618
When the pressure drop ratio exceeds 0.65, the
Whisper Trim I cage loses its effectiveness.
Diffusers, used in conjunction with the Whisper
Trim I cage to divide the overall pressure drop into
two stages, can extend the useful capability and
also improve noise performance (figure 6-2). The
diffuser provides a fixed restriction, which
increases backpressure to the valve thereby
reducing the pressure drop across the valve. This
decreases the pressure drop ratio which in turn
decreases the sound pressure level. The use of a
diffuser allows the Whisper Trim I cage to remain
within its most efficient P/P
1
range. Diffusers are
only effective for the condition they are sized for.
They are not effective in throttling applications. At
this optimum condition they can provide up to an
additional attenuation of 25 dBA.
When pressure drop ratios are high, a Whisper
Trim III cage (figure 6-3) may be used. Fluid flows
from the inside of the cage out through many
orifices. The performance of these cages is
closely tied to spacing of these orifices. As the
pressure drop ratio increases, the centerline
distance to hole diameter of these orifices also
needs to increase to prevent jet recombination.
Therefore, as the level of the Whisper Trim III
cage increases, so does the centerline distance to
hole diameter. For many applications involving
high pressure drop ratios, a baffle is installed
outside the cage. For very high pressure drop
Figure 6-3. Whisper Trim III
W9039
ratios a baffle is often used to act on the fluid jets
exiting from the cage to further reduce turbulence.
Cages similar to the Fisher Whisper Trim III cage
can reduce control valve noise by as much as 30
dBA. These cages are most effective when the
maximum downstream velocity of the fluid is equal
to or less than 0.3 of the sonic velocity of that
fluid.
67
Figure 6-4. WhisperFlo Technology
W7065
W7056
Fisher WhisperFlot trim (figure 6-4) is well-suited
for applications that have high noise levels and
require large Cvs. It is effective in applications that
have a pressure drop ratio up to 0.99. When a
pressure drop ratio of .94 or higher is expected,
and WhisperFlo is desired, the noise calculations
will be performed by the engineering experts at
Emerson Process Management. This design is a
multi-path, two-stage design that has the
capability of reducing noise up to 50 dBA. The key
factor behind this attenuation is allowing the
pressure to recover between stages. This allows
for the pressure drop ratio of the second stage to
be less than the pressure drop ratio of the first
stage. In achieving this, along with special
passage shapes, the frequency is shifted to a
higher spectrum, velocities are managed, and the
jets maintain independence.
All of the Whisper Trim cages and WhisperFlo
trims are designed for sliding stem valves. In
applications requiring rotary valves that have high
noise, an attenuator, diffuser, or combination there
of may be applied. Applications with ball valves
can apply an attenuator to obtain up to 10 dBA
reduction in noise. These attenuators are
designed to reduce both aerodynamic and
hydrodynamic noise. With butterfly valves you can
only attenuate aerodynamic noise utilizing an
inline diffuser. As mentioned above, these
diffusers can provide up to a 25 dBA reduction in
noise.
Figure 6-5. Vee-Ball Noise Attenuator
W6116
For control valve applications operating at high
pressure ratios (P/P
1
is greater than 0.8), a
series approach can be very effective in
minimizing the noise. This approach splits the total
pressure drop between the control valve and a
fixed restriction (such as a diffuser) downstream of
the valve. In order to optimize the effectiveness of
the diffuser, it must be designed for each unique
installation so that the noise levels generated by
the valve and diffuser are equal.
Control systems venting to atmosphere are
generally very noisy, as well. This is because of
the high pressure ratios and high exit velocities
involved. In these applications, a vent silencer
may be used to divide the total pressure drop
between the actual vent and an upstream control
valve (figure 6-6). This approach quiets both the
valve and the vent. A properly sized vent silencer
and valve combination can reduce the overall
system noise level by as much as 60 dBA.
Path Treatment
Path treatment can be applied where source
treatment is more expensive, or in combination
with source treatment where source treatment
alone is inadequate. Path treatment consists of
increasing the resistance of the transmission path
to reduce the acoustic energy that is transmitted
to the environment. Common path treatments
include the use of:
D Heavy walled pipe
The noise attenuation possible with heavy-walled
pipe varies with the size and schedule used. As an
example, increasing a pipeline from schedule 40
to schedule 80 may reduce sound levels by
approximately 4 dB.
68
Figure 6-6. Valve and Vent Diffuser Combination
W2672
D Acoustical or thermal insulation
The noise level near the valve can be lowered by
applying insulation to absorb the noise. Insulation
absorbs much of the noise that would normally
reach the atmosphere, but does not absorb any of
the noise going up or down inside the pipe walls.
Thermal insulation can give 3 to 5 dBA noise
reduction per inch of insulation thickness to a
maximum attenuation of 12 to 15 dBA. Acoustical
insulation can give 8 to 10 dBA noise reduction
per inch of blanket type insulation. The maximum
attenuation that should be expected is 24 to 27
dBA.
Path treatments such as heavy-walled pipe or
external insulation can be a very economical and
effective technique for localized noise abatement.
However, they are effective for localized noise
reduction only. That is, they do not reduce the
noise in the process stream, but only shroud it
where the treatment is used. Noise propagates for
long distances via the fluid stream and the
effectiveness of the treatment ends where the
treatment ends.
D Silencers
The silencer differs from other path treatments in
that it does actually absorb some of the noise
energy. Therefore, it reduces sound intensity both
in the working environment and in the pipeline. In
gas transmission systems, in-line silencers
effectively dissipate the noise within the fluid
stream and attenuate the noise level transmitted
to the solid boundaries. Where high mass flow
rates and/or high pressure ratios across the valve
exist, an in-line silencer is often the most realistic
and economical approach to noise control. Use of
absorption-type in-line silencers can provide
almost any degree of attenuation desired.
However, economic considerations generally limit
noise attenuation to approximately 35 dBA.
Hydrodynamic Noise
The primary source of hydrodynamic noise is
cavitation. Recall that cavitation is the formation
and subsequent collapse of vapor bubbles in a
flowing liquid. This phenomenon sounds similar to
that of gravel flowing down the pipe.
Source treatment for noise problems associated
with control valves handling liquid is directed
primarily at eliminating or minimizing cavitation.
Cavitation and its associated noise and damage
can often be avoided at the design stage of a
project by giving proper consideration to service
conditions. However, where service conditions are
fixed, a valve may have to operate at pressure
conditions normally resulting in cavitation. In such
instances, noise control by source treatment can
be accomplished by using one of several methods;
multiple valves in series, a special control valve, or
the use of special valve trim that uses the series
restriction concept to eliminate cavitation.
Cavitrol Trim is a source treatment solution as it
eliminates cavitation across the control valve. This
is achieved by staging the pressure drop across
the valve so the pressure of the fluid never drops
below its vapor pressure (figure 6-7). Cavitrol Trim
is only effective in clean processes. If a process
contains particulate, it will require Dirty Service
Trim (DST). DST also operates on the concept of
staging the pressure drops (figure 6-8).
While path treatment of aerodynamic noise is
often an economical and efficient alternative, path
treatment of hydrodynamic noise is not generally
recommended. This is because the physical
damage to control valve parts and piping produced
by cavitation is generally a much more serious
issue than the noise generated.
69
Figure 6-7. Cavitrol III Trim
W2479
Figure 6-8. NotchFlo DST Trim for
Fisher Globe Style Valves
W8538
However, if cavitation damage can be eliminated
using the special trims discussed, it becomes
practical to use the path treatment method to
further reduce the local noise caused by the
cavitating liquid. This may be accomplished
through the use of heavy-walled pipe and
acoustical or thermal insulation.
Much technology now exists for predicting and
controlling noise in the industrial environment.
Prediction techniques accurately alert the designer
to the need for noise control. When it is a problem,
a variety of solutions are available ranging from
simple path insulation to sophisticated control
valves which eliminate noise at the source.
Two-Phase Noise
As the properties of the fluids vary, the noise
generation, propagation, and pipe excitation
processes area are all affected. Acoustical wave
speed and the density of the fluid are key
considerations. In an all gas or all liquid
application, these are reasonably predictable at
any point from the inlet of the downstream piping.
However, for a multiphase fluid, either
one-component or two-component, there can be
tremendous variations in these important
parameters. In fact, at the vena contracta where
the velocities are greatest, the phases may
separate and form annular flow, with the gas and
the liquid phases having different velocities. This
possibility makes the noise generation process
nearly impossible to model.
Between the vena contracta and the downstream
piping, the phases may be re-oriented to a
homogenous mixture. Propagation of a pressure
wave in this region would be again nearly
impossible to model, as even if it is perfectly
homogenous, the void fraction would be constantly
changing with pressure.
Wave speed and density are also important in
determining the efficiency with which a sound field
is coupled to the pipe wall to cause vibrations and
subsequent external noise radiation.
Emerson engineers have conducted field studies
on applications where flashing noise was present
in an attempt to quantify the problem, if indeed
there was one. After an extensive search there
were not any applications which were considered
noise problems, nor have any surfaced since.
Based upon this experience, two conclusions were
made:
1. 1. A technically appropriate two-phase noise
prediction method does not exist
2. Two-phase, or pure flashing, applications do
not create noise problems.
610
Control Valve Noise Summary
The requirement for noise control is a function of
legislation to protect our wellbeing and to prevent
physical damage to control valves and piping.
Noise prediction is a well defined science. Actual
results will be within 5 dBA of predicted levels.
Prediction is based upon contributions for:
D Pressure drop
D Flow rate
D P/P
1
and trim style
D Piping and insulation
D Downstream pressure
Noise reduction is accomplished in two general
ways:
1. Source treatment, which acts upon the amount
of noise generated
2. Path treatment, which blocks transmission on
noise to the environment.
There are two common source treatments:
1. Valve noise trim is based on principles of
dividing the flow to create many small noise
sources which combine to a lower level than a
single large flow noise. Diffusers used with control
valves share pressure drop creating two lower
noise sources which again combine to an overall
lower level.
2. Path treatment involves use of insulation or
absorptive devices to lower the sound level which
reaches observers.
Hydrodynamic noise from liquid flow streams can
mainly be traced to cavitation. In this case,
damage from the cavitation is of more concern
than the noise. Appropriate treatment of the
cavitation source should be initiated through
staging the pressure drop.
Two-phase, or pure flashing, applications do not
create noise problems, and there is no technically
appropriate two-phase noise prediction method.
www.Fisher.com
Chapter 7
Steam Conditioning
Introduction
Power producers have an ever-increasing need to
improve efficiency, flexibility, and responsiveness
in their production operations. Changes resulting
from deregulation, privatization, environmental
factors, and economics are combining to alter the
face of power production worldwide. These
factors are affecting the operation of existing
power plants and the design of future plants
resulting in a myriad of changes in the designs
and operating modes of future and existing power
plants. 3-
Competing in todays power market requires
heavy emphasis on the ability to throttle back
operations during non-peak hours in order to
minimize losses associated with power prices
falling with demand. These changes are
implemented in the form of increased cyclical
operation, daily start and stop, and faster ramp
rates to assure full load operation at daily peak
hours.
Advanced combined cycle plants are now
designed with requirements including operating
temperatures up to 1500F, noise limitation in
urbanized areas, life extension programs,
cogeneration, and the sale of export steam to
independent customers. These requirements
have to be understood, evaluated, and
implemented individually with a minimum of cost
and a maximum of operational flexibility to assure
profitable operation.
Great strides have been made to improve heat
rates and increase operational thermal efficiency
by the precise and coordinated control of the
temperature, pressure, and quality of the steam.
Most of the steam produced in power and process
plants, today, is not at the required conditions for
all applications. Thus, some degree of
conditioning is warranted in either control of
pressure and/or temperature, to protect
downstream equipment, or desuperheating to
enhance heat transfer. Therefore, the sizing,
selection, and application of the proper
desuperheating or steam conditioning systems are
critical to the optimum performance of the
installation.
Thermodynamics of Steam
Highly superheated steam, (i.e. 900 - 1100F) is
usually generated to do mechanical work such as
drive turbines. As the dry steam is expanded
through each turbine stage, increasing amounts of
thermal energy is transformed into kinetic energy
and turns the turbine rotor at the specified speed.
In the process, heat is transferred and work is
accomplished. The spent steam exits the turbine
at greatly reduced pressure and temperature in
accordance with the first law of thermodynamics.
This extremely hot vapor may appear to be an
excellent source for heat transfer, but in reality it is
just the opposite. Utilization of superheated steam
for heat transfer processes is very inefficient. It is
only when superheated steam temperatures are
lowered to values closer to saturation that its heat
transfer properties are significantly improved.
Analysis has shown that the resultant increase in
efficiency will very quickly pay for the additional
desuperheating equipment that is required.
In order to understand why desuperheating is so
essential for optimization of heat transfer and
efficiency, we must examine the thermodynamic
relationship of temperature and the enthalpy of
water. Figure 7-1 illustrates the changes of state
that occur in water over a range of temperatures,
at constant pressure, and relates them to the
enthalpy or thermal energy of the fluid.
72
Figure 7-1. Temperature enthalpy diagram for
water. Note that the greatest amount of thermal
energy input is used to vaporize the water.
Maximum efficiency in heat transfer requires
operation at near saturation temperature to recover
this energy.
E0117
300
200
100
32
0
0 500 1000
Btu added to 1 pound of water
T
e
m
p
e
r
a
t
a
u
r
e
,

d
e
f

F
1/2 Btu per degree
Ice heating at about
144 Btu to melt ice
Water heating at 1 Btu per degree
Atmospheric pressure
Evaporation at 14.7 psi
Evaporation at more than 14.7 psi
All data for 1 lb. water
which water cannot
exist as a liquid
These lines curve and meet at
705.4 deg F the critical
temperature, above
S
t
e
a
m

s
u
p
e
r
h
e
a
t
i
n
g

a
t

a
b
o
u
t
0
.
4

B
t
u

p
e
r

d
e
g
r
e
e
212 deg F
970 Btu to
boil water
In the lower left portion of the graph, the water is
frozen at atmospheric pressure and below 32F.
At this point, heat is being rejected from the water
as it maintains its solid state. As heat is gradually
added the ice begins to change. Addition of heat
to the ice raises the temperature and slows the
rate of heat rejection. It requires approximately
1/2 BTU of thermal energy to be added to a pound
of ice to raise its temperature 1F. Upon reaching
32F, the addition of more heat does not
immediately result in an increase in temperature.
Additional heat at this point begins to melt the ice
and results in a transformation of state from a
solid to a liquid. A total of 144 BTUs is required to
melt one pound of ice and change it to water at
32F.
Once the phase change from a solid to a liquid is
complete, the addition of more heat energy to the
water will again raise its temperature. One BTU of
heat is required to raise the temperature of one
pound of water by 1F. This relationship remains
proportionate until the boiling point (212F) is
reached. At this point, the further addition of heat
energy will not increase the temperature of the
water. This is called the saturated liquid stage.
Figure 7-2. Temperature enthalpy diagram for
water showing that saturation temperature varies
with pressure. By choosing an appropriate
pressure, both correct system temperature and
thermal efficiency can be accommodated.
T
e
m
p
e
r
a
t
a
u
r
e
,

d
e
f

F
T-H DIAGRAM
WATER
LIQUID
800 PSIA
14.7 PSIA
LIQUID-VAPOR
VAPOR
ENTHALPY, BTU/LBM
E0118
The water begins once again to change state, in
this case from water to steam. The complete
evaporation of the water requires the addition of
970 BTUs per pound. This is referred to as the
latent heat of vaporization, and is different at each
individual pressure level. During the vaporization
process the liquid and vapor states co-exist at
constant temperature and pressure. Once all the
water, or liquid phase, has been eliminated we
now have one pound of steam at 212F. This is
called the saturated vapor stage. The addition of
further thermal energy to the steam will now again
increase the temperature. This process is known
as superheating. To superheat one pound of
steam 1F requires the addition of approximately
0.4 BTUs of thermal energy.
The potential thermal energy release resulting
from a steam temperature change differs
significantly depending on temperature and
superheat condition. It is much more efficient, on
a mass basis, to cool by addition of ice rather than
by the addition of cold fluids. Similarly, it is more
efficient to heat with steam at temperatures near
the saturation temperature rather than in the
superheated region. In the saturated region much
more heat is liberated per degree of temperature
change than in the superheated range because
73
production of condensate liberates the enthalpy of
evaporation, the major component of the total
thermal energy content. The temperature-
enthalpy diagram in figure 7-2 is generalized to
show the thermodynamic relationship at various
pressures.
The graph in figure 7-2 illustrates three distinct
phases (i.e., liquid, vapor, and liquid-vapor) and
how enthalpy relates to temperature in each phase
at constant pressure. The rounded section in the
middle of the graph is called the steam dome
and encompasses the two-phase, liquid-vapor
region. The left boundary of the steam dome is
called the saturated liquid line. The right boundary
line is the saturated vapor line. The two
boundaries meet at a point at the top of the dome
called the critical point. Above this point, 3206 psi
and 705F, liquid water will flash directly to dry
steam without undergoing a two-phase
coexistence. When conditions exceed this critical
point they are considered to be existing in the
supercritical state.
In the lower left side of the graph, the saturated
liquid line intersects the temperature axis at 32F.
At this point we have water and a defined enthalpy
of 0 BTU/LB. As heat is added to the system, the
temperature and enthalpy rise and we progress up
the saturated liquid line. Water boils at 212F at
14.7 psia. Thus, at 212F and 180 BTU/LB, we
note a deviation from the saturated liquid line.
The water has begun to boil and enter a new
phase; Liquid-Vapor.
As long as the liquid stays in contact with the
vapor, the temperature will remain constant as
more heat is added. At 1150 BTU/LB (at 14.7 psi)
we break through to the saturated vapor line.
Thus, after inputting 970 BTU/LB, all of the water
has been vaporized and enters the pure vapor
state. As more heat is added, the temperature
rises very quickly as the steam becomes
superheated.
Why Desuperheat?
Desuperheating, or attemperation as it is
sometimes called, is most often used to:
D Improve the efficiency of thermal transfer in
heat exchangers
D Reduce or control superheated steam
temperatures that might otherwise be harmful to
equipment, process or product
D Control temperature and flow with load
variation
Dry superheated steam is ideally suited for
mechanical work. It can be readily converted to
kinetic energy to drive turbines, compressors and
fans. However, as the steep temperature-
enthalpy line slope would indicate, the amount of
heat output per unit of temperature drop is very
small. A heat exchanger using superheated
steam would have to be extremely large, use great
quantities of steam, or take tremendous
temperature drops. A 10F drop in temperature
liberates only 4.7 BTU per pound.
If this same steam had been desuperheated to
near saturation the thermal capabilities would be
greatly enhanced. The same 10F drop in
temperature would result in the release of over
976 BTU of heat. This illustrates the obvious
advantages of desuperheating when thermal
processes are involved. Only by desuperheating
the superheated steam is it possible to
economically retrieve the energy associated with
vaporization. By changing steam pressure, the
saturation temperature can be moved to match the
temperature needs of the process and still gain
the thermal benefits of operating near saturation.
The previous discussion centered on why we
superheat steam (to do mechanical work) and
when it should be desuperheated back to
saturation (to heat). There are many situations
when saturated steam suddenly and
unintentionally acquires more superheat than the
downstream process was designed to
accommodate. This unintentional superheat
produces the same thermal inefficiencies
mentioned previously. In this case, we are talking
about the sudden expansion and temperature
change associated with a pressure reducing valve.
Take the following steam header conditions for
example:
Conditions: P
1
= 165 psia
T
1
= 370F
Enthalpy = 1198.9 BTU/LB
Saturation temperature at 165 psia is 366F.
Therefore, the steam has only 4F of superheat
and would be excellent for heat transfer. Assume
that another thermal process requires some
steam, but at 45 psia rather than 165 psia. The
simple solution is to install a pressure reducing
valve. Since throttling devices, such as valves
and orifices, are isenthalpic (constant enthalpy
processes) the total heat content of the steam will
not change as flow passes through the restriction.
74
After the valve, the steam will have the following
conditions:
Conditions: P
2
= 45 psia
Enthalpy = 1198.9 BTU/LB
Referencing a set of steam tables, we see that at
the above conditions the steam temperature is
328F giving the impression that it has cooled.
However, from the steam tables we see that the
saturation temperature for 45 psia steam has also
dropped to 274F. The net result is that our steam
now has 54F of superheat (328F - 274F). Use
of this steam for heat transfer could be
uneconomical and return on investment on a
desuperheater would be most favorable.
Desuperheating
In this section we will briefly discuss the process
of desuperheating. The need to desuperheat is
usually performed simply to control the steam
temperature, or heat content, of the flowing vapor
media. Depending on the process downstream of
the main steam source, a desuperheater will be
utilized to transform the steam into a medium that
is more efficient for heat transfer or just more
conducive for interaction with its surrounding
components. One means of accomplishing this is
with a direct contact heat transfer mechanism.
This can easily be achieved by the use of a single
spray injection nozzle that, when properly placed,
diffuses a calculated quantity of liquid into the
turbulent flow stream. Vaporization of the liquid
phase proceeds while mass, momentum, and
energy transfer occurs, and the resultant vapor
exits the process at the desired temperature or
heat content level.
Desuperheaters
A desuperheater is a device that injects a
controlled amount of cooling water into a
superheated steam flow in an effort to reduce or
control steam temperature (figure 7-3).
Desuperheaters come in various physical
configurations and spray types that optimize
performance within specified control and
installation parameters. Selection should also
always include attention to those details that would
provide the most economic solution without
sacrificing required performance.
Figure 7-3. Insertion style desuperheater injects a
controlled amount of cooling water into super-
heated steam flow.
E0865
The success of a particular desuperheater station
can rest on a number of physical, thermal, and
geometric factors. Some of the factors are quite
obvious and others are more obscure, but they all
have a varying impact on the performance of the
equipment and the system that it is installed in.
Considerable research has been conducted into
the characteristics of desuperheaters and the
transformation of spraywater to vapor. The
findings are of considerable interest to both design
and process engineers. In the next several
sections, we will discuss these findings and how
they relate to the desuperheating system as a
whole.
The most important factor is the selection of the
correct desuperheater type for the respective
application. Units come in all shapes and sizes
and use various energy transfer and mechanical
techniques to achieve the desired performance
criteria and optimize the utilization of the system
environment. These design criteria include:
D Mechanically Atomized Fixed and Variable
Geometry Spray Orifice
D Geometrically Enhanced
D Externally Energized
The mechanically atomized style of desuperheater
is the most popular and simplistic style that
provides nominal performance over a wide range
of flow and conditions. These models are of the
internally energized variety. The atomization and
injection of the spray water is initiated by the
pressure differential between the spraywater and
the steam. The DMA, fixed geometry spray
orifice, units are the simplest and by design have
a constant area flow path. These units are highly
75
Figure 7-4. The DMA/AF desuperheater
utilizes variable-geometry, back-pressure
activated spray nozzles.
W6310-1
dependent on the pressure differential and thus
provide levels of performance that are
commensurate with the magnitude of the
difference. Obviously, the larger the water/steam
differential the better the unit will perform (i.e.,
penetration velocity, flow variation and droplet
size). Since the equipment turndown is usually
limited to 4:1, it is best suited for near steady load
applications.
An upgrade from the fixed geometry unit is the
DMA/AF (figure 7-4) variable geometry nozzle
desuperheater. Here the actual flow geometry of
the unit is varied to maintain an optimum
differential across the discharge orifice. As a
result of this change, the level of flow variation is
greatly enhanced and so is the performance.
Equipment turndowns can exceed 40:1, thus
making this style a good choice for medium to
high load change applications.
Another form of mechanically atomized
desuperheater is the DVI, Geometric Enhanced
style, (figure 7-5). Here, the unit is supplied a high
pressure recovery flow restriction that alters flow
geometry and helps to keep the level of turbulence
and kinetic energy at a high level during all phases
of the units operation due to an increased velocity
at the point of spray water injection. This
increased level of surrounding energy helps to
Figure 7-5. The DVI desuperheater injects
spraywater in the outlet of the venturi section,
assuring excellent mixing and rapid atomization.
W6313-1
impart energy transfer to the droplets and assists
in break-up, mixing, and vaporization. This style is
best suited for medium turndown applications
typically around 15:1.
The last group of desuperheater units utilizes an
external energy source for the atomization of the
spraywater. The most common medium is a high
pressure steam source. In this case, the high
levels of kinetic energy are provided by a critical
pressure reduction in the desuperheater
sprayhead. The critical drop is used to shear the
water into a fine mist of small droplets, which is
ideal for vaporization, as shown in figure 7-6. This
type of system can provide a very high degree of
flow variation without requiring a high pressure
water supply. Applications requiring turndown
ranges greater then 40:1 utilize this type of
equipment for best performance. In addition to an
external spraywater control valve, the system will
also require an atomizing steam shut-off valve
(figure 7-7).
Other factors that have a large amount of impact
on the performance of a desuperheating system
include:
D Installation Orientation
D Spray Water Temperature
D Spray Water Quantity
D Pipeline Size
D Equipment vs. System Turndown
76
Figure 7-6. The DSA desuperheater uses
high-pressure steam for rapid and complete
atomization of spraywater in low-velocity steam
lines.
W6311-2
Installation orientation is often overlooked, but a
critical factor in the performance of the system.
Correct placement of the desuperheater can have
more impact on the operation than the style of the
unit itself. For most units, the optimum orientation
is in a vertical pipeline with the flow direction up.
This flow direction is ideal, as the natural flow
direction of the injected water tends to be in the
counter direction due to effect of gravity. The role
of gravity in this orientation will suspend the
droplets in the flow longer while they are being
evaporated, thus shortening the required
downstream distance or efficient mixing.
Other orientation factors that are of concern
include downstream pipefittings, elbows, and any
other type of pipeline obstruction that can provide
a point for water impingement or fallout.
Spraywater temperature can have an great impact
on the desuperheater performance. While it goes
against logical convention, hotter water is better
for cooling. As the temperature increases and
moves closer to saturation, its flow and thermal
characteristics are improved and impact most
significantly the following:
D Surface Tension
D Drop Size Distribution
D Latent Heat of Vaporization
D Vaporization Rate
Improvement in all these areas will act to improve
the overall performance of the system, as the
spraywater will evaporate and mix with the steam
at a faster rate.
The quantity of water to be injected will, as with
any mass flow calculation, have a directly
proportionate affect on the time for vaporization.
The heat transfer process is time dependent; thus,
the quantity of spray water will increase the time
for complete vaporization and thermal stability.
Another concern for proper system performance is
pipeline size. Pipe size should be determined in an
effort to balance the velocity of the steam flow.
Steam traveling at a fast rate will require longer
distances to effectively cool, as heat transfer is a
function of time. Steam traveling at low velocity
will not have enough momentum to suspend water
droplets long enough for evaporation. As a result,
water will fall out of the steam flow to collect along
the bottom of the pipe, and it will not cool the
steam effectively. Ideal velocity is typically in the
range of 250 ft/sec to 300 ft/sec.
As the pipeline size increases to limit steam
velocity, more attention must be paid to the
penetration velocity of the spray and the coverage
in the flow stream. Experience shows that single
point injection type desuperheaters will have
insufficient nozzle energy to disperse throughout
the entire cross-sectional flow area of the pipeline.
As a result, the spray pattern collapses and
thermal stratification occurs (i.e., sub-cooled
center core within a superheated outer jacket.)
This condition normally is eliminated after the flow
stream undergoes several direction changes,
although this is not always possible within the
limits of the control system or process. Proper
placement of high-energy TBX-T (figure 7-8)
multi-nozzle steam coolers in the larger pipelines
will normally prevent thermal stratification.
The most over used and misunderstood word in
the field of desuperheating is turndown. When
applied to a final control element, such as a valve,
it is a simple ratio of the maximum to minimum
controllable flow rate. Turndown is sometimes
used interchangeably with rangeability; however,
the exact meaning differs considerably when it
77
Figure 7-7. The DSA desuperheater utilizes two external control valves: a spraywater unit and an atomizing steam valve.
DSA DESUPERHEATER
C0817 / IL
Figure 7-8. TBX-T Cooler
W8786-1
comes to actual performance comparisons. Since
a desuperheater is not a final control element its
performance is linked directly to its system
environment; thus, the actual turndown is more a
function of system parameters rather than based
on the equipments empirical flow variations. Once
this is understood, it is obvious that even a good
desuperheater cannot overcome the limitations of
a poorly designed system. They must be
evaluated on their own merits and weighed
accordingly.
A final design parameter for all insertion type
desuperheaters is its ability to withstand high
levels of thermal cycling. Due to the nature of
operation of todays plants, desuperheaters should
be designed with the intent to operate under daily
cycling environments. Exposure to frequent daily
cycling can lead to thermal fatigue and
desuperheater failure if the unit is not designed for
the operation. Design upgrades for this application
consist of thermal liners to reduce thermal loads
and structural optimization to reduce induced
vibration at stress sensitive welds.
To summarize the requirements to correctly size a
desuperheater, the following system and operating
information is required:
D Minimum and Maximum Steam Flow
D Steam Pressure and Temperatures
D Cooling Water Pressure and Temperature
D Required System Turndown Ratio
D Pipe Size and System Layout
D Planned Mode of Operating
Steam Conditioning Valves
Steam conditioning valves represent
state-of-the-art control of steam pressure and
temperature by integrally combining both functions
within one control element unit. These valves
address the need for better control of steam
conditions brought on by increased energy costs
and more rigorous plant operation. Steam
conditioning valves also provide better
temperature control, improved noise abatement,
and require fewer piping and installation
restrictions than the equivalent desuperheater and
pressure reduction station.
78
Figure 7-9. The TBX utilizes an external
spraywater manifold with multiple nozzles for
moderate to large volume applications.
W8493-1
Steam conditioning valve designs can vary
considerably, as do the applications they are
required to handle. Each has particular
characteristics or options that yield efficient
operation over a wide range of conditions and
customer specified requirements.
The TBX steam-conditioning valve (figure 7-9)
combines pressure and temperature control in a
single valve. Finite element analysis (FEA) and
computational fluid dynamic (CFD) tools were
used in its development to optimize the valves
operating performance and overall reliability. The
rugged design of the TBX proves capable of
handling full mainstream pressure drops, while its
flow-up configuration, in conjunction with Whisper
Trim technology, prevents the generation of
excessive noise and vibration.
The simplified trim configuration used in the TBX
accommodates rapid changes in temperature as
experienced during a turbine trip. The cage is
casehardened for maximum life and is allowed to
expand during thermally induced excursions. The
valve plug is continuously guided and utilizes
cobalt-based overlays both as guide bands and to
provide tight, metal-to-metal shutoff against the
seat.
Figure 7-10. Detail of AF Spray Nozzle.
W8494-1
The TBX incorporates a spraywater manifold
downstream of its pressure reduction stage. The
manifold features variable geometry, backpressure
activated AF nozzles that maximize mixing and
quick vaporization of the spraywater.
The AF nozzle (figure 7-10) was developed
originally for condenser dump systems in which
the downstream steam pressure can fall below the
saturation level. In these instances, the
spraywater may flash and significantly change the
flow characteristic and capacity of the associated
nozzle at a critical point in the operation.
Spring loading of the valve plug within the AF
nozzle prevents any such changes by forcing the
plug to close when flashing occurs. With flashing,
the compressibility of the fluid changes, and the
nozzle spring will force closure and
re-pressurization of the fluid leg. Once this is
done, the fluid will regain its liquid properties and
reestablish flow to the condenser.
The TBX injects the spray water towards the
center of the pipeline and away from the pipe wall.
The number of injection points varies by
application. With high differentials in steam
pressure, the outlet size of the valve increases
drastically to accommodate the larger specific
volumes. Correspondingly, an increased number
of nozzles are arranged around the circumference
of the outlet making for a more even and complete
distribution of the spray water (figure 7-11).
The simplified trim arrangement in the TBX
permits extending its use to higher pressure
classes (through ANSI Class 2500) and operating
temperatures. Its balanced plug configuration
79
Figure 7-11. The TBX showing external
spraywater manifold.
W8520
provides Class V shutoff and a linear flow
characteristic.
The TBX typically uses high-performance,
pneumatic piston actuators in combination with
FIELDVUE Digital Valve Controllers to achieve full
stroke in less than two seconds while maintaining
highly accurate step response. The FIELDVUE
instruments along with AMS ValveLinkt software
provide a self-diagnostic capability that gives
answers about valve performance. The current
valve/actuator signature (seat load, friction, etc.)
can be compared against previously stored
signatures to identify performance changes before
they cause process control problems.
When piping dictates, the TBX valve can be
provided as separate components, allowing
pressure control in the valve body and
temperature reduction in a downstream steam
cooler. The steam cooler is equipped with a water
supply manifold (multiple manifolds are also
possible). The manifold provides cooling water
flow to a number of individual spray nozzles that
are installed in the pipe wall of the cooler section.
The result is a fine spray injected radially into the
high turbulence of the axial steam flow.
Installation Guidelines
Installation of desuperheaters and steam
conditioning valves is key to long term success
and performance. It is best to install
desuperheaters in a straight run of horizontal or
vertical pipe. Installation in elbows is also possible,
but it can affect system turndown and thermal
stratification due to momentum caused changes in
the velocity profile.
Momentum forces the majority of the steam flow
to the outside surfaces of the bend. This results in
a low velocity void on the inside of the elbow. If
high turndowns are not required, this installation is
satisfactory since the voids would rarely be below
minimum velocity at maximum flow. As the flow is
reduced, however, these areas may lose their
ability to perform as required to desuperheat the
steam.
Other installation parameters that are always of
interest to the piping designer are how much
straight run of pipe is required and where the
temperature sensor should be located. Both are
thermally derived questions and require thermally
derived answers. It is desirable to have the
thermal sensor as close as possible to the
desuperheater in order to reduce the signal lag
time. It is also desirable not to have any piping
components (e.g., elbows or tees) that would
detract from the thermal process.
The following equations provide guidelines for
designing a proper system. These equations
relate to time required for complete vaporization
and mixing.
Downstream Straight Pipe Requirements (SPR):
SPR (ft) = 0.1 Sec. x Maximum Steam Velocity
(ft/sec)
Downstream Temperature Sensor Distance (TS):
15% Spraywater or less:
TS (ft) = 0.2 Sec. x Maximum Steam Velocity
(ft/sec)
Greater than 15% Spraywater:
TS (ft) = 0.3 Sec. x Maximum Steam Velocity
(ft/sec)
Temperature control is not limited to receiving a
signal from a downstream temperature sensor.
Another valid alternative is feed-forward control.
Feedforward control is accomplished using an
algorithm that is characterized specifically to the
valve installed in the application. The algorithm is
programmed into the distributed control system to
provide an accurate calculation of the spray water
that is required to reduce the steam enthalpy and
temperature to the desired outlet set point. The
algorithm requires input of upstream temperature
710
and pressure as well as the position of the valve.
Upstream and spraywater enthalpies are then
determined using an inherent steam table within
the DCS. The total spraywater required is
calculated from a heat balance using the final
enthalpy into the condenser. This method of
temperature control is a practical solution for
applications that do not have enough downstream
pipe distance for accurate measurement by a
temperature sensor.
Turbine Bypass Systems
The most severe and critical application of any
steam conditioning installation is that of the turbine
bypass.
The concept of the turbine bypass has been
around for a long time; however, its application
and importance has broadened significantly in
recent years. Steam turbine bypass systems
have become essential to todays power plant
performance, availability, responsiveness, and
major component protection.
The following will concentrate on the general
application of bypass systems as used in fossil
fueled utility power plants. The closed
water/steam heat cycle of such typical units may
be comprised, but not limited to, sub- or
super-critical pressures, to single, double, or triple
reheat sections and to condensation at or near
ambient temperatures. The steam generating
principles where such bypass systems are
employed include natural or assisted circulation
drum boilers, combined circulation boilers, and
once-through boilers. The turbine may be of
single or double shaft design and operated either
at fixed inlet pressure or on sliding pressure.
Bypass System Benefits
Just how beneficial a bypass system proves to be
depends upon many factors (e.g., plant size,
mode of operation, age of existing components,
size of the condenser, main fuel type, control
philosophy, etc). However, the main benefits for
the application of a comprehensive bypass system
in the 25-100% size range are:
D The matching of steam and heavy turbine
metal component temperatures during the
startup and shutdown phase. This has proven
to be of major economic significance in terms of
fuel savings and the thermal protection of critical
heavy wall boiler and turbine components. By
limiting temperature differentials during turbine
admission the effects of thermal fatigue are
minimized and longevity of components
maximized. This is especially important for life
extension programs where the role and
justification of the bypass system may be centered
solely on this aspect.
D The ability to avoid a boiler trip following
a full load rejection. A boiler (HRSG) / turbine
unit with a bypass can withstand a complete
system load rejection and remain available for
rapid reloading after the disturbance has been
removed. This important advantage for system
flexibility and operating efficiency can make the
difference between a more costly and time
consuming warm start and a hot start.
D Reduction in solid-particle erosion of
turbine components. The loss of material from
the boiler tubing and internals is most prevalent
during commissioning startup and after the unit
has been shutdown for an expended period of
time. Thermal transients assist in the dislodging
of scale, oxides, and weldments within the boiler
circuit to form an abrasive steam flow that, over
time, could accelerate the wear of sensitive
turbine blades and seriously affect operating
efficiencies and maintenance costs. Damage can
be reduced or eliminated by routing the steam
through the bypass system.
D Independent operation of the boiler and
turbine set. The ability to operate the boiler
without the turbine, at any load up to the limit of
the bypass capacity, can be surprisingly useful for
operational or testing purposes. For example, all
boiler controls and firing systems can be tested
and fine-tuned independent of the turbine
operation. This significantly reduces both cost
and time relating to initial commissioning of the
plant, retrofitting and checking equipment
performance, and system troubleshooting.
General System Description
A complete and comprehensive turbine bypass
system can be comprised of many inter-linked and
coordinated components. These include the
bypass valves, spray water control valves, control
system, and the actuation and positioning system.
For this discussion, we will center our attention on
the bypass valves themselves.
The bypass system incorporates the dual
operating function of steam conditioning valves
(i.e., for the controlled reduction of both pressure
and temperature). The bypass valve incorporates
711
Figure 7-12. Turbine Bypass System
E0866
the latest technology in pressure-reducing/low
noise trim to handle the flow and reduction of
pressure energy to acceptable levels. However,
since steam throttling in a control valve is an
isenthalpic process, desuperheating is required to
control the discharge temperature and enthalpy
levels. As a result, the valves are equipped with a
special spraywater injection system that produces
a finely atomized and evenly distributed water
interface for rapid vaporization and steam
temperature control.
The bypass system can be supplied with one or
two control inputs depending on the role it plays in
the control scheme. If the valve is used solely for
startup and shutdown, it will receive a single
modulating control signal to position the trim as a
function of the startup and shutdown curves for
the respective unit. If the valve must also act to
relieve pressure during a turbine trip or load
rejection, an additional discrete input is included
that will ramp open the valve quickly to a
predetermined position, before reverting to a
modulating configuration in accordance with the
boiler control requirements. Fast positioning speed
and resultant alternate flow path are critical to
counteract the pressure build-up resulting from the
isolation of the boiler piping circuit when the
turbine valves close in this trip situation.
High Pressure Bypass
During startup, shutdown, or on turbine trip, the
HP bypass system directs steam from the
superheater outlet to the cold reheat line, thereby
bypassing the HP turbine section (figure 7-9). The
major advantages of such an action have been
generally outlined above. However, more specific
duties are:
1. Pressure and temperature controlled bypass
of the HP turbine section.
2. Controlled main steam pressure build-up in
the boiler.
3. Cooling of the reheat section of the boiler.
4. Prevention of the opening of spring-loaded
HP safety valves during minor disturbances.
5. Avoidance of condensate loss and noise from
blowing safety valves.
6. Protection of the boiler against exceeding
design pressures.
The failure mode of the HP bypass system is very
dependent on local design codes and the
performance scenario for the system. If it is
designed as a safety bypass system and replaces
the standard safety relief valve function, the valves
must always fail in the open position. However, if
the standard safety relief valves are in place, the
valve is normally required to fail closed, especially
in over-temperature situations on drum boilers.
712
Control of the HP bypass is normally initiated via
feedback input signals from the main steam
pressure and the cold reheat temperature. The
ratio of steam to spraywater is normally inversely
proportional to the respective valve position,
especially during startup and shutdown. This is
because startup conditions normally require large
valve Cvs, due to the large specific volumes
associated with low pressures at high
temperatures, even though flow is greatly
reduced.
During trip conditions, the opposite is true, and
large quantities of spraywater are required at
lower valve openings. For this situation, special
control algorithms usually are incorporated into the
control system to provide independent feedforward
control. This is especially important during a trip
sequence where time of response is critical to
maintain system integrity, performance, and
component protection.
Spraywater for cooling is normally obtained from
the boiler feed pump discharge and is regulated by
an external spraywater control valve that is
properly sized to handle the required flow and
pressure drop.
Hot-Reheat and Low Pressure
Bypass
During startup, shutdown, or on turbine trip, the
HRH and LP bypass systems direct steam from
the hot reheat line to the condenser, thus
bypassing the IP and LP turbine sections (figure
7-12). The major advantages of such an action
have been generally outlined above. However,
more specific duties are:
1. Pressure and temperature controlled
bypassing of the IP and LP turbines.
2. Controlling pressure build-up in the boiler
reheat section.
3. Prevention of condensate losses during load
trips and minor disturbances.
4. Protecting the condenser against excessive
pressure, temperature, and enthalpy
excursions during bypass operation.
In contrast to the HP bypass, the HRH and LP
bypass valves only fail closed as a failure mode.
While it is important to control the hot reheat
pressure, it is even more critical to protect the
condenser against damage from uncontrolled or
improper admission of steam. The condenser
manufacturer interfaces specific condenser control
permissives with these bypass control systems. If
Figure 7-13. TBX WhisperFlo Sparger.
W8684-2
any of these permissives is not met or is exceeded
during bypass operation, the valve is quickly shut.
These permissives include, but are not limited to:
1. Condensate level high
2. Condenser temperature high
3. Condenser pressure high
4. Spraywater pressure low
5. Loss of coolant
Another added challenge of the HRH and LP
bypass system is to properly control the amount of
backpressure on the bypass valves. A condenser
or condenser duct, which is downstream of these
bypass valves, typically operates at a vacuum in
the range of 1 - 3 psia. Given this scenario, it is
crucial to create backpressure in order to maintain
a desired velocity within reasonable pipe sizes.
A second challenge to this application is to create
these desired conditions while minimizing the
noise generated by this process. Dumping high
velocity steam into a low pressure, thin wall
condenser/turbine exhaust duct requires careful
evaluation in order to assure steam jets do not
converge. Hole spacing within the sparger and
sparger placement within the duct are critical for
maintaining low noise levels.
A typical bypass to condenser installation requires
a steam conditioning valve to control pressure and
temperature, a spraywater valve to regulate the
water supply, and a downstream TBX sparger to
create backpressure. Low noise WhisperFlo trim
713
alternatives are also available for the TBX sparger
(figure 7-13).
Control of the HRH and LP bypass valves
normally is initiated via feedback input signals
from the hot reheat steam pressure and the
specified condenser inlet temperature/enthalpy.
The steam entering the condenser must be
controlled specifically to guard against excessive
thermal expansion of the tubing and shell. As in
the case of the HP bypass, the ratio of steam to
spray water is normally inversely proportional,
especially during startup and shutdown. In
addition, the dual role of the HRH and LP bypass
system in controlling the thermal admission
parameters to the condenser normally results in
the requirement for a prescribed amount of
over-spray.
This situation is compounded by the close
proximity of these valves to the condenser. This
makes any kind of feedback temperature control
almost impossible considering the quantity of
spray water to be vaporized and the short distance
available to measure the process. It is highly
recommended that feedforward control algorithms
be incorporated into the control system to provide
independent feedforward control for the
spraywater admission.
Spraywater for cooling is normally obtained from
the condensate boost pump discharge and is
regulated by a properly sized external spraywater
control valve.
Bypass Size
A comprehensive bypass system includes HP
bypass, HRH bypass and LP bypass valves.
However, they may or may not be sized for the
same capacity. There are many variables that can
influence the required size of each bypass system.
Bypasses for once-through boiler plants are
generally designed for 100% of full-load steam to
suit startup and part-load operation. If
conventional safety valves are omitted, 100%
bypass capacity is essential.
Bypass capacity for drum boiler plants involve
several different issues. Some argue that 100%
capacity bypasses are worthwhile, but experience
has proven that bypasses with capacities of
between 25 - 70% normally are sufficient to handle
most operating and trip conditions.
For temperature matching in a drum plant during
hot startup only, it may be possible to use a
bypass of only 30% when firing with oil and
40-50% for coal. Overall, these values are
considered the lowest practical load for the boiler
under automatic control.
On bypass applications requiring the control of a
full turbine trip, the values increase to 40% on gas
and oil-fired drum units and up to 70% for coal. In
selecting the bypass capacity, it is important to
consider all control systems and plant components
and their ability to turn down instantaneously from
full to auxiliary load.
Note also that if the high pressure bypass capacity
exceeds approximately 50%, and the low pressure
bypass passes all the steam to the condenser,
then condenser duty during bypass operation is
more severe than during normal, full-load turbine
operation. This fact may limit bypass capacity,
especially on systems being retrofit to existing
plants.
Starts, Trips, Load Rejection,
Two-Shift Operation
The worth of a turbine bypass and the flexibility,
added efficiency, and responsiveness are never
more apparent than during starts, trips, or load
rejections. Modern bypass systems operate
during:
D Cold starts
D Warm starts
D Hot starts
D Load rejection
D Quick turbine shutdown
D Two-shift operation
Bypass valves and systems that are designed
correctly have noteworthy advantages for these
individual modes. They are detailed as follows:
Cold Starts
A cold start typically occurs after the unit has been
down for over a week. Preheating of the system
is required as first stage and reheat temperatures
are normally below 200F. The bypass system
permits involvement of the furnace, superheaters,
and reheater very early in the steam/water cycle.
714
This is important in the production of steam purity
before the turbine start. Steam flow through the
superheater and reheater enhances the tube
cooling effect, thereby allowing greater latitude in
gas and steam temperatures. During the startup,
thermal stresses are controlled while achieving the
fastest possible loading rate. Depending on the
size of the bypass system, the unit can typically
be brought on line in 4.5 - 9 hours.
Warm Starts
A warm start is indicative of a weekend shutdown.
In this case, the HP turbine casing is usually
above 450F. As with the cold start, the steam
temperature can be controlled to permit the
matching of steam and metal temperatures under
all operating conditions. Expected startup time is
between 2.5 - 5 hours.
Hot Starts
A hot start is usually associated with a minor
disturbance that created a unit trip. The bypass
allows the boiler to remain on line until the
disturbance is cleared and the unit can be
reloaded in the shortest possible time, which is
usually between 1 - 2 hours.
Load Rejection/Quick Restart
During load rejection, the bypass system provides
the necessary control and flow path for unit
runback to minimum load and for the
establishment of a definitive course of action (i.e.,
complete shutdown or quick restart). All systems
are protected, and a minimum of condensate is
lost.
Two-Shift Operation
Two-shift operation may become necessary if a
utility grid has a number of large base-loaded
units, which are not as maneuverable as the
smaller fossil fueled units used for peaking
purposes. This would require that the smaller
units be shutdown every night and restarted every
morning, which is a very material-life consuming
means of operating. Once again, the bypass
system provides a means for the efficient and
timely matching of steam and metal temperatures.
This allows the efficient startup of the units every
morning without thermally stressing the
components, yet it increases unit efficiency and
availability.
Chapter 7 Steam Conditioning
Summary
The implementation of a properly designed turbine
bypass system can be beneficial and instrumental
in the pursuit of increased efficiency, flexibility,
and responsiveness in the utility power plant.
Component life can be extended as the ability to
regulate temperatures between the steam and
turbine metal is enhanced. Commissioning time
and cost can be reduced through independent
boiler and turbine operation. The magnitude of
return on investment hinges on the specific
application mode, style or service of plant, and
equipment supplied. While not discussed here,
this logic applies as well to combined cycle plants,
cogeneration facilities, and industrial power
facilities.
Short Notes:
D A desuperheater is a device that sprays a
precisely controlled amount of water into a steam
line to modify steam temperature.
D System parameters and required turndown
are the most influential parameters in
desuperheater selection.
D Desuperheating is done primarily to improve
efficiency of thermal transfer devices and to
provide temperature protection for process,
product and equipment.
D Another reason to desuperheat is to control
the unintentional superheat created by pressure
reduction valves.
D Proper installation is key to best
performance. Guidelines for piping geometry and
placement of downstream temperature sensors
are available.
D Steam conditioning is the process of
combining pressure reduction and desuperheating
into a single control element.
D Turbine bypass systems are beneficial and
instrumental for achieving high efficiency,
flexibility, and responsiveness in todays power
plants.
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Chapter 8
Process Overview
The modern pulp and paper mill is a complex
manufacturing process involving many varied
types of operation. Many factors influence the type
of process used by a specific mill. Some of these
factors include: type of wood available (hardwood
or softwood), type of paper or paperboard
produced, age of mill, and availability of an
abundant supply of water. This sourcebook will
focus primarily upon the Kraft or sulfate pulping
process as illustrated in figure 1.
Wood Preparation
Wood preparation is a series of steps that
converts logs to a suitable form for use in the pulp
mill. This area of the mill is commonly referred to
as the woodyard.
Logs from the forest are usually received from a
truck, rail car, or barge. Large overhead cranes
are used to unload and sort the logs into piles for
long or short logs. Logs may pass through a
slasher, which cuts the logs into segments, if a
certain length is required.
The next step involves debarking, which removes
both dirt and bark from the logs. The most
common method employed is mechanical
debarking via a barking drum. Logs are fed into
the rotating cylinder and the rotating/tumbling
action rubs the bark from the logs. The bark falls
out of the cylinder via slots and debarked logs exit
the opposite end of the cylinder. Bark is used as
fuel for the power boiler or log boiler.
Following debarking, the logs are fed to the
chipper. The chipper uses high speed rotating
blades to reduce the logs to chips of a suitable
size for pulping. Chips are then screened for
acceptable sizes by passing them over a set of
vibratory screens. The rejects are returned for
further chipping and acceptable chips are stored in
large outdoor piles or silos for pulp mill use.
Pulping
Pulping is the process of separating the wood
chips into fibers for paper manufacture. This is
accomplished primarily by mechanical, chemical,
or combined mechanical/chemical processes.
Some mills that produce various grades of paper
have both mechanical and chemical pulping
processes.
Mechanical pulping, or the groundwood process,
involves pressing logs against a rotating
grindstone and washing away the torn fibers with
water. This process is a large consumer of electric
power due mainly to the grindstone motor. This
type of pulp is used primarily for the production of
newsprint grade paper.
More modern methods of mechanical pulping
involve shredding and grinding of wood chips
between the rotating disk of a refiner. The product
is referred to as refiner mechanical pulp (RMP).
Variations of this process involve pretreating of
wood chips with steam and/or chemicals. This is
commonly referred to as thermo-mechanical pulp
(TMP) or chemithermomechanical pulp (CTMP).
The majority of pulping processes in North
America are chemical processes. The most
common are the sulfate and sulfite processes. Of
these two, the sulfate or Kraft process is the
dominant process. The Kraft cooking process is
part of a larger process called the Kraft recovery
cycle. A typical Kraft recovery cycle is illustrated in
figure 2.
The Kraft process involves cooking the wood
chips under pressure in an alkaline solution of
82
sodium hydroxide (NaOH) and sodium sulfide
(Na
2
S). This solution, known as white liquor,
breaks down the glue-like lignin which binds the
cellulose wood fibers together. Cellulose fibers are
used to form a paper sheet on the paper machine.
The primary piece of equipment in the pulp mill is
the cooking vessel or digester. The digester is a
vessel in which wood chips and white liquor are
steam heated to a predetermined pressure and
temperature. The objective is to remove as much
lignin as possible without decreasing fiber
(cellulose) strength.
Both batch and continuous processes are used to
cook wood chips. The batch process involves
filling a vessel with wood chips and white liquor.
The contents are then heated to a predetermined
cooking temperature and pressure via direct or
indirect steam heating. After a prescribed cooking
time, the contents are blown to a holding tank and
the process repeated.
As its name implies, the continuous digester has a
fairly constant input of chips and outflow of pulp
fibers. The chips are usually preheated in a
steaming vessel before they are conveyed to the
digester. As the chips move down through the
digester (vertical type), they are successively
heated, cooked, and washed prior to cooling and
discharge to the blow tank. Indirect steam heating
of the cooking liquor is used to control the
temperature in each section of the digester. Most
of the newer pulp mills have favored the
continuous digester cooking process over the
batch process.
Following cooking, the pulp from the blow tank
must be washed to remove residual cooking
chemicals. This is sometimes referred to as brown
stock washing. The resulting process stream from
washing the stock is referred to as weak black
liquor.
For many years, the standard method of washing
has been a series of rotary vacuum washers. The
pulp and wash filtrate (black liquor) flow in a
countercurrent sequence with clean water used
only for the final washing stage. This allows an
increase in wash solids as it flows toward the first
stage washer and a decrease in pulp solids as it
moves to the last stage washer.
As mills face growing economic and environmental
pressures, new methods of washing have been
developed. Some of these systems include rotary
pressure filter systems, continuous digester
washing, and pressure diffusion washers. Each of
these systems are designed to achieve clean pulp
and reclaim cooking chemicals with less wash
water.
A final step in the pulping process involves
passing the pulp through knotter and screen
equipment. These steps may occur before, after,
or split around brown stock washing. The knotters
remove uncooked wood chips, knots, and fiber
bundles called shives. Screening is removal of
other tramp rejects such as rocks, steel, plastic or
conveyor parts.
Recovery of Kraft Pulping Liquors
Due to the high cost of pulping chemicals (sodium
and sulfur), effective recovery following cooking
has an important economic impact on mill
operating cost. The primary purpose of the Kraft
recovery cycle (see figure 2) is to reclaim these
chemicals and regenerate them to cooking liquor
form. A secondary objective is efficient heat
recovery and steam generation from the
combustion of wood organics in black liquor fuel.
This complex process will be covered in three
steps: evaporation, burning, and causticizing or
regeneration.
Evaporation
Weak black liquor from the brown stock washers
contains spent cooking chemicals, wood organics
such as lignin, and water. At this stage, the solids
content is typically 12 - 18%. Before burning,
water must be evaporated to raise the solids
content to 65 - 70%. The bulk of this task is
commonly accomplished by multiple-effect
evaporators.
A set of evaporators commonly consists of six
vessels and interconnecting pumps and piping.
Steam is used as a heating medium to evaporate
water from the liquor. Steam typically flows
countercurrent to the liquor for maximum
economy. Since the vessels operate at different
pressures, the vapors from one vessel serve as
the steam supply for the next vessel. Liquor
typically leaves the evaporators at 50% solids with
5 - 6 lbs. of water evaporated per pound of steam
used.
83
Burning
Black liquor from the evaporators at 50 - 55%
solids cannot be burned in the recovery boiler.
Further evaporation to 65 - 70% solids must be
attained prior to combustion. This is accomplished
by evaporator-like vessels called concentrators or
by direct contact evaporators (cascade or cyclone
type) which use boiler flue gas for evaporation. If
direct contact evaporators are used (older
designs), air is mixed with the black liquor in the
black liquor oxidation system prior to direct
heating. This helps prevent the release of odorous
gases due to direct heat contact. Most new boilers
use concentrators for final evaporation since
indirect steam heating emits fewer odors. This is
commonly referred to as low odor design.
The recovery boiler is one of the largest and most
expensive pieces of hardware in the mill. It is the
heart of the chemical recovery process. The heavy
black liquor is sprayed into the furnace for
combustion of organic solids. Heat liberated from
burning serves to produce steam in the water
circuit and reduce sulfur compounds to sulfide.
The molten sodium compounds accumulate to
form a smelt bed on the furnace floor. The molten
smelt, consisting primarily of sodium carbonate
(Na
2
CO
3)
and sodium sulfide (Na
2
S), flows by
gravity to the dissolving tank. The dissolving tank
is filled with a water solution (weak wash) to cool
the smelt. This solution is called green liquor and
is transferred to the causticizing area.
Causticizing
Green liquor is sent to the causticizing area for
transformation to white liquor for cooking. The
process begins with clarification of the green liquor
to remove impurities called dregs. Clarified green
liquor is then mixed with lime in the slaker to form
white liquor. The lime (CaO) activates the
conversion of Na
2
CO
3
in the green liquor to form
sodium hydroxide (NaOH) for white liquor. To
allow time for a complete reaction, the white liquor
passes to a series of agitated tanks called
causticizers.
A second chemical reaction resulting from the
addition of CaO is the precipitation of lime mud
(CaCO
3
). The lime mud is removed from the white
liquor by filtration or gravity settling and the
clarified white liquor is stored for digester chip
cooking.
Lime mud filtered from the white liquor is washed
to remove residual cooking chemicals. The wash
water, or weak wash, is sent to the recovery boiler
dissolving tank. The washed lime mud is sent to
the lime kiln where heat is added for conversion to
lime. This calcined lime, along with purchased
make-up lime, is used to supply the slaker.
Although many variations exist, this completes a
typical Kraft recovery cycle as illustrated in figure
2. The next step is the preparation of the pulp for
paper making.
Bleaching
The primary objective of bleaching is to achieve a
whiter or brighter pulp. If a mill produces brown
paper such as linerboard, a bleaching sequence is
not required. However, if white paper such as
writing or magazine paper is produced, bleaching
is required. Bleaching removes the lignin which
remains following digester cooking. Lignin is the
source of color and odor for pulp.
The bleach plant has recently evolved to the most
controversial area of pulp and paper production
due to the formation of dioxin from chlorine
bleaching. Environmentalists claim dioxin in pulp
mill effluent is contaminating rivers while other
studies indicate levels of dioxin in effluent are too
low to pose any danger. Nevertheless, many
technology changes have occurred in the past
decade that have significantly reduced dioxin
emissions.
Bleaching practices prior to 1980 used large
amounts of chlorine to achieve the desired level of
brightness. Although other stages using sodium
hydroxide, chlorine dioxide, and hypochlorite were
used, chlorine was the prime bleaching agent.
Following each stage, washing was required to
remove residuals. Large quantities of water were
used following the chlorination stage where the
majority of toxic byproducts are formed. Various
methods of post bleaching treatment of effluent
were used with mixed success.
Beginning in the mid-1980s, mills began making
significant changes due to increasing
environmental awareness. One change is the
increased use of oxygen (O
2
) delignification prior
to bleaching with chlorine and chlorine dioxide.
This provides lignin removal with the benefit of
chlorine-free effluent. This also allows for less
chemical use in subsequent bleaching stages.
A second change is extensive reuse of washer
filtrate to reduce fresh water usage. This reduces
the amount of effluent to be treated prior to
discharge from the mill. Some modern plants use
84
totally enclosed pressure diffusion washers
following O
2
delignification to further reduce toxic
effluent.
Another change involves increased substitution of
chlorine dioxide for chlorine gas. Chlorine dioxide
does not release the chlorine ions responsible for
forming dioxin. Although chlorine dioxide is more
expensive to produce, it requires 2.5 - 3 times less
to bleach the same amount of pulp. Some
processes which use O
2
delignification prior to
bleaching have achieved 100%.
Though evolution has caused dioxin emissions to
decrease overtime, changes such as this will
continue to take place in the future. Federal and
state regulator agencies continue to disagree on
allowable emission limits. Future technology will
continue to move toward zero discharge limits for
dioxins and other by-products of the bleaching
process.
Stock Preparation
Pulp, as produced in the pulp mill, is not suitable
for manufacture of most grades of paper.
Properties must be added to the pulp which will
aid in uniform sheet distribution and bonding of
fibers. Two major steps used to impart desired
properties are stock proportioning and mechanical
treatment by beating and refining pulp fibers.
Stock proportioning involves the addition of other
types of pulp and chemical additives to achieve a
desired grade of paper. Different pulps, along with
water, are added to achieve proper consistency.
Consistency is defined as the percentage by
weight of dry pulp fiber in a combination of pulp
and water. Typical consistencies in the paper
machine range from 1/2 - 3%. Broke pulp may
also be added to the mixture. Broke pulp
consists of paper breaks and trim ends from the
paper machine which have been beaten in a broke
repulper.
Various chemical additives are required to aid in
proper sheet formation and drainage of water.
Some additives and their effects are:
D Starch improves paper strength and
surface feel at the dry-end of the paper machine
D Alum pH control and chemical retention
onto pulp fibers
D Fillers common fillers are clay, calcium
carbonate, or titanium dioxide. These particles
serve to fill gaps between fibers to produce a
smoother, brighter sheet.
These are a few of the many additives that may
be used. The chemical additives and various pulp
are mixed in a blending chest and the mixture is
commonly referred to as furnish.
Another step in pulp treatment involves
mechanical action. The two most common
treatments are referred to as beating and refining.
This action tends to separate and shear pulp
fibers which increases paper strength and allows
fibers to more easily absorb water and additives.
Two basic types of refiners are conical and disk
refiners. Both types consist of rotating elements
and a stationary housing to provide shearing
action. Refining is often done in two stages. One
stage involves treatment of virgin pulp fiber only
and a second stage for treatment of virgin fiber,
broke, and chemical additives.
Finally, the mixture of pulp and chemicals from the
blending chest is pumped through refiners to the
machine chest. The machine chest is also
supplied by the save-all. The save-all screens
fibers from white water drained from the paper
sheet into the wire pit.
Paper Machine
Following stock preparation, the furnish is sent to
the machine room for final sheet forming. Even
though different types of paper machines exist for
manufacture of various grades of paper, most all
perform the same basic functions which can be
divided into two broad categories. The wet end is
where the pulp and water solution is spread onto a
moving wire and dewatered to form sheet. The
sheet then moves to the dry end for further
evaporation of water and smoothing of the sheet.
The type of machine used most today is the
Fourdrinier paper machine.
The portion of the wet end that supplies stock to
the machine is referred to as the approach
system. Primary components in this system are
the wire pit, machine chest, fan pump, basis
weight valve, screens, and cleaners. The system
involves the fan pump accepting a mixture of white
water from the wire pit and stock from the
machine chest. The basis weight valve controls
the flow of stock from the machine chest to the fan
pump. The mixture of stock and white water is
85
pumped through screens and cleaners to the head
box. Screen and cleaners remove undesirable
particles such as dirt, grit and clumps of fibers, or
chemical additives. The next step involving the
head box and forming wire actually begins the
formation of a paper sheet. The head box accepts
stock and white water from the fan pump and is
required to deliver a uniform flow onto the moving
machine wire. Most modern head boxes are
pressurized. Proper control for achieving an even
and uniform outflow is critical for proper sheet
formation. The continuous fine screen wire
provides for the formation of a mat of fibers and
drainage of water. Modern wires run at speeds of
3000 - 5000 feet per minute. Due to the high wire
speeds, drainage is aided by a vacuum system
found under the wire screen.
After initial sheet formation and dewatering, the
sheet moves to the dry end of the machine. From
the machine wire, the sheet is transferred to the
press section. The press section rolls provide a
mechanical means for water removal and pressure
which consolidates and smooths the sheet. The
sheet is conveyed through the various presses on
a felt or synthetic fabric. The fabric provides for
transfer of pressing forces onto the paper and
volume space for removal of water and air. A
paper sheet leaving the presses is typically at 30 -
35% consistency (70% water).
The paper sheet is now transferred to the dryer
section where heat is applied to evaporate the
moisture content to 5 - 10%. The system consists
of a series of large diameter cylinders that are
internally steam heated. The paper sheet is
conveyed by a synthetic fiber over the cylinders
where moisture is evaporated and carried away by
a ventilation system. Condensate formed in the
dryer cylinders is removed by siphons and
returned to the powerhouse. Even drying across
the entire sheet is a major challenge in this
section.
Following drying, the paper is sent to the calendar
where large roll presses consolidate the paper to
its final thickness and smoothness. The calendar
stack consists of hard cylinders capable of
providing high compression forces. Paper from the
calendar is fed onto spools and rolled into large
reels. These reels are then processed to meet
customer size specifications by the winder and roll
finishing areas prior to shipment.
Utilities
So far, attention has focused on processing of the
primary raw ingredient, wood. However, other raw
materials such as water and electricity, as
illustrated in figure 3, play important roles in the
production of paper.
A paper mill requires large volumes of water for
use throughout the process. Although a few
processes can use raw water directly from the
source, most users require a higher quality of
water. Most water requires treatment in a
sedimentation basin followed by filtration to
remove suspended solids and other impurities.
The degree of treatment required depends on the
source of the water such as a river, lake, or well.
Additional treatment for removing dissolved
minerals is required for water used in boilers.
Failure to remove these deposits results in
build-up of sludge and scale which eventually
leads to operational problems in the boilers. The
most common method employed to remove the
dissolved minerals is with ion-exchange resins
called demineralizers. Demineralized water
production has a high capital and operating cost.
Water required for boilers demands special
treatment. In addition to demineralizers, further
treatment involving mechanical deaeration and
chemical additives is required to remove oxygen.
This ultra-pure water is used to produce steam in
both the power and recovery boilers. Steam
produced is used for both process heating and
generating electricity with steam turbine
generators. Dual use of fuel energy is called
cogeneration. Since the cost of making
demineralized water is high, it is important that
clean steam condensate be returned to the boiler
for reuse. A typical return rate is about 50%.
The other basic raw material, electrical power, is
typically provided by a combination of own-make
and a tie to the local utility. Own-make electricity is
produced via high pressure superheated steam
from the power and recovery boilers fed to steam
turbines. The turbines extract energy from the
steam which, in turn, drives an electrical
generator. The power boiler produces steam from
burning wood waste such as bark and is
supplemented with coal or oil. In most cases,
approximately 185 pound steam is sent to the
digester and turbine while 80 pound steam is used
in the steam room. Additionally, the recovery
boiler burns black liquor as fuel.
Since a mill typically does not produce enough
power to meet all of its electrical requirements, a
86
tie is usually established with the local utility. This
also allows the mill to remain in operation if their
electrical production is curtailed or down
completely. Most mills try to use as little
purchased electricity as possible.
Waste Treatment
An important consideration for modern pulp and
paper mills involves the effective treatment of
water and air waste streams. Increased
environmental awareness has led to stringent
emission limits. This aspect of pulp and paper
mills could be one of the most controversial and
capital intensive areas in the future.
The primary concern for water is treatment of
effluent which is returned to the source (river or
lake). Water used in areas such as the pulp mill
and bleach plant picks up contaminants which
would make it harmful for fish and people. The
waste effluent is typically treated in sedimentation
clarifiers and/or aeration lagoons to remove
contaminants. Although some methods are highly
effective, future trends will be toward closed
systems with no effluent waste stream.
Air pollution from pulp and paper mills involves
both particulate and odor emissions. The major
sources of particulate emissions involve power
and recovery boilers. Fine particulate from various
sodium compounds are emitted from recovery
boilers and coarse particulate from burning wood
waste in the power boiler. Treatment for
particulate typically involves collection devices
such as scrubbers or electrostatic precipitators.
Although odor emissions in general are not
dangerous to the public, resentment due to the
smell requires pollution control application. The
various sulfur gases causing the odor are referred
to a TRS (Total Reduced Sulfur). Since odor
pollution is difficult to treat, in-process methods
resulting in less generation of odorous gases is
preferred. However, absorption of gases with wet
scrubbers is often used to achieve final
abatement.
87
C0810 / IL
Figure 8-1. Kraft Pulp and Paper Mill Process Overview
88
C0811 / IL
Figure 8-2. Kraft Recovery Cycle
89
C0812 / IL
Figure 8-3. Utilities
810
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Chapter 9
Pulping
Pulping is the process of converting wood material
to separate pulp fibers for paper making.
Processes range from purely mechanical, in which
the wood is ground into fibers by refiners or
grindstones, to chemical processes, in which the
fibers are separated by chemically degrading and
dissolving the lignin that binds fibers together. In
many cases, mills will produce various grades of
paper having both mechanical and chemical
pulping processes.
Mechanical Pulping
Stone Groundwood
Process:
The most basic type of mechanical pulping is
known as stone groundwood (SGW), and has
been virtually unchanged since its development in
the 1840s. This process involves rotating
manufactured grindstones to be pressed against
small wood logs that are oriented parallel to the
axis of the stone where a typical modern SGW
plant will consist of only four to six grinders to
supply a large paper machine.
The quality of the produced pulp (strength and
drainage properties) depends primarily on the
surface characteristics of the stone. Water is
added to wash away the torn fibers. Virtually all
stones are artificially manufactured using a hard
grit material, typically embedded with silicon
carbide or aluminum oxide.
This process is a large consumer of electric power
due to the rotating grindstone, and the pulp
produced is typically used for the production of
newsprint grade paper.
Refiner Mechanical Pulp
Process:
Commercial production of refiner mechanical pulp
(RMP) began in 1960. It is produced in most
modern mills using chips rather than logs and
rigged metal discs used for shredding and grinding
of the wood chips. The chips are ground between
the rotating discs in a refiner, producing RMP.
This process is typically done in two separate
stages operating in series, and produces a
longer-fibered pulp than SGW. As a result, the
pulp is stronger, freer, bulkier, and usually
somewhat darker in color.
Thermomechanical Pulping
Process:
The first major modification to RMP was the
addition of steam before the refiner. This is known
as thermomechanical pulping (TMP). The
steaming serves to soften the chips, resulting in
the pulp having longer fibers and fewer shives
than RMP. These longer fibers produce a stronger
pulp than either SGW or RMP, making for a
stronger final sheet of paper. This process is still
employed on a large scale to produce high-tier
pulps for newsprint and board.
Referring to figure 1, chips are fed by a feeding
plug and screw feeder to a presteamer, which is
heated by PCV-1 to typically 15 to 30 psig and
265 to 285F. After a retention time of a couple of
minutes, the pressurized chips are fed to the
92
E1387
PRESTEAMER
CHIPS
FRESH STEAM
PCV-2
TMP PULP
PCV-3
REFINER
CYCLONE
STEAM TO
STACK
PCV-1
PCV-4
PROCESS
STEAM
STEAM TO
RECOVERY
Figure 9-1. Thermomechanical Pulping Process
refiner. The refiner may then be fed with fresh
steam via PCV-4, during startup, to increase the
pressure to 60-75 psig or 300F.
The refiner discharges the pulp and steam to the
cyclone, which separates the steam from the pulp.
The PCV-1 and PCV-2 valves control the pressure
in the refiner. During production, this steam is sent
to heat recovery, while during startup it goes to the
steam stack for disposal. The TMP pulp
(approximately 35% solids) is discharged through
valve PCV-3 from the first stage refiner to the
second stage, and from there, to further treatment
in the screening and cleaning stages.
Valve Selection:
The control of clean steam from PCV-4 can be
easily accomplished by the Fisher Vee-Ball
segmented ball valve. Where fibers can build up
and result in potential plugging problems, namely
PCV-1 and PCV-2, the Vee-Ball has proven
successful with its V-notch ball, as this shears
through any pulp fibers. However, any use of the
Vee-Ball attenuator must be evaluated with care.
The Fisher Control-Disk can also be used in this
service.
The TMP discharge, or blow valve, PCV-3
contains pulp at 35% consistency, and
steam/condensate. Because of the high pressure
drop of the system, this valve must withstand
erosion. One solution is the Vee-Ball with stellited
internals and trim, including the ball seal. The
water control valve should be a Vee-Ball to ensure
optimal control.
Valve Selection
Tag Application Recommended Alternate
PCV-1,
PCV-1
Steam
(process)
Vee-Ball
segmented ball
Control-Disk
PCV-3 Refiner Blow
Vee-Ball segmented
ball w/ stellited trim
PCV-4 Steam (fresh)
Vee-Ball
segmented ball
Control-Disk
- - -
Water (control)
Vee-Ball
segmented ball
Control-Disk
Chemithermomechanical Pulp
Process:
Wood chips can be pretreated with sodium
carbonate, sodium hydroxide, sodium sulfide, or
other chemicals prior to refining with equipment
similar to a mechanical mill. The conditions of the
chemical treatment are much less vigorous than in
a chemical pulping process since the goal is to
make the fibers easier to refine rather than
removing the lignin as in a fully chemical process
(described later in this section). Pulp made using
these hybrid processes are known as
chemithermomechanical pulp (CTMP).
93
Chemical Pulping
Chemical pulp is produced by combining wood
chips and chemicals in large pressure vessels
known as digesters (see chapter 3) where heat
and the chemicals break down the lignin, which
binds the cellulose fibers together, without
seriously degrading the cellulose fibers. Chemical
pulp is used for materials that need to be stronger
or combined with mechanical pulps to give a
product with different characteristics.
Sulfite
Process:
The sulfite process produces wood pulp, which is
almost pure cellulose fibers, by using various salts
of sulfurous acid to extract the lignin from wood
chips in digesters. This process is used to make
fine paper, tissue, glassine, and to add strength to
newsprint. The yield of pulp is higher than Kraft
pulping as the process does not degrade lignin to
the same extent as the Kraft process, and sulfite
is easier to bleach.
Sulfite pulping is carried out between a pH of 1.5
and 5, depending upon the counterion to sulfite
and the ratio of base to sulfurous acid. The pulp is
in contact with the pulping chemicals for four to
fourteen hours, and at temperatures ranging from
265F to 320F, again depending upon the
chemicals used.
The pulping liquor for most sulfite mills is made by
burning sulfur with the correct amount of oxygen
to give sulfur dioxide (SO
2
), which is then
absorbed into water to give sulfurous acid
(H
2
SO
3
).
S + O
2
SO
2

SO
2
+ H
2
O H
2
SO
3
Care must be given to avoid the formation of sulfur
trioxide (SO
3
) as this produces sulfuric acid
(H
2
SO
4
) when it is dissolved in water. This
promotes the hydrolysis of cellulose without
contributing to delignification (removal of lignin),
and ultimately damages the cellulose fibers. This
is one of the largest drawbacks of the sulfite
process, and leads the pulp fibers not being as
strong as Kraft pulp fibers.
The cooking liquor is prepared by adding the
counter ions, such as hydroxide or carbonate
salts. The relative amounts of each species
present in the liquid depends largely on the
amounts of sulfurous acid used.
For monovalent hydroxides (Na
+
, K
+
, and NH
4
+
),
MOH:
H
2
SO
3
+ MOH MHSO
3
+ H
2
O
MHSO
3
+ MOH M
2
SO
3
+ H
2
O
For divalent carbonates (Ca
2+
, Mg
2+
), MCO
3
:
MCO
3
+ 2H
2
SO
3
M(HSO
3
)
2
+ CO
2
+ H
2
O
M(HSO
3
)
2
+ MCO
3
2 MSO
3
+ CO
2
+ H
2
O
The spent cooking liquor from the process is
known as brown or red liquor. Pulp washers, using
countercurrent flow, remove the spent cooking
chemicals and degraded lignin and hemicellulose.
The extracted brown liquor is then concentrated in
multiple effect evaporators. The concentrated
brown liquor can be burned in the recovery boiler
to generate steam and recover the inorganic
chemicals for reuse in the pulping process, or it
can be neutralized to recover the useful
byproducts of pulping.
The most common recovery process used is
magnesium-based sulfite pulping, called the
Magnefite process. The concentrated brown
liquor is burned in the recovery boiler, producing
magnesium oxide (MgO) and sulfur dioxide, both
of which are recovered from the flue gases
created by the burning of the brown liquor.
Magnesium oxide is recovered in a wet scrubber
to give a slurry of magnesium hydroxide
(Mg(OH)
2
).
MgO + H
2
O Mg(OH)
2
This magnesium hydroxide slurry is then used in
another scrubber to absorb sulfur dioxide from the
flue gases, producing a magnesium bisulfite
(Mg(HSO)
3
) solution that is clarified, filtered, and
used again as the pulping liquor.
Mg(OH)
2
+ 2 SO
2
Mg(HSO
3
)
2
Sulfate (Kraft)
Process:
The sulfate or Kraft process is the dominant
chemical process used by pulp mills today. The
Kraft process involves cooking the wood chips
under pressure in an alkaline solution of sodium
hydroxide (NaOH) and sodium sulfide (Na
2
S). This
solution breaks down the glue-like lignin which
94
binds the cellulose wood fibers together. This
process produces stronger pulp than the other
processes, but is darker in color than the other
pulp processes. However, the benefit to this
process is the wide range of fiber sources that can
be used, and the regeneration of cooking liquors.
Woodchips are fed into digesters where they are
impregnated with the cooking liquors of warm
black liquor and white liquor (see chapter 3). The
warm black liquor is spent cooking liquor coming
from the blowtank. White liquor is a mixture of
sodium hydroxide and sodium sulfide, produced in
the Kraft recovery process. Delignification requires
several hours of cooking at 265F to 355F. Under
these conditions, the lignin and some
hemicellulose degrade to give fragments solubility
in a strongly basic liquid.
White Liquor:
NaOH Na
+
+ OH

Na
2
S + H
2
O 2Na
+
+ OH

+ HS

The lignin is removed by the following reaction,

where the HS

ion the component that ultimately

removes the lignin.
E1388
The finished cooked wood chips are blown from
the digester, and the action of the cooked wood
chips hitting the walls of the blowtank produce
individual pulp fibers. The solid pulp (about 50%
by weight based on dry wood chips) is then
collected and washed. The washing stages
separate the cooking liquors from the cellulose
fibers, where the pulp is brown after cooking and
is known as brown stock.
The combined liquids, known as black liquor due
to its color, contains lignin fragments,
carbohydrates from the breakdown of
hemicellulose, sodium carbonate, sodium sulfate,
and other inorganic salts.
Recovery Process:
The excess black liquor is concentrated in a
multiple effect evaporator (see chapter 4) into
heavy black liquor, and burned in the recovery
boiler (see chapter 5) to recover the inorganic
chemicals for reuse in the pulping process. More
concentrated black liquor increases the energy
and chemical efficiency of the recovery cycle. The
combustion is carried out such that sodium sulfate
(Na
2
SO
4
) is reduced to sodium sulfide by the
organic carbon in the mixture:
1. Na
2
SO
4
+ 2 C Na
2
S + 2 CO
2
The molten salts (smelt) from the recovery boiler
are dissolved in process water known as weak
wash (see chapter 6). The solution of Na
2
CO
3
and
sodium sulfide results in green liquor. This liquid is
mixed with calcium hydroxide (Ca(OH)
2
) to
regenerate the white liquor in the pulping process.
2. Na
2
S + Na
2
CO
3
+ Ca(OH)
2
Na
2
S + 2 NaOH
+ CaCO
3
Calcium carbonate (CaCO
3
) precipitates from the
white liquor and is recovered and heated in a lime
kiln where it is converted to calcium oxide (lime).
3. CaCO
3
CaO + CO
2
Lime is reacted with water to regenerate the
calcium hydroxide used in reaction 2.
4. CaO + H
2
O Ca(OH)
2
The combination of reaction 1 through 4 forms a
closed cycle with respect to sodium, sulfur, and
calcium. The recausticizing process where sodium
carbonate is reacted to regenerate sodium
hydroxide is the main reaction in the process
where approximately 98% of the original
chemicals are regenerated.
www.Fisher.com
Chapter 10A
Digesters
Batch Digesters Kraft Pulping
Kraft batch digesters have been produced in
several different configurations, including rotating,
horizontal, and spherical vessels. By far the most
prevalent configuration is the upright, cylindrical
batch digester.
Typically a batch digester is two to three and a
half stories tall and has 2500 to 7000 cubic feet of
capacity. The quantity of pulp produced per batch
ranges from five to 25 tons.
Wood chips, chemicals, and steam are combined,
coked under pressure to a schedule, and then
dumped to a blow tank on a batch basis. Mills with
batch digesters have been between four and 36
units. Some mills have both batch and continuous
digesters.
There are two methods of heating batch digesters:
D Directly steam batch digesters (figure
10A-1): These units are the least complicated
and are usually of older design. Steam at 50 to
150 psi is injected at the base of the digester into
direct contact with the wood chips and cooking
liquor.
D Indirect steam batch digesters (figure
10A-2): Cooking liquor is extracted from the
digester through a screen to prevent removal of
wood chips or pulp. The liquor is passed through
an indirect heat exchanger and then recirculated
to the top and bottom of the digester. Chip
packing, air evacuation systems, and presteaming
are incorporated with indirect heating to produce a
more modern batch digester design. A relatively
new derivation of the modern, indirectly steamed
batch digester is the low energy process. The
low energy process batch digester is covered later
in the chapter.
A drawback to the directly steamed digester is the
dilution effect from condensed steam. Indirectly
steamed digesters; however, require more
maintenance due to the screens, pumps, and
external heat exchangers. Regardless of the
digester steaming method, the process objective
is the same: to elevate the temperature and
pressure of the chip-liquor mass such that the
alkaline component in the cooking liquor can
dissolve the desired amount of lignin and
extractives from the cellulose fiber.
Batch Digester Process Parameters
The Kraft pulping process is also known as the
sulfate or alkaline process. The actual cooking
liquor is a mixture of white liquor from the
chemical recovery boiler and recausticizing
operations, and black liquor (spent white cooking
liquor), which has been separated from previous
batches by brown stock washers. The main
constituents in the white liquor that contribute to
dissolving away the lignin binder material are
NaOH and Na
2
S. The Kraft cooking liquor is
alkaline, or basic, with a starting pH above 13
units. The temperature of the cooking liquor, when
added to the digester, is typically 160 to 190F.
The temperature of the wood chips is typically 60 -
80F, but may be much colder in northern
climates. The following paragraphs describe the
various process parameters associated with the
Kraft batch pulping process.
Chemical Concentration of Cooking
Liquors
A key process parameter in the production of Kraft
pulps is the chemical strength of the white cooking
liquor being added to the wood chips in a digester.
To achieve a target pulp yield at a target K (or
Kappa) number, a specific quantity of white and
black cooking liquors must be added per unit of
10A 2
Figure 10A-1. Directly Steamed Batch Digester
10A 3
Figure 10A-2. Indirectly Steamed Batch Digester
10A 4
dry wood. However, these total liquor-to-wood and
liquor-strength-to-wood ratios are difficult to
enforce because on-line measurement of chip
moisture and weight have proven unreliable, and
the chemical strength of the white liquor solution is
not a stable or directly measurable variable.
Sensor developments in both areas are rapidly
advancing.
Cooking Time
A digester begins to cook slowly as soon as the
white liquor and black liquor solutions are applied
to the wood chips (even at atmospheric pressure,
i.e., before capping). Typically, a digester cooking
cycle is as follows: the digester is capped,
steaming is begun, and the temperature and
pressure ramp up to a predetermined pressure (or
temperature). Further steaming is then regulated
to maintain the desired target pressure (or
temperature). When the target H factor has been
reached, the digesters contents are blown to the
blow tank.
The total length of the cooking cycle per batch
digester will depend on the desired pulp grade and
the mills criteria of operations. Consequently, a
batch cooking cycle can range from two hours
cap-to-cap for a hard cook (high yield), to five
hours for a soft cook (low yield).
Cooking Temperature
The batch digester temperature is also a
significant factor in achieving cooking uniformity
(delignification) throughout the mass of chips.
Higher temperatures accelerate the rate of
chemical reaction between the wood chips and the
cooking liquors. The quantity of rejects (i.e., knots
or partially cooked chips) in a batch is related to
uneven temperature distribution in the digester.
For example, if poor convection mixing causes
temperature differences between the bottom and
top, it is not uncommon for pulp at the bottom of a
digester to be several Kappa units different from
pulp at the top of a digester.
Typically, a charged batch digester at atmospheric
pressure is at around 165F to 195F. Upon
capping and steaming, the maximum desired
cooking temperatures will range from 330F to
350F at pressures of 100 to 120 psi. Normally,
there is at least a top and a bottom temperature
sensor on each digester. A middle temperature
probe is encouraged for improved indication of
temperature distribution. The bottom temperature
usually exceeds the top temperature due to
hydrostatic liquor head on directly steamed units,
because the sensor is closer to the entry point of
steam.
Cooking Pressure
Digester pressure rises as the steam flow to the
digester raises the temperature of the chip and
liquor mass. Batch temperature is considered to
be the key variable, but batch pressure is an
easier and faster variable to measure than a
representative chip and liquor mass temperature.
The pressure/temperature relationship is based on
saturated steam tables. The implied digester
temperature should include a slight increment for
the boiling point rise of the cooking liquor. The
elevated boiling point over water is due to organic
and inorganic solids in the liquor. Digester
pressure ranges from atmospheric at liquor
charging to a maximum of 100 to 120 psi for the
extended cooking period.
Digester pressure causes the cooking liquor to
more readily impregnate the wood chips so that
the delignification reactions proceed from the
inside of the chip to the outside of the chip, as well
as vice-versa. Pressure in a batch digester ranges
from atmospheric at liquor changing to a
maximum of 100-120 psi for the extended cooking
period.
Pressure Profile
The batch digester cooking cycle is usually
represented in text books by a graph of the
internal digester pressure vs. time, such as that
shown in figure 10A-3. In real life, the cooking
cycle pressure profile is never this rigid. The time
interval at each different phase of the cook can
vary significantly from one grade of pulp to
another and from mill to mill. Figure 10A-4 shows
a more realistic representation of the pressure
profile over the entire cooking cycle. Figure 10A-5
shows the steam demand profile required to
complete this representative cooking cycle. The
vertical axis defining the amount of steam
demanded is not labeled because different pulp
grades or different sized digesters will require
different quantities of steam. However, a typical
3-hour cooking cycle at 100 psig consumes from
4000 to 6500 pounds of steam per ton of pulp
produced. Therefore, a 7-ton digester could
consume about 40,000 pounds of steam per
cooking cycle.
10A 5
Figure 10A-5. Steam Demand Profile
Figure 10A-4. Actual Batch Cooking Cycle
Figure 10A-3. Theoretical Batch Cooking Cycle
10A 6
False Pressure
A batch digester is basically a large pressure
cooker. As steam is applied to the mass of chips
and liquor, a quantity of resinous vapors are
distilled off. These vapors, along with air initially
entrained with the chips and a small quantity of
non-condensed steam, migrate to the top of the
digester. These vapors and gases are
systematically drawn off through the digester relief
(gas off) piping. The vapors are a major source of
the distinctive Kraft mill odor.
If the non-condensable portions of these gases
are not relieved from the digester they would
eventually accumulate sufficiently in the top of the
digester to indicate a falsely high pressure relative
to the steam saturation temperature. Under such
conditions, the correct control action would be to
reduce the steam flow to the digester. The cook
would then take place at a steam saturation
temperature corresponding to say, 102 psig
instead of the 100 psig target. The resulting batch
would be very undercooked and possibly ruined.
Therefore, the non-condensable portion of the
relieved gases must be removed from the digester
in order to maintain the correct
temperature-pressure relationship.
Overpressure
Overpressure of a digester means that the actual
digester pressure is above the desired target.
Overpressure may result from trying to maintain
the proper temperature while false pressure exists
(overshooting), or via exothermic reactions once
the target pressure has been reached. For
insurance and safety purposes, each digester will
have an upper pressure limit rating. Overpressure
exposes production personnel to a hazardous
environment and is a contributor to off-quality
pulp.
Relief or Gas Off
The previous discussions of digester overpressure
and digester false pressure outlined the necessity
for relieving excess gases from a digester. Figure
10A-1 shows a typical relief piping arrangement.
When the gas off valve is open, the blow back
valve must be closed. This interlock must exist for
both safety and economic reasons.
In general, a relief line is connected to the neck of
the digester through a relief screen. The screen
prevents large quantities of cellulose fibers or
chips from entering the relief line piping system.
Liquor, being a fluid, can readily pass through the
screen, but it is undesirable to allow any chemical
loss to occur. All relief gases and liquids pass from
their respective digesters into a common header.
This header directs all such materials to a central
separating device which separates
non-condensable gases from condensable gases
and liquor, pulp, etc. The non-condensable gases
are quite odorous. These gases are usually
scrubbed and/or burned in a lime kiln. The
condensable gases, however, can contain, in
addition to steam, a significant quantify of a
valuable byproduct, i.e., crude turpentine. Three to
four gallons of crude turpentine can be distilled off
and recovered per ton of resinous southern pine
pulp produced.
Blow Back
Blow back is basically a short reversal of steam
flow through the gas off line to the top of the
digester for the purpose of cleaning the relief
screen and/or collapsing the steam bubble, which
may form within the chip mass in the lower area of
the digester. The sequence is typically: (1) shut off
the high pressure steam valve to the base of the
digester, (2) shut off the gas-off valve to the
common header, and (3) open the blow back valve
(see figures 10A-1 and 10A-2). This sequence
allows high pressure steam to be briefly injected
through the relief lines and into the top of the
digester. The surge of high pressure steam blows
the screen clean while the increased pressure
from the top forces the chip mass down,
collapsing the bubble. A blow back typically lasts
only 10-30 seconds, and then the valves revert to
the original status.
Blow Tank
When a digester cooking cycle is completed, the
blow valve is opened to connect the digester with
a common blow tank. The blow tank is a low
pressure receiving vessel, which is usually
capable of holding several blows. Several batch
digesters producing the same grade of pulp will
discharge into the same blow tank. The high
pressure in the digester will blow the entire mass
of chips and black liquor into the blow tank.
Typically, a blow tank is equipped with both
vacuum and pressure relief valving systems
because 100 to 120 psi is released when the blow
valve is opened. A significant quantity of vapor will
be flashed off the pulp and liquor as it enters the
blow tank. A blow tank is not designed to
10A 7
withstand digester-like pressures and so the relief
valve will pop if the outlet for gas-off is plugged
with pulp. Similarly, flashed vapor to a condensing
device can create sufficient vacuum to collapse a
blow tank. The vacuum relief valve provides a
margin of safety against such an occurrence.
From the blow tank the brown stock is pumped to
washing and screening stages.
Control Valve Selection
Digester Capping Valve
The chips are conveyed to the chip chute which is
mounted directly to the capping valve (see figures
10A-1 and 10A-2). One of the most important
valves, this valve is used to automate the chip
filling operation. This is an erosive service as the
chips impinge on the sides of the body and ball, so
hardened materials and trim must be used. In
addition, tight shutoff is necessary to ensure the
appropriate pressure can be reached within the
digester for chip cooking.
General Service Valves
Refer to figure 10A-1.
PROCESS FISHER CONTROL VALVE PRODUCT DESIGN
Valve
Tag #
DIRECT STEAMED
BATCH DIGESTER
V150 V300 V500 CV500 ED/ET
Typical
Valve Size Application
Description
Control
Function
HV-1 Liquor fill O/O P 10
FV-1 White liquor to digester T S S P 8
FV-2 Black liquor to digester T S S P 8
HV-2 Blow back steam valve O/O P 2
PV-1 Gas off T P 3
TV-1 Cooking valve T S P 8
Refer to figure 10A-2.
PROCESS FISHER CONTROL VALVE PRODUCT DESIGN
Valve
Tag #
INDIRECTLY STEAMED
BATCH DIGESTER
V150 V300 V500 CV500 ED/ET
Typical
Valve Size Application
Description
Control
Function
HV-1 Liquor fill O/O S P 10
FV-1 White liquor to digester T S P 8
FV-2 Black liquor to digester T S P 8
HV-2 Blow back valve O/O P 2
PV-1 Gas off T P 3
TV-1 Indirect steam valve T S P 3
FV-3 Digester top recirculation T P 8
FV-4 Digester bottom recirculation T P 8
TV-2 Condensate return T P S 3
TV-3 Direct steam valve T S P 6
CODE:
P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
10A 8
Batch Digester Low Energy
Process
Much has been written about the relatively new
low energy cooking process. Studies indicate
improved pulping properties and operating
efficiencies over conventional batch digesters.
Some of the reported benefits of the low energy
process are:
D Significant steam savings
D Reduced evaporator load
D Lower black liquor viscosities
D Lower alkali consumption
D Fewer brown stock washing stages
D Stronger pulp
D Lower environmental impact
The Process
The main difference between the low energy
cooking process and a conventional batch digester
is the tank farm associated with the heat recovery
system. Accumulator tanks are added with each
stage of process. A typical three-stage design is
shown in the process schematic (see figure
10A-6). Actual mill installations have duplicate sets
of pumps, valves and piping to handle odd and
even digesters. Also there are typically sets of A,
B, and C accumulator tanks. This arrangement
allows for operations flexibility.
The function of the tank farm and management of
the transfer of liquors is key to understanding the
low energy process and cooking cycle. First,
empty digesters are filled with wood chips. If
desired, packing of the chip bed can be
accomplished with steam or liquor. Steam
provides higher compaction. Compaction of the
bend increases capacity of the cook.
Cool black liquor from the atmospheric A tank is
added to provide a liquor pad in the bottom of the
digester. Warm black liquor from the pressurized
B tank is then pumped into the digester
displacing entrained air. The discharge valves are
then closed. The warm liquor pump brings the
digester up to pressure by pre-impregnating the
chips and hydraulically filling the vessel.
The chips are further heated by pumping both hot
black and hot white liquor into the digester. The
white liquor is preheated through an indirect heat
exchanger between the C and B tanks using
hot black liquor as the heat source. The hot white
liquor is then stored in a pressurized accumulator
tank for delivery to the digesters. Warm black
liquor is displaced to the A tank where soap is
skimmed and excess liquor is sent to the weak
liquor filters.
After completion of the hot liquor fill operation, the
pulp mass is generally close to the required cook
temperature and pressure. If necessary, further
heating is done by an external liquor heater.
As the pulp is cooked, resinous vapors are given
off. These vapors, along with any remaining
entrained air, migrate to the top of the digester.
These gases are systematically drawn off through
the digester relief valve. If these gases were not
drawn off a false pressure relative to the steam
saturated temperature would be indicated. Under
such conditions the control action might be to
reduce steam to the digester and thus undercook
the pulp. From time to time between relief cycles,
steam is blown back through the relief line to clean
debris off the relief screens.
Once the proper degree of cooking (H-factor) has
been reached, cooking is stopped by pumping
washer filtrate into the bottom of the digester.
Most of the cooking liquor remains hot and is
displaced to the C tank, ready to use for the next
cook. The cooler liquor goes to B and A tanks.
As a result, the pulp in the digester is washed and
cooled below flash point at atmospheric
conditions. This in-digester washing reduces load
on both the brown stock washers and evaporators.
The pulp is then transferred to the blow tank by
cold-blowing the digester with compressed air. A
high pressure air receiver is used for this air
supply. Since the pulp is blown cool a number of
benefits arise including improved pulp quality and
lower emissions of total reduced sulfur.
10A 9
Figure 10A-6. Typical Three-Stage Design
10A 10
Control Valve Selection
General Service Valves
Refer to figure 10A-6.
PROCESS FISHER CONTROL VALVE PRODUCT DESIGN
Valve
Tag #
WARM BLACK LIQUOR
ACCUMULATOR
V150 V200 V300 V500 CV500 A81
Control-
Disk
Typical
Valve
Size
Application
Description
Control
Function
HV4 Warm liquor to warm fill pump O/O P S 14
TV2
Mill water temperature control
valve through cooler
T P S 6
HV5 Digester liquor return header O/O P S 12
HV6 Digester liquor return header O/O P S 12
FV2
Warm liquor flow through
liquor cooler
T P S 4
FV6 Warm fill control valve T P S 10
Refer to figure 10A-6.
PROCESS FISHER CONTROL VALVE PRODUCT DESIGN
Valve
Tag #
WARM BLACK LIQUOR
ACCUMULATOR AND DISPLACEMENT
TANK
V150 V200 V300 V500 CV500 A81
Control-
Disk
ED/ET
Typical
Valve
Size Application
Description
Control
Function
HV1 Digester liquor return header O/O P S 12
HV2 Displacement tank bypass O/O P S 12
LV1
Cool liquor level control valve
to liquor filter
T P S 10
TV1
Warm liquor to cool-temp
control
T S P 2
HV3
Cool liquor pad to warm fill
pump
O/O P S 12
LV2D
Brown stock filtrate level
control
T P S 12
Refer to figure 10A-6.
PROCESS FISHER CONTROL VALVE PRODUCT DESIGN
Valve
Tag #
HOT BLACK LIQUOR ACCUMULATOR
AND WHITE LIQUOR ACCUMULATOR
V150 V200 V300 V500 CV500 A81
Control-
Disk
ED/ET
Typical
Valve
Size
Application
Description
Control
Function
HV7 Digester liquor return header O/O P S 10
HV8
Displacement liquor return
header
O/O P S 10
FV3
Cool white liquor to heat
exchanger
T P S 6
FV4 Hot liquor to hot fill pump T P S 8
FV5
Hot white liquor to hot fill
pump
T P S 10
10A 11
Refer to figure 10A-6.
PROCESS FISHER CONTROL VALVE PRODUCT DESIGN
Valve
Tag #
DIGESTER
V150 V200 V300 V500 CV500 A81
Control-
Disk
ED/ET
Typical
Valve
Size
Application
Description
Control
Function
HV9 Digester hot header return O/O P S 10
HV10 Digester warm header return O/O P S 10
PV1
Digester main pressure
control valve
P 12
HV11 Air to receiver to digester O/O P S 6
HV12 Digester air evacuation O/O P S 12
FV7 Relief to blow tank P 9
HV13 Digester steam packer valve P 8
PV2
Digester relief to hot
accumulator
P 3
HV14
Digester relief screen blow
back
P 3
HV15 Digester top recirculation O/O P 12
TV3 Digester sparger steam valve P 3
HV16 Digester bottom recirculation O/O P 12
HV17 Digester cone flush dilution O/O P 9
HV18 Digester displacement fill O/O P 10
HV19 Digester warm fill inlet O/O P 12
HV20 Digester hot fill inlet O/O P 10
CODE:
P=Primary Selection, S=Secondary selection, T=Throttling, O/O=On/Off
10A 12
www.Fisher.com
Chapter 10B
Kamyr
R
Continuous Digesters
Kamyr
R
continuous digesters vary depending
upon the type of raw material, end product, the
cost of chemicals, steam or power, as well as
geographical location of the mill. There are five
basic configurations:
D Single vessel hydraulic digester (the original
design).
D Two vessel hydraulic digester (with separate
high pressure impregnation vessel).
D Single vessel steam/liquor phase digester
(with high pressure feeding system). Developed
primarily for sulfite cooking, it has also been used
for Kraft, pre-hydrolysis Kraft, and neutral sulfite
semi-chemical pulp.
D Two vessel steam/liquor phase digester (with
separate high pressure impregnation vessel)
D Steam/Liquor Phase Digester (with asthma
feeder) used for pulping sawdust, shavings or
non-wood fibers such as straw, bamboo, jute, etc.
The single vessel hydraulic digester was the
original Kamyr digester. It is so named because
the digester consists of a single vessel, which is
operated completely full of liquor (no vapor being
present). Digester heating is accomplished by
heating the cooking liquor indirectly in heat
exchangers using 150 to 175 psi steam and
circulating this heated cooking liquor through the
downward flowing chips in the digester vessel.
Over the years, this hydraulic digester system has
constantly improved. The modern single vessel
hydraulic digester has an improved steaming and
feeding system, which improves its tolerance of
dry and degraded chips. The combination
improved cooking circulations and steps in the
vessel diameter have made it possible to produce
a more uniform pulp, with a poor quality of chip
furnish.
The main features of a hydraulic digester are:
D Metering and steaming of the wood chips.
D Feeding chips to the digester via the high
pressure feeder and top circulation loop.
D High pressure impregnation of the chips with
cooking liquor.
D Heating to cooking temperature through
liquor circulation, using indirect heating.
D Hi-heat-in-digester washing followed by a
diffusion washer.
The hydraulic type digester with its long
impregnation and cooking times produces a very
uniform, high quality, strong pulp and is suitable
for the production of either liner grade or
bleachable grade pulps.
The two vessel hydraulic digester was originally
designed to provide optimum pulp quality in very
large digester systems (above 1200 TPD), but has
been used for smaller tonnages.
For large tonnages, the digester vessel becomes
large in diameter. This, in turn, makes it more
difficult to ensure uniform circulation in the normal
cooking liquor heating system.
In order to ensure uniform heating of the larger
chip mass, an impregnation vessel is added to
heat the chips to cooking temperature before they
enter the second vessel (digester). This allows for
all of the chips to be heated to exactly the same
cooking temperature, helping to optimize pulp
uniformity.
This digester is essentially unaffected by varying
chip furnish, as there is a homogeneous chip
10B 2
mass throughout the chip column which explains a
growing use of the two vessel digester system.
Process
Regardless of the type, a Kamyr continuous
digester combines the digesting and washing
process into one vessel so that only one washing
stage is required following the blow tank. Chips
from the wood yard are fed to a surge bin (chip
bin) in the digester building. They are then
metered continuously through a chip meter to a
low pressure feeder. The chips then fall into the
steaming vessel, and are conveyed to the chip
chute and the high pressure feeder. Chips are
then sluiced to the top of the digester and the top
separator at a predetermined temperature and
pressure. Cooking liquor is also fed continuously
into the top of the digester in the desired ratio to
the wood chips. The chips move slowly by gravity
to the bottom where they are discharged as pulp.
Along the way, they are heated to simulate the
heating of a batch digester and its contents. The
temperature is varied in the mid-section, or
cooking zone, to suit different production rates.
The bottom digester section is used as a washer
and, at this point, any similarity between batch and
continuous cooking ends.
With a vacuum drum washer, liquor is drained
from the pulp and replaced by water. In the Kamyr
digester wash system, the liquor is displaced by
introducing very weak black liquor from the
vacuum washer, diffuser or even warm water at
the bottom of the digester, making it flow
counter-currently to the pulp mass which is
moving to the bottom. This is known as hi-heat
diffusion washing. The up-flowing weak black
liquor wash displaces the stronger residual black
liquor, which is drawn off through a screen in the
wall of the digester located about half-way up from
the bottom, but below the cooking zone. This
allows the pulp to be effectively washed before it
is blown to the blow tank.
Although all components of the Kamyr digester
are closely interrelated, the following is a logical
step by step explanation of controlled loops, which
will provide an understanding of the various stages
of the Kamyr system.
Pressurizing
Weak black liquor (filtrate) or warm water,
approximately 170_F, is pumped to the digester
through the cold blow pump. There, it is used to
maintain digester pressure. The digester pressure
control system has three major components:
D An automatic pressure control valve on an
input liquor line.
D An automatic pressure relief control valve on
the digester relief line.
D A pressure pump kick-out switch on the
digester.
The digester pressure can be controlled by moving
the set point on the input control valve to 165 psig
(normal digester pressure). A rise in the set point
would then cause the valve to open to admit more
liquor to the digester and, therefore, increase the
pressure. The reverse occurs when the pressure
set point is lowered. This is a rapid response
controller.
The secondary pressure control element consists
of the automatic relief valve, which bleeds liquor
from the lower cooking zone header to the No. 2
flash tank. The relief valve is set slightly higher (15
psig) than the input valve and bleeds off liquor
when the pressure exceeds this set point. The
relief valve should always be in a closed position
under normal conditions. It is only used as a
pressure relief valve.
The third control device is primarily an emergency
safety device, which is activated when the first two
control devices fail. A pressure switch is mounted
on the digester shell and stops the cold blow pump
when the pressure rises too high. Digester
pressure is normally set at 165 psig, the pressure
relief valve is set on 180 psig, and the pressure
switch at 225 psig. As the pressure continues to
rise, the make-up liquor pump will kick-out.
Chip Feeding
Processed chips from the wood room are
transmitted to the chip bin, which also serves as a
short term chip storage bin. This storage can
facilitate continued digester operation during small
upsets between the wood room and the digester
building. Chips flow by gravity from the bin through
a tapered hopper into the chip meter. The chip
meter is a rotating star feeder with seven pockets
yielding a certain volume of chips per revolution.
Digester production is regulated by a variable
10B 3
Figure 10B-1. Chip Feeding
E1214
speed drive on the chip meter drive. It is important
to keep the chip meter full in order to maintain a
steady feed rate. A vibrator is provided on the chip
hopper for intermittent use, as required, to ensure
a steady feed of chips to the chip meter.
Chips leaving the chip meter drop into a second
feeder, called a low pressure feeder. It is simply a
continuously rotating, tapered star feeder, which
forms a seal between atmospheric pressure and
15-18 psig of the next stage. Its primary function is
to prevent steam leakage and to deliver chips to
the steaming vessel. Steam is injected into the
ends of the rotor housing in order to blow sawdust
and chip fines out. The pressure remains in the
empty pocket after the chips have dropped out
and is relieved through a pipe connected to the top
of the chip hopper. To ensure a steady feed, the
low pressure feeder is designed so that one
pocket is being filled with chips, one pocket is
discharging chips, and one pocket is relieving
steam to the chip hopper.
Valve: TV-2A Chip bin temperature
This valve provides an alternate source of low
pressure steam to the steaming vessel where the
wood chips are pre-steamed at atmospheric
pressure.
D Typical process conditions:
Fluid: Steam
T = 325 400_F
P = 60 80 psig
10B 4
Figure 10B-2. Steaming Vessel
E1215
dP = 50 60 psid
Q = 2900 5000 lbs/hr
D Typical valve selection:
This is specified by Kamyr as a NPS 8 to
NPS 10 Fisher Vee-Ballt V150 valve, and
could need an attenuator. Carbon steel body
material has been used successfully,
although stainless steel would provide an
added level of durability. HD metal seats are
specified with PTFE packing, PEEK
bearings, and Nitronic 50 shafts.
Valve: TV-4 Fresh steam to chip bin
This valve provides hot water to the chip bin.
D Typical process conditions:
Fluid: Hot water
T = 312_F
P = 230 psig
dP = 135 145 psi
D Typical valve selection:
This valve is specified by Kamyr as a
NPS 1/2 globe valve with a 300 lb. rating. A
reduced port may be needed depending
upon flow requirements. A carbon steel body
is suggested with 316 SS equal percentage
trim.
Pre-steaming and Conditioning
The steaming vessel is a normally horizontally
mounted cylinder with an internal screw conveyor
for carrying chips along from the low pressure
feeder through steam to the next stage. Its main
functions are to remove gases and air from the
chips, raise the temperature to approximately
250_F, and bring the chips to a more uniform
moisture content. A secondary aim is to maintain a
pressure balance in the feeding system. This
means that the steam pressure (15-18 psig) in the
steaming vessel must always be higher than the
vapor pressure of the liquor in the top circulation
line so that the latter does not start to boil when it
leaks back into the chip chute low pressure area.
Removal of air and gases enables the cooking
liquor to penetrate the chips more easily.
The steam is supplied from two sources: flash
steam from the No. 1 flash tank and from a fresh
make-up low pressure steam header.
In order to obtain an effective pre-steaming, the
steam is introduced at the bottom of the steaming
vessel (bottom steaming). There are no controls
on the steam from the flash tank as it is
dependent upon extraction flow from the digester.
The venting of exhaust and non-condensable
gases controls the amount of fresh steam usage.
The exhaust line is equipped with a screen that
prevents sawdust and fine particles from being
carried into the heat recovery area.
After passing through the steaming vessel, the
chips fall from the end of the screw conveyor,
down a chute known as the chip chute, into a pool
of liquor. At this point, the chips start to absorb
liquor. An inspection port is provided on the
steaming vessel for the monitoring of the flow of
chips into the chute.
The chip chute is a vertical pressure vessel with
an internal slotted screen plate. It sits directly on
top of the high pressure feeder. The liquor in the
10B 5
chip chute is maintained at a constant level by the
use of a level control valve on the overflow line,
which carries excess liquor to a surge tank known
as a level tank. The source of chip chute liquor is
mainly leakage from around the high pressure
feeder and some steaming vessel condensate. In
order to take sudden flow surges, such as when
the high pressure feeder starts rotating or when
chips fall into the chute, the overflow control valve
response is extremely rapid. The screen plates
prevent chips from being carried with the overflow
to the level tank, and keep the chips in the chip
chute to feed the pockets of the high pressure
feeder.
A pressure switch is connected to the make-up
liquor pump from the same pressure-sensing unit
that stops the cold blow pump. This safety device
is necessary to avoid over-pressurizing the
digester and it is set at approximately 240 psig.
The digester operates at 165 psig, measured at
the bottom heating zone. The transfer of chips and
liquor from a 15-18 psig steaming vessel pressure
to the digester operating pressure needs to be
accomplished via a pressure lock system. This is
accomplished by the high pressure feeder, which
is similar to the low pressure feeder. The high
pressure feeder has a tapered rotor with four
helical type pockets which go from one side of the
rotor to the other and are set at an angle of 45_ to
each other. The feeding of chips is continuous.
Two liquor pumps are used to aid in filling and
discharging the high pressure feeder. They are as
follows:
1. Chip chute pump Chips falling into the chip
chute pool of liquor tend to float or be drawn to the
side screen plates by the liquor overflowing to the
level tank. In order to counteract this effect, the
chip chute circulating pump is set to pull or suck
the chips downward into the rotating high pressure
feeder with a force greater than the sideways pull
of the overflowing liquor. The discharge of the
pump re-circulates the liquor to a point located
above the pool of liquor in the chip chute. When
severe conditions of sawdust and fines are
prevalent, an in-line grainer may be installed
between the pump discharge and the entry above
the pool of liquor. Its function is to take liquor
around the screen section, thus cutting down on
the sideways pull of overflowing liquor. The
pressure drop across the screens will reduce,
allowing the natural wiping action of moving chips
to keep the screens from plugging. As the pump
will deliver 2,000 - 2,500 GPM, closing the valve
between the in-line drainer and the level tank will
allow the in-line drainer to clear itself by liquor flow
to the chip chute.
2. Top circulation pump The pump circulates
liquor to the top of the digester and back out. Its
action is to flush the chips out of the feeder pocket
once it has rotated to the discharge point and to
carry the chips into the digester. The liquor is then
separated from the chips via the top separator
screen and returned to the suction of the pump to
form a continuous loop.
When a pocket is in a vertical position, the chips
are fed with the help of the chip chute pump.
When the pocket has rotated 90_ to a horizontal
position, the chips are flushed out into the high
pressure system with the liquor from the top
circulation pump. The whole system is arranged
so that there is always one pocket being filled
while another is being emptied.
As mentioned previously, there is liquor leakage
around the rotor due to the pressure differential
between the operating digester pressures and the
pressure in the chip chute and steaming vessel.
This liquor leakage is an important feature of the
high pressure feeder operation, as it provides
constant lubrication between the feeder plug and
housing, and washes sand and grit from this area.
As the liquor is at a high temperature, it will boil in
the chip chute unless held under higher pressure
than the vapor pressure of the liquor. This is
particularly true following a shutdown when heat
rises to the top of the digester from the cooking
zones due to convection currents. The hot liquor
boils rapidly, or flashes, at the high pressure
feeder and chip chute if the high pressure feeder
is started. Therefore, the high pressure feeder
must never be started unless the top section of
the digester is first cooled below 240_ F by
addition of cold filtrate through the make-up liquor
pump. The plug clearance is adjusted from time to
time as it wears. Excessive wear of gap between
the plug and housing allows too much liquor to
pass to the chip chute and overloads the make-up
liquor pump due to excess flow of liquor from the
level tank to the make-up liquor pump. This can
cause liquor to back up through the level tank into
the chip chute and even back up as far as the chip
bin. The high pressure feeder serves to complete
the transfer of the chips from 15 psig to digester
pressure without subjecting the chips to any harsh
mechanical action, which would damage the fiber
and degrade the resulting pulp quality.
The top circulation line, a part of which is a hole
through the high pressure feeder, is a part of the
digester vessel itself during normal operation. This
means that it is under the influence of the digester
10B 6
Figure 10B-3. Cooking Flow Diagram
pressure control valve. Two large piston-operated
valves are designed to isolate the top circulation
line from the digester. These valves cannot be
opened unless there is equal pressure on each
side of the valve. This prevents damage to piping
and valves by a sudden surge of liquor from the
digester flowing into the lines. A pressure switch is
mounted on the return leg and is set to hold the
valves closed until the pressure in the line is
almost equal to that in the digester. Only then can
these valves be opened by hand switches on the
instrument panel. Chips only enter the digester
through the top separator. This unit consists of a
cylindrical screen with continuous vertical slots
that separate the liquor from the chips so the
liquor may be re-circulated through the high
pressure feeder back to the top separator again. A
slow-moving vertical screw conveyor inside the
screen pushes the chips downward into the
digester, keeping the screen clear. The chips fall
onto the top of the column of chips. This is
continuous throughout the entire digester. In other
words, there is a solid body of chips from the top
to the bottom of the digester undergoing various
stages of treatment.
The sluicing liquor is extracted through the top
separator screen and is returned to the suction of
the top circulation pump to be recycled with chips
to the top of the digester. Built into the top
separator is a level-indicating device, which allows
the operator to have an indication of the level of
chips inside the digester. This level device is a
small paddle which turns with the top separator
down in the chip mass. The resistance of the chips
against the paddle is measured by a torque
indicator on the top of the top separator. This
measurement is transmitted to the control panel,
which has a low level light (green), a normal
(yellow) and a high (red). The digester is normally
run at a yellow-red level indication. If the level gets
high enough so that the chips ride against the
screw conveyor, an increase in amperage of the
motor will be seen on the control panel. When the
load becomes severe, the top separator alarm will
go off, warning the operator to take corrective
measures. The drive shaft of the top separator is
sealed by packing. Digester pressure compresses
the packing, forming a seal. When the pressure is
radically changed, the packing may not properly
seal for some time.
Valve: FV-3A High pressure feeder
purge
Note: In older systems, this is HV-3A or HV-35.
D Typical process conditions:
Fluid = White liquor
10B 7
T = 190_F
P = 240 psig 280 psig
dP = 75 psi 110 psi
Q= 50-125 gpm
D Typical valve selection:
NPS 2 to NPS 3 valves with alloy 6
scraper seats are utilized due to concerns
over white liquor scaling. A SST V300 valve
with an alloy 6 HD seal and alloy 6 bearings
should be used in this application.
Valve: TV-2 Flash steam to chip bin
temperature control
This valve controls the flow of low pressure steam
from the No. 2 flash tank to the steaming vessel
where the wood chips are pre-steamed at
atmospheric pressure.
D Typical process conditions:
Fluid: Saturated steam
T = 220_F
P = 2.5 30 psid
dP = 1.0 psi
Q= 29000 50000 lbs/hr
D Typical valve selection:
This is specified as a Fisher HPBV by
Kamyr. Valve size is in the range of NPS 10
to NPS 18. Metal bearings and a metal seat
are recommended by Kamyr. However,
PEEK bearings and Teflon seats in a
stainless steel body and with a 17-4 splined
shaft are also appropriate.
Valve: PV-5A Steam vessel pressure
relief
This valve is used for steam pressure relief in the
chip steaming vessel at the beginning of the
pulping process.
D Typical process conditions:
Fluid: Steam
T = 256 280_F
P = 18 30 psig
dP = 16 psi
D Typical valve selection:
Kamyr specifies this valve as a NPS 8
one way, tight, spring assisted full bore ball
valve due to relief valve sizing downstream.
The V300 valve in stainless steel with alloy 6
trim would be a good alternative in this
application if the specification allows.
Valve: PV-5 Steaming vessel pressure
relief
This valve vents air and non-condensable gases
from the steaming vessel.
D Typical process conditions:
Fluid: Steam and non-condensable gases
T = 312_F
P = 60 psig
dP = 17 - 40 psid
Q = 4300 lbs/hr
D Typical valve selection:
In cases where entrained particles are
found in the flow, the recommended valve is
a CV500 with hardened trim due to the
potential erosion. If no particles are found in
the flow, a standard Vee-Ball may be used.
This is typically specified as a NPS 8 valve.
Valve: HV-5 Steaming vessel relief
steam flow
This valve sends clean steam from the steaming
vessel pressure relief to the steam condensers.
D Typical process conditions:
Fluid: Steam
T = 255_F
P = 18 33 psig
dP = 16 psi
Q = 1200 lbs/hr
D Typical valve selection:
This is a throttling application and Kamyr
has specified a V150 valve with attenuator
for this application. Stainless steel body
material together with a Nitronic 50 shaft, HD
metal seal, and PEEK bearings are
recommended. The valve is typically in the
NPS 6 size range.
Valve: PV-2 Steaming vessel pressure
control
This valve controls the steam pressure from the
No. 1 flash tank and fresh make-up low pressure
steam.
D Typical process conditions:
Fluid: Low pressure saturated steam
T = 320_F
P = 80 psig
10B 8
dP = 42 psi
D Typical valve selection:
In cases where entrained particles are
found in the flow, the recommended valve is
a CV500 with hardened trim due to the
potential erosion. If no particles are found in
the flow, a standard Vee-Ball may be used.
This is typically specified as a NPS 8 valve.
Valve: LV-6 Chip chute level control
This valve controls the liquor level in the chip
chute. The recommended value for this application
is a Vee-Ball, possibly with an attenuator. Carbon
steel body can be used, although stainless steel
would provide an added level of durability.
D Typical process conditions:
Fluid: Black liquor
T = 235_F
P = 25 60 psig
dP = 3 psi 7 psi
Q = 600 1700 gpm
D Typical valve selection:
The Fisher CV500 will handle this
application with alloy 6 seal and in the
reverse flow orientation. This is a scaling
application which calls for the eccentric plug
action of the CV500. If the valve fails to
respond to changing levels in the chip chute,
there is a danger of liquor and chip spillage.
Valve: FV-3B White liquor pump to
bottom circulation
These valves are used to control the amount of
white liquor which is added to the wood chips.
They maintain the proper wood/liquor ratio. As
production increases, these valves open more to
maintain the proper ratio.
D Typical process conditions:
Fluid: White liquor
T = 190_F
P = 260 psig 290 psig
dP = 60 psi 90 psi
D Typical valve selection:
These are NPS 2 to NPS 3 valves with
alloy 6 scraper seats due to concerns over
white liquor scaling. A SST V300 valve with
an alloy 6 HD seal and alloy 6 bearings
should be used in this application.
Valve: FV-3C White liquor to wash
circulation pump
D Typical process conditions:
Fluid: White liquor
T = 190_F
P = 270 psig 290 psig
dP = 75 psi 90 psi
D Typical valve selection:
NPS 2 to NPS 3 valves with alloy 6
scraper seats due to concerns over white
liquor scaling are used. A SST V300 with an
alloy 6 HD seal and alloy 6 bearings should
be used in this application.
Valve: FV-3D White liquor to MC
circulation
These valves are used to control the amount of
white liquor which is added to the wood chips.
They maintain the proper wood/liquor ratio. As
production increases, these valves open more to
maintain the proper ratio.
D Typical process conditions:
Fluid: White liquor
T = 190_F
P = 270 psig 290 psig
dP = 70 psi 90 psi
Q = 180 gpm
D Typical valve selection:
NPS 2 to NPS 3 valves with alloy 6
scraper seats due to concerns over white
liquor scaling. A SST V300 valve with an
alloy 6 HD seal and alloy 6 bearings should
be used in this application.
Valve: FV-3E White liquor to wash
circulation
D Typical valve selection:
NPS 2 to NPS 3 valves with alloy 6
scraper seats due to concerns over white
liquor scaling are utilized. A SST V300 with
an alloy 6 HD seal and alloy 6 bearings
should be used in this application.
Valve: FV-3F White liquor make-up to
impregnation vessel
These valves are used to control the amount of
white liquor, which is added to the wood chips.
They maintain the proper wood/liquor ratio. As
production increases, these valves open more to
maintain the proper ratio.
10B 9
D Typical process conditions:
Fluid: White liquor
T = 190_F
P = 260 psig 280 psig
dP = 35 psi 60 psi
Q = 200 900 gpm
D Typical valve selection:
NPS 2 to NPS 4 valves with alloy 6
scraper seats due to concerns over white
liquor scaling. A SST V300 valve with an
alloy 6 HD seal and alloy 6 bearings should
be used in this application.
Valve: LV-7 Digester level control valve
This valve controls liquor flow to the top of the
impregnation vessel. This is a critical and difficult
application on the Kamyr digester. This valve
needs to be operable with up to 300 psi of
differential pressure on some digesters. This
requires a valve capable of tight shut-off and high
pressure throttling. Cavitation is a common
problem with this valve.
D Typical process conditions:
Fluid: Black liquor
T = 235_F
P = 300 psig
dP = 45 psi 90 psi
Q = 1000-3000 gpm
D Typical valve selection:
The V500 valve or CV500 in stainless
steel has proven to be a successful valve in
this application. The design of the Fisher
valves provides higher flow velocities which
tends to reduce the problems with scaling
that are seen at this location. Both the V500
valve and the CV500 should be supplied with
alloy 6 seats and installed in reverse flow
orientation.
NPS 6 valve. This may be the most
critical valve in the system other than blow
line control. Capacity issues are a concern.
Valve: FV-61A Impregnation vessel
upper slouse flow
This valve is found only on dual vessel digesters
where it is used to add liquor to the upper dilution
zone to assist in the discharge of chips and liquor
from the impregnation vessel.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
P = 250 psig 290 psig
dP = 15 psi 82 psi
D Typical valve selection:
NPS 6 to NPS 8 valve with an alloy 6
scraping seat due to concerns over the
precipitation of calcium carbonate causing
plating or scaling buildup. A SST V300 valve
with an alloy 6 HD seal and alloy 6 bearings
should be used in this application.
Valve: FV-61 Impregnation vessel
lower slouse flow
This valve is found only on dual vessel digesters
where it is used to add liquor to the dilution zone
to assist in the discharge of chips and liquor from
the impregnation vessel.
D Typical process conditions:
Fluid: Black liquor
T = 345_F
P = 235 psig 260 psig
dP = 25 psi 52 psi
D Typical valve selection:
NPS 4 to NPS 6 valve with an alloy 6
scraping seat due to concerns over the
precipitation of calcium carbonate causing
plating or scaling buildup. A SST V300 valve
with an alloy 6 HD seal and alloy 6 bearings
should be used in this application.
Valve: PV-30 Impregnation vessel
pressure relief
This valve is used to relieve excess pressure in
the impregnation vessel by releasing excess liquor
to the No. 2 flash tank.
D Typical process conditions:
Fluid: Black liquor
T = 235_F
P = 180 psig
dP = 155 psi
Q = 2800gpm
D Typical valve selection:
A CV500 (NPS 3) in stainless steel with
alloy 6 trim is a good valve for this
application.
Valve: FV-60 Black liquor to
impregnation vessel (bottom
circulation flow)
This valve is found only on dual vessel digesters
and is used to add black liquor to the outlet of the
10B 10
impregnation vessel to raise the temperature of
chips and liquor going to the digester.
D Typical process conditions:
Fluid: Black liquor
T = 345_F
P = 250 psig 275 psig
dP = 38 psi 75 psi
D Typical valve selection:
NPS 6 to NPS 8 valve with an alloy 6
scraping seat due to concerns over the
precipitation of calcium carbonate causing
plating or scaling buildup. A SST V300 valve
with an alloy 6 HD seal and alloy 6 bearings
should be used in this application.
Valve: TV-60A-C Bottom circulation
temperature
These valves control steam to the bottom
circulation heaters which, in turn, control the
temperature of liquor leaving the heaters for the
bottom zone of the impregnation vessel.
D Typical process conditions:
Fluid: Steam
T = 400 525_F
P = 165 psig
dP = 60 psi
Q = 10000 40000 lbs/hr
D Typical valve selection:
These are throttling valves, typically NPS
6, for which Kamyr has specified V300
valves with stainless steel bodies and
stainless steel trim. Nitronic 50 shafts, PEEK
bearings, and HD metal seals are also called
for.
Valve: PV-10 Digester pressure relief
This valve is used in emergency situations to
relieve elevated digester pressure by releasing
black liquor from the top screens to the No. 2 flash
tank. This valve requires tight shutoff and
fail-closed spring return actuation.
D Typical process conditions:
Fluid: Black liquor
T = 350_F
P = 180 psig
dP = 180 psi maximum
Q = 2600 gpm
D Typical valve selection:
Kamyr has specified full bore ball valves
for this application. However, a CV500 (NPS
3 to NPS 6) in stainless steel with alloy 6 trim
is an excellent valve for this application.
Valve: PV-11 Digester pressure control
This is a critical valve in the digester process. This
valve is used to maintain pressure in the digester
and to distribute fresh cool water to the pulp. This
prevents the overheating of the pulp, which would
result in the degradation of the pulp fibers. This
valve is typically interlocked with PV-10 to prevent
over-pressurization of the process.
D Typical process conditions:
Fluid: Washer filtrate
T = 180_F
P = 250 psig
dP = 55 psi
D Typical valve selection:
Kamyr has specified a Vee-Ball V300
valve, NPS 4 to NPS 6 size, for this
application. The valve should have a
stainless steel body and ball, Nitronic 50
shaft, PEEK bearings, and an HD metal seal.
A piston actuator is typically used.
Valve: HV-54 Top circulation pressure
control
This valve is used primarily during start-up to
supply cooking liquor to pressurize the top
circulation lines prior to pumping.
D Typical process conditions:
T = 170_F
P = 320 psig
dP = 45 psid
Q = 400 gpm
D Typical valve selection:
The V300 valve is an appropriate
alternate valve for this tag. This valve is
typically in the NPS 3 size range.
Valve: HV-52 Top circulation isolation
valve
This valve serves to isolate the high pressure
feeder line from the impregnation vessel. It is
typically installed on the main chip/liquor feed-line.
D Typical process conditions:
T = 240_F
P = 250 psig
10B 11
Q = 9000 gpm
D Typical valve selection:
This valve is specified as a full bore ball
valve by Kamyr, and is referred to as the
RO1 valve. It is normally open, and only
closed when the digester must be isolated
from the HP feeder. NPS 12 to NPS 16 in
size with additional 1/8 inch thickness on RF
male flange.
This unique size makes this valve a
non-ANSI flange thickness. Fisher does not
have an offering available for this valve.
Valve: HV-51 Top circulation isolation
valve
This is an isolation valve for liquor being sent back
to the high pressure feeder from the impregnation
vessel.
D Typical valve selection:
This valve is specified to be a full bore
ball valve by Kamyr, and is referred to as the
RO2. It too has the special male flange
requirement as referenced in HV-52.
Valve: PDV-18 Digester outlet device
differential pressure
This valve adds liquor to the bottom of the digester
to assist in chip discharge and to help regulate
consistency.
D Typical process conditions:
Fluid: Washer filtrate
T = 170_F
P = 238 psig
dP = 45 psi
Q = 100 1000 gpm
D Typical valve selection
This is typically a NPS 4 valve for which
Kamyr has specified a V300 valve with
stainless steel body and ball. The valve
should be offered with a Nitronic 50 shaft,
PEEK bearings, and an HD metal seal. A
piston actuator is normally specified.
Impregnation
The chips at the top of the column now enter the
liquor impregnation zone. In this zone, chips are
subjected to a complete soaking or penetration of
the cooking liquor at a temperature of
approximately 250_F. The impregnation stage
lasts about 45 to 60 minutes at design tonnage. It
is important that thorough penetration takes place
before the heating stage. If penetration is
incomplete, chips with uncooked centers will
result.
The white liquor, or cooking liquor, is added to the
digester together with black liquor, which is
recovered from the chip chute overflow. It is also
possible to put weak black liquor into the makeup
liquor pump suction, but this is normally not
required.
The chip chute overflow goes to the surge tank
(level tank). There, it is controlled at a constant
level, and then goes to the make-up liquor pump
where it is combined with the white liquor. The
make-up liquor pump transports the mixture to the
top of the digester and injects it at a point just
below the top separator. All of this liquor returns to
the high pressure feeder by the top circulation
return line, and is mixed with fresh chips to be
returned to the inside of the top separator and
then to flow down the digester. The amount of
white liquor added is based upon the production
rate and is in direct proportion to the chip feed
rate.
Valve: TV-3A White liquor to make-up
liquor line temperature
D Typical process conditions:
Fluid: White liquor
T = 120_ F
P = 55 psig
dP = 10 psi
D Typical valve selection:
This valve has been specified by Kamyr
to be a NPS 3 V150 valve with stainless
steel body and 317 stainless chrome plated
ball, Nitronic 50 shaft, HD metal seal, PEEK
bearings, and a fail-close actuator.
Valve: FV-4 Black liquor flow
This valve only sees infrequent use in the process.
Its function is to add cool washer filtrate liquor to
the black liquor line coming from the level tank in
the event the black liquor and the temperature at
the top of the digester exceed specified
temperature limits.
D Typical process conditions:
Fluid: Washer filtrate
T = 180_F
P = 30 60 psig
dP = 10 60 psid
10B 12
Q = 500 gpm
D Typical valve selection:
Kamyr has specified a V150 Vee-Ball
valve, NPS 2 NPS 3 size, with stainless
steel body and ball, Nitronic 50 shaft, PEEK
bearings, and an HD metal seal. Typically, a
fail closed actuator is used.
Valve: LV-17 No. 2 Flash tank level
Black liquor level in the No. 2 flash tank is
controlled by LV-17, located between the No. 2
flash tank outlet and the evaporators.
D Typical process conditions:
Fluid: Black liquor
T = 220_F
P = 60 psig
dP = 10 20 psid
Q = 1000 2000 gpm
D Typical valve selection:
NPS 8 to NPS 10 butterfly valve that
Kamyr has specified as a stainless steel
HPBV with stainless steel disc, alloy 6
bearings, 17-4 shaft, and a NOVEX metal
seal.
Valve: LV-16 No. 1 Flash tank level
Black liquor level in the No. 1 flash tank is
controlled by LV-16 located at the outlet of the
tank. This valve flows into the No. 2 flash tank.
D Typical process conditions:
Fluid: Foamy black liquor
T = 260_F
P = 20 50 psig
dP = 2 12 psid
Q = 500 1500 gpm
D Typical valve selection:
This valve is specified by Kamyr as a
HPBV with a stainless steel body and disc
and a NOVEX metal seal. alloy 6 bushings
and a 17-4 shaft are recommended. This
valve is in the NPS 8 to NPS 14 size range.
Valve: LV-81 Clean condensate flash
tank level
D Typical process conditions:
Fluid: Clean condensate
T = 312_F
P = 90 psig
dP = 90 psi maximum
D Typical valve selection:
This valve has been specified by Kamyr
to be a NPS 2 to NPS 3 V150 valve with
stainless steel body and trim, Nitronic 50
shaft, HD metal seal, PEEK bearings, and a
fail-close actuator.
Valve: LV-91 Contaminated condensate flash tank
level
D Typical process conditions:
Fluid: Condensate
T = 212_F
P = 11 psig
dP = 10 psi
D Typical valve selection:
This valve has been specified by Kamyr
to be a NPS 2 to NPS 3 V150 valve with
stainless steel body and trim, Nitronic 50
shaft, HD metal seal, PEEK bearings, and a
fail-close actuator.
Valve: KV-24 Sand separator valve
This is also called the pocket valve. This is a full
bore ball valve with one of the normally open ends
of the ball sealed. It is used to collect sand at the
bottom of the sand separator. Occasionally, the
valve rotates 180_ to dump the collected sand.
D Typical valve selection:
Full bore valves that can rotate 145
degrees are chosen. It is typically NPS 6 to
NPS 8, and cycles every five to ten minutes.
El-O-Matict actuators with 180 degree
rotation with an adjustment are used
commonly. Due to high cycle life, this valve
assembly needs to be inspected on a regular
basis.
Heating Stage
From the impregnation zone, the chip column
continues to move down until the upper cooking
zone is reached. Chips and liquor are pre-heated
to within 20_F of the actual cooking temperature
while the lower cooking zone controls the final
cooking temperature. This is accomplished by
withdrawing liquor from the digester through a
screen plate, circulating it through an indirect
heater and returning the heated liquor down
through a central distribution chamber. Then, it is
discharged at a point opposite and slightly above
the screen plates. This allows the chips to receive
uniform heating as the liquor enters at the center
10B 13
and flows to the outer shell equally in all
directions.
Chips continue down the digester for a short
distance into the lower cooking zone, where a
second heating process occurs. In this case, the
chips are heated to the desired cooking
temperature. To accomplish this, liquor is again
extracted radially through screen plates to a
second heater. It is returned through a pipe, which
is located inside the central distribution chamber,
and is discharged at a point just above the lower
cooking screen plates. A spare heater is provided
and may be valved as either the upper or lower
heater so that the heat exchangers, which
periodically become fouled by liquor scale, can be
acid-cleaned while the digester is still in operation.
Normally, the impregnation zone is subject to
considerable scaling and the upper heater will
require more cleaning than the lower. The time a
heater may be run before it requires cleaning must
be determined by operating experience on your
liquor, wood, and cooking conditions. Once
determined, heaters may be cleaned before they
become fouled so severely that the tubes plug.
The function of all circulations is two-fold: first, to
carry heat and chemicals into the digester;
second, to homogenize the conditions in the
digester cross-section. If the circulation is to work
properly, the screen plates must be kept clean.
This will not be possible if the chip column stands
still and a large quantity of liquor is drawn through
them. Therefore, the screen sections are built in
two sections, one above the other. These two sets
operate alternately, one set sucking while the
other rests and is cleaned by the wiping action of
the downward moving chip column. The change is
accomplished by digester switching valves
mounted in the circulation suction lines. The chip
column is not too dense at this point, and alternate
automatic switching time is fairly short (typically 90
seconds).
Temperature recorders on the upper and lower
cooking zone heaters show a cycle of 5_ to 10_F.
The temperature cycle is due to the temperature
differential across the heating zone screens and
follows the timing of the switching valves. The
recorded temperatures are averages for the entire
screen section, and provided the liquor circulation
is adequate, the end temperature is in control. The
inlet and outlet of each heater should be within
10_F of each other.
The temperature recorders serve as an indication
of the chip column movement. Interruptions of
movement are reflected by temperature changes.
Failure of the chip column to move is reflected by
the coming together of the inlet and outlet heater
temperatures, whereas a sudden drop of the chip
column is shown by a sharp drop in the heater
inlet temperature.
Valve: KV-8A and B Trim liquor
switching valves
These valves extract liquor through screens
located in the upper part of the digester. The
extracted liquor is then sent to the bottom
circulation heaters. The KV tagged valves are
required to fully stroke approximately every 90
seconds. This causes a flow reversal through the
extraction screens preventing the screens from
plugging with chips and fiber.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
P = 130 psig
dP = 130 psi
Q = 1500 gpm
D Typical valve selection:
NPS 6 to NPS 8 size range. The DSV
valve is suitable for this application. This is a
modified 8510 body with a strengthened
shaft and no seal. Used in conjunction with
the 1061 actuator with a quad seal option,
this assembly is capable of a relatively long
life in this service.
Valve: KV-60A and B Bottom
circulation return switching valves
These valves extract liquor from the digester (in
the upper region of the digester vessel) and send
liquor to the bottom circulation heaters. These
valves are only found on dual vessel digesters.
The KV tagged valves are required to fully stroke
approximately every 90 seconds. This causes a
flow reversal through the extraction screens
preventing the screens from plugging with chips
and fiber.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
P = 120 psig
dP = 120 psi
D Typical valve selection:
NPS 12 to NPS 14 size range. The DSV
valve is suitable for this application. This is a
modified 8510 body with a strengthened
10B 14
shaft and no seal. Used in conjunction with
the 1061 actuator with a quad seal option,
this assembly is capable of a relatively long
life in this service.
Valve: KV-60C and D Bottom
circulation screen backflush valves
These valves work in conjunction with tags KV-60
A and B to ensure that the bottom circulation
screens remain free of chips. These valves are
only found on dual vessel digesters. The KV
tagged valves are required to fully stroke
approximately every 90 seconds. This causes a
flow reversal through the extraction screens,
preventing the screens from plugging with chips
and fiber.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
P = 120 psig
dP = 120 psi
D Typical valve selection:
NPS 6 to NPS 8 size range. The DSV
valve is suitable for this application. This is a
modified 8510 body with a strengthened
shaft and no seal. Used in conjunction with
the 1061 actuator with a quad seal option,
this assembly is capable of a relatively long
life in this service.
Valve: PV-16 PV-17 No. 1 Flash tank
relief steam pressure valves
These valves are used to slightly pressurize the
flash tanks in order to reduce foaming of the black
liquor in the tanks.
D Typical process conditions:
Fluid: Steam
T = 220_F
P = 60 psig
dP = 5 psi
Q = 15000 75000 gpm for PV-16
Q = 20000 100000 gpm for PV-17
D Typical valve selection:
Both of these valves have been specified
by Kamyr as HPBV valves with PV-16 being
an NPS 8 or NPS 10 valve and PV-17 being
an NPS 16 to NPS 18 valve. Both valves
should be supplied with a stainless steel
body and disc, 17-4 shaft, PEEK bearings,
and a NOVEX metal seal.
Cooking Zone
Below the heating zones, the chips enter the
cooking zone at the full cooking temperature.
Here, the actual cooking takes place. The active
chemicals in the cooking liquor are sodium
hydroxide, NaOH, and sodium sulfide, Na
2
S.
These chemicals react with the lignin in the wood
chips, converting it into chemical compounds
which dissolve in the alkaline cooking liquor. The
lignin, as it exists in wood, is somewhat like a
cementing material and holds the individual fibers
together; however, when it is made soluble during
cooking, the fibers are set free and can be
separated into the fibrous mass called wood pulp.
The chemicals in the cooking liquor also react with
the pulp fibers themselves. This is not desirable
because the fibers are required in their original
condition. Therefore, cooking conditions are used
which result in the highest removal of lignin with
the least attack on the cellulose fibers.
The chips continue to fall and will increase slightly
in temperature until cooking is complete and it has
reached the next stage (hi-heat washing). The
cooking reaction is stopped by cooling the chip
mass down to about 280_ - 300_F. This is done by
extracting the residual cooking liquor through
screens on the side of the digester, and replacing
it with cool liquor, which rises from the wash zone.
The amount of cool liquor used is determined by
the quantity of wash liquor required to wash the
pulp to a suitable low soda content. In order to
control the uniformity of temperature, a portion of
the extracted cooking and washing liquor is
returned to the digester via the quench circulation
pump through a pipe inside the central distribution
chamber. This re-circulation lowers the
temperature of the entire chip mass and permits
washing to be carried out without further
delignification or over-cooking.
Valve: KV-19 A-D A-F Modified cooking
extraction switching valves
These valves extract liquor in the modified cooking
zone of the digester located near the middle of the
digester vessel. The extracted liquor is then sent
to the modified cooking heater. The KV tagged
valves are required to fully stroke approximately
every 90 seconds. This causes a flow reversal
through the extraction screens preventing the
screens from plugging with chips and fiber.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
10B 15
P = 170 psig 10
dP = 170 psi
D Typical valve selection:
These are typically in the NPS 8 size
range for KV-19 A, B, C, D and in the NPS 3
size for KV-19 E and F. The DSV valve is
suitable for this application. This is a
modified 8510 body with a strengthened
shaft and no seal. Used in conjunction with
the 1061 actuator with a quad seal option,
this assembly is very capable of a relatively
long life in this service.
Extraction and Hi-Heat Washing
Chips, having now passed through the cooking
zone, reach the extraction screens. The column is
considerably denser following cooking and has a
better wiping action so that a cycling system is not
required at this zone. The section from the
extraction screens down to the bottom of the
digester is the wash zone. Black liquor is extracted
from two rows of screen plates. The upper screen
extracts primarily the hotter spent liquor from the
downward flow of chips and the lower screen
extracts cooler liquor flowing upward, or
countercurrent, from the washing zone.
The portion of extracted cooking liquor that is not
returned to the digester through the quench
circulation pump goes to the No. 1 flash tank,
which serves as the first stage of the digester heat
recovery system. The liquor leaves the digester at
about 180 psig and discharges to the flash tank at
15-18 psig. The sudden pressure drop causes the
liquor to boil rapidly, or flash, and form steam,
which goes to the steaming vessel. The amount of
steam produced is directly proportional to the hot
liquor flow through the extraction line and reduces
the flow of the fresh make-up steam required at
the steaming vessel. The remaining liquor then
bleeds off to the No. 2 flash tank and is pumped to
the unoxidized weak black liquor storage tank. As
the No. 2 flash tank is under atmospheric
pressure, again flashing occurs and the flash
steam goes to a condenser.
Counter-current hi-heat washing is accomplished
by extracting a greater volume of liquor through
the extraction screens than the liquor volume
coming down with the chips, causing an upflow of
wash filtrate. The wash filtrate is pumped in at the
bottom of the digester where it fills the voids
created by the increased extraction. It also flows
out through the blow line with the pulp acting as
dilution liquor.
Wash filtrate is weak black liquor produced by
extraction and shower displacement of residual
liquor from the pulp. This filtrate is returned to the
digester, mixes with the stronger cooking liquors,
and cools the pulp before it is discharged (cold
blow). The ratio of the number of pounds of
excess filtrate (upflow) added per minute to the
number of pounds of O.D. pulp produced per
minute is called dilution factor. For example, a
dilution factor of two would require a net upflow in
the wash zone of two pounds per minute of filtrate
to each pound of A.D. pulp. The amount of filtrate
is determined by the remaining soda content in the
pulp and should be held to a minimum value. More
filtrate produces less soda loss, but at some point,
filtrate addition, which later has to be evaporated
by steam heat, is greater than the cost of soda. It
can, therefore, be seen that a balance must be
made at the most efficient point.
Washing efficiency increases with increased
temperature. Therefore, it is necessary to heat the
wash liquor. Thus, another extraction screen is
located near the bottom of the digester which
draws liquor out. This liquor is circulated via the
wash pump through a steam heater and returned
through yet another chamber located inside the
central distribution chamber. This heated liquor
discharges at the lower wash screen and diffuses
upward through the downflowing chips. It
effectively washes the mass as it replaces
stronger liquor, which has been extracted above.
The reason for injecting the cold liquor into the
bottom and then extracting it to be heated for
washing is explained in the next section. The pulp
column has now reached the final or blowing
stage.
Valve: HV-16 Digester washer
extraction flow
This valve controls the flow of black liquor to the
flash tank.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
P = 130 psig
dP = 45 psi 60 psi
Q = 500 2500 gpm
D Typical valve selection:
This application is typically specified as a
full-bore ball valve. A CV500 in stainless
steel will be a suitable valve for this
application due to its ability to handle scaling
process conditions.
10B 16
Valve: KV-16A-D Digester extraction
switching valves
These valves provide screened liquor extraction
from the upper wash zone of the digester. This is
located near the middle of the digester vessel. The
extracted liquor is then sent to flash tank No. 1.
The KV tagged valves are required to fully stroke
approximately every 90 seconds. This causes a
flow reversal through the extraction screens
preventing the screens from plugging with chips
and fiber.
D Typical process conditions:
Fluid: Black liquor
T = 325_F
P = 10 psig
dP = 150 psi
Q = 1500 gpm
D Typical valve selection:
NPS 6 to NPS 8 size range. The DSV
valve is suitable for this application. This is a
modified 8510 body with a strengthened
shaft and no seal. Used in conjunction with
the 1061 actuator with a quad seal option,
this assembly is capable of a relatively long
life in this service.
Valve: TV-9H Modified cooking
circulation temperature valve
This valve controls steam to the Modified cooking
heater which, in turn, controls the temperature of
liquor going to the upper wash zone.
D Typical process conditions:
Fluid: Steam
T = 379_F
P = 165 psig
dP = 80 psi
D Typical valve selection:
This is a throttling valve, typically NPS 4
to NPS 6, for which Kamyr has specified
V300 valves with stainless steel bodies and
stainless steel trim. Nitronic 50 shafts, PEEK
bearings, and HD metal seals are also called
for.
Valve: HV-20 Washer heater circulation
flow
This valve controls the flow of wash liquor from the
bottom of the digester to the wash circulation
heater of the main digester.
D Typical process conditions:
Fluid: Black liquor
T = 255_F
P = 250 psig
dP = 20 psi 60 psi
D Typical valve selection:
This is typically not a scaling application.
A V300 valve or a CV500 will be suitable.
Valve: FV-14 Inner counterwash flow
This valve controls the flow of washer filtrate to
the pulp washing section of the digester vessel
and is typically a NPS 4 valve.
D Typical process conditions:
Fluid: Washer filtrate
T = 170_F
P = 235 350 psig
dP = 5 130 psid
Q = 100 1000 gpm
D Typical valve selection:
Kamyr has specified a V300 valve with
stainless steel body and ball. The valve
should be offered with a Nitronic 50 shaft,
PEEK bearings, and an HD metal seal. A
piston actuator is normally specified.
Valve: TV-20 Wash circulation
temperature control
This valve controls the flow of low pressure steam
to the wash circulation heater for the digester.
D Typical process conditions:
Fluid: Steam
T = 379_F
P = 165 psig
dP = 55 psi
D Typical valve selection:
This is a throttling valve, typically NPS 6
to NPS 8, for which Kamyr has specified
V300 valves with stainless steel bodies and
stainless steel trim. Nitronic 50 shafts, PEEK
bearings, and HD metal seals are also called
for.
Valve: KV-20A-D Wash extraction
switching valves
These valves extract wash water from screens
located near the bottom of the digester vessel.
The extracted wash water is then sent to the wash
heater.
10B 17
D Typical process conditions:
Fluid: Black liquor
T = 260_F
P = 185 195 psig
dP = 185 195 psi
Q = 1500 gpm
D Typical valve selection:
These are typically in the NPS 3 to NPS 8
range. The DSV valve is suitable for this
application. This is a modified 8510 body
with a strengthened shaft and no seal. Used
in conjunction with the 1061 actuator with a
quad seal option, this assembly is capable of
a relatively long life in this service.
Blowing
At high temperatures, particularly over 220_F, the
mechanical action of the chips resulting from the
violent expansion during the blow is harmful to the
fibers. As mentioned before, washing efficiency
increases with increased temperature; however,
damage to fibers will be reduced by blowing at a
lower temperature. In order to overcome any loss
in pulp strength, the pulp mass is cooled to about
190_F by the weak black liquor filtrate. This liquor
is pumped via the cold blow pump into the digester
at two locations: a portion through a screen plate
around the digester shell near the bottom and
another portion through four nozzles located under
the paddles of the outlet device. The liquor
entering through the screens regulates the
digester pressure, whereas the flow under the
outlet device is fixed by the operator and provides
the required dilution before the pulp is actually
blown from the digester.
Summarizing, we find that the chips undergo three
basic temperature changes that take place from
the extraction zone to the blowing of pulp from the
digester:
First, the chips are cooled or quenched 40 to 50_F
at the extraction zone. This drop occurs where the
up-flowing wash liquor meets the down-flowing
residual cooking liquor and both are drawn off.
Most of the residual liquor goes to the No. 1 flash
tank for heat and chemical recovery. The
remainder is re-circulated via the quench
circulation pump before being recovered at the
flash liquor tank. Re-circulation provides a more
uniform temperature control and is important to
avoid over-cooking the pulp.
The chips are then cooled (30_F) gradually
throughout the wash zone until a second sharp
drop occurs in the blowing dilution zone. Here the
chips are cooled rapidly again by about 60_F
before blowing to avoid mechanical damage to the
exploding chip fibers. The blow line temperature
must be maintained at 210_F or less. The gradual
temperature drop over the wash zone is simply a
result of gradual heat exchange between the
up-flowing wash liquor and the down-flowing chips.
The reverse procedure occurs with the cold filtrate
liquor (160_F). After entering the digester, it is
heated to about 190_F by heat transfer from the
chips and is then extracted to be heated by the
wash heater (260 - 280_F) before returning to the
digester wash zone. It gradually increases in
temperature as it picks up heat from the
down-flowing chips and reaches the lower
extraction at about 290_F to provide the quench at
the end of the cook zone. The wash heater control
point is, therefore, set to arrive at the proper
quench temperature and it is affected by the
production rate, cooking temperature, and dilution
factor.
Chips, upon reaching the outlet device, are now
ready to be discharged from the digester. A load
reading ammeter on the outlet device motor
serves to indicate the consistency in the bottom of
the digester. It has a variable speed drive and the
speed at which it runs directly affects the
consistency; the faster it runs, the higher the
consistency and vice-versa. The reason for this is
that the arms of the outlet device are designed to
scrape the chips from the bottom of the column
and carry them into the discharge port. Through
experience, the operator learns the best speeds
for each production rate. It can also be seen from
the above that the outlet device is used in the fine
control of the digester chip level.
The chips then enter a 12-inch blow line and goes
to a small cigar shaped vessel called the blow unit.
The blow unit is equipped with an agitator and two
exit lines to the blow tank. The purpose of the
agitator is to act as a consistency indicator for the
digester operator by a torque or power-sensing
device. As the consistency goes up or down, the
power required to turn the agitator goes up or
down. The variation is recorded on a chart at the
control panel.
The chips and liquor flow out of the blow unit into
one of the blow lines, and the flow is measured
and recorded by a magnetic flowmeter. Cooked
chips are at digester pressure up to the final ball
valve before the blow tank. As they pass through,
they are subjected to a sharp pressure drop which
causes the chips to explode and break up into
individual fiber bundles which are a form of raw
10B 18
pulp. The pressure drop is from digester pressure
to atmospheric in the blow tank.
As in the top circulation line, there are two
isolation valves against digester pressure. There is
a large isolation valve between the digester
pressure and the blow unit. If the blow unit is
empty and the valve is opened under full digester
pressure, the sudden surge severely damages the
blow unit and valves. The blow unit must,
therefore, be filled with liquor and pressurized
before the large valve can be opened in a similar
manner to the top circulation lines. A pressure
switch prevents the valve from opening until the
blow unit pressure is increased to at least 175
psig.
The pulp flows to the blow tank, which is simply a
storage tank with a predetermined retention time,
before it goes to the next stage in the pulping
group, pulp washing and high density storage.
Valve: HV-87 Blow line pressurization
This valve provides dilution and pressurization in
the blow line prior to the opening of the blow valve.
D Typical process conditions:
Fluid: Washer filtrate
T = 170_F
P = 225 350 psig
dP = 10 50 psid
Q = 165 gpm
D Typical valve selection:
It is typically a NPS 2 valve. Kamyr has
specified a V300 valve with stainless steel
body and ball. The valve should be offered
with a Nitronic 50 shaft, PEEK bearings, and
an HD metal seal. A piston actuator is
normally specified.
Valve: FV-12A Blow line flow control
D Typical process conditions:
Fluid: High consistency pulp (10%)
T = 180_F
P = 170 psig
dP = 80 psi
D Typical valve selection:
The requirement for full bore is based on
the potential for plugging as large deposits
come out of the digester. This is a very
demanding and critical loop. The shape of
opening and flow area of the V300, by
design, has a lower potential for plugging
than a full bore valve. Recommended valve
construction includes: SST body with alloy 6
insert, alloy 6 V-notch, alloy 6 taper key,
alloy 6 silver plated bearings, alloy 6 HD
seal, and PTFE ENVIRO-SEAL packing. An
oversized, piston actuator is also suggested.
In addition, the valve should be sized to
operate at >60% opening.
Valve: FV-12B Blow line flow control
D Typical process conditions:
Fluid: High consistency pulp (10%)
T = 180_F
P = 170 psig
dP = 80 psi
D Typical valve selection:
The requirement for full bore is based on
the potential for plugging as large deposits
come out of the digester. This is a very
demanding and critical loop. The shape of
opening and flow area of the V300 valve, by
design, has a lower potential for plugging
than a full bore valve. Recommended valve
construction includes: SST body with alloy 6
insert, alloy 6 V-notch, alloy 6 taper key,
alloy 6 silver plated bearings, alloy 6 HD
seal, and PTFE ENVIRO-SEAL packing. An
oversized piston actuator is also suggested.
In addition, the valve should be sized to
operate at >60% opening.
Valve: HV-81B Blow line isolation valve
This valve is an on/off valve that serves to isolate
the digester blow line.
D Typical valve selection:
It is specified by Kamyr as a full bore ball
valve.
Valve: HV-90A and B Blow line
isolation valves
D Typical process conditions:
Fluid: High consistency pulp (10%)
T = 180_F
P = 70 psig
dP = 4 psi
D Typical valve selection:
These valves are generally the same
valves as the flow control valves with the
exception that they are often one line size
larger and used for isolation only. These
10B 19
valves are on/off valves but are usually
equipped with positioners so that they can be
used as backup flow control valves.
Control Valve Selection
The following charts list Fisher valve selections for
a typical Kamyr process. Control valve metallurgy
has usually been 316 SST except for some valves
on the bleach plant. On the C/D, D1 and D2
extractions and stock flow to these stages, the
valves are usually titanium and sometimes 317
SST. More recently, the use of carbon steel valves
on steam and some filtrate service has been
considered. Metal seated ball valves are used
where the service requires a scraper seat (HD
design) such as white liquor and cooking
circulations on the digester. Metal seats are also
sued on throttling service that have high pressure
drops where the metal seat is more resistant to
erosive wear at the resultant high velocity. The
heavy duty butterfly valve (Special 8500) is used
almost exclusively for digester circulation
switching. The main features of this valve for this
service are the stellite bearings, double packing,
and extra heavy design shaft. There are no seats
in this valve so that it will not jam due to scale
buildup. It is also sometimes used on throttling
service where tight shutoff is not required, but
where there is a scaling tendency. The history of
valve selection has not been determined solely by
the process requirement but in many cases by
what valve technology was available at the time.
The choice is sometimes limited due to Kamyrs
requirement for flanges on all except butterfly
valves.
10B 20
KAMYR
TAG#
KAMYR CONTINUOUS DIGESTER
FISHER CONTROL VALVE
PRODUCT DESIGN
Application Description
Control
Function
V150 V200 V300 V500 CV500 8580
Typical
Valve
Sized
FV-3A
High Pressure Feeder Purge
White liquor flow control to purge
High Pressure Feeder end bells
T P 2
FV-3B
White Liquor to Bottom Circulation
Controls white liquor to Bottom Circulation
T P 2
FV-3C
White Liquor to Bottom Circulation
Controls White Liquor to Bottom Circulation
T P 2
FV-3D
White Liquor to Modified Cooking Circulation
Controls white liquor to Modified Circulation
T P 3
FV-3F
White Liquor Flow to Make-Up Liquor Line
this is the white liquor flow to the
Impregnation Vessel
T P 3
FV-4
Black Liquor Flow
Washer filtrate is sent to black liquor line
from Level Tank to cool black liquor
T P 3
FV-12A
Blow Line Flow (a)
Controls flow from main Digester.
10-12% consistency
T P 6
FV-12B Blow Line Flow (B). See FV12A T P 6
FV-14
Inner Counterwash Flow
Controls liquor flow to pulp washing section
T P 4
FV-60
(1)
Bottom Circulation Flow
Black liquor added to outlet of Impregnation
Vessel to raise temperature of chips and liquor
to Digester
T P 8
FV-61
(1)
Impregnation Vessel Bottom Dilution (Lower)
Adds liquor to dilution zone to assist discharge
of chips and liquor from Digester
T P 6
FV-61A
(1)
Impregnation Vessel Bottom Dilution (Upper)
See FV61 except upper zone
T P 6
PDV-18
Digester Outlet Device Differential Pressure
Adds liquor to assist in chip discharge
from Digester and regulate consistency
T P 4
LV-6
Chip Chute Level
Controls liquor level in Chip Chute
T P 8
LV-7
Level Tank Level
Valve controls liquor level in tank.
Full 300 psi drop across valve is possible
T S P 6
LV-16
No. 1 Flash Tank Level
Controls level in No. 1 Flash tank
T P 30
LV-17
No. 2 Flash Tank Level
Controls level in No. 2 Flash tank
T P 20
PV-5
Steam Vessel Pressure
provides low pressure steam to Steaming
Vessel
T P 8
PV-5A
Steaming Vessel Safety Relief
Relief valve for Steaming Vessel
T P 8
PV-10
Digester Pressure Relief
this valve relieves excess liquor from
top screens to Flash Tank No. 2
T P 4
PV-11
Digester Pressure
This valve regulates digester pressure and
controls temperature using washer filtrate in the
discharge zone
T P 6
1. Dual vessel only.
CODE: P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
10B 21
KAMYR
TAG#
KAMYR CONTINUOUS DIGESTER
FISHER CONTROL VALVE
PRODUCT DESIGN
Application Description
Control
Function
V150 V200 V300 V500 CV500 8580
Typical
Valve
Sized
PV-16
No. 1 Flash Steam Pressure
this valve controls pressure in No. 1 Flash Tank
T P 10
PV-17
No. Flash Steam Pressure
This valve controls pressure in No. 2 Flash Tank
T P 18
PV-30
(1)
Impregnation Vessel Pressure Relief
Relieves excess liquor from Impregnation
Vessel to No. 2 Flash Tank
T P 4
TV-2
Chip Bin Temperature
Takes steam from flash tank #2 to provide
steam for atmospheric presteaming in Chip bin
T P 18
TV-2A
Chip Bin Temperature
Provides alternate source of steam from low
pressure steam line to Chip Bin
T P 8
TV-19H
Modified Cooking Circulation Temperature
Valve controls steam to Modified Cooking
Heater which controls temperature of liquor to
upper wash zone
T P 6
TV-20H
Wash Circulation Temperature
Controls low pressure steam to Wash
Circulation Heater of the Digester
T P 6
TV-60A
(1)
Bottom Circulation Temperature
Valve controls steam to Bottom Circulation
Heaters which control temperature of liquor
leaving heaters to bottom zone of the
Impregnation Vessel
T P 6
TV-60B
(1)
Bottom Circulation Temperature
Same as TV60A
T P 6
TV-60C
(1)
Bottom Circulation Temperature
Same as TV60A
T P 6
HV-5
Steaming Vessel Relief
Relief Valve, sends steam to Condenser
T P 6
HV-5A
Steaming Vessel Relief Screen Blowback
This valve is used to blow back fresh steam to
clean relief screen
O/O S P 1.5
HV-8
(1)
Trim Liquor Downflow
Controls liquor extracted from upper screens
and sends it to bottom Circulation Heater
T P 8
HV-16
Digester Extraction to No. 1 Flash Tank
this valve controls extraction flow from
extraction screens KV16A, B, C, D to Flash
Tank #1
T P 8
HV-19
Modified Cooking Circulation Flow
Control liquor flow to modified cooking zone
from Modified Cooking Heater
T P 8
HV-20
Wash Circulation Flow Controls wash liquor
from bottom of digester to the Wash Circulation
Heater of the main Digester
T P 4
HV-51
(2)
Top Circulation Isolation Isolation valve for
liquor being sent back to High Pressure Feeder
from Impregnation Vessel. Special male flanges
O/O 14
HV-52
(2)
Top Circulation Isolation this valve isolates
high pressure feeder from the Impregnation
Vessel. Installed on main chip/liquor feedline
O/O 14
1. Dual vessel only.
CODE: P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
10B 22
KAMYR
TAG#
KAMYR CONTINUOUS DIGESTER
FISHER CONTROL VALVE
PRODUCT DESIGN
Application Description
Control
Function
V150 V200 V300 V500 CV500 DSV 8580
Typical
Valve
Sized
HV-54
Top Circulation Pressurization
This valve supplies cooking liquor to top
circulation line to pressurize it before pumping
T P 3
HV-62
(1)(2)
Bottom Circulation Isolation
This valve isolates Impregnation Vessel. It is
on the discharge line feeding the digester
O/O 12
HV-65
(1)
Impregnation Vessel Cooling Liquor Flow
filtrate from blow line is added to the
Impregnation Vessel to bottom dilution zone
T P 6
HV-81
(2)
Blow Line Isolation
Valves isolates digester blow line
O/O 10
HV-87
Blow Line Dilution
Blow line dilution and pressurization line prior
to opening HV81
T P 2
HV-90A
Blow Line Isolation (A)
Valve isolates blow line A from blow line B
T P 8
HV-90B
Blow Line Isolation (B)
See HV90A
T P 8
HV-120
(2)
Sample Valve (Digester)
This valve is used to monitor pulp quality
O/O 1-1/2
HV-120B
(2)
Sample Valve (Blow Line)
See HV120A
O/O 1-1/2
QV-27
White Liquor to Sand Separator
This valve is a purge for the Sand Separator
O/O P 1
KV-8A
(1)
Trim Liquor Switching This valve extracts
liquor through screens to Bottom Circulation
Heaters.
O/O P 6
KV-8B
(1)
Trim Liquor Switching
Same as KV8A
O/O P 6
KV-16A
Digester Extraction Switching
These valves provide screened liquor
extraction from upper wash zone to Flash
Tank No. 1
O/O P 8
KV-16B
Digester Extraction Switching
See KV-16A
O/O P 8
KV-16C
Digester Extraction Switching
See KV-16C
O/O P 8
KV-16D
Digester Extraction Switching
See KV-16A
O/O P 8
KV-19A
Modified Cooking Extraction Switching
These valves extract liquor in the modified
cooking zone and send it to the Modified
Cooking Heater
O/O P 8
KV-19B
Modified Cooking Extraction Switching
See KV-19A
O/O P 8
KV-19C
Modified Cooking Extraction Switching
See KV-19A
O/O P 8
KV-19D
Modified Cooking Extraction Switching
See KV-19A
O/O P 8
KV-20A
Wash Extraction Switching This valve
extracts wash water to the wash heater
O/O P 8
KV-20B
Wash Extraction Switching
See KV20A
O/O P 8
KV-24
(2)
Sand Separator Dump Valve
This valve is known as the pocket valve
O/O
1. Dual vessel only.
CODE: P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
10B 23
KAMYR
TAG#
KAMYR CONTINUOUS DIGESTER
FISHER CONTROL VALVE
PRODUCT DESIGN
Application Description
Control
Function
V150 V200 V300 V500 CV500 DSV 8580
Typical
Valve
Sized
KV-60A
(1)
Bottom Circulation Return Switching
These valves extract liquor from digester and
send it to bottom circulation heaters. *Digester
switching valve
O/O P 14
KV-60B
(1)
Bottom Circulation Return Switching
See KV-60A
O/O P 14
KV-60C
(1)
Bottom Circulation Screen Backflush
This valve works with KV-60A
O/O P 6
KV-60D
(1)
Bottom Circulation Screen Backflush
This valve works with KV-61C
O/O P 6
LV-19
M.C. Heater Condensate Level
This valve controls level in Modified Cooking
Heater. *Not shown on schematic
T P 1.5
LV-20
Wash Heater Condensate Level
This valve controls Wash Heater Level. *Not
shown on schematic
T P 2
LV-60A
B.C. Heater A Condensate Level
This valve controls level in Bottom Circulation
Heater A. *Not shown
T P 1.5
LV-60B
B.C. Heater B Condensate Level
See LV60B except heater B
T P 1.5
LV-60C
B.C. Heater C Condensate Level
See LV60A except heater C
T P 1.5
LV-81
Condensate Flash Tank Level
Not shown on schematic
T P 3
CV-80A
Condensate Conductivity to Tank
*Not shown on schematic
O/O P 6
CV-80B
Condensate Conductivity to Dump
*Not shown on schematic
O/O P 6
CV-80C
Water Conductivity to Dump
*Not shown on schematic
O/O P 3
1. Dual vessel only.
CODE: P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
10B 24
KAMYR
TAG#
KAMYR CONTINUOUS DIGESTER
FISHER CONTROL VALVE
PRODUCT DESIGN
Application Description
Control
Function
V150 V200 V300 V500 CV500 8580 EZ
Typical
Valve
Sized
LV-23 First Stage Backflush Tank Level O/O P 4
LV-24A
First Stage Filtrate Tank (Bypass)
This valve takes black liquor from Filtrate
Tank to weak black liquor storage
T P 6
LV-24B
First Stage Filtrate Tank (Makeup)
This valve takes wash water to add to weak
black liquor from Filtrate Tank
T P 6
LV-33
Second Stage Backflush Tank Level
This valve controls level in Backflush Tank
O/O P 4
LV-34
Second Stage Filtrate Tank Level Makeup
This valve controls level in second stage
Filtrate Tank
T P 6
QV-22 First Stage Backflush O/O P 10
QV-32 Second Stage Backflush O/O P 10
PV-23
First Stage Backflush Tank Pressure
Controls pressure in Backflush Tank No. 2
O/O P 1/2
PV-33
Second Stage Backflush Tank Pressure
Controls pressure in Backflush Tank No. 2
O/O P 1/2
FV-27
First Stage Wash Flow
This valve controls flow of first stage wash
in Diffusion Washer
T P 8
FV-28 Wash Water Flow for Float Out T P 2
FV-37
Second Stage Wash Flow
This valve controls flow of filtrate to second
stage wash
T P 8
HV-21A
(2)
Blow Line Isolation
Valve isolates blow line from Diffusion Washer
O/O 16
HV-21B
(2)
Blow Line Isolation
Valve isolates blow line from high
density storage
O/O 8
HV-22
First Stage Extraction Flow
This valve controls flow of filtrate from first
stage to Filtrate Tank
T P 8
HV-30 Second Stage Wash Isolation O/O P 8
HV-32
Second Stage Extraction Flow
This valve controls filtrate flow from second
stage to Filtrate Tank
T P 10
TV-13
Filtrate to Digester Temperature
This valve control temperature of
washer filtrate to Digester
T S P 6
1. Dual vessel only.
TCODE: P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
www.Fisher.com
Chapter 11
Black Liquor Evaporator & Concentrator
The evaporator/concentrator system serves as a
bridge between the pulp mill and powerhouse.
This is the first step in reclaiming spent cooking
chemicals. The evaporator receives weak black
liquor from the pulp washers (or continuous
digester) and concentrates the solution by
evaporating a large portion of the water content.
The concentrated black liquor is then sent to the
powerhouse for combustion in the recovery boiler.
A portion of the water content must be removed to
maintain safe and efficient combustion in the
recovery boiler. Although various methods exist
for this process, the primary purpose of
economical evaporation of water is a common
goal.
Multiple-Effect Evaporator
The most common method, referred to as a
multiple-effect evaporator, uses a series of
evaporator bodies to remove water from weak
black liquor. These evaporator bodies typically
receive weak black liquor at 12 - 15% solids
concentration and evaporate a portion of the water
to raise the solids concentration to 50 - 60%.
Solids refers to the organic wood constituents
and inorganic cooking chemicals. The product is
referred to as heavy or strong black liquor.
The primary advantage of multiple evaporator
bodies is steam economy. A series of evaporator
bodies makes it possible to remove 4 - 6 pounds
of water per pound of motive steam used. This is
accomplished by connecting the bodies in series
so the vapor generated from one evaporator
becomes the steam supply for the next evaporator
in the series. Effects are numbered in order of the
steam flow. Weak black liquor starts at the last
effect, thus moving in a counter-current flow to
steam. Although the number of effects may vary,
six, or a sextuple-effect, is most common. Capital
cost usually offsets any increase in steam
economy if more effects are used.
A typical sextuple-effect evaporator set is shown
in figure 11-1. Each individual evaporator consists
of a heating element and a vapor head. Each
heating element consists of a tube bundle with
upper and lower tube sheets. Liquor flows on the
inside of the tubes and steam on the outside of the
tubes. Some designs use plate-type heating
elements instead of tubes. In either design, the
transfer of heat causes the liquor to boil and the
vapor that forms is carried to the next effect to
continue the evaporation process. Condensate
formed by condensing steam vapor is also
removed.
Motive steam is fed to the first effect and weak
black liquor feed split between the 5th and 6th
effects. The black liquor increases in solids
content and boiling temperature as it progresses
toward the first effect. In order for boiling to take
place, the pressure on the liquor side of the tubes
must be less than the pressure on the steam side.
Thus, the pressure must be different in each effect
and decrease from a high in the first effect of 30 -
40 psig to a low in the sixth effect of 20 - 25
inches of Mercury (Hg) vacuum. Maintaining this
partial vacuum is accomplished by piping vapors
from the sixth effect to a condenser and removing
non- condensible gases with an ejector or vacuum
pump.
Evaporator Types
As mentioned earlier, the most common type of
evaporator is the multiple-effect type. However,
many variations of this concept are used. The
largest installed base of evaporators is the rising
film or long tube vertical (LTV) type (see figure
11-1). This was the prevalent design until the late
1970s. In this design, the liquor enters a cavity
112
E
0
8
9
4
Figure 111. Multiple-Effect Evaporator Six Effect / Rising Film / LTV
113
below the lower tube sheet. As it boils or
percolates, a thin film of liquor rises up the inside
of the tube or plate. The liquor overflows the upper
tube sheet and falls via a downcomer pipe to a
transfer pump. The vapor exits via a centrifugal
separator and is piped to the next effect. This
design provides high evaporation capacity at a low
cost, but is sensitive to scaling and plugging above
50% solids.
Although the rising film design is predominant in
installed base, the falling film design has become
increasingly popular since the early 1980s and is
now the most common type of evaporator. This
design looks like an upside-down rising film
evaporator (vapor dome at the bottom and the
tube bundle extending upward). As its name
implies, liquor is fed into the upper tube sheet area
and flows as a thin film down the inside of the
tubes. The liquor collects in the lower dome and is
discharged from the evaporator body. Since the
liquor flow is in the same direction as gravity and
flowing in a thin film, higher heat transfer
coefficients are realized. The higher coefficients
allow for lower temperature differentials (vapor vs.
liquor) resulting in the ability to achieve higher
solids concentration and less scaling than a LTV
design. The main disadvantage is associated with
the high pumping cost of multiple-pass forced
circulation employed on most falling film designs.
A number of alternative systems and variations to
the classical multiple effect system has emerged
recently in an effort to obtain higher solids
concentrations, and reduce fouling of heating
surfaces. Some of the variations to the classical
sequence involve changing the feed liquor input
location and using lower solids liquor to wash
surfaces where higher solids liquor are normally
made. This extends the time between general
washings or boilouts.
A recent alternative system involves combining
rising and falling film evaporator bodies in a
multiple effect system. In this design, the first two
or three effects are falling film evaporators and the
last three or four effects are rising film
evaporators. This gives the advantage of pumping
energy conservation on the back end where
solids and scaling potential are lower and the
resistance to fouling on the front end as solids
increase.
Another system has emerged in recent years
known as mechanical vapor recompression
(MVR). This system typically employs a single
evaporator body, a compressor, and heat
exchangers. This system reuses vapors by raising
the temperature and pressure with a compressor.
It is used mainly where steam supply is
inadequate and electrical power is economical.
Auxiliary Equipment
Various pieces of auxiliary equipment are required
to support the operation of an evaporator set.
Some of this equipment is briefly described below:
D Soap Skimming/Removal
Soap or tall oil soap is composed of fatty and resin
acids found in wood products. During evaporation,
the soap will not stay dissolved beyond 25 - 30%
solids concentration. Failure to remove the soap
results in excessive foaming and a lower efficiency
for the entire recovery cycle. Typically, liquor
leaving the fourth effect is diverted to a skimming
tank where the soap is removed for processing.
After the soap is removed, the liquor is transferred
to the third effect to continue evaporation.
D Flash Tanks
Flash tanks are used to recover heat from flashing
liquor or condensate to a lower pressure. Typical
flash tank locations are product liquor and clean
steam condensate from the first effect. The flash
steam is then used for process heating.
D Condenser and NCG Removal
As mentioned earlier, a condenser is used to
maintain a vacuum at the back end of the
evaporator set. The condenser is connected to the
vapor duct from the sixth effect. The condensed
vapors from the sixth effect, referred to as foul
condensate, contains contaminants such as sulfur
gases and black liquor organics. These
contaminants are removed by a steam stripping
system since they create odor and pollution
problems.
Non-condensible gases (NCG) such as hydrogen
sulfide, mercaptans, and carbon dioxide also tend
to accumulate in the condenser. These gases are
removed with a steam or air fed ejector system
and sent to an incinerator. Failure to remove these
gases will limit an evaporator set by reducing the
available vacuum and temperature differential.
D Foul Condensate Stripping
114
Figure 11-2. Falling Film Concentrator
E0895
Foul condensates are formed in both the
evaporators and digesters. The primary reason for
stripping foul condensate is pollution control. A
common method of treatment involves feeding the
condensate to a stripping column or tower, which
is supplied with fresh steam. The steam tends to
remove most of the contaminants and leaves
clean condensate suitable for pulp washing. The
contaminants are usually carried in a gaseous
form to an incinerator.
Concentrators
Concentrators are an extension of the evaporation
of water from black liquor. As mentioned earlier,
evaporators are typically limited to 50 - 60% solids
concentration due to scale build-up of sodium salts
on heating surfaces. Concentrators accept the 50
- 60% solids from the evaporators and further
concentrate it to 65 - 80% solids. A typical falling
film concentrator is shown on figure 11-2.
D Direct Contact Concentrators
The first type of concentrator used in the pulp and
paper industry was a direct heated type. Even
though it served the same basic purpose as
115
todays concentrator, it was often referred as a
direct contact evaporator. The two most widely
used types, the cyclone and cascade evaporators,
utilized hot flue gas exiting the recovery boiler to
further concentrate the black liquor. However, the
direct contact of flue gas and black liquor strips
sulfur compounds from the liquor which results in
air pollution and sulfur loss. Most mills have
eliminated direct contact evaporators in favor of
more modern indirectly heated concentration
equipment.
D Forced Circulation Concentrators
To overcome the limitations of direct contact
evaporators, indirectly heated concentrator bodies
are used for final liquor concentration. This type of
installation typically involves one or more
additional effects ahead of the first effect in the
multiple-effect evaporator set. The first effect is
fed with a separate supply of steam and
concentrates the product liquor from the first effect
of the multiple-effect evaporators.
The concentrator effects are generally used in a
switching arrangement such that one effect is
concentrating high solids black liquor while the
other effect is concentrating lower solids liquor.
This type of arrangement uses the lower solids
liquor to wash deposits left from concentrating
high solids liquor.
D Falling Film Crystallizers
One of the most recent concentrator designs is
referred to as a falling film crystallizing
concentrator. As mentioned earlier, salt crystals
tend to form once black liquor becomes saturated
at about 55% solids. In typical evaporators these
crystals tend to stick to heat exchange surfaces
and prohibit heat transfer. Crystallizers are
designed to control crystal formation such that
newly formed crystals will bond to crystals
contained in the recirculating liquor rather than the
heating surfaces. This allows for extremely high
solids concentration (up to 80%) with reduced risk
of fouling. The FFC concentrator can be used for
all effects in an evaporator system where
crystallization will occur.
D Other Designs
A couple of other designs may also be used as
concentrators. One type is a single concentrator
body with two or three separate sections. In this
design one section(s) is washed with weak liquor
from the evaporators while the other section(s) are
used to achieve final liquor concentration. A
second type combines preheat, falling, and rising
film sections in one body. These units typically use
forced circulation and are complicated to operate.
Although figures 11-1 and 11-2 indicate many of
the critical control valves, other general service
control valves are required for the successful
operation of an evaporator/concentrator set. Many
of the valves are on mill supply water, instrument
air, plant air, or low pressure steam heating lines.
Control Valve Selection
Black liquor is a thick media which can be erosive,
corrosive, or cause scaling problems in valves.
Valves must be able to perform in both control and
tight-shutoff applications, with special
consideration give to valves where black liquor is
the thickest; typically before entering and exiting
the concentrator.
In applications where black liquor has lower solids
content, the Control-Disk butterfly valve may be
used. However, in most cases, the Vee-Ball
segmented ball valve is the primary valve of
choice.
116
Valve
Tag #
EVAPORATORS/CONCENTRATORS FISHER CONTROLS VALVE PRODUCT DESIGN
Application Description
Control
Function
V150 V500
8580/
Control-
Disk
A81 EBody
Typical
Valve
Size
LV-1 1st Effect Liquor Level T P S 6I
LV-2 2nd Effect Liquor Level T P S 6I
LV-3 3rd Effect Liquor Level T P S 6I
LV-4 4th Effect Liquor Level T P S 8I
LV-5 5th Effect Liquor Level T P S 8I
LV-6 6th Effect Liquor Level T P S 6I
LV-7 1st Effect Condensate Level T P S 4I
LV-8 2nd Effect Condensate Level T P S 4I
LV-9 3rd Effect Condensate Level T P S 6I
LV-10 4th Effect Condensate Level T P S 6I
LV-11 5th Effect Condensate Level T P S 8I
LV-12 6th Effect Condensate Level T P S 8I
LV-13 Clean Condensate Flash Tank Level T S P (ET) 4I
LV-14 Intermediate Product Liquor Flash Tank Level T P S 6I
LV-15 Soap Skimming Tank Level T P S 8I
LV-16 Foul Condensate Hotwell Level T S P (ED) 8I
LV-17 Concentrator Condensate Level T S P (ET) 4I
LV-18 Concentrator Liquor Level T P S 6I
LV-19 Product Liquor Flash Tank Level T P 6I
PV-1 Steam to 1st Effect T S P (EWD) 12I
PV-2 Flash Steam from Intermediate Product Flash Tank T P 8I
PV-3 Flash Steam from Clean Condensate Flash Tank T P 8I
PV-4 Steam to Concentrator T S P (EWD) 10I
PV-5 Vapor from Concentrator T P 14I
PV-6 Flash Steam from Product Liquor Tank T P S 8I
FV-1 Contaminated Condensate to Sewer O/O P 6I
FV-2 Soap to Processing T P S 6I
FV-3 Liquor Feed to 5th Effect T P 6I
FV-4 Liquor Feed to 6th Effect T P 6I
FV-5 Cooling Water to Condenser T P 18I
FV-6 Steam to NCG Ejector T S P (EZ) 2I
FV-7 NCG to Incinerator T P S 6I
FV-8 Feed Liquor to Concentrator T P 6I
FV-9 Contaminated Condensate to Sewer O/O P 6I
P=Primary Valve Choise
S=Secondary Valve Chice
T=Throttling Service
O/O=On/Off Service
www.Fisher.com
Chapter 12
Kraft Recovery Boiler Black Liquor System
The kraft recovery boiler is the heart of a complex
series of chemical processes referred to as the
kraft recovery cycle. The two main functions of the
kraft recovery boiler are to:
1. Reclaim digester cooking chemicals, sodium
and sulfur, in a suitable form for regeneration of
cooking liquors.
2. Provide efficient heat recovery and steam
generation from combustion of organics in black
liquor fuel.
Since the kraft recovery cycle is far removed from
the finished product of the paper mill, it sometimes
does not receive the attention it deserves.
However, efficient chemical and heat recovery
have a critical impact in overall mill efficiency and
profitability.
Recovery Process Overview
As mentioned earlier, the recovery boiler is a
major component of the kraft recovery cycle.
However, other components perform important
functions in the cycle. For continuity, a brief
description is given to indicate the role of the
recovery boiler in the overall cycle.
The basic components of the kraft recovery cycle
are:
Digester(s)
Wood chips are mixed with a solution of cooking
chemicals called white liquor (sodium sulfide and
sodium hydroxide). The contents are cooked
under pressure with steam to dissolve the glue-like
lignin, which holds the wood fibers together. After
cooking, the contents are blown into a holding
tank.
Washers
The holding tank contents, known as pulp or
stock, are transferred to the washers where water
is used to wash residual cooking chemicals from
the wood fibers. The wash water is sent to the
evaporators and washed pulp to paper making.
Evaporators
The wash water, containing wood by-products and
cooking chemicals, is transferred to the
evaporators. This solution is commonly known as
weak black liquor. Evaporators employ a series of
effects or bodies using steam which evaporates
much of the weak liquor water content. The final
product is referred to as strong black liquor.
Recovery Boiler
Strong black liquor is transferred to the recovery
boiler for combustion. The combustion process
burns the organics (for steam production) and
transforms the chemicals to a molten liquid known
as smelt. The smelt flows from the boiler into a
tank of water (or weak wash) and produces green
liquor.
Recausticizing Plant
The green liquor is transferred to a series of
components which add lime to regenerate the
cooking chemicals or white liquor. Clarified white
liquor is then pumped to the digesters to begin the
cooking process again.
Black Liquor Preparation
As stated in the overview, black liquor preparation
for the recovery boiler actually begins with the
evaporators; however, other components (see
figure 12-1) presented in this guide also play
important roles.
122
Two components commonly employed on older, or
conventional boilers, are direct contact
evaporators and black liquor oxidation systems.
Direct contact evaporators may be the cascade
evaporator or cyclone evaporator type.
Black Liquor Oxidation
Black liquor oxidation is the exposure of black
liquor to air (oxygen) to form more stable sulfide
compounds. This exposure prevents the release
of hydrogen sulfide and mercaptans when the
liquor is exposed to hot flue gas in the direct
contact evaporators. Release of these gases
results in sulfur loss and odor emission. The
oxidation process is commonly performed by a
blower forcing compressed air into a liquor filled
tank via a sparger ring.
Direct Contact Evaporators
Direct contact evaporators are used for final liquor
concentration from 45-50% solids to 60-65%
solids. They are so named because the boiler
induced draft fan pulls the hot flue gas into direct
contact with the black liquor to evaporate water
prior to combustion.
The cyclone evaporator, commonly used with
Babcock and Wilcox recovery boilers, consist of a
cylindrical vessel with an opening which allows
flue gas to enter tangentially. Black liquor is
sprayed into the swirling gas to allow mixing and
evaporation of water.
The most common type of evaporator for the past
two decades has been the falling film or cascade
evaporator. This evaporator consists of a rotating
assembly of hot plates or tubes that are alternately
submerged and then exposed to hot flue gas.
These tend to be more efficient and versatile.
Due to the high flue gas temperatures and the
presence of black liquor fuel, the potential for a fire
exist in both types of evaporators. A common
method employed to combat this potential is the
injection of steam to displace oxygen and smother
a fire.
Low Odor Design
As mentioned earlier, both black liquor oxidation
and direct contact evaporators are employed on
older or conventional type boilers. However, most
modern designs referred to as low odor type use
indirectly heated concentrators (similar to
evaporators) to raise the black liquor solids
concentration to the 65-70% range. Similar to the
falling film evaporator, concentrators eliminate the
need for direct contact evaporators, which, in turn,
eliminates the need for black liquor oxidation.
Lower sulfur and odor emissions are a result of
the flue gas and liquor having no direct contact.
This design also requires additional boiler
economizer section(s) to absorb the flue gas heat
which had been removed in the direct contact
evaporators. The concentrator is more energy
efficient and environmentally friendly than its
predecessors.
Precipitator Ash
Following preparation by concentrators or black
liquor oxidation, liquor is transferred to the
electrostatic precipitator. Ash, consisting primarily
of salt cake (Na
2
SO
4
or sodium sulfate), is
collected from the flue gas and mixed with the
liquor. In some older designs, referred to as wet
bottom, the liquor fills the precipitator bottom and
salt cake falls directly into the pool. Since this
presents a potential fire hazard and a source for
odor emissions, most newer precipitators have the
dry bottom design. In this design, chains or screws
convey the dry ash into a liquor filled sluice tank.
Salt Cake Mix Tank
Before introduction to the recovery boiler furnace,
the liquor is mixed with more ash and salt cake in
the blending tank or salt cake mix tank. Salt cake
addition is required due to small chemical losses
occurring in the recovery cycle. Salt cake is
typically added from two sources. One source is
via fallout hoppers below the steam generating
and economizer sections of the boiler. A second
source is purchased make-up. Direct steam
heating of the tank is typically used to maintain
liquor viscosity at suitable values for pumping.
In order to reduce emissions, some mills have
eliminated salt cake as a soda makeup chemical
because of its high sulfur content. Caustic soda
(NaOH) and soda ash (Na
2
CO
3
) have been
substituted since they are sulfur free chemicals.
Liquor Divert
Black liquor is typically at 65-70% solids before it
is sent to the recovery furnace for combustion.
Density, or percent solids, is usually measured
between the liquor heater and liquor guns via
123
magnetic flow meters. If solids drop below 60%,
auxiliary fuel is added due to the potential of a
smelt/water explosion or bed blackout. If solids
fall below 57-58%, the liquor is diverted from the
furnace to the mix tank until solids reach an
acceptable level. Each individual liquor feed line
typically has a valve connected to emergency
shutdown interlocks. These valves snap close on
a trip or shutdown signal.
Black Liquor Heating
A final preparation stage for the liquor involves
heating. Liquor is typically heated to 230F-250F
to impart the desired viscosity and burning
characteristics before spraying into the furnace.
Many older designs employ direct steam heaters,
but most newer designs are using indirect steam
heating. The indirect heating does not add water
content to the liquor which is a safety and
efficiency consideration. Recirculation systems
and steam desuperheating are often used with
indirect heating.
Liquor Flow/Pressure Control
A common method used to control the flow or
pressure of black liquor to the furnace is
recirculation to the mix tank. This allows the
nozzle pumps to run at a constant speed and keep
the liquor moving to avoid potential plugging of
transport piping.
Auxiliary Fuel
Black liquor is not used as a fuel to start-up a
recovery boiler. Natural gas or fuel oil is typically
used to bring the boiler up to a prescribed
temperature before black liquor fuel is introduced.
This is done primarily as a safety consideration
due to the potential of a smelt-water explosion in
the lower furnace.
Kraft Recovery Boiler
While recovery boiler design considerations vary
among each manufacturer, their basic two-fold
purpose of chemical recovery and steam
production is common to all. Since the primary
function is chemical recovery, black liquor flow to
the furnace is a constant and steam production is
a by-product. This requires the recovery boiler
steam outlet header to be piped to a common
header with a power boiler steam outlet. Swinging
steam demands due to mill processes are
accommodated by manipulating fuel to increase
steam production of the power boiler.
Combustion Air
Air required for combustion in the furnace is
introduced separately from the black liquor.
Ambient air is forced into the boiler through an air
heater via the forced draft fan(s). The air heater
typically uses steam coils to heat the incoming air.
Most modern designs introduce air at three levels:
primary, secondary, and tertiary. These various
levels are used to ensure chemical reduction,
complete combustion of organics, and proper
shape of the smelt bed. The primary air ports are
located a few feet above the hearth and carry the
responsibility to provide as low a velocity as
practical while still supplying between 50-65% of
the total air requirement. Secondary and tertiary
ports establish higher velocities to ensure
complete mixing and combustion of the unburned
gases. Combustion flue gas is pulled from the
furnace section to the convective section of the
boiler via induced draft fan(s). This creates a
slightly negative pressure inside the boiler. This
action prevents hot gases from leaving boiler
openings and is commonly referred to as
balanced draft.
Black Liquor Combustion
Black liquor is introduced into the recovery furnace
via nozzles or liquor guns. The guns produce a
spray of coarse droplets exposed to hot flue gas.
Depending on the manufacturer, the guns may be
stationary or oscillating, and spray the liquor on
the walls or into the center of the furnace. The
flow of this black liquor to the guns is controlled by
a valve. When selecting a control valve for this
application, it is crucial to select proper materials
due to corrosion. As the organics burn and release
heat to the flue gas, the remaining char, consisting
of the sodium and sulfur cooking chemicals, falls
to the smelt bed on the furnace floor.
Sootblowers
Application Summary:
The efficiency of a fossil-fuel boiler is highly
dependent on the heat transfer effectiveness of
the boiler tubes. These tubes are fairly delicate,
and hot spots (due to soot buildup cannot) be
124
tolerated as a leak could result. A cleaning
process for the boiler tubes is needed even while
the boiler is in operation. This process is called
soot blowing.
Process:
When firing fuels such as coal, oil, biomass or
other waste products fouling of the boiler tubes
becomes a concern. Deposits from the
combustion process can collect on the heat
exchanging tubes reducing thermal efficiency and
can cause operational difficulties. In order to keep
the unit operating, an online cleaning method must
be used. This is usually accomplished by using
what are called sootblowers.
Most sootblowing systems utilize either air or
steam. Widespread use of water has been limited
due to the possibility of thermal shock on the tube
banks. Air or steam systems each have their own
advantages, but one is not considered better than
the other.
Air systems have much simpler piping
arrangements. This is due to the elimination of
condensate drain piping. The number of
compressors, compressor capacity and the
sootblower flow requirement; however, limits this
system.
Steam systems have an advantage in terms of
expansion. The supply of steam (typically
removed after the primary superheater) is virtually
unlimited, but leads to additional maintenance
concerns related to the numerous valves required.
Also, as stated above, the steam systems require
additional piping to address the possibility of
condensate in the steam lines.
As high pressure air or steam is required to
remove the deposits from the boiler tubes, the
control valve must be able to withstand high
pressures. Steam systems present a greater
challenge due to the combination of high pressure
and temperature. Because of the high inlet
pressure, downstream pressure and pipe size, the
valve must also withstand issues with noise and
vibration. As the sootblowers operate
intermittently, tight shutoff (class V) is required for
valve trim protection and when using steam,
maintaining unit efficiency. These valves modulate
over a wide range of flows and are required to
maintain downstream pressure.
Design Considerations and Service
Conditions:
D High pressure class rating due to the
pressures and temperatures.
D Tight shutoff so valves dont leak valuable
steam.
D Large pressure drops can create noise,
vibration, and excessive wear to trim.
D Cyclic conditions as valve are operated
numerous times a day.
Typical Process Conditions:
D P
1
= 800 - 1400 psig
D P
2
= 0 psig
D T = 400 - 800F
125
Typical Specification:
ES flow-down for on/off sootblowers.
To conserve energy, mills have moved to
throttling sootblower valves. Use an ED.
Tight shutoff not needed as sootblower nozzles
have tight shutoff.
Model:
ES for on/off, flow down, quick opening cage,
Class V
ED for throttling, =% cage, flow down, Class II
These units provide high pressure and
temperature capability along with the tight
shutoff required.
Drilled-hole cage (flow-up)
Body: WCC
Trim: Quick opening cage or Whisper
cage for noise attenuation
Cage: S31600 CoCr-A seat and
guide
Plug: 316 CoCr-A
Seat: R30006 (alloy 6)
Seat Ring Retainer: R30006
(alloy 6)
Stem: Nitronic 50. Optional
oversized stem or oversized
VSC
Bonnet:: PTFE packing
Actuator: 667 spring-and-diaphragm or
585C piston
Positioner: DVC6010 c/w performance
diagnostics
Fisher Engineered Specification:
The Fisher ES and ED cage-guided globe valves
provide maximum stability and ruggedness in high
pressure drop applications. The ES is offered with
an unbalanced plug and the ED with its balanced
plug to minimize actuator thrust requirements.
Both designs have hardened trim for superior
erosion resistance. The plug and stem assembly
is reinforced through the use of high tensile
materials and oversized valve stem connection.
High noise levels are often present in high
pressure drop, high flow steam applications.
Noise attenuation can be achieved with
engineered valve trim combined with an inline
diffuser for additional noise reduction when
required. Typically Whisper Trimt I and a Fisher
6011 downstream diffuser are the most practical
and economical solution; however, there are other
options available that allow for full attenuation at
the valve such as the Fisher Whisper Trim III or
WhisperFlot trim. There are many factors to
consider such as capacity, turndown, line size,
and overall economics when selecting an
appropriate solution.
Chemical Reduction
Chemical reduction occurs via the char bed at the
floor of the recovery furnace. The molten liquid
bed typically operates at temperature of 1600F -
2500F. The introduction of air via the primary air
ports provides the oxygen required to burn the
carbon and reduce the sulfate to sulfide. The
molten smelt, consisting primarily of Na
2
CO
3
and
Na
2
S, flows by gravity to the dissolving tank. The
dissolving tank is filled with weak wash to cool the
smelt and produce a solution suitable for pumping.
The solution formed, known as green liquor, is
then transferred to the recausticizing area for
addition of lime and regeneration of white liquor.
The dissolving tank is vented to the atmosphere
via a tall stack. Since the sodium and sulfur
compounds in the smelt present a source of odor
emission, the vented gas is often treated with a
scrubber. Although the scrubbers vary in design
and complexity, a solution of weak wash is often
used as the scrubbing medium.
Control Valve Selection
Although table 12-1 indicates many of the critical
control valves, other general service control valves
are required for the successful operation of a
recovery boiler. Many of the valves are on mill
supply water, instrument air, plant air, or low
pressure steam heating lines.
126
Table 12-1. Kraft Recovery Boiler / Black Liquor System Valve Selection
PROCESS FISHER VALVE PRODUCT DESIGN
Valve
Tag
Kraft Recovery Boiler / Black Liquor System
V150/
V300
V500
Control-
Disk
A81 E-Body
Typical
Valve Size Application Description
Control
Function
LV-1 BLOX Tank Level Control T P P 6I
LV-2 Sluice Tank Level Control T P P 6I
LV-3 DCE Level Control T P P 6I
FV-1 Black Liquor Emergency Divert O/O P S 6I
FV-2 Black Liquor Emergency Divert O/O P S 6I
FV-3
Black Liquor Recirculation Flow or
Pressure Control
T P 2I
FV-4 Auxiliary Fuel/Natural Gas T P 3I
FV-4 Auxiliary Fuel/Fuel Oil T P 2I
FV-5 Black Liquor Shutoff O/O P 6I
FV-6 Green Liquor from Dissolving Tank T S P 6I
FV-7 Weak Wash to Dissolving Tank T P 4I
FV-8 Weak Wash to Scrubber T P 2I
FV-9 Sootblower Steam O/O P S 4I
FV-10 Smothering Steam to Precipitator O/O S P 2I
FV-11 Smothering Steam to DCE O/O S P 2I
TV-1 Steam to Mix Tank T S P 2I
TV-2 Steam to Black Liquor Heater T S P 2I
TV-3 Steam to Air Preheater T S P 2I
P=Primary Valve Choice
S=Secondary Valve Choice
T=Throttling Service
O/O=On/Off Service
127
E
0
8
9
3
Figure 12-1. Kraft Recovery Boiler Black Liquor System
128
www.Fisher.com
Chapter 13
Recausticizing and Lime Recovery
The recausticizing and lime recovery plant is the
final step in the Kraft recovery process. It serves
as a link between the Kraft recovery boiler and the
digester. The function of the recausticizing area is
to convert the inorganic chemicals in the green
liquor from the recovery boiler dissolving tank to
white liquor for cooking chips in the digester. This
process consumes lime and produces lime mud.
The purpose of lime recovery is to convert the lime
mud back into lime for the recausticizing process.
Proper control of the recovery and reclaim of the
cooking chemicals is essential in the economic
success of a Kraft recovery mill.
Recausticizing
As mentioned earlier, the recausticizing process
involves reclaiming the cooking chemicals
contained in the green liquor and converting or
regenerating them to produce white liquor. The
white liquor is then used to cook wood chips in the
digester. A typical flow sheet is shown in figure
13-1.
Dissolving Tank
Green liquor is produced in the recovery boiler
dissolving tank by mixing weak wash and smelt.
Smelt, consisting primarily of Na
2
CO
3
and Na
2
S,
is produced by burning black liquor in the recovery
boiler furnace. Weak wash, which is basically
water, is a product of lime mud washing. In
addition to the chemical components, the green
liquor contains impurities known as dregs which
consist of unburned carbon and inorganic
impurities such as calcium and iron.
Valve: FV-9 Weak wash to dissolving
tank
D Typical process conditions:
Fluid: Secondary condensate
T = 176F
P = 70 - 75 psig
P = 40 - 45 psig
D Typical valve selection:
NPS 6 valves with alloy 6 scraper seats
due to concerns with scaling. A SST
valve with an alloy 6 HD seal and alloy 6
bearings should be used in this
application. Depending upon process
conditions, the Control-Disk could act as
a great alternative.
Green Liquor Clarifier
The dregs, which cause the green color, are
impurities that must be removed from the green
liquor. These fine particles are removed by
pumping the green liquor to a sedimentation tank
or clarifier. Since the density of the dregs is
greater than the green liquor, settling of the dregs
by gravity occurs. A slow moving rake pulls the
material to a discharge cone in the center of the
clarifier where it is concentrated and removed.
The clarified liquor exits via overflow piping to a
storage tank.
Dregs Washing
Before disposing of the dregs, they must be
washed to recover any residual cooking
chemicals. This is important from an economical
and environmental aspect. Most mills employ a
pre-coat filter to wash the dregs. The system
consists of a rotating cylindrical filter in a vat. Lime
132
mud is admitted to precoat the outside of the filter.
A vacuum is maintained on the inside of the filter
with a vacuum pump. The dregs slurry is pulled
through the lime mud and filter media. A knife
blade removes the lime mud as it becomes
saturated with dregs. The lime mud/dregs are
hauled to a landfill and the clear filtrate is recycled
to the green liquor clarifier.
Valve: LV-1 Dregs Precoat Filter Level
D Typical process conditions:
Fluid: Lime mud
T = 212F
P = 55 - 65 psig
D Typical valve selection:
These are typically NPS 2 or NPS 3 SST
valves with solid VTC (ceramic) internals
and alloy 6 bearings.
Valve: FV-3 Dregs Slurry Underflow
from Green Liquor Clarifier
Please reference the lime mud underflow
information below as this application closely
resembles its process.
Slaker
The slaker is the heart of the recausticizing
operation. At this point, clarified green liquor is
mixed with lime to produce white liquor. The
reburned lime (CaO) from the lime kiln and
makeup lime are added and react with the water in
the green liquor to form calcium hydroxide
(Ca(OH)
2
). This reacts with Na
2
CO
3
in the green
liquor to form sodium hydroxide (NaOH) or caustic
and precipitate calcium carbonate (CaCO
3
) or lime
mud. A retention time of approximately fifteen
minutes is allowed in the slaker. Recausticizing
efficiency is improved by steam heating the
incoming green liquor to near boiling and adding
an agitator to the slaker.
Valve: FV-5 Green Liquor to Slaker
D Typical process conditions:
Fluid: Green liquor
T = 212F
P = 80 - 85 psig
P = 5 - 10 psig
D Typical valve selection:
NPS 6 valves with alloy 6 scraper seats
due to concerns with green liquor scaling.
A SST valve with an alloy 6 HD seal and
alloy 6 bearings should be used in this
application.
Causticizers
The retention time in the slaker is not enough to
allow a complete reaction between the lime and
green liquor. Causticizers consist of a series of
two or more agitated tanks having a total retention
time of 1-1/2 - 3 hours. The white liquor slurry
usually flows by gravity from the slaker and
through the causticizers.
White Liquor Clarifier and Lime Mud
Washer
The white liquor clarifier is essentially the same as
the green liquor clarifier described earlier. The
white liquor slurry is pumped in from the last
causticizer and the lime mud solids (CaCO
3
) settle
to the bottom of the clarifier due to density
differential. The lime mud, at 35-40% suspended
solids, is raked to a center discharge cone where
it is concentrated and removed. The clarified white
liquor containing sodium hydroxide and sodium
sulfide overflows and is pumped to the digester for
cooking wood chips.
The lime mud underflow from the white liquor
clarifier must be washed to recover residual
cooking chemicals. The lime mud washer is very
similar to a white liquor clarifier with the possible
exception of multiple compartments. The feed to
the washer is from a mix tank, which accepts
filtrate streams from the lime mud filter and lime
kiln scrubber in addition to the lime mud
underflow. The washed lime mud is removed at
45-50% suspended solids and sent to storage.
The overflow, referred to as weak wash, is sent to
weak wash storage and primarily used in the
recovery boiler dissolving tank.
Valves: FV-6/FV-8/FV-16/FV-19 Lime
Mud Underflow
D Design Considerations and Service
Conditions
Lime mud is extremely erosive and
difficult to handle due to fine particulate
and high solids concentration.
The underflow valve is throttled to control
mud density which directly impacts the
133
operation and efficiency of the lime kiln.
An accurate and reliable control valve is
required for optimum performance.
The underflow valve must be
appropriately sized to ensure the mud
level in the tank never reaches the filter
socks. The filter cannot operate properly
if this occurs.
D Typical Process Conditions:
Fluid: Lime mud
P
1
= 20 - 50 psi
P
2
= 0 - 5 psi
T = 175 F
Q = 100 - 300 USGPM
SG = 1.36
D Typical Valve Selection:
NPS 3 - NPS 6 V500 ANSI 150/Reverse
flow/Trim #4 for erosive service
Plug: VTC Ceramic on alloy 6 Hub
Seat: Solid VTC Ceramic
Shaft: Oversized, 17-4PH Stainless Steel
Retainer: Solid alloy 6 with Ceramic bore
Bearings: Sealed alloy 6 construction
Packing: PTFE
Actuator: 2052, fail closed
Positioner: FIELDVUE DVC6200 with
Performance Diagnostics
White Liquor and Lime Mud Pressure
Filters
Although white liquor clarifiers and lime mud
washers are predominate in installed base, the
trend in recent years has been to substitute
filtration equipment. This is possible because of
the relatively large size of lime mud particles. A
typical filtration system is shown in figure 13-2.
The white liquor pressure filter performs the same
function as the white liquor clarifier. The vessel is
divided into two compartments by a tube sheet.
The tube sheet supports a number of perforated
tube filter elements. Each perforated tube is
covered with a polypropylene filter sock. The white
liquor slurry must pass through the filters to reach
the upper compartment. As lime mud builds up on
the filters backflushing is required to restore
normal operation. Backflushing is accomplished by
recirculating the feed white liquor back to the
causticizer. This allows the level to drop and the
air cushion at the head of the vessel to expand
and force the liquor into the socks. This knocks
the lime mud from the sock filters. The lower
portion of the pressure filter acts as a settling zone
for the lime mud following backflushing. Clarified
white liquor is removed from the upper
compartment above the filter elements.
The lime mud pressure filter performs the same
function as the lime mud washer and the principle
of operation is the same as the white liquor
pressure filter. The lime mud is removed from the
bottom of the unit and the filtrate known as weak
wash is removed from the upper compartment
above the filter elements.
Valve: FV-17 Lime Mud to Filter
D Typical process conditions:
Fluid: Lime mud
T = 176F
P = 50 - 60 psig
D Typical valve selection:
These valves can range from NPS 4 to
NPS 10. A SST body with 316 CRPL
ball, alloy 6 hard faced seat and alloy 6
bearings should be used in this
application.
Valve: FV-18 Lime Mud Recirculation
to Lime Mud Mixer
D Typical process conditions:
Fluid: Lime mud
T = 176F
P = 50 - 60 psig
D Typical valve selection:
NPS 2 or NPS 3 SST valves with solid
VTC (ceramic) internals and alloy 6
bearings.
Lime Mud Filter
Lime mud from storage at 45-50% suspended
solids is pumped to a precoat filter for dewatering.
Dilution water is added at the intake of the transfer
pump to dilute the solution to 25% suspended
solids. The lime mud slurry is pumped to a vat
containing a rotating filter. The lime solids build to
a sufficient thickness on the filter and are
dewatered by means of a vacuum maintained on
the inside of the filter with a vacuum pump. A
134
fresh water spray may also be used for further
washing of cooking chemicals from the lime mud.
The dewatered lime mud is removed with a
scraper blade and the filtrate sent to a mix tank
feeding the lime mud washer (or pressure filter).
The operation is very similar to the dregs precoat
filter.
Valve: FV-10 Dilution water for lime
mud transfer
D Typical Process Conditions:
Fluid: Clean condensate
T = 176F
P = 30 - 40 psig
P = 5 - 10 psig
D Typical valve selection:
NPS 2 carbon steel valves with 316
CRPL ball and TCM plus seat to achieve
class VI shutoff. Depending upon process
conditions, the Control-Disk could serve
as a great alternative.
Valve: FV-11 Lime Mud to Filter
D Typical process conditions:
Fluid: Clean condensate
T = 176F
P = 50 - 60 psig
P = 5 - 10 psig
D Typical valve selection:
These valves can range from NPS 4 to
NPS 10. A SST body with 316 CRPL ball,
alloy 6 hard faced seat and alloy 6
bearings should be used in this
application.
Lime Recovery
Lime recovery, lime reburning, or calcining are
terms commonly used to describe this portion of
the chemical recovery cycle. As mentioned earlier,
the lime recovery area accepts the lime mud
(CaCO
3
) from the lime mud filter and converts it to
lime (CaO) for use in the slaker. This solves any
problems associated with lime mud disposal and
also has a significant economic impact by
reducing the need to purchase lime. With lime
recovery, purchased lime is only required to make
up system losses.
The conversion of the lime mud to lime is usually
accomplished in a rotary lime kiln. A rotary kiln is a
large steel tube lined with refractory bricks. The
cylinder is mounted on an incline, supported on
rollers, and rotated at a slow speed with an
electric motor/gear reducer set.
The lime kiln accepts the lime mud from the lime
mud filter at 60-70% solids. It is conveyed from
the upper to lower end by the rotation of the kiln. A
burner, utilizing oil or gas, is installed at the lower
end. The heat of the flame evaporates the
remaining moisture and yields lime and carbon
dioxide from the lime mud. This process also
causes the lime mud powder to agglomerate into
pellets which can be handled.
The lime product is conveyed to a storage silo for
use in the slaker. A scrubber is also used to
alleviate the dusting and pollution problem
associated with the exiting flue gas.
Valve: FV-12 Natural gas to lime kiln
burner
D Typical process conditions:
Fluid: Fuel gas
T = 86F
P = 50 - 60 psig
P = 1 - 3 psig
D Typical valve selection:
NPS 4 carbon steel valves with 316
CRPL ball and TCM plus seat to achieve
class VI shutoff. Depending upon process
conditions, the Control-Disk could serve
as a great alternative.
Valve: FV-13 Fuel Oil to lime kiln
burner
D Typical process conditions:
Fluid: Fuel Oil
T = 260F
P = 210 - 220 psig
P = 20 - 25 psig
D Typical valve selection:
These valves are usually NPS 2 carbon
steel valves with SST internals.
135
C
0
8
1
4

/

I
L
Figure 13-1. Recausticizing and Lime Recovery
136
Figure 13- 2. White Liquor and Lime Mud Pressure Filters
C0813 / IL
137
Control Valve Selection
PROCESS FISHER VALVE PRODUCT DESIGN
Valve
Tag #
Recausticizing and Lime Recovery
V150/
V300
V500
Control-
Disk
A81 EBody
Typical
Valve
Size
Application Description
Control
Function
FV-1 Steam to Green Liquor Heater T S P 1I
FV-2 Green Liquor from Dissolving Tank T S P 6I
FV-3 Dregs Slurry Underflow from Green Liquor Clarifier T P 2I
FV-4 Lime Mud to Dregs Filter O/O P 1-1/2I
FV-5 Clarified Green Liquor to Slaker T P 6I
FV-6 Lime Mud Slurry Underflow from White Liquor Clarifier T P 3I
FV-7 Clarified White Liquor to Digester T P S 6I
FV-8 Lime Mud Washer Underflow T P 3I
FV-9 Weak Wash to Dissolving Tank T P S 6I
FV-10 Dilution Water for Lime Mud Transfer T S P 2I
FV-11 Lime Mud to Filter T P 4I
FV-12 Natural Gas to Lime Kiln Burner T P S 4I
FV-13 Fuel Oil to Lime Kiln Burner T S P 2I
FV-14 White Liquor Recirculation to Causticizer O/O P 18I
FV-15 White Liquor Feed to Pressure Filter O/O P 18I
FV-16
Lime Mud Slurry Underflow from White Liquor Pressure
Filter
T P 6I
FV-17 Lime Mud Feed to Pressure Filter O/O P 18I
FV-18 Lime Mud Recirculation to Lime Mud Mixer O/O P 18I
FV-19 Lime Mud Pressure Filter Underflow T P 6I
LV-1 Dregs Precoat Filter Level T S P 2I
LV-2 Causticizer Level T P 6I
LV-3 Lime Mud Filter Level T S P 4I
LV-4 Lime Kiln Scrubber Level T P 2I
P=Primary Valve Choice
S=Secondary Valve Choice
T=Throttling Service
O/O=On/Off Service
138
www.Fisher.com
Chapter 14
Bleaching and Brightening
Bleaching and Brightening
If the kraft pulp being produced is going to be
bleached, then pulping is allowed to proceed until
90% or more of the lignin originally found in the
wood is removed; however, the small amount of
lignin that is left gives unbleached pulp its
characteristic light brown color. Bleaching is the
way to remove the residual lignin while causing
minimal damage to the fibers and produce white
pulp.
The differences between bleaching and
brightening are as follows:
Bleaching This process removes the lignin and
is used to increase the brightness of chemical
pulps.
Brightening This process converts chemical
groups in lignin to forms that do not darken pulp,
thereby making it whiter. This process is used for
mechanical or chemi-mechanical pulps that still
contain vast amounts of lignin.
The Process
Oxygen Delignification
This process is typically found midway between
pulping and bleaching. Oxygen can be used in
sodium hydroxide (NaOH) solution under pressure
to delignify (i.e. remove lignin for the wood)
unbleached pulp (see figure 14-1). Up to one-half
Figure 14-1. Oxygen Delignification Diagram
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
142
of the remaining lignin can be removed; further
delignification would cause excessive cellulose
degradation. Lignin removal in oxygen
delignification significantly reduces the amount
and cost of the bleaching which follows, and
reduces the load on effluent treatment facilities
because the filtrate from the post-oxygen washers
goes back to the brown stock washers and the
chemical recovery system.
Oxygen delignification is typically done at a
medium to high consistency. Although good
results are obtained from both high and
low-consistency systems, medium-consistency is
favored because of its lower capital costs and
inherently safe operation.
In a medium-consistency system, pulp coming
from the brown stock washer at about 10-14%
consistency is delignified. It is then preheated in a
low pressure steam mixer and pumped through
one or more medium-consistency gas mixers to an
upflow pressurized reaction tower. Steam and
oxygen are added upstream of the consistency
mixer or added directly to the pulp slurry. The
most recent mills have two consecutive stages in
order to improve the chemical efficiency of the
treatment.
Bleaching
Pulps that have or have not been delignified are
bleached in a continuous sequence of process
stages, typically three, four, or five. The chemistry
changes in each stage and the pulp is washed
between stages.
The common bleaching chemicals and
nomenclature are:
Chlorination (C): Reaction with elemental chlorine
in an acidic medium (Cl)
Alkaline Extraction (E): Dissolution of reaction
products with sodium hydroxide (NaOH) - ref
Chlorine Dioxide (D): Reaction with chlorine
dioxide in acidic medium (ClO
2
) - ref
Oxygen (O): Reaction with molecular oxygen at
high pressure in alkaline medium (O
2
) - ref
Hypochlorite (H): Reaction with hypochlorite in
alkaline medium (ClO) - ref
Peroxide (P): Reaction with peroxide in alkaline
medium - ref
Ozone (Z): Reaction with ozone in acidic medium
(O
3
) - ref
For many years, chlorination was always the first
stage of bleaching. However, since the 1990s, it
has largely been replaced by chlorine dioxide to
avoid the formation of dioxins. This is due to the
environmental push for all pulp and paper mills to
be ECF, or elemental chlorine free. A few paper
mills are TCF, or totally chlorine free.
Conventional Bleaching
The equipment is the most common aspect of the
stages. This includes: a steam mixer to heat the
pulp suspension with direct steam, a pump to
transport the pulp, a chemical mixer to combine
the pulp with the aqueous bleaching agent, a
retention tower to allow time for the bleaching to
occur, and a washer to separate the spent
bleaching solution from the pulp.
Referring back to the common bleaching
nomenclature, a typical bleach plant has a
DE
OP
DED sequence, or a low-consistency
chlorine dioxide first stage with one or two
chemical mixers, an upflow tower, and a rotary
vacuum drum filter for pulp washing. The chlorine
dioxide comes to the mixer at a solution
concentration of about 10 grams per liter in cold
water. The pulp suspension is around 3.5%
consistency and has been heated to about 140_F.
After mixing, the pulp and chlorine dioxide go to
the retention tower to react for about 45 minutes.
The pulp is then washed afterward.
Each bleaching stage has its own set of process
conditions. The amount of bleaching agent,
consistency of the pulp, pH, temperature, and time
may all vary in each stage. Pulp consistency is
around 3-4% in the chlorine dioxide stage and
about 10% in all subsequent stages. The
temperature is the lowest in the first stage at
140_F, and between 140-176_F, in the other
stages. How much bleaching agent required
depends on which chemical, which stage in the
sequence, and what kind of pulp. With chlorine
dioxide, progressively less is used as you go along
the sequence (figure 14-2).
The objective of bleaching is to remove the
residual lignin from the unbleached pulp. Chlorine
dioxide is the preferred bleaching reagent
worldwide. It is selective in dissolving residual
lignin without degrading the cellulose and
hemicelluloses. In a bleaching sequence, chlorine
dioxide stages are always interspersed with
alkaline extraction stages (see figure 14-2). This
143
Figure 14-2. Conventional Bleaching Process
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
alternating pattern of acidic and alkaline stages
helps to break down the increasingly smaller
amounts of residual lignin, ultimately dissolving the
majority of the lignin so it can be washed out of
the pulp.
Pulp brightness only increases modestly in oxygen
delignification and does not increase uniformly
across the bleaching sequence. This is due to the
action that each chemical has on the lignin.
Brightness increases substantially in the first and
second chlorine dioxide stages and modestly
again in the final chlorine dioxide stage (see figure
14-2). The alkaline extraction stages do not
chemically whiten the pulp, they actually darken.
The alkaline stages are there to dissolve and
remove the lignin which has already been broken
down by the chlorine dioxide. Kraft market pulps
are normally bleached to a final brightness of 90%
or higher; however, the final brightness is based
solely on customers standards and needs for the
marketplace.
The filtrate flow in a bleach plant is counter-
current, or opposite that of the pulp flow. In this
case, there are actually two filtrate flows (see
figure 14-3). Filtrate from the final chlorine dioxide
stage washer is used as shower water on the third
chlorine dioxide stage washer, and its filtrate is
used on the first chlorine dioxide stage washer.
Some of the acidic filtrate from the first chlorine
dioxide stage washer is used to dilute and control
the consistency of the pulp effluent treatment.
Chlorine dioxide is always used with other chlorine
dioxide stages and not mixed with the alkaline
stages.
The filtrate flows of the two alkaline stages are
connected in a similar fashion (see figure 14-4).
Filtrate flow from the second extraction stage is
used as shower water on the first extraction stage
and the filtrate from the first extraction stage
washer goes to the effluent treatment. Unlike the
yellowish acidic filtrate stream, the effluent from
this process is brown due to the lignin.
Fiberline
The fiberline refers to the equipment and
processes that the pulp travels through as it is
being processed from chips to final bleached pulp
(figure 14-1). Kraft pulps strength declines along a
fiberline. This loss is due to the degradation of the
cellulose fibers during the pulping and bleaching
process. Chip quality, appropriate pulping
equipment, and good operating practices are key
aspects to produce strong kraft pulps.
Other quality aspects of bleaching includes pulp
cleanliness, i.e. no dark particles caused by bark,
pitch, small stones, and a minimal amount of
extractives such as resins, which cause problems
in the papermaking process. Fiber bundles, known
as shives, have to be removed and reconverted
into good pulp fibers. Metal ions must be removed
via chelation, or the binding of ions similar to
calcium being removed by a water softener.
Totally Chlorine Free
As previously mentioned, a few paper mills are
TCF. This process eliminates organo-chloride
compounds from bleach plant filtrates and makes
it possible to recycle these filtrates back to
144
Figure 14-3. Chlorine Dioxide (ClO
2
) Filtrate Flow Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 14-4. Alkaline Filtrate Flow
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
chemical recovery plants. TCF sequences use
various combinations of oxygen-alkali chemistry,
hydrogen peroxide, and ozone. This process tends
to be more expensive, have lower brightness, and
is susceptible to strength loss problems.
Mechanical Pulping
This process dissolves most of the lignin in the
original wood. High-yield mechanical pulps cannot
be bleached the same way because they contain
too much lignin. Bleached or brightened
mechanical pulps will never receive the high
brightness like that of a chemical pulp. The
145
brightness effect is even reversible when the final
product is exposed to sunlight.
Mechanical pulping bleaching is done with sodium
hydrosulfite (Na
2
S
2
O4) and hydrogen peroxide
(H
2
O
2
). A two-stage alkaline sequence can be
used to raise the brightness of chemi-
thermomechanical pulp to 85% or higher. Both
hydrosulfite and peroxide attack the chemical
groups that can cause darkening of the paper.
Unlike the case in chemical pulp bleaching, lignin
is not removed in brightening.
Caustic (NaOH) Valve Applications
Sodium hydroxide (NaOH) solution is a caustic
chemical used to break down the lignin that binds
cellulosic fibers. This is a highly used chemical but
requires precise control so accurate addition to the
wood chips is provided. Poor control can lead to
economic loss both in NaOH solution and wood
chip degradation.
Chips are fed via a screwfeeder into the top of a
digester where it is mixed with cooking liquor
where it is then cooked to a schedule. In modern
Kraft mills, the lignin is removed by the action of
sodium hydroxide and sodium sulfide under heat
and pressure. This solution is known as white
liquor. As the chips are cooked the lignin and other
components are dissolved, and the cellulose fibers
are released as pulp.
Design Considerations
D Material choice highly temperature
dependent
D Low flows require low flow trims
D Tight shutoff
Typical Specification
Body:
Fisher V150 in CG8M (317SST)
CW2M (Hastelloy-C) premium selection
Trim:
Ball: CG8M chrome coated (Microscratch,
Micronotch, or Macronotch)
Seal: Alloy 6 HD (Alloy 255HD also
acceptable)
Shaft: Nitronic 50
Bearings:
Alloy 6 (PEEK if temperature allows)
Packing:
PTFE
Actuator:
Spring-and-diaphragm
Positioner:
FIELDVUE DVC6200 PD level
Chlorine Dioxide Applications
Due to environmental restrictions many mills are
going to elementally chlorine free (ECF) bleaching
practices. This has pushed the mills of today to a
new chemical compound to bleach and brighten
their pulp rather than the traditional pure,
elemental chlorine. Chlorine dioxide (ClO
2
) has
been the choice by the majority of mills today. This
is because the compound minimizes degradation
to the cellulose fibers while still achieving higher
final brightness to the pulp. However, it is an
expensive chemical to generate and highly
corrosive, so proper care must be given to choose
the correct solution.
Depending on the type of furnish created at each
mill, pulp from the digester can head toward the
bleaching section of the mill. Bleaching is done by
removing the lignin whereas brightening pulps
changes the chemical groups in lignin to forms
that do no darken pulp. Chlorine dioxide is rapidly
becoming an industry standard as a bleaching
agent because of its high selectivity in destroying
lignin without degrading the cellulose fibers, thus
preserving pulp strength while still providing a
stable brightness.
After the oxygen delignification stage (typically
found in modern mills), the medium consistency
stock (10-14% bone dry) heads to the
conventional bleaching sequence which can vary
from four to six separate stages depending on the
end-users brightness requirements. A standard
mill would utilize a DE
OP
DED sequence, or an
alternating sequence of chlorine dioxide (D) and
alkaline extraction stages (E) and an oxygen (O)
and peroxide (P) brightening stage.
One will always see chlorine dioxide stages
interspersed with alkaline extraction stages. This
alternating pattern of acidic and alkaline stages
helps to break down the increasingly smaller
amount of residual lignin. But this combination of
chlorine dioxide and alkaline mixture also makes
146
this a very corrosive solution and potentially
erosive due to the percentage of stock content.
Design Considerations
D Highly corrosive chemical (not the same as
chlorine applications)
D Erosive depending on stock consistency and
velocity through valve
D Accurate control needed due to cost for
chlorine dioxide
D Material choice dependent on chemical
concentrations; high concentrations must be
titanium. Hastelloy C (CW2M) can be used.
Typical Specification
Model:
V150 or V300
(V150S with titanium and ceramic trim can also
be used. No liner required.)
Body:
Titanium C3 (R50550) or Hastelloy C (CW2M)
Trim:
Ball: Titanium C3 (R50550) or Hastelloy C
(CW2M)
Seal: TCM Plus
Shaft: Titanium Grade 5 or Hastelloy C
(N10276)
*Pin and Taper Key should also be Titanium or
Hastelloy C
Bearings:
Titanium C3 (R50550) or Hastelloy C (N10276)
lined with PTFE
Packing Box:
ENVIRO-SEAL PTFE
Actuator:
Spring-and-diaphragm
Positioner:
FIELDVUE DVC6200 digital valve controller
with Performance Diagnostics (PD)
The following diagrams are typical valve layouts
for the various bleaching stages.
Chlorine Dioxide (D) Stage
Valve
Tag #
Application
Description
Control
Function
Vee-Ballt
High Pressure
Butterfly Valve
(HPBV)
V150E
1 Medium Consistency (MC) Control T S P
2 Pulp/Chemical Mixing O/O P S (8580)
3 Filtrate Valve O/O P (8580)
4 Bleaching Agent Valve T P
5 Bleached Pulp Valve T P
6 Washed Pulp Valve T P
7 Filtrate Valve O/O P (8580)
8 Filtrate Valve O/O P (8580)
CODE:
P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
Alkaline Extraction (E), Hypochlorite (H), Peroxide (P) and Ozone (Z) Stages
Valve
Tag #
Application
Description
Control
Function
Vee-Ball HPBV V150E
1 MC Control T S P
2 Pulp/Chemical Mixing O/O P S (8580)
3 Filtrate Valve O/O P (8580)
4 Bleaching Agent Valve T P
5 Bleached Pulp Valve T P
6 Washed Pulp Valve T P
7 Filtrate Valve O/O P (8580)
CODE:
P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
147
Oxygen (O) Stage
Valve
Tag #
Application
Description
Control
Function
Vee-Ball HPBV V150E
1 MC Control T S P
2 Bleaching Agent Valve T P
3 Pulp/Chemical Mixing O/O P S (8580)
4 Control Valve T P
5 Pump Valve O/O P (8580)
6 Control Valve T P
7 Discharge Tank Valve T P
8 Washed Pulp Valve T P
9 Filtrate Valve O/O P (8580)
CODE:
P = Primary selection, S = Secondary selection, T = Throttling, O/O = On/Off
Figure 14-5. Alkaline Extraction (E), Hypochlorite (H), Peroxide (P) and Ozone (Z) Stages
Figure 14-6. Chlorine Dioxide (D) Stage
148
Figure 14-7. Oxygen (O) Stage
www.Fisher.com
Chapter 15
Stock Preparation
Stock preparation is the start of the papermaking
process and is the controlling factor over final
paper quality and how well the paper machine
runs. To be more specific, this process prepares
the fibers for the paper machine. In order for this
to occur, the fibers must be blended and the
consistencyor the percentage of fibers in the
watercontrolled. Any contaminants must be
removed from the slurry and fibers mechanically
abraded or refined so they will bond well in the
papermaking process to form a clean sheet.
The stock flows through the various preparation
steps where additives including sizing agents,
fillers, starch, retention and drainage agents, and
dyes are added to the fiber furnish. The stock is
then further diluted to the final consistency so the
slurry can be pumped to the headbox and on to
the paper machine wire.
The stock preparation system can be broken down
into two main areas:
1. Thick stock system (figure 15-1): The initial
part of the stock prep system where fibers are
screened, refined, and blended to prepare the
slurry for each grade of paper to be made. This
process has a consistency of 3% to 5% solids.
2. Thin stock system: This system cleans,
screens, and dilutes to papermaking consistency.
This process has a consistency of 0.4% to 1.0%
solids.
Thick Stock Process
This process begins with in-coming bales of
purchased pulp, secondary fiber that might be
found in the high density storage chests, or fibers
from the pulp mill. The pulp is broken down and
Figure 15-1. Thick Stock System
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
152
Figure 15-2. Pulper
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
diluted to a slurry in order to break the fibers apart
before they are pumped toward the paper
machine.
Pulpers
Pulpers, also known as repulpers or slashers, help
to break down the bales into individual fibers
(figure 15-2). The bales of pulp or waste paper are
fed to the pulper, either by a forklift truck or by a
conveyor. In some mills, different fiber
components are re-pulped separately and blended
together later in stock prep. Water is added to the
pulper, the pulp bales are added, and the
remaining water is added to bring the pulp to the
right consistency; typically around 4 to 5% solids
for low consistency pulpers or up to 18% solids for
high-consistency pulpers.
Pulping can be done by one of two types of
pulpers:
D Batch pulper: Typically, this process is
completed in a single vessel.
D Continuous pulper: Supplemental in-line
treatment is commonly used following the pulper
to ensure complete dispersion.
The agitator in the bottom, or side, of the pulper
provides the repulping action. Steam is often
added along with sodium hydroxide or caustic to
raise the pH of the slurry. Dyes and fillers can also
be added at this point.
Figure 15-3. Pulper Dump
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Depending on the type of pulp, a batch pulper
might take 30 minutes or more to break up the
fibers. Once all the fibers are individually broken
apart, the pulp slurry can be pumped into the
pulper dump or storage chest (figure 15-3). Once
the broken apart pulp is pumped away, a new
batch of bales is re-filled into the pulper.
A continuous pulper is similar to a batch pulper
except the bales of pulp are continually added and
the slurry is continually removed through an
extraction plate under the rotor. The extraction
plate has holes of 3/8 to 5/8-inch.
Refining
This process helps the individual pulp fibers to
bond together by employing both mechanical and
hydraulic forces to alter the fiber characteristics.
This is done by imposing shear stress on the
fibers through rolling, twisting, and other tensional
actions occurring in a refiner. This process can be
performed by two different types of continuous
refiners.
1. Disc refiner: The most common type of
refiner, this unit has a rotating disc and a set of
stationary plates, typically with a plate on each
side of the disc (figure 15-4). These discs are set
closely together so only a small passage between
the bars exists. Stock can flow in a parallel
arrangement (duo-flow) or a series arrangement
(mono-flow). Fibers pass between the moving
bars where they are mechanically abraded. The
water can then enter the walls of the fiber and
cause it to swell. This process also helps to break
off the extra small pieces of fiber, called fines.
153
Figure 15-4. Disc Refiner
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
2. Jordan (or Conical) refiner: In this type, the
rotating plug (rotor) and its housing (stator) are
fitted with metal bars oriented lengthwise. The
fibers flow parallel to the bars. The position of the
plug determines the clearance of the bars and
controls the amount of work done on the fibers for
a constant stock throughout.
It has been shown that having a disc refiner is
more advantageous to a mill. They have lower
no-load energy consumption, which lowers energy
costs. They have greater versatility of their refiner
plate designs and, because of these designs, can
take on higher stock consistencies. They are more
compact than the Jordan and are a lower capital
investment.
Blend Chest
All the furnish components including hardwood
pulp, softwood pulp, and broke are mixed together
in the blend chest. All components must be well
blended before the stock is diluted down to
papermaking consistency.
Stock Screening
In some mills, this process follows the blend chest.
High consistency pulp of around 4% is run through
fine slotted screens to remove hard debris that
could cause defects in the sheet of paper (figure
15-5). Arranged in multiple stages, the screens
generally have a protection screen followed by two
stages of fine slotted screens using 6 to 10
thousandth of an inch, although this size varies
based on the furnish or grade of paper (figure
15-6). The first two stages run at a high
consistency, but the final tailing screen runs at a
Figure 15-5. Fine Slotted Screens
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 15-6. Stock Screening Process
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
somewhat lower consistency, around 1.0 to 1.5%,
in order to make a better split between good fiber
and debris.
Machine Chest
This is the last chest in the thick stock part of
stock prep. By this point, all the fibers have been
blended and the consistency controlled. It is
important that the consistency, anywhere from 3%
to 4%, is controlled when going forward in the
system as this stock controls the basis weight of
the paper. It is from here the stock will enter the
thin stock portion of stock prep.
154
Figure 15-7. Thin Stock System
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 15-8. Fan Pump
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Thin Stock Process
This section will describe the thin stock processes
of cleaning, screening, and diluting to
papermaking consistency (figure 15-7). The thick
slurry in the machine chest is pumped to the
suction-side of a fan pump and is diluted to 1% or
less with white water drained from the sheet
forming process into a stuffbox (figure 15-8).
Stuffbox
The stuffbox is located high in the air, near the
wet-end of the paper machine, and ensures the
basis weight valve has enough, and constant
pressure so the stock flow can be accurately
controlled to the paper machine (figure 15-9).
Stuffboxes are frequently replaced with variable
speed pumps that supply the basis weight valve
directly.
Basis Weight Valve
The stock from the stuffbox flows by gravity
through a pipe leading down into the basis weight
Figure 15-9. Stuffbox
Drawing is from
TAPPIs Making
Pulp and Paper Series
and is used with
permission.
valve (figure 15-10). It influences moisture, caliper,
brightness, opacity, draws, strength, machine
stability, and product uniformity. If it is not within
acceptable limits, machine performance and
product quality will suffer. Most paper machines
use a precision basis weight valve to control the
amount of stock going to the fan pump. Basis
weight is the key variable in paper quality control.
Typical Specification
D Fisher Vee-Ball V150 with either a 2052
actuator or SKF actuator.
D FIELDVUE DVC6200 digital valve controller
with Performance Diagnostics
White Water
The water used to dilute thick stock in preparation
for forming the paper sheet comes from the
155
Figure 15-10. Fisher Vee-Ball and SKF
Actuator Basis Weight Valve
Figure 15-11. Disc Saveall
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
forming section of the paper machine and is
continually recycled back to the headbox. The
water, called white water due to its cloudy
appearance, is collected in a silo under the paper
machine. White water has fiber, fillers, and other
valuable chemicals, so it must be collected and
recycled. Most of the valuable components in the
white water are eventually retained by the sheet
forming process.
Saveall
The excess white water is sent to this device
where the fiber and fillers are removed from the
white water. A disc saveall is made up of
screen-covered segments (figure 15-11). A
vacuum is applied after the segments enter the
white water and the fibers collect in a mat on the
outside of the screen. The water that filters
through is called clear water and can be used for
Figure 15-12. Cleaner
Drawing is from TAPPIs Making
Pulp and Paper Series and is
used with permission.
diluting water on consistency control or other
uses.
The collected fibers are washed off the segments
as they leave the white water pond. The recovered
fiber is diluted and blended with the other fiber
sources in the blend or machine chest.
Cleaners
The fibers, after being diluted by white water in the
silo, then proceed to the cleaners (figure 15-12).
Each cleaner is only capable of handling a small
portion of the total flow so many are needed for
cleaning. The stock enters the cleaner tangentially
causing the flow to form a vortex. The spinning
action causes the heavy particles to be thrown
outside the vortex. These heavy contaminants
move down the inner wall of the cleaner and are
rejected through the bottom discharge hole of the
cleaner. Lighter fibers stay near the center and
exit through the top.
Some of the good fiber is rejected through the
bottom. In order to reclaim this good fiber, the
rejects will flow from the primary to the secondary
cleaners (figure 15-13). The rejects enter a
secondary cleaner to reclaim the good fibers.
There can also be tertiary, a fourth and fifth
cleaner as well if needed (figure 15-14). Each
156
Figure 15-13. Primary Cleaners
Drawing is from
TAPPIs Making
Pulp and Paper
Series and is used
with permission.
Figure 15-14. Secondary Cleaners
Drawing is from
TAPPIs Making
Pulp and Paper
Series and is used
with permission.
successive bank of cleaners contains fewer
individual units than the previous bank.
Deaeration Chamber
Depending on the stock, small air bubbles can
form around the fibers. This slows drainage during
the sheet forming process and can cause pinholes
in the sheet. In order to remove these bubbles, a
deaeration chamber is used (figure 15-15).
The chamber or tank is connected to a vacuum
pump so the stock in the tank is also under
vacuum. This vacuum allows the stock to boil
even though the stock temperature is below
100C. This boiling action helps to release air in
the stock.
Screens
Almost all paper machines have a screen before
the headbox to remove contaminants from the
furnish. These screens have a basket of either
holes or slots that allow fibers to pass through that
collects shives, pieces of plastic, or fiber flakes.
These slots are generally 10 thousandths of an
inch wide and are more efficient at removing small
debris than holes.
These screens also have a way to backflush the
holes to prevent plugging. Generally, this is done
with a rotor and hydrofoils. The foil passes over
the hole and produces a low-pressure pulse
followed by a high vacuum pulse. These pressure
pulses keep the openings in the basket from
binding.
Broke Handling
Broke is better known as internal waste paper
generated by the paper mill. This might be from
the wet-end from the forming or press sections, or
the dry end from the dryer section, reel, winder, or
other finishers. Broke contains good fiber and
chemicals that should not be lost.
Broke is generally captured in an under the
machine repulper or broke pulper. The broke
either drops down into the pulper along a chute or
is conveyed or blown into the repulper. Wet-end
broke is easy to break up into the individual fibers,
but fully dried broke requires more aggressive
agitation. Sometimes, broke is sent through a high
density centrifugal cleaner to remove large heavy
particles. This then goes through a deflaker, which
mechanically breaks up the underfibered flakes.
Compact Stock Process
Recently, some paper makers have moved to a
more simplified stock prep. Rather than relying on
large volumes to reduce variation, there is more
reliance on modern process control to make the
necessary adjustments to correct for variations
(figure 15-16). For instance, for thick stock
blending and feeding, instead of having two chests
to blend the various components and then feed
the stock to the fan pump, those functions are
handled by a small mixing tank (figure 15-17). As
for deaeration, one can replace the large silo and
deaeration chamber with a small centrifugal
deaeration pump (figure 15-18). This new system
has quicker response time and less total volume.
Brown Stock Rejects Valve
Process impurities have a negative affect on end
product quality. These impurities may damage
process equipment and cause runnability
problems. As such, all solids contaminants have to
be removed from pulp. Some contaminants can be
157
Figure 15-15. Deaeration Chamber
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 15-16. Compact Stock Prep System
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
separated from pulp on screens, whereas others
similar or smaller than fibers may be removed by
other methods (figure 15-19).
Pulp from cooking always contains some
unwanted solid material. Some of the chips may
not have been fiberized properly, and some of the
fibrous material may not be completely in the form
of individual fibers. The main purpose of the pulp
screening process is to separate harmful
impurities from pulp with minimal fiber loss, and at
an acceptable cost level. Bark, sand, shives, and
rocks are typically found within the cooked chips
and must be removed. There are multiple ways to
separate out the impurities. This can be done
mechanically by screen plates where separation is
based on particle size, whereas gravimetric or
centrifugal force field is needed for weight-based
particle separation. However, pressure screening
in multiple stages is the preferred method for
removal of impurities such as sand and shives
from the pulp. These operate by separating the
feed pulp into either acceptable (impurity free) or
rejects (impurity rich). The acceptable pulp passes
through the device, and the rejected pulp is
removed for further processing. This is
accomplished in stages since most pressure
screens cannot sufficiently concentrate the
impurities in only one screening stage due to
thickening of the reject on the screen itself. The
purpose of the rejects stages is to concentrate the
impurities in the reject stream, and to return the
good fibers to the main process line.
Design Considerations
D Tight shutoff not required.
D Hardened materials to protect valve body
from wear.
D Ball valve to shear through impurities.
158
Figure 15-19. Centrifugal Deaeration Chamber
Figure 15-17. Compact Stock Mixing Tank
Drawing is from TAPPIs
Making Pulp and Paper Se-
ries and is used with per-
mission.
Figure 15-18. Centrifugal Deaeration Chamber
Drawing is from TAPPIs
Making Pulp and Paper
Series and is used
with permission.
Typical Specification
D Fisher Slurry Vee-Ball V150S with high
chrome iron trim.
Medium Consistency (MC) Pump
Valve
The medium consistency centrifugal pump (MC
pump) is used for continuously pumping pulp stock
up to 18% bone dry (BD) consistency and can be
located in numerous areas of the mill. In
processes where the flow control valve is
responsible for controlling the pumps head
pressure, special care should be given to the valve
selection.
In some cases, concerns of pulp stock flow
behavior and buildup are addressed by specifying
an expanded outlet valve. Many MC pump
manufacturers require expanded down stream
piping.
Design Considerations:
D Expanded Outlet
D Ball valve to shear through impurities
D Precise control
Typical Specification:
D Fisher Vee-Ball V150E
www.Fisher.com
Chapter 16
Wet-End Chemistry
In this chapter, we will be discussing materials,
other than fibers, that are added to the slurry of
fibers before paper is formed. It is important to
keep in mind that there are two types of additives.
1. Functional additivesThese additions are
treatments necessary to meet the particular needs
of an end-customer.
2. Process additivesThese additions modify
the properties of the paper. They can be used in a
multitude of different fashions.
Sizing
The purpose of sizing is to enable paper products
to resist penetration by fluids. This is critical for
printing operations. If appropriate sizing is not
taken into account, the ink will diffuse into the
sheet and cause severe quality problems. Sizing
can be achieved by using wet-end additives or by
applying a coating to the surface of the dried paper.
The traditional wet-end sizing agent is a modified
rosin, better known as rosin size. This additive
can actually make paper repel water under acidic
papermaking conditions. Rosin size comes from
softwoods as a byproduct during the Kraft pulping
process. To make rosin work as a sizing agent,
papermakers also add aluminum sulfate
(Al
2
(SO
4
)
3
), better known as papermakers alum.
This combination is an effective way to make
paper resist water and other fluids. The process is
also known as acid sizing as this combination
works well in acidic aqueous environments.
Internal Strength
Many natural and synthetic polymeric substances
can be added to stock at the wet-end to improve
the physical properties of the dry paper sheet.
They are to reinforce the fiber-to-fiber bonds
thereby improving tensile strength, reduce fuzz
or lint on the paper surface, and can reduce the
rate of water penetration.
Traditional internal strength additives are natural
and modified starches and gums. Starches are
polymers of glucose whereas gums are polymers
of mannose and galactose. However, the trend is
now toward the use of synthetic polymers as
latexes and polyacrylamides used in combination
with starches and gums. These new products
have now met a wider range of specific
requirements for greater paper strength with
different degrees of stiffness and stretch.
Wet-Strength Resins
The purpose of wet-strength resins is to tie fibers
and fines together with additional bonds that are
not taken apart by water. Wet-strength paper is
defined as paper that retains more than 15% of its
tensile strength when wet.
The most common wet-strength agents are
ureaformaldehyde, melamine-formaldehyde, and
polyamide resins, and are water soluble. These
long-chain polymers can be used on paper for juice
containers or other liquid containers so the fibers
remain strong even after getting wet. However,
because these agents are water soluble, they must
be fixed onto fibers with the help of retention fillers.
162
Figure 16-1. Stock Approach System
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Fillers
For most copy paper, around 15 - 30% of the
papers are fillers; the majority of which is clay and
PCC precipitated calcium carbonate. These
additions are generally made to lower the overall
cost of materials and can be used for brightness,
opacity, or even the smoothness of the paper.
However, fillers do not bond together in the same
way cellulose fibers do, so they reduce the
strength of the paper.
This limits the amount one can put in the sheet.
Another difficulty is trying to get the filler to remain
with the fiber during the sheet forming process. It
is not uncommon to lose fillers while on the
moving wire or forming fabric. Additives are used
to increase the retention of the fillers so they are
not lost during this process.
All of these wet-end additives are either soluble in
water or are small enough to fit through the small
openings of the forming fabric. To keep these
additives from falling out of the process, retention
aids are added. These retention aids insure that
the fillers attach to the fibers. These are typically
added just before the headbox or before the
headbox screen (figure 16-1 ). They are added
late in the process because excess agitation could
break up the polymer chains.
The size and shape of mineral additives can
greatly affect the properties of the paper. For
instance, most grades of paper have a thickness
specification. Papermakers want to make the
paper as thick as possible all while using the least
amount of fiber. The more flat the microscopic
filler, the more dense the paper. However, many
times these fillers are so small the filler gets
between the fibers and makes the paper
smoother.
The common papermaking fillers are clay, calcium
carbonate (CaCO
3
), talc, and titanium dioxide
(TiO
2
). Clay is the most popular since it is cheap,
stable, and generally provides good performance.
Calcium carbonate is a better opacifier than clay
and has higher brightness. Titanium dioxide is the
brightest and most effective opacifier, however, is
high cost. Talc is used as a soft filler that helps
to give paper a soft, silky feel to the product.
Finally, due to the amount of water being pumped
through the system, foam can be formed. This can
create spots or pinholes in the paper. To alleviate
this problem, defoamers are added to help the
bubbles coalesce into bigger bubbles. These
larger bubbles will then rise to the surface and
break. The water and warm temperatures can also
create a wonderful environment for bacteria and
fungal slimes. These are called bugs in the paper
mill. These bugs can lead to holes and spots in
the paper and frequent sheet breaks but can be
controlled with the addition of biocides to the
paper machine white water system.
163
Titanium Dioxide (TiO
2
) Applications
Titanium dioxide is used as a paper additive to
increase brightness and opacity. It is a fine white
powder that is added at a low flow rate as a slurry
to pulp stock. The process is very erosive and
requires fine control and tight shutoff.
Typical Specification
D Fisher Vee-Ball V150 Micro-Scratch,
Micro-Notch, Macro-Notch with Ceramic Trim
D V500, Reverse Flow with ceramic trim
164
www.Fisher.com
Chapter 17
Paper Machine
Wet End
The paper machine is essentially a series of
processes all tied together (figure 17-1). These
processes are designed to take fibers in a dilute
slurry of water and produce a dried web of paper.
The paper machine is described in two parts: the
wet end, which is the forming section, and the dry
end, which includes the pressing and drying
operations.
Fourdrinier Single-Ply Process
The following are the steps taken to form the
fibers onto the wet end of the paper machine in
new and more modern pulp and paper mills:
Tapered Manifold
The stock heading toward the headbox is coming
from the headbox pressure screen (figure 17-2).
This stock is to be spread uniformly over the entire
width of the paper machine where some machines
are up to 400 inches wide. This is accomplished
by using a tapered manifold (figure 17-3).
The tapered manifold starts large at the inlet end
and tapers down over the length of the device.
This allows the pressure to remain the same even
though stock is being diverted through numerous
tubes to the headbox. At the end of the manifold is
a recirculation line that allows one to balance the
manifold for different flow rates.
Figure 17-1. Fourdrinier Paper Machine
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
172
Figure 17-2.
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 17-3. Multitube Tapered Manifold
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Headbox
From the manifold, stock enters the headbox
through a series of tubes. The headbox has
several purposes. It needs to eliminate the
turbulence coming out of the tubes from the
manifold, it has to break up the fiber flocs, and it
must ensure the amount of stock coming out of
the slice is uniform all the way across the width of
the machine. Below are the major types of
headboxes:
D Rectifier Roll (Air-padded) This type of
headbox has a number of hollow rolls within the
stock stream, inside the headbox. The rolls are
perforated with approximately one inch diameter
holes throughout the surface of the roll (figure
Figure 17-4. Rectifier Roll (or Air-Padded) Headbox
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
17-4). Typically, there is one roll at the entrance of
the box, a second roll in the main pond area, and
a third roll near the discharge of the headbox. The
stock fills the box almost to the top of the rectifier
roll so a cushion of air remains above the stock.
This cushion of air helps to lessen pressure
variations, thus lessening changes in the basis
weight of the paper being produced. The rolls
rotate slowly to help eliminate any large-scale
173
Figure 17-5. Hydraulic Headbox
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
turbulence inside the headbox and to break up the
fiber flocs so fibers are well distributed. This type
is good for slower paper machines and specialty
machines with a wide range of flow requirements.
D Hydraulic These devices are completely
filled with stock. Because no air cushion exists
many hydraulic headboxes use a pressure
attenuator at the headbox manifold to reduce any
pressure variations. Since hydraulic headboxes
have no rectifier rolls, they are designed to
deflocculate the stock by changes in velocity as
the stock passes through tube bundles or across
flat sheets. The discharge velocity from the slice
depends directly on the feeding pump pressure.
This type of headbox can be found on most new
paper machines (figure 17-5).
D Dilution Control This type uses dilution
or consistency control across the width of the
headbox to correct errors in basis weight (figure
17-6). By opening a particular dilution valve, the
computer will add dilute white water to the inside
of the headbox in precisely the right point to dilute
a heavy streak. If the sheet is too light, the
computer removed some of the dilute water by
closing the valve. There can be as many as one
hundred or more dilution valves located along the
Figure 17-6. Dilution Control Headbox
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
back of the headbox, all of which are individually
controlled.
Each type of headbox contains a headbox slice.
The slice is a full-width orifice or nozzle with a
completely adjustable opening to give the desired
flowrate. The jet of stock emerging from a typical
headbox slice contracts in thickness and deflects
downward as a result of slice geometry. The jet
thickness, together with the jet velocity,
determines the volumetric discharge rate from the
headbox.
Every slice has a top lip and an apron (bottom lip),
both constructed of suitable alloy materials to
resist corrosion. The top lip is adjustable up or
down as a unit (main slice) and also in local areas
by the use of individual micro-adjusters. These
small adjustment rods are attached to the slice lip
and, with manual adjustments or the help of a
computer system, can improve the distribution of
the stock and allow for a more uniform basis
weight across the width of the paper machine. The
rectifier and hydraulic headboxes utilize adjustable
slices in the same way.
Forming Wire
The stock leaving the headbox slice, typically
between 0.5 - 1% solids, is deposited onto a
synthetic forming fabric (or wire). Water
immediately begins to drain through the forming
174
fabric producing a mat of fiber on the fabric
surface. The jet velocity at which the stock is
deposited onto the fabric is very important. This
process controls fiber alignment and affects the
strength properties in the direction of web travel.
This wire will continuously travel the length of the
wet-end of the fourdrinier machine providing time
for sufficient water removal.
Forming Board
This is the first static element under the wire used
to remove additional water. This element supports
the wire at the point of jet impingement. This
device is needed to prevent wrinkles in the forming
fabric. This is accomplished by correctly spacing
the blades of the forming board at the correct
angle so jet delivery can be optimized for best
sheet formation. This element also serves to
retard initial drainage so fines and fillers are not
washed through the sheet.
Foil Units
Following the forming board, water is drained from
the sheet over foil units. These foil units have a
blade with a high slope or angle towards the rear
of the blade. This creates a small vacuum which
pulls more water through the mat. The foils also
create turbulence to help break up any cellulose
flocs that are beginning to form. The higher the foil
angle, the greater the vacuum created thus more
turbulence and water drainage.
Flatboxes
The sheet on the forming fabric is still very wet as
the action of the foils is not enough to remove any
more water. A flatbox, or vacuum box, is a narrow
box positioned under the forming fabric, across
the width on the paper machine and is connected
to large vacuum pumps that provide a differential
pressure or vacuum that is needed for further
removal of water. These vacuums are capable of
increasing the sheet to around 15% solids.
Couch Roll
The final device used to remove water on the
forming section, the couch roll, consists of a
hollow outer shell that rotates with the wire and a
stationary inner vacuum box. The vacuum box is
connected to a large vacuum pump. The holes in
the shell allow the vacuum inside to remove water
from the sheet. This removes water to make the
consistency 20 - 25% solids. The overall goal of
this final section is to get the sheet as dry as
possible to improve the strength of the sheet
before it is peeled, or couched, from the wire and
sent for further de-watering to the press section of
the paper machine.
Fourdrinier Multi-Ply Process
This process is exactly the same as the single-ply
process except multiple layers or plies are
eventually combined into a single sheet. This can
be accomplished in a multitude of ways:
D Stratified Headbox This device is
capable of depositing two or three different layers
of stock on the fourdrinier wire at the same time
(figure 17-7).
D Secondary Headbox This device is
simply a common paper machine with a second
headbox to put a secondary layer on top the
preexisting layer.
The above two options still have an issue; all
drainage occurs through the bottom layer thus,
causing some mixing of the fibers. To alleviate this
problem, papermakers have devised a few other
options.
D Multiple Fourdriniers These machines
actually have multiple fourdrinier machines running
on top of one another. The sheets all wind into a
central area where the sheets are pressed
together to make a multi-layer paper.
D Cylinder Former This device consists of
a vat and a large diameter wire-covered cylinder
(figure 17-8). The sheet is formed on the wire as
the cylinder rotates through the dilute stock slurry.
The water is then drained into the cylinder. The
wet sheet is then consolidated and couched off
onto a wet felt. This is most effective in the
multi-ply process as each cylinder lays down an
individual ply of paper, which are each individually
couched to the previous ply, thus, making a
heavyweight paperboard.
Twin Wire Formers
This device now holds the speed and production
record for the majority of paper grades. This
technology is becoming more popular than the
fourdrinier machine because:
D Water can drain from both sides of the sheet
rather than one, leading to the top and bottom of
the sheet being more alike.
175
Figure 17-7. Stratified Headbox
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 17-8. Cylinder Former
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
D Water can be drained in a much shorter
distance.
D The technology is much faster than a
fourdrinier machine.
These twin-wire formers can be broken up into two
types.
Figure 17-9. Gap-Wire Former
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
D Gap Formers These devices inject the
headbox jet between two converging wires (figure
17-9). Many gap formers have a large forming roll
where the majority of the sheet drainage occurs.
There are also several high vacuum boxes and a
suction couch roll where the two wires eventually
separate and the sheet is taken into the press
section.
Gap formers hold the speed records for single-ply
grades of paper such as newsprint or copy
papers. This technology is also becoming
competitive in the multi-ply paperboard market.
176
Figure 17-10. Top-Wire Former
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
D Top-Wire or Hybrid Formers This device
sits on top of a conventional fourdrinier single-wire
former and deposits a jet from the headbox onto
the single wire (figure 17-10). The wire passes
over an expanse called the free drainage zone
where the initial drainage is downward. The
second wire then covers the top of the sheet
allowing dewatering to occur in both directions.
Multiple configurations can be found with vacuum
shoes and blades throughout the forming area to
help the dewatering process.
What makes this device more advantageous to a
Gap Former is that a top-wire unit can be readily
fitted to an existing fourdrinier to improve sheet
quality and allow for machine speedup.
Dry End
After the forming section of the paper machine,
the sheet is still approximately 20% solids. Now
that the forming section cannot take or vacuum
out any additional water, we must mechanically
press out the water.
Before discussing the press section, one must
understand the nip. Most paper machines have at
least two nips, and can have as many as five. The
nip is a process of removing water by mechanical
means by passing the wet paper sheet, almost
always with a felt, between two rotating press
rolls. Nips generally follow these steps:
1. Compression of the sheet and felt between two
rolls begins. Air flows out of both structures until
the sheet is saturated.
2. Now that the sheet is saturated, hydraulic
pressure within the sheet structure causes water
to move from the paper into the felt. Once the felt
becomes saturated, water moves out of the felt.
This phase brings the paper to its maximum
hydraulic pressure.
3. The nip expands until the hydraulic pressure in
the paper is zero, corresponding to the point of
maximum paper dryness.
4. In this phase, both paper and felt expand and
the paper becomes unsaturated. Although a
negative pressure is created in both structures, a
number of factors cause water to return from the
felt to the paper; also known as rewetting.
The top roll is mechanically loaded to create the
desired pressure within the nip. The higher the
pressure applied at each nip, the more effective
the water removal. However, too much pressure at
the nip will take the felt and sheet beyond the
point of saturation. This condition is called
crushing and significantly weakens the sheet
strength in the nip. Operating a nip at the point of
crushing will cause the sheet to break. At faster
machine speeds, higher pressure will have a
diminished effect because of the brief residence
time in the nip.
Press
The primary objective of the press section is to
remove water from the sheet and consolidate the
paper web. This section can also provide other
product requirements such as providing surface
smoothness, reducing bulk, and promoting higher
wet web strength.
The oldest style of presses is a straight through
press arrangement (figure 17-11). For the more
modern arrangements, the most widely used
presses can be described in full below.
D Roll This press consists of two
large-diameter rolls, loading arms to supply
pressure, and a press felt (figure 17-12). As the
177
Figure 17-11. Straight-Through Press
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 17-12. Roll Press
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
sheet enters the ingoing nip between the two rolls,
pressure builds and the sheet is compressed. As
pressure continues to rise, the water in the sheet
is forced out of the sheet into the press felt. This
pressure can be anywhere from 500 - 2,000
pounds per square inch where the higher the
pressure, the dryer the sheet will become.
However, press rolls normally have rubber covers
that essentially smash together. The footprint
that is created on the rolls, better known as the nip
width, can be larger or smaller depending on how
hard we press the rolls together. Past the
mid-point of the nip, the pressure begins to
decrease and some of the water is actually sucked
back into the sheet or re-wetted. How dry the
press can get paper is also determined by the nip
time. Generally, the roll press can increase sheet
consistency to 38 - 32% solids.
D Shoe Rather than a roll press, some
paper machines use a shoe press (figure 17-13).
Figure 17-13. Shoe Press
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
This type of device has a stationary roll that is
actually a hydraulically loaded stationary shoe
which is concave shaped in order to fit the other
roll. The shoe is covered by a rotating
polyurethane blanket lubricated with oil to
eliminate any type of friction between the shoe
and blanket. This creates a high pressure and long
time in the nip thus allowing for better drying
(figure 17-14). This drying can get the sheet to
approximately 50% solids.
D Fabric Press For this type, a
multiple-weave, non-compressible fabric belt
passes through the nip between the felt and the
rubber-covered roll to provide void volume to
receive the water. The water is removed from the
178
Figure 17-15. Modern Straight-Through Press
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 17-14. Shoe Press Nip
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
fabric by passing over a suction box on the return
run.
D Extended Nip This type of press features
a wide nip to give the sheet a long dwell time at
high pressure. When used as the last nip, this
press provides not only a much drier sheet, but
also a stronger sheet due to improved
consolidation of the web structure.
Mechanically pressing the water from the sheet is
eight times cheaper than trying to dry the sheet.
Because less drying would be needed, faster
machine speeds and production can also be
achieved.
One of the most important things on the press is
the press felts. In the past, these were woven
woolen blankets. Now, these are commonly
composted of a woven synthetic base fabric and
fiber matt, attached by a sewing punching
process. These must be strong enough to
withstand the compression of the rolls while still
providing void volume for the water that is
removed from the sheet in the press nip.
Press Arrangements
Below are the typical press arrangements that can
typically be seen in pulp and paper mills.
D Straight-Through The oldest and
simplest of the press arrangements, this type can
still be found on paper and board machines. Each
press within this design has a smooth top roll and
a bottom felted roll so only the top surface of the
sheet received smooth roll contact. Later, an
inverse second press allowed the bottom of the
sheet to be in contact with the smooth roll.
D Modern Straight-Through This unit has
two, double felted presses, which is common in
new paper machines (figure 17-15). In this design,
the sheet is fully supported off the couch, between
the individual presses, and into the dryer section.
Depending on the weight of paper, the more shoe
presses are necessary for water removal.
179
Figure 17-16. Two-Tier Drying System
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Drying
After pressing, the sheet is conveyed through the
dryer section where the residual water is removed
by evaporation. This is due to the cellulose fibers
being hydrophilic and wanting to hold onto water.
At this stage, the wet web is approximately 40 -
45% solids.
Most paper is dried on cast iron or steel drying
cylinders, each cylinder being 60 - 72 inches in
diameter, that are fed with steam from the boiler
with pressures between 15 - 150 psi, depending
on the type of paper. The wet web is held tightly
against the cylinders by a synthetic, permeable
fabric called the dryer felt. The evaporated water
is carried away by ventilation. The final result of
the dryer section is paper with 5 - 8% moisture.
Most paper machines have three to five
independently-felted dryer sections, each with
their own speed control to maintain sheet tension
between sections and adjust for any sheet
shrinkage. The two-tier configuration is the most
common arrangement for dryers. The sheet
passes from dryer to dryer where it is tightly
pressed against the dryer cylinders by the dryer
fabric (figure 17-16). The paper passes
unsupported between each of the dryers. Once
the remaining water in the sheet rises to its boiling
temperature, water is converted into steam. This
steam is collected in a containment hood to
remove the water vapor. On the inside of the dryer
cylinders, the steam is condensed back into water,
or condensate. This conversion of steam into
water supplies the majority of the energy that dries
the paper.
Figure 17-17. Single-Tier Dryer Section
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
At high speeds, the unsupported paper between
the dryers can flutter and occasionally break.
Because of this, many modern paper machines
are going with a single-tier or Uni-run
arrangement where the dryer fabric is in constant
contact with the sheet (figure 17-17). This allows
for the machine speed to increase.
The condensate that collects within the dryer
cylinders must constantly be removed. This is the
job of the siphons.
Steam and Condensate System
The heat energy for paper drying comes from
steam as it condenses inside the dryer cylinders.
This is known as latent heat. Steam always
condenses at the saturation temperature, as
defined by the pressure in the system. This is
important when trying to have uniform drying
across the machine. The condensate that forms in
the dryer cylinders is removed by a specially
designed pipe assembly called a siphon. On
slower machines, the condensate collects in a
puddle at the bottom of the cylinder. For
high-speed machines, a true rimming condition
can be reached where the condensate covers the
entire inside surface due to centrifugal force.
In siphoning, differential pressure pushes the
condensate through the siphons (figure 17-18).
The siphons carry the condensate from the dryer
to a separator that collects the condensate and
recycles any steam that has been blown through.
The condensate is reused by sending it back to
the mills boiler feedwater system (figure 17-19).
Hood Ventilation
It is important to realize that a ventilation hood
exists over the entire dryer section beginning from
the press section up to calendaring. Depending on
1710
Figure 17-18. Steam Drum and Siphon
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
Figure 17-19. Condensate Process
Drawing is from TAPPIs Making Pulp and
Paper Series and is used with permission.
1711
the type of hood arrangement, 7 - 20 pounds of air
are utilized for each pound of water evaporated.
To prevent drips, buildup and corrosion within the
hood, the volume and temperature of exhaust air
must be sufficient to avoid localized condensation.
Modern generation hoods, also called high-dew
point hoods, are well sealed and insulated.
Diffusion air is totally eliminated, and the amount
of fresh makeup air is sharply reduced by
operating at high temperature with high recycle.
Size Press
Sizing solution is commonly applied within a
two-roll nip which gives the name size press. This
device is found about three quarters of the way
down the dryer section where starches and other
materials can be applied at this station in order to
improve sheet surface, internal strength,
smoothness, and resistance to water penetration.
The objective is to flood the entering nip with
sizing solution so the paper absorbs some of the
solution.
The basic mechanisms that incorporate starch
solutions into the sheet is the sheets ability to
absorb the sizing solution and the amount of
solution film passing through the nip. Sheet
absorption is greatly affected by sheet moisture as
higher sheet moisture promotes absorption.
However, the level is typically controlled to 4 - 5
percent or less to ensure the sizing agent is kept
nearer to the surface.
Modern paper machine speeds can create
turbulence due to changing nip pressures. This
affects the size press ability to evenly distribute
the solution. To overcome this issue, most size
presses have larger diameter rolls to keep solution
turbulence more manageable. Others have begun
to use a metering size press, which applies the
starch to the surface of the size press rolls by
metering the amount applied to the sheet with a
blade or rotating rod.
Today, the size press can also be used for coating
applications; including pigmented coatings and
other specialized surface applications. Some
manufacturers are beginning to include pigment in
the starch application.
Calendaring
This process helps to smooth and flatten the
sheet, better known as the thickness or caliper
variation of the sheet. This is done by
compressing the higher areas in the sheet more
than the lower. Surface smoothness improves so
the paper prints better. Sheet density is increased
so the paper becomes thinner and denser. Making
the sheet denser also makes the paper less stiff.
Calendaring changes the surface and interior
properties of the sheet by passing the web
through one or more two-roll nips where the rollers
may or may not be of equal hardness. By using
extreme pressures, the objective is to press the
paper against the smooth surface with sufficient
force by using one of the calendaring types below.
D Hard-Nip Both rolls are made of either
iron or steel. Although this type smooths the sheet
by calendaring to a uniform thickness via flattening
the higher areas in the sheet, it can create areas
that are more dense as well. These density
variations are due to basis weight variations and
can turn into variations in surface properties
D Soft-Nip For this type, the loading roll is
still hard but the opposing roll has a soft polymeric
cover, usually some type of polyurethane. Since
the side contacting the metal roll receives a much
better finish than the side contacting the resilient
roll, it is necessary to have two nips for equal
finish.
Calendaring at high temperatures is desirable
because the paper becomes more pliable and can
be calendared at lower pressure.
Reel
After drying and calendaring, the paper product
must be collected in a convenient form for
subsequent process off-machine. This is typically
done by a drum reel which collects the product to
a specified diameter.
Most reels are motor-driven under sufficient load
to ensure adequate tension on the sheet from the
calendars. The web wraps around the reel drum
and feeds into the nip formed between the drum
and the collection reel, which is held by the
secondary arms. While the reel builds up, an
empty spool is positioned on the primary arms.
To transfer from a full roll to empty spool, the
parent roll needs to be removed. An empty spool
is held in the primary arms and is brought up to
speed before contacting the paper on the reel
drum. The paper is transferred to the new spool
and the full parent reel is released from the reel
drum. Once the parent roll is removed, the primary
arms move the new roll down to the rails. The
secondary arms are brought forward to take the
1712
spool and the primary arms return to their original
position.
Winder
The purpose of the winder is to cut and wind the
full-width, large diameter paper reels into suitable
sized rolls. These rolls may then be wrapped and
sent directly to the customer or may be processed
through subsequent coating, calendaring, or
sheeting operations. During winding, the two
edges of the reel are trimmed off and conveyed
back to the dry-end pulper, or broke pulper.
The full-width machine reel is transferred from the
reel stand to the unwind stand by an overhead
hoist. From the unwind stand, the paper is
threaded through the web-tensioning rolls, the
adjustable slitters, adjustable spreader bar and
onto fiber or plastic cores. Typically, a steel shaft
is inserted through the cores to provide a locking
arrangement. However, some of the newer
winders operate shaftless by providing a
retaining surface on one side to prevent
cross-machine wandering.
The winder drive must be capable of speeds of
two and a half to three times faster than the paper
machine in order to have time to change rolls,
change reels, repair breaks, remove defective
paper, set up the slitting arrangement, and adjust
the spreader bar.
Roll Finishing
The steps in roll finishing are scaling, wrapping,
crimping, heading, and labeling. Each of these is
done manually at one time. Today, most wrapping
operations are carried out semi-automatically, and
the labeling function is handled by a data
processing print unit.
www.Fisher.com
Chapter 18
Boilers Water/Steam Cycle
The efficient production of steam and electricity is
an important function in the overall process of pulp
and paper production. These items are basic raw
materials required in large quantities for the
manufacturing of pulp and paper.
In years past, the cost of operating the powerhouse
may not have been a priority; however, with
increasing prices of fuel and purchased electricity
affecting bottom line profits, the industry has
evolved to a more efficient and conservation
conscious powerhouse. One key item in a more
efficient powerhouse involves utilization of a
reliable control system. The final element for many
of these controls is the control valve.
Although design will vary from mill to mill, a
generic water/steam cycle is shown in figure 18-1.
This process is commonly referred to as
cogeneration due to the simultaneous use of fuel
energy for both process steam requirements and
electrical power generation via steam driven
turbines. Figure 18-2 details the upper, or
convective, section of a boiler and indicates valves
required for process control.
Condensate Return System
Water pumped to the boilers for production of
steam is composed of condensate returned from
process and demineralized make-up water. This
mixture is commonly referred to as boiler
feedwater (BFW).
The condensate returned from process is
demineralized water, which was used to produce
steam in the boiler and has condensed after giving
up vaporization energy to process. In a typical mill,
about 40-50% of the condensate is returned to the
powerhouse. Most of this comes from indirect
heating such as paper machine dryers and various
heat exchangers. A large portion will also be
returned from the condenser if a condensing turbine
is used. Losses occur in direct heating or cleaning
applications such as pulp cooking and sootblowers.
Other losses occur in the transport system
(pumps, valves, tanks, and piping) and condensate
contaminated by leakage (mixing with process).
Serious operational problems may result if
contaminated condensate (with black liquor, white
liquor, etc.) enters the boilers. To prevent this, a
condensate dump system is used. A conductivity
element is used to sense contaminants and sends
a signal to valves which dump the condensate to
sewer until the problem is corrected. Automation
of this system can save the time lost to a manual
operated system.
Demineralized or deionized (DI) water involves
treatment with ion exchange resins to remove
hardness (minerals) and silica, which would
deposit on boiler tubes. This process involves
large equipment and operational expense. Most
mills are equipped to supply only a portion of the
feedwater required with demineralized water.
Thus, the return of as much clean condensate as
possible is critical from an economic and
operational standpoint.
Condensate is usually brought to a single
collection tank from various process users and the
turbine condenser. It is then sent through a
condensate polisher to remove any scale deposits
picked up in the return system. From the collection
tank the condensate is pumped to the deaerator
(DA) heater. In some mills an indirect feedwater
heater is used before the DA to raise temperature
to near saturation. Low pressure (150 psig) steam
is used for heating and the resulting condensate is
returned to a lower pressure reservoir such as the
condenser hotwell or DA.
182
Boiler Feedwater System
The BFW system begins at the DA and ends at
the inlet to the economizer. The main components
are the DA, the boiler feed pump, and the high
pressure feedwater heaters. The main purpose of
the BFW system is to condition the feedwater for
entry into the boiler. The DA removes unwanted
oxygen from the feedwater, which, in turn,
prevents corrosion in the entire piping system. The
boiler feed pump raises the pressure and the high
pressure feedwater heaters raise the temperature
of the feedwater. The critical valves within the
boiler feedwater system are the boiler feedwater
recirculation, feedwater startup, and feedwater
regulator valves.
Feedwater Recirculation Valve
In order to protect the feed pump, there must be a
recirculation system. The boiler feed pump
recirculation valve takes feedwater from the boiler
feed pump and recirculates it to the DA. It is there
to protect the pump from cavitation and excess
temperature rise. There are three basic methods
of providing feed pump recirculation. Two older
methods are continuous recirculation and on/off
recirculation. The current method is modulating
recirculation. This provides minimum recirculation
flow to protect the pump and optimize efficiency. It
requires a high technology recirculation valve. The
recirculation valve typically experiences cavitation
and if not properly taken into account with valve
selection, cavitation damage will result. Because
of the cavitation, tight shutoff is required. Any
fluids leaking past the valve will cavitate and
cause damage to the seat. A leaking recirculation
valve can cause decreased unit capacity, reduced
efficiency and repeated maintenance and repair
cost. Plugging can occur if feedwater is not clean.
A common issue with all feedwater applications is
corrosion due to materials chosen. Amine or
hydrazine treated feedwater is corrosive to the
cobalt binding in alloy 6. If the feedwater is
treated, use of this material should be avoided.
Design Considerations:
D Cavitation
D Tight shutoff (Class V)
D Typical process conditions are 800-1200 psig
and 200-400 F
Typical Specifications:
D easy-e, HP, EH, or Cavitrol IV trim
D Cavitrol III Trim
D HTS1 option with improved pressure balance
seal
D FIELDVUE digital valve controller with low
travel cutoff
Optional:
D NotchFlo or Dirty Service Trim
D Protected inside seat
Feedwater Startup and Regulating
Valves
The feedwater startup valve is used to initially fill
the boiler. Depending upon the design, this can be
through the main feedwater pumps or the
condensate pumps. The valve transitions
operation to the feedwater regulator valve, or
variable speed drive, once drum pressure has
been built up. During drum fill operation, the boiler
is under minimal pressure. This causes the entire
pressure drop to be taken across the feedwater
startup valve. Because of this, the formation of
cavitation becomes a concern. Sizing of the
startup valve must be done in combination with
the feedwater regulator valve. This is to ensure
that the feedwater regulator valve does not
experience any service conditions that lead to
damaging cavitation. The most common split is
that 80% capacity in the startup valve is equal to
20% capacity in the regulator valve. Once the
transition to the regulator valve has begun, the
startup valve closes. Improper use is one of the
main issues surrounding two valve feedwater
systems. For example, the startup valve is not
being used at all and the regulator valve is being
used to perform both functions. This can be a
major problem if the boiler feedwater regulator
was not sized or selected to perform both
functions. There can also be an issue if switching
between the startup and the regulator valve is
happening too quickly. Because of the cavitation
concerns and taking the full pressure drop, the
startup valve should utilize some form of
anti-cavitation trim. Typically, in process plants,
since the pressures are not as high as power
plants, Cavitrol III trim is selected. 440C trim is
recommended for the case of treated feedwater.
For cases where one valve is performing the
startup and regulator duties, characterized Cavitrol
183
trim can be designed to handle the cavitating
conditions at startup and then standard equal
percentage or linear characteristic for steady-state
conditions to maximize capacity. Another common
issue in both the startup and regulator valves is to
see them operated below the minimum operating
point. This can cause gear-toothing damage on
the plug.
Design Considerations:
D Cavitation
D Tight shutoff (Class V)
D Typical process conditions are 800-1200 psig
and 200-400 F
Typical Specifications:
D easy-e, HP, or EH
D Cavitrol III Trim
D HTS1 option with improved pressure balance
seal
D FIELDVUE digital valve controller with low
travel cutoff
Optional:
D NotchFlo or DST
D Protected inside seat
Steam Generation
The number and types of boilers used for steam
production varies considerably from mill to mill.
Figure 18-1 indicates a simple system consisting
of one power boiler and one recovery boiler
discharging into a common high pressure
superheated steam header. For this system, the
recovery boiler is base loaded at a constant flow
of black liquor fuel with steam flow and pressure
allowed to fluctuate. The steam header pressure
(typically 1000-1500 psig) is controlled by varying
the fuel input to the power boiler. Power boiler fuel
is typically base loaded with bark or hog fuel and
supplemented with coal, oil, or gas.
Figure 18-2 provides an enlarged view of the
upper convective section of a boiler. BFW enters
the economizer at 800-1200 psig and 200-400F
before flowing to the steam drum of the generating
section. As mentioned earlier, demineralized water
is used in boilers due to high operating pressures
and temperatures. Even so, as saturated steam
leaves the steam drum, trace amounts of solids
are left behind. These solids must be removed via
continuous bleed or blowdown of a small amount
of water to prevent accumulation. The mud drum
is also a low point for solids to settle and has
provision for intermittent blowdown to prevent
accumulation.
Saturated steam leaving the steam drum passes
through the superheater section for further heating
and moisture evaporation. Most superheaters
consist of a primary and secondary section.
Attemperation or desuperheating is used between
the sections to control final temperature and
prevent overheating of tubes. The source of water
must be of demineralized quality to prevent
accumulation of deposits on the inside of the
tubes. A common source is boiler feedwater from
the discharge of the boiler feedwater pump.
A vent is indicated on the superheated steam
outlet before the high pressure steam header. This
vent may serve multiple purposes. One use is to
clear the superheater of any moisture during
start-up. This is to assure no water droplets reach
the steam turbine. A second function is pressure
relief in case an alarm indicates a build-up of
pressure. A final function may involve setting the
valve to open on high pressure just before the
spring operated safety valve would lift. Due to high
flow and pressure drop creating excessive noise,
the valve is often used in series with a diffuser
and/or silencer. Also shown in figure 18-2 is a
valve for controlling the flow of steam to the
sootblowers.
Sootblower Valve
When firing fuels such as coal, oil, biomass, or
other waste products, fouling of the boiler tubes
becomes a concern. Deposits from the
combustion process can collect on the heat
exchanging tubes reducing thermal efficiency and
can cause operational difficulties. In order to keep
the unit operating, an online cleaning method must
be used. This is usually accomplished by using
what are called sootblowers. Sootblowers utilize
flowing media such as water, air, or steam to
remove deposits from boiler tubes. Widespread
use of water has been limited due to the possibility
of thermal shock on the tube banks so steam is
the most common media. There are several
different types of sootblowers used. Wall blowers
184
are used for furnace walls and have a very short
lance with a nozzle at the tip. The lance rotates as
it moves into the furnace and cleans the deposits
from the wall in a circular pattern. Retractable
sootblowers are used in high flue gas temperature
zones. These operate the same as the wall
blower, but the lance is inserted into the boiler to
clean the internal tubes and can be partially or
fully retractable. Partially retractable sootblowers
are used where sootblower materials can
withstand the flue gas temperature.
Design Considerations:
D Noise and vibration
D Tight shutoff (Class V)
D High cycling operation
D Typical service conditions are 800-1200 psig
at 300-500 F
Typical Specifications:
D easy-e, HP, or EH
D Whisper Trim
D FIELDVUE digital valve controller with low
travel cutoff
Optional:
D Oversized stem/VSC and/or welded stem
connection
Steam Turbine Generators
The majority of steam from the high pressure
header is used by large power generating steam
turbines. Most mills use a backpressure turbine(s)
(discharges to a lower pressure process header)
and at least one condensing turbine (discharges to
a condenser). Extraction steam from the turbines
is used to supply the medium and low pressure
process headers. These headers typically operate
at 400-600 psig and 60-150 psig respectively.
Pressure reducing valves are also used between
headers to balance demand vs. extraction or to
provide process steam during a turbine outage. If
desuperheating is required, a steam conditioning
valve is recommended for this service.
While electrical power produced by the turbines
(typically 30-70 MW) is important to mill
operations, supplying the process with steam is of
primary concern. Most mills are connected to a
local utility and purchase the balance of electrical
power required. By nature, the back pressure
turbine provides more than double the utilization of
available fuel energy as the condensing turbine.
The majority of steam discharged from the back
pressure turbine is utilized by process, while the
latent heat in the steam of the condensing turbine
exhaust is wasted in the condenser.
Main Steam PRV and Turbine
Bypass
Control of steam pressures and temperatures are
likely the most critical applications in a pulp and
paper mill. Steam is used for wood chip
preparation, process heating, pulp and paper
drying, boiler cleaning, energy production, and in
many other applications. Without steam, a pulp
and paper mill cannot operate. To accommodate a
variety of steam pressure requirements most sites
utilize three headers; high (1000-2000 psig),
medium (500 psig), and low (100 psig) pressure.
The power and recovery boilers supply high
pressure, high temperature steam to the high
pressure header. Much of the high pressure steam
undergoes a pressure reduction and is directed to
the medium and low pressure headers. When
demand for low pressure steam is high, the
medium pressure header also supplies steam to
the low pressure header.
Main Steam PRV
Pressure reduction between headers can be
achieved through the use of a pressure reducing
valve (PRV) or a steam turbine (also called turbo
generator). Main steam PRVs are often used to
bridge the high (1000-2000 psig), medium (500
psig), and low (100 psig) pressure headers. Each
PRV can perform only a single pressure reduction,
so multiple PRVs are required.
Design Considerations:
D High pressure and temperature
D Noise and vibration
D Tight shutoff (Class V)
185
Typical Specifications:
D easy-e, EW, or HP
D Whisper Trim
D FIELDVUE digital valve controller with low
travel cutoff
Optional:
D Inline diffuser (if extra noise attenuation is
needed)
Turbine Bypass
Steam turbines generate electricity through
pressure reduction and are becoming increasingly
popular. Each turbine can have multiple take-off
points so one unit can simultaneously feed the
medium and low pressure headers. In order to
minimize unplanned downtime, a bypass valve is
installed in parallel with the turbine to ensure
pressure reduction occurs even when the turbine
is offline. Most of the steam produced in paper
mills is not at the required conditions for all
applications. Thus, some degree of steam
conditioning is warranted in either control of
pressure and/or temperature to protect
downstream equipment. Steam conditioning
valves represent state-of-the-art control of steam
pressure and temperature by integrally combining
both functions within one control element unit.
These valves address the need for better control
of steam conditions brought on by increased
energy costs and more rigorous plant operation.
These valves also provide better temperature
control, improved noise abatement, and require
fewer piping and installation restrictions than the
equivalent desuperheater and PRV.
Design Considerations:
D High pressure and temperature
D Noise and vibration
D Large turndown
D Tight shutoff (Class V)
D High cycling operation
D Stroking speed
Typical Specifications:
D TBX
D Whisper Trim
D Bore-Seal
D FIELDVUE digital valve controller with low
travel cutoff
Optional:
D Separate PRV (easy-e, HP or EH) with a
Desuperheater
D WhisperFlo Trim
D 2625 booster(s)
Condensing and Cooling System
Even though it decreases cycle efficiency, a
condenser is essential to provide a cushion or
location to dump steam when a portion of the
process is down and still benefit from electrical
power production. The condenser is a shell and
tube heat exchanger which operates at a vacuum.
Cooling water passes through the tubes and
condenses the steam on the outside of the tubes.
The cooling water passes through a closed
system back to a cooling tower where the heat is
discharged to the atmosphere. Due to seasonal
temperature variations, all cells of a cooling tower
are not always in use. Butterfly valves are used to
isolate cells or even bypass the cooling tower.
Condensed steam accumulates at the bottom of
the condenser in the hotwell. The condensate is
then pumped to the condensate collection tank to
begin the cycle again. Since the condensate is
near saturation, a minimum level must be
maintained to prevent pump cavitation and a
minimum flow is required to prevent overheating.
Condensate Recirculation Valve
The condensate recirculation valve is similar to the
feed pump recirculation valve in that it also
protects the pump from cavitation. Inlet pressure
and temperature differ from the feedwater system.
The dissimilarities from the feedwater system
include the inlet pressure and temperature. Inlet
sizing often indicates that flashing is occurring,
however, experience shows this is always a
186
cavitating application. The end user needs to
ensure that there is not a sparger or diffuser
downstream emitting back pressure on the valve.
This will cause cavitation rather than flashing.
Tight shutoff is needed on this application because
it prevents loss of condenser vacuum, loss of
condensate pressure and flow to the deaerator,
and saves money in terms of wasted pump
horsepower.
Design Considerations:
D Cavitation
D Tight shutoff (Class V)
D Typical service conditions are 300-500 psi at
100-150 F
Typical Specifications:
D easy-e, HP, EH or Cavitrol IV trim
D Cavitrol III Trim
D HTS1 option with Improved Pressure
Balance Seal
D FIELDVUE digital valve controller with low
travel cutoff
Optional:
D NotchFlo or Dirty Service Trim
D Protected Inside Seat
Control Valve Selection
PROCESS FISHER VALVE PRODUCT DESIGN
Valve
Tag #
Water/Steam Power Cycle
V150/
V300
V500
Control
-Disk
E-Body EH HP
Steam
Condi-
tioning
Typical
Valve
Size
Application Description
Control
Function
LV-1 M.P. Heater Drain T S P 2I
LV-2 L.P. Heater Drain T S P 2I
LV-3 Condensate Collection Tank Level T P P 4I
LV-4 Demineralized Make-up Water T P S 4I
FV-1 BFW Regulator T S P 6I
FV-2 BFW Regulator Bypass T S P 2I
FV-3 BFW Pump Recirculation T S P 2I
FV-4 Deaerator Heating Steam T S P 12I
FV-5 Condensate to Deaerator T P S 4I
FV-6 Contaminated Condensate Dump O/O P S 4I
FV-7 Condenser Hotwell Recirculation T P S 2I
FV-8 Condenser/Cooling Tower Water O/O P 18I
FV-9 Sootblower Steam O/O P S 4I
FV-10 High Pressure Steam Vent T S P 4I
FV-11 Superheater Attemperation Water T S P 1I
FV-12 Continuous Blowdown T P (HPA) 1I
FV-13 Intermittent Blowdown O/O P (HPA) 1I
PRV-1
High/Medium Steam Pressure
Reducing
T P S (TBX) 8I
PRV-2
Medium/Low Steam Pressure
Reducing
T P S (TBX) 8I
P=Primary Valve Choice
S=Secondary Valve Choice
T=Throttling Service
O/O=On/Off Service
187
E
1
3
8
5
Figure 18-1. Water/Steam Cycle Diagram
188
Figure 18-2. Power or Recovery Boiler Upper Convective Section
E1386
D103540X012 Printed in USA / 3M / 01-11 / IL
Emerson Process Management
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Chatham, Kent ME4 4QZ UK
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.EmersonProcess.com/Fisher
The contents of this publication are presented for informational purposes only, and while every effort has
been made to ensure their accuracy they are not to be construed as warranties or guarantees, express
or implied, regarding the products or services described herein or their use or applicability. All sales are
governed by our terms and conditions, which are available upon request. We reserve the right to modify
or improve the designs or specifications of such products at any time without notice. Neither Emerson,
Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selec-
tion, use, or maintenance of any product. Responsibility for proper selection, use, and maintenance of
any product remains solely with the purchaser and end-user.