Product Specification Sheet: Outlet Entry Combined Pressure Reducing & Desuperheatering Valves (PRDS)
Product Specification Sheet: Outlet Entry Combined Pressure Reducing & Desuperheatering Valves (PRDS)
Product Specification Sheet: Outlet Entry Combined Pressure Reducing & Desuperheatering Valves (PRDS)
INTRODUCTION
o Steam conditioning
o Process pressure and temperature control
o Turbine bypass systems
o Dump steam systems
o Steam vent systems.
DESCRIPTION
Reference to Figure 1 will show the basic construction of a PRDS valve. It will be observed from this
illustration that the valve body is angle style, with a second smaller branch at 180 from the main
branch for the coolant entry. The valve body incorporates a single web, which divides the body into a
high-pressure inlet section and a low-pressure outlet section. The web is the location and anchor
point for the valve trim, which consists of a balanced single seat throttling plug, seat, coolant shroud,
piston guide and shank guide. The shank guide acts as the trim-retaining member, holding and
sealing the coolant shroud by a tight screw thread and locking pin.
The piston guide screwed and secured into the valve body guides the plug through the stroking
distance. In larger units, the plug is of the balanced variety. The plug is hollow to allow pressure
equalization between the balancing chamber and the outlet section of the valve. This configuration is
desirable due to the low operating loads required. Small and more economical actuators can therefore
be selected.
The coolant shroud, and seat assembly create a coolant annulus. Coolant enters the annulus through
the coolant branch and is distributed around the coolant shroud where it is introduced to the vapour
flow through a continuous discharge ports. By providing complete shrouding of the coolant and
vapour mixture through the body, the effects of thermal stress and temperature shock in the body
material are minimized. The shank guide acts as a diffuser to subject the vapour and coolant mixture
to a final pressure drop before leaving the valve and assures final mixing.
The trim used in the PRDS valve can be a plug throttle form, a specially ported cage, a single stage
"Hush" trim or a multi-stage "Hush" trim. The latter two being selected where audible noise is to be
controlled. The single stage and multi stage "Hush" trims are shown in Figure 2 and Figure 3
respectively.
All trim components enter the body through the special valve outlet flange, the dimensions for which
are shown in Figure 4. Other outlet end connections such as RTJ type flanges can be
accommodated.
The valve bonnet incorporates the gland assembly for sealing the valve stem where it exits the valve
body, and in addition, provides a mounting platform for the valve actuator to give the motive force for
repositioning the valve plug by means of the valve stem.
The PRDS valve can be supplied with a variety of actuators, including pneumatic spring opposed
diaphragm, Pneumatic spring opposed or double acting piston, electro-mechanical or electro-
hydraulic.
PRINCIPLE OF OPERATION
High pressure, high temperature vapour enters the PRDS valve through the branch inlet connection
and passes into the chamber in the valve body surrounding the plug. With the valve in the closed
position, the vapour is unable to go any further. Flow to the outlet side of the valve is prohibited by the
plug contacting the seat. The piston rings in the balancing piston grooves limit the flow into the
balancing chamber. As the plug moves away from the seat the vapour can begin to flow through the
gap formed. The position of the plug to the seat will determine how much port area is exposed and
how much flow can pass from the inlet side of the valve to the outlet side.
In passing through the restriction formed between the seat and plug, the vapour is throttled and its
pressure reduced by the regulation of flow into the downstream system. As the vapour exits, its
velocity will increase. In the vena contracta zone immediately downstream of the trim the vapour will
achieve its highest velocity. It is at this point that the coolant enters the vapour flow, and the
desuperheating process begins.
The coolant shroud is extended below the coolant annulus area and contacts the shank guide; this
arrangement was chosen to protect the valve body from impingement by the coolant as it mixes with
the incoming vapour.
The shank guide acts as a diffuser plate and serves two purposes: Firstly, the diffuser takes some of
the pressure drop away from the valve trim, thus reducing the pressure drop across this item. This
together with the fact that the diffuser plate contains a large number of drilled holes that breaks the
vapour flow down into many small flow streams results in a lower noise level being generated as a
result of the pressure reducing function. Secondly the diffuser plate subjects the vapour and coolant
mixture to a pressure drop before it leaves the PRDS valve which is instrumental in providing
complete absorption of the coolant by the vapour as it leaves the valve, ensuring that there is no risk
of thermal shock to the downstream piping. This enables pipe bends to be fitted close to the valve
outlet and avoids the need for thermal liners to be used in the outlet piping.
On all sizes except the 1 x 2, the valve can also be provided with single and multi stage pressure
profiling trim options. In the single stage option (see Figure 2), the seat is extended as a cage to
shroud the plug, a large number of holes drilled in the cage provide a diffused area that becomes
larger as the valve opens. In the multi stage option (see Figure 3), a similar cage assembly consisting
of multiple cylinders, which have large numbers of drilled holes that are offset to create a series of
tortuous paths, each containing a number of restriction and expansion regions through which the
vapour has to pass. These tortuous paths are designed to break the overall pressure drop down in
stages while at the same time controlling the velocity of the vapour to a level that will not give rise to
excessive noise levels. This feature can also be used to enhance the pressure reducing function and
to create a lower exit pressure from the cage where it may be required to use a low-pressure coolant
source.
The plug in the PRDS valve is of balanced construction having a hollow centre that communicates the
pressure in the valve outlet chamber to the balancing chamber behind the plug. This feature also
prevents a build up of pressure behind the plug in the event of any leakage passed the piston rings on
the balancing piston of the plug. The only exception to this is the 1 x 2, which has an unbalanced plug
with a small unbalanced area.
The pressure retaining parts are designed in accordance with the requirements of ASME B16.34
1996. Other relevant standards are:
SIZES
The PRDS valve is available in 5 standard sizes, the outlet being twice the size of the inlet to allow for
expansion of the vapour at the lower pressure.
NOTE: Larger sizes utilizing a similar design can also be provided. Units larger than 6" x 12" typically
have fabricated bodies and branches to suit customer specific requirements. However, the operating
concept remains similar to that described in this specification.
PRESSURE RATINGS
The design of the valve allows the use of the pressure temperature ratings shown in ASME B16.34.
Table 1 shows the range of ratings available for each of the PRDS valve sizes.
MATERIALS OF CONSTRUCTION
The valve can be manufactured from any material to meet specific design requirements. However,
standard materials are available:
Body
Bonnet
Bonnets will be supplied in the same materials as the valve body or in a forged version as
follows:
For applications over 800° F t0 1050° F in low alloy steel (WC6 and WC9)
The packing follower stud and nut materials for temperatures up to 1050° F are:
Plug, Piston guide, Shank guide and Cylinder assembly (Cylinder trim option)
BS 970 420 S37 Hardened to Rockwell C 38-43 for applications below 800° F and pressure drops
less than 2000psi. Hardened and nitrided for applications above 800° F and pressure drops greater
than 2000psi.
ORIENTATION
The outlet entry pressure reducing and desuperheating station can be installed in any orientation.
TRIM INSTALLATION
The trim is of the screwed in design; access to the valve internals is via the outlet flange. If it is
intended to leave the valve in the line during maintenance, then provision should be made to remove
a sufficient length of outlet piping to give access to the valve for inspection and to permit removal of
the internals. The recommended minimum length of removable piping is 2 feet.
The stem is connected to the plug by a tapered junction. The tapered junction provides accurate
alignment between the plug and stem. Protection from unscrewing is provided by pinning the plug and
stem together after they have been assembled.
The trim is single seated, metal-to-metal. A seat leakage of ANSI FCI 70-2 Class IV is achievable with
trims fitted with piston rings. ANSI FCI 70-2 Class II is the standard leakage rate when the piston rings
are omitted. However, Class III is also achievable. All trims fitted to the 1 x 2 PRDS are non-balanced
and a Class IV seat leakage can be achieved without the need for piston rings.
VELOCITY LIMIT
If a noise limit has been specified, the outlet velocity should be limited to one-third sonic. Caution
should also be taken when sizing the downstream diffuser plate as a critical pressure drop taken
across the diffuser plate could become a noise generator in its own right.
MINIMUM SUPERHEAT
The unit can maintain final temperature down to 10° F above saturation.
ACCURACY
COOLANT PRESSURE
When a plug throttle type trim is used, the coolant pressure required at the PRDS coolant inlet must
be equal to or greater than the backpressure provided by the diffuser. When a ported cage trim or
any of the single stage and multi stage noise reduction trims are provided, the coolant pressure
should be greater than 25 psi higher than the backpressure provided by the diffuser.
In all cases an additional allowance of at least 25 psi should be made for the pressure differential
across the coolant control valve.
The pressure sensing point can be at a minimum distance of 5 feet from the outlet flange. Ideally
however, this should be positioned at the point of usage of the vapour, the PRDS valve will then
compensate for any line losses.
The temperature-sensing element should be located downstream of the valve at the point where dry
superheated fluid exists. The widely ranging conditions of the PRDS make it difficult to pick an exact
location. In order to provide stable control and minimum time delays (response between the coolant
valve and temperature-sensing element), the recommended location of the temperature sensing point
is between 13 and 20 feet from the outlet of the PRDS valve.
Table 2 shows the maximum available CV values for plug throttle trims. Accurate control of vapour
pressure and temperature is possible from 100% to 12% of full load.
Table 3, Table 4, Table 5 and Table 6 show maximum and minimum controllable Cv values for single
stage and multi stage "Hush" trim options.
TRIM CHARACTERISTIC
All plug throttle trim designs have a modified parabolic characteristic with exception to the 1 x 2 PRDS
options, which have linear characteristics. All single stage and multi stage "Hush" trims have a
characteristic, which is close to linear. PRDS ported cages are non-standard equipment. However,
ported trims can be profiled to give any characteristic that is required.
LINE INSTALLATION
The unit can be installed in any orientation, however for ease of maintenance it is recommended that
the valve be installed with the outlet flow direction vertically upward, or in any horizontal position. The
pipework should be in accordance with good piping practice with a minimum straigth length of 2 feet,
which ideally should be arranged as a removable section to give access to the PRDS internals. This
removable section should couple with the PRDS with a flat face flange or raised face that matches the
PRDS outlet flange.
Any bend following the PRDS outlet should have a minimum pipe bend radius of 1.5 times the pipe
diameter.
An expansion piece to reduce fluid velocity downstream of the unit may be required directly at the
outlet. The final pipe diameter should be calculated to give an acceptable pipe velocity relative to the
downstream pressure conditions.
To provide the best temperature control, it is good practice to locate the coolant control valve at a
lower elevation than the PRDS coolant inlet. This configuration will ensure that the coolant line
remains full under light load conditions.
A non-return valve should be installed between the coolant control valve and the PRDS and an
isolated drain point included between the non-return valve and the PRDS.
THERMAL LINER
A shroud is standard in each unit to protect the body from any coolant impingement. No thermal liner
is required in the downstream pipe.
All plug throttle trims are supplied with a shank guide to guide the plug through the valve stroke. A
range of diffuser shank guides are shown in Table 7, these should be fitted in the following instances:
All single stage and multi-stage trims are fitted with standard diffuser plates to amid missing. The
range of diffuser plates is shown in Table 8.
END CONNECTIONS
Except for the class 2500 inlet that has a butt weld connection as standard, all end connections are
flanged to ASME B16.5. The exception to this is the special outlet flange raised face dimensions,
which are shown in Figure 4. Coolant flanges are rated to suit the outlet flange; the standard coolant
branch sizes are shown in Table 9.
An option for supplying butt weld ends at the inlet and coolant branches is available.
CAPACITIES
Refer to Table 2 to Table 8 for trim and diffuser plate capacities. The capacity of multi stage "Hush"
trims is dependent on the number of trim sleeves that are employed to attenuate audible noise to an
acceptable level. These trims are custom engineered to meet specific conditions.
ACTUATION
The valve is designed to accept COPES-VULCAN, INC. diaphragm and piston actuators which a
screwed yoke-mounting feature. The stem sizes and actuator mounting diameters are shown in Table
10.
DIMENSIONS
The fitting dimensions for the standard range of PRDS valves is shown in Figure 5, Figure 6, Figure 7
and Figure 8
Class
1x2 2x4 3x6 4x8 6 x 12
Rating
600 N 4.25 6.88 9.50 11.88 16.25
P 3.81 6.12 8.75 10.62 15.06
Q 3.06 5.31 7.62 9.31 13.88
900 N - 7.12 9.50 12.12 16.50
P - 6.12 8.75 10.62 14.91
Q - 5.31 7.62 9.31 13.44
1500 N 4.88 7.62 9.75 12.50 17.25
P 3.81 6.12 8.75 10.62 14.91
Q 3.06 5.31 7.62 9.31 13.44
TABLE 2
Plug Throttle
1x2 2x4 3x6 4x8 6 x 12
trim
Minor 2 10 - - -
Mini 4 19 35 94 139
Reduced 7 34 68 137 263
Standard 10 45 103 180 397
Full 15 50 126 224 502
Stroke 0.75” 1.50” 1.50” 2.00” 2.50”
Characteristic Linear Modified Modified Modified Modified
Parabolic Parabolic Parabolic Parabolic
TABLE 4
TABLE 5
TABLE 7
TABLE 9
Note: The coolant flange rating will be the same as the outlet flange
TABLE 11
OUTLINE DRAWING FOR CLASS 600, 900 AND 1500 PRDS VALVES
1 x 2 PRDS
Class
Dimension 1x2
Rating
600 4.50
D 1500 6.00
600 5.50
E 1500 7.00
600 5.50
F 1500 7.00
600 4.50
G 1500 6.00
600 2.44
H 1500 2.50
OUTLINE DRAWING FOR CLASS 600, 900 AND 1500 PRDS VALVES
2 x 4 to 6 x 12 PRDS
Class
Dimension 2x4 3x6 4x8 6 x 12
Rating
600 7.25 8.00 10.50 11.12
D 900 - 11.06 12.88 15.12
1500 8.38 11.06 14.00 16.88
600 6.69 8.25 9.50 11.75
E 900 - 9.50 9.81 11.75
1500 7.62 9.50 9.81 11.75
600 7.62 9.50 10.00 14.12
F 900 - 11.75 10.75 18.00
1500 8.62 11.75 10.75 18.00
600 6.75 7.62 10.50 12.25
G 900 - 10.00 12.88 16.25
1500 7.38 10.00 14.00 18.00
600 10.94 11.56 12.81 18.00
H 900 - 15.56 16.81 22.81
1500 13.56 15.56 16.81 22.81