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APPLICATION DIGEST

March 2008 First Edition

We Solve Control Valve Problems.

INDEX

1. 2. 3. 4. 5. 6. 7.

History . Technology Centers . Valve Doctors .. CCI in Oil and Gas .. CCI in Power CCI in Nuclear . Product Sheet ..

5 7 9 21 23 24 25

DRAG PRODUCTS 100 DSV spray water valve 100 D choke valve V0 600 ABJ desuperheater 100 DR boiler feed pump recirculation valve Compressor recycle anti surge valve 800 D Korean valve 100 DLC feed water control valve 100 DPC well head production choke valve KOREAN PRODUCTS 840 G/H Korean valve 830 T three way valve 840/860 TBS (LLP) Korea FLUID KINETICS Desuperheaters DAM, DAM-D, DAM-E Silencers Blow off silencer 3

Control valve silencer Gas diffuser silencer Compressor silencer Reactive silencer Hydraulic acoustic filter Liquid pulsation dampener SSC/Stabilizer/Separator Steam vent silencer

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

Derivative unit

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

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

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

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

CCI VALVE DOCTOR


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

TECHNOLOGY CENTERS
CCI-Korea 10F, Sinwon B/D, 210-1, Hangangno-2GA, Yongsan-Gu Seoul, South Korea Ph : +82 (0)31 980 9960 Fax: CCI-KK 6-2-2 Takatsukadai, Nishi-ku Kobe City, Hyogo 651-2271 Japan Ph : +81 78 991 5940 Fax: CCI-RSM 22591 Avenida Empresa Rancho Santa Margarita, CA 92688 U.S.A. Ph : +1 949 858 1877 Fax: +1 949 858 1878

CCI-STI Via G. Pascoli, 10 a-b 24020 Gorle (Bergamo) Italy Ph : +39 035 2928 Fax: +39 035 2928 247

CCI-Sweden Industrigatan 1-3, Box 603 SE-661 29 Saffle Sweden Ph : +46 533 689 600 Fax: +46 533 689 601 CCI-Switzerland lm Link 11, P.O. Box 65 8404, Winterthur Switzerland Ph : +81 78 991 5940 Fax: +41 52 264 95 00 CCI-Vienna Lembockgasse 63/1 AT-1233 Vienna Austria Ph : +43 1 869 27 40 Fax: +43 1 865 36 03

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VALVE DOCTORS
Ron Adams Technical Specialist CCI-RSM +1 949-858-1877 REA@ccivalve.com
Expertise: DRAG

Kiho Ahn Manager-Technical Service CCI-Korea +82 31-980-9930 KHAN@ccivalve.com


Expertise: 800 Series

Franz Albrecht Technical Service CCI-Vienna +43 1 869 2740 127 Franz.albrecht@ccivalve.at
Expertise: BTG, DRAG, Fossil Power

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Sina Alikhani Director-Nuclear Product Dev CCI-RSM +1 949-888-4168 SA@ccivalve.com Expertise: DRAG, Nuclear

Peter Baumann Testbed & Actuator Manager CCI-Switzerland Peter.baumann@ccivalve.ch


Expertise: Sulzer

Urs Blumer Sr Consultant Nuclear Services CCI- Switzerland +41 52 264 9556 Urs.blumer@ccivalve.ch
Expertise: Sulzer, Nuclear

Peter Borzsony Mktg Mgr Fossil Power CCI-UK +44 (0) 161-655-1688 Peter.borzsony@ccivalve.ch
Expertise: BTG, DRAG, Fossil Power

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Eddie Chau Engineering Manager O&G CCI-RSM +1 949-858-1877 ECC@ccivalve.com


Expertise: DRAG, Oil & Gas

Jay Faramarzi Vice President - R&D CCI-RSM +1 949-888-4190 JF@ccivalve.com


Expertise: DRAG, Fossil Power, Oil & Gas

Konrad Fluri Sr. Manager CCI- Switzerland +41 52 264 9756 Konrad.fluri@ccivalve.ch
Expertise: Sulzer, Fossil Power

Tord Forslund Chief Engineer CCI-Sweden +46 533 689 671 Tord.forslund@ccivalve.se
Expertise: BTG , Fossil Power, Pulp

& Paper

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Steve Freitas Development Manager, Power CCI-RSM +1 949-858-1877 SF@ccivalve.com


Expertise: DRAG , Fossil Power

George Friedrichs Manager, Technical Services CCI-RSM +1 949-888-4191 GPF@ccivalve.com


Expertise: DRAG, Fossil Power, Oil & Gas

Charlie Hart R&D Lab Manager, RSM CCI-RSM +1 949-858-1877 chart@ccivalve.com


Expertise: DRAG

Mauro Giovanelli Engineering Manager CCI-STI +39 035 292 8227 maurogiovanelli@stistrumentazione.
Expertise: STI, Actuator Accessories

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Martin Huber Engineering Manager, Power CCI-Vienna +43 1 869 2740 Martin.huber@ccivalve.at
Expertise: BTG, DRAG, Fossil Power

Sven-Ake Jacobsson Development Engineer CCI-Sweden +46 533 689 657 Sven-ake.jacobsson@ccivalve.se
Expertise: BTG, Fossil Power

Ulrich Kaegi Mgr Tech Services CCI- Switzerland +41 52 264 9757 Ulrich.kaegi@ccivalve.ch
Expertise: Sulzer, DRAG, Fossil Power

Thang Ly Manager- Global Standards CCI-Vienna +43 1 869 2740 * 129 Thang.Ly@ccivalve.at
Expertise: DRAG, Oil & Gas

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Brian Metz Program Manager Development CCI-RSM +1 949-888-4314 BDM@ccivalve.com


Expertise: DRAG, Nuclear, Fossil Power

Herb Miller Consultant, Principal Engineer CCI-RSM +1 949-888-4049 HLM@ccivalve.com


Expertise: DRAG

Stan Miller Director of Development, Power CCI-RSM +1 949-858-1877 SFM@ccivalve.com


Expertise: DRAG, Fossil Power

Tomoaki Miyoshi VP-Operations CCI-KK +81 78 991 5967 Tom.miyoshi@ccijapan.co.jp


Expertise: AB Japan, Fossil Power

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Antonio Negri Operations Manager CCI-STI +39 035 2928228 antonionegri@stistumentazione.com


Expertise: STI, Actuator & Accessories

Steven Oh Operation Manager, China CCI-China +86 21 6518 8455 SKOH@ccivalve.com


Expertise: DRAG, Fossil Power

Shigekazu Nishiyama Engineering Manager CCI-KK +81 78 991 5940 nishiyama@ccijapan.co.jp


Expertise: AB Japan, Fossil Power

Arvind Patel Principal Engineer CCI-RSM +1 949-888-4006 ACP@ccivalve.com


Expertise: DRAG

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Chris Peterson Engineering Manager Power CCI-RSM +1 949-858-1877 cpeterso@ccivalve.com


Expertise: DRAG, Fossil Power

Francesco Rusmini Quality Manager CCI-STI +39 035 2928 262


francescorusmioni@stistrumentazione.com

Expertise: STI, Actuator & Accessories

Dale Schmaeman Chief Engineer CCI-Ventura +1 805-644-5587 dschmaeman@ccivalve.com


Expertise: Fluid Kinetics, Silencers, Fossil Power

Sanjay Sherikar Manager- Tech Development CCI-RSM +1 949-888-4133 SVS@ccivalve.com


Expertise: DRAG, Fossil Power, Oil & Gas

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Kouichi Shibata Project Management CCI-KK +81 78 991 5940 shibata@ccijapan.ci.jp


Expertise: AB Japan, Fossil Power

Ricardo Simeoni Manager, Factory Sales CCI-Houston +1 713-869-5233 RS@ccivalve.com


Expertise: DRAG, Oil & Gas, AntiSurge/Compressor Recycle

Joe Steinke Development Manager, O&G CCI-RSM +1 949-888-4195 JHS@ccivalve.com


Expertise: DRAG, Fossil Power, Oil & Gas

Curtis Sterud Consultant, Principal Engineer CCI-RSM +1 949-858-1877 CGS@ccivalve.com


Expertise: DRAG, Fossil Power

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Larry Stratton Manager, Technical Services CCI-RSM +1 949-888-4136 LRS@ccivalve.com


Expertise: DRAG, Fossil Power, Oil & Gas

Sam Sturtevant Project Manager- Development CCI-RSM +1 949-888-4126 SCS@ccivalve.com


Expertise: DRAG

Per Sundberg Upgrades manager EAME CCI-Sweden +46 533 689 734 Per.sundberg@ccivalve.se
Expertise: BTG

Flavio Tondolo Engineering Manager CCI-STI +39-035-2928-241 Flavio.tondolo@stistrumentazione.co


Expertise: STI, Actuator & Accessories

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Tobias Zieger Deputy Director Nuclear D CCI- Switzerland +41 52 264 9759 Tobias.zieger@ccivalve.ch
Expertise: Sulzer

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CCI IN FOSSILE POWER


Types of Power Plant are supercritical, combined cycle, conventional drum.

CONTROL VALVES IN A POWER PLANT:


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Condensate pump minimum recirculation valve. Deaerator level control valve (Main condensate control valve). LP/IP/HP heater drain valves. Deaerator pegging steam valves. Startup feed pump recirculation valve. Boiler feed pump minimum recirculation valve. Feed water control valve. Feed water startup valve. Superheater spray control valve. Superheater spray block valve. Block valve. Soot blower valve. Header drains. APRDS PRV. APRDS spray control valve. Reheater spray control valve. Reheater spray block valve. LP/IP/HP Turbine stop valve. LP//IP/HP Turbine control valve LP/IP/HP Turbine Bypass valve. Turbine drains. LP/IP/HP DSH spray control valve. Cooling water control valve.

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

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CCI IN OIL & GAS


Types of Oil and Gas industries are LNG, Oil and Gas extraction, Gas treatment, Petrochemical, Pipe Transportation.

CONTROL VALVES IN OIL & GAS:


Production chokes Separator level control Gas lift/injection Injection pump recycle Overboard dump Gas regulator Surge relief Hot gas bypass Gas to flare Amine letdown Expander bypass Vent to atmosphere Feed water regulator Feed water pump recirculation Spray water Steam header pressure control.

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CCI IN NUCLEAR
Types of Nuclear plants are PWR, BWR, AGR, CANDU.

CCI IN CHP
Types of CHP are Desalination, Ethylene Plants, Refineries, steel Mills, Aluminum Plants, Chemical Plants, Paper and Pulp, Waste to Energy.

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PRODUCTS DATASHEET

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27

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

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

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DRAG
Type: 100DSV

100DSV
SPRAY WATER VALVE

Sizing Tool: Valsiz PowerSiz Design Loc: CCI-RSM CCI-Vienna CCI-Korea

Application:
The 100DSV is designed for Spray water Control valves application used in: Superheat; Reheat; Main Steam Bypass to Cold Reheat; and Auxiliary, Export, or Process Steam. These valves regulate steam temperature by controlling the flow of water into desuperheater nozzles. The pressure drop across the valves (P) is dependent upon the size of the desuperheater nozzles.

Description:
The 100DSV is available in angle and globe configuration and in four trim sizes (3/8, 5/8, 1.0, and 1.5). The same base valve body is used for globe or angle pattern valves. It is designed for up to ASME 2500 rating with a gasket seal design. The trim is an equal-percentage, over the plug flow disk stack design. The standard is a spring diaphragm actuator.

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DRAG
Features:

100DSV

DRAG Velocity Control Protects Valve Trim. Up to 20 stages used to limit trim exit velocity to 100 ft/sec (30 m/sec) or less. Eliminates erosion and cavitation damages. Improve Heat Rate Efficiencies. The 100DSV minimizes lost energy through leakage and lost production which results in significant cost savings. Reliable and Repeatable Long Term Shutoff Eliminates Leakage. Designed with a hard seating surface, DRAG velocity control and actuator sized to 500 PLI, the trim maintains a tight shutoff. Improve Temperature Control. Equal-percentage trim characteristic to meet your plant specifications combined with a long stroke and high actuator resolution to improve control. Reduce Maintenance Costs. Costly and frequent maintenance procedures are eliminated by DRAG velocity control, actuator sizing and seat ring design. Erosion is eliminated. Easy to Service Design. Top entry design minimizes service time, and no welding or inline machining required.

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DRAG
Quality Specifications:

100DSV

Valve Specifications:
Body Configuration Pressure Rating Max. Inlet Temperature Flow Direction Rangeability Shut-Off Class Actuator Failure Mode Manual Override I/P Transducer Position Transmitter Limit Switch Globe or Angle ASME 2500 500 F (260 C) Over-the-Plug (Flow-to-Close) 100:1 ANSI/FCI 70.2 Class V Spring Diaphragm Positioner (3-15 psig) & Filter Regulator Fail Close (standard) Fail Open (optional) Optional Integral (4-20 mA) Integral (4-20 mA) Optional (DPDT)

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DRAG
Trim Specifications:
Trim 3/8 (10mm) Btm Labs 0.01 3.3% 0.01 3.3% 0.03 3.3% 0.03 3.3% 0.03 3.3% 0.03 3.3% 0.06 3.3% 0.06 3.3% 0.06 3.3% 0.06 3.3% 0.06 3.3% 0.22 2% 0.22 2% 0.22 2% 0.22 2% 0.22 2% Top Labs 0.02 19% 0.02 19% 0.06 19% 0.06 19% 0.06 19% 0.06 19% 0.12 19% 0.12 19% 0.12 19% 0.12 19% 0.12 19% 0.37 12% 0.37 12% 0.37 12% 0.37 12% 0.37 12% 1st Disk 0.03 24% 0.03 24% 0.09 24% 0.09 24% 0.09 24% 0.11 24% 0.21 24% 0.21 24% 0.27 24% 0.27 24% 0.27 24% 0.54 17% 0.54 17% 0.54 17% 0.71 17% 0.71 17%

100DSV
Cv Max Cv Max Globe Angle 0.74 1.06 1.7 2.2 2.7 3.6 3.0 4.6 6.0 7.8 9.9 8.0 10.4 13.3 17.4 23.1 0.77 1.15 1.7 2.3 2.9 4.1 3.0 4.7 6.3 8.4 11.5 8.1 10.7 14.0 18.9 27.0

5/8 (16mm)

1 (25mm)

1.5 (38mm)

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DRAG
Materials:

100DSV

Component Body Bonnet Seat Ring Spindle Disk Stack Balance Seal Stem Packing Gasket

Item No. 1 2 3 4 5 6 7 8

Material Of Construction A216WCB/WCC A105 316SS 410 Heat Treat 410 Heat Treat Glass Filled Teflon Glass Filled Teflon Flexitallic (Graphite/Stainless Steel)

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DRAG
Standard Dimensions:

100DSV

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DRAG
CHOKE VALVE
Type: 100D Choke

100D

Sizing Tool: Valsiz Design Loc: CCI-RSM CCI-Vienna

Application:
Choke valves are almost always angle valves. Are used to control wellhead fluids or process fluids. Higher wellhead pressures due to deeper, more difficult to produce wells. Higher pressure gas wells, much higher velocities through choke trim. Increased sand production.

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

The DRAG valve concept:

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DRAG

100D

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

Features:

Solid Tungsten Carbide Disk Stack Bolted Bonnet. Easy maintenance. Pressure Balancing Seals. Reduces actuator/handwheel force. Provided with dual scrapers to keep solids out of sealing areas. Solid Tungsten Carbide Plug. Solid tungsten carbide eliminates galling. Excellent erosion resistance. Large balance holes will not clog. Solid Tungsten Carbide Disk Stack. Solid tungsten carbide for erosion resistance. Multi-step letdown to control velocity, erosion and noise. Large flow passages, easily handle solids and dirty fluids. Solid Tungsten Carbide Venturi Seat. Tungsten carbide venturi seat in high turbulence zones. Venturi seat transition flows smoothly into valve outlet and piping. Optional Stellite Insert. Extra erosion resistance.

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DRAG
Valve Specifications:
Body Configuration Pressure Rating Max. Inlet Temperature Flow Direction Shut-Off Class Actuator Failure Mode Manual Override Positioner I/P Transducer Position Transmitter Limit Switch

100D

Angle ASME 2500 API 10000 -40 to 250 F (-40 to 120 C) Over-the-Plug (Flow-to-Close) ANSI/FCI 70.2 Class IV Pneumatic Actuator Fail Close (standard) Optional Standard or Smart Integral (4-20 mA) Integral (4-20 mA) Optional (DPDT)

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DRAG

100D

Materials:
No. 1 2 3 4 5 6 7 Description Body Bonnet Disk Stack Seat Plug Stem Insert (Optional) Standard AISI 4130 AISI 4130 Tungsten Carbide Tungsten Carbide Tungsten Carbide INC 718 Stellite 6 Optional All ASME, API materials All ASME, API materials ---17-4PH, Duplex, INC625 --

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AB Japan
Type: Sizing Tool: Design Loc: CCI-KK VO600

VO600

The VO600 type desuperheater (DSH) puts innovation cooling method into practice, thus it can fully satisfy your demand of strict temperature control of steam. The VO600 is capable of functioning with inlet flow velocities as low as 3m/sec, thus ensuring efficient performance at high turn-downs. It can stabilize superheated steam at a distance of only 6m from the outlet. This is because of the structure of the VO600 which permits very thorough mixing of the steam and cooling water in the upper chamber of the body. Further, the structure is highly simplified since there are no spray nozzles.

Principle of Operation:
When there is no steam flow, the flow-plug sits on the plug seat, thus automatically shutting the orifice. During operation, the flow-plug is pushed up to a height that is selfdetermined by its weight and steam flow. The flow-plug changes its position corresponding to the flow rate, but the pressure drop is usually to an extent of 0.034MPa. The cooling water enters the lower chamber when the pressure drop reaches its maximum. Since the plug is supported in the center of the orifice because of the balancing spring, the steam flows uniformly around the plug

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AB Japan

VO600

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

Features:
Easy Maintenance. The VO600 is divided into two pressure boundary sections and flanged together. The main body is easily removed for installation and inspection. Limited moving components. The moving portion of the VO600 is limited to the flow plug and its balancing spring. Less moving parts mean longer lasting trim components. Maintains Fixed Pressure Drop. The streamlined flow plug is constantly exposed to high speed steam flow, and due to its own weight and the balancing action of the spring, it maintains a fixed pressure drop regardless of the steam load.

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AB Japan

VO600

Quality Specifications:

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AB Japan

VO600

Valve Specifications:
Body Configuration Pressure Rating Max. Inlet Temperature End Connection Flow Direction Pressure Loss Rangeability Temperature Control Superheated Steam Temperature Inline, Vertical JIS, ASME 150-2500 < 1100 F (600 C) JIS, ANSI, JPI Flanges Under-the-Plug (Flow-to-Open) 0.034 MPa Control is possible up to a minimum inlet flow velocity of 3 m/sec. Maintains desuperheater steam at 3 deg C. Saturated temperature +6 deg C or higher Measurable up to 6 m from outlet side

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AB Japan

VO600

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Description Housing Manifold Pipe Manifold Flg Plug Seat Gauge Set Distr. Plate Seal Packing Cap Screw Screw Lock Flow Plug Spring Wear Button Gasket Mix Chamber Plug Stop Stat Bolt Nut Name Plate

Material Of Construction SCPH2 A216 WCB STPT370 STPT370 ASTM A105 ASTM A105 SCPH2 A216 WCB SS 400 SS 400 Non Asbestos Non Asbestos SNB7 SNB7 SUS304 SUS304 SCPH21 SCPH21 A638.660 A638.660 SUS420J2 SUS420J2 Non-Asbestos Non-Asbestos SCPH2 A216 WCB SB410 SB410 SNB7 SNB7 S45C S45C SUS304 SUS304

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AB Japan

VO600

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AB Japan

VO600

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DRAG

Anti-surge valve

Compressor recycle anti-surge valve


Type : Compressor recycle anti-surge valve Sizing Tool: Valsiz Design Loc: CCI-RSM CCI-Vienna

Application:
Surge is a powerful disturbance that can disrupt or trip a process. It can damage equipment, and in catastrophic incidents, may result in the complete destruction of the compressor rotor. Because the consequences of surge are too costly to ignore, surge protection is necessary for all turbo compressors. The valve capacity must be large enough to prevent surge under all possible operating conditions including start-up and shut down without being oversized. An excessively large valve will provide poor control precision and will drive the compressor into choked flow when fully open. The CCI anti-surge valve design maximizes control while providing reliable and safe protection from compressor surge

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

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DRAG

Anti-surge valve

Customized DRAG Technology and Actuation systems: CCI custom-designed DRAG trim is ideally suited to minimize noise while providing the capacity and control that is necessary in anti-surge and compressor recycle application. For these applications, the multi-stage DRAG disk stack is in the lower portion of the trim to provide control and maximize noise attenuation. Slotted or drilledhole-cage trim can be provided in the upper portion of the stack to provide additional capacity for when compressor bypass is required in addition to anti-surge.

Features:
Accurate control and Reliable Operation For anti-surge and recycle applications, CCIs fast acting pneumatic actuation system can deliver stroke speeds of less than one second while maintaining precise resolution and control. This solution with combine established trim and actuation designs to provide optimal performance and continued valve longevity.

Valve position v/s Time opening

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DRAG

Anti-surge valve

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

DRAG disk stack with multi-stage tortuous path in the lower portion and slotted cage in the upper portion DRAG disk stack in the lower portion of the trim provides controlled flow and maximizes noise attenuation and the Drilled hole cage trim in the upper portion provides additional capacity.

Quality specifications:

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DRAG

Anti-surge valve

Valve Applications in compressor recycle service:


Application Differential Pressure Temperature Inlet/Outlet

Gas production Separation 300-3000 psi 2.1-21 Mpa Reinjection Gas Hydrogen Natural gas Ammonia 3000 psi 21 Mpa 70-300 psi 0.48-2.1 Mpa 100-150 psi 0.69-1 Mpa 50-100 psi 0.34-0.69 Mpa 50-700 psi 0.34-4.8 Mpa 80-400 psi 0.55-2.7 Mpa 150-700 psi 1-4.8 Mpa 300-500 psi 2.1-3.4 Mpa 50-150 psi

100-200F 37-93C 100-150F 37-65C 100-130F 37-54C 100-120F 37-93C 100-200F 37-93C 100-200F 37-93C -94-248F -70-120C -49-212F -45-100C 100-120F 37-49C 50-150F

4-12/6-16 100-300 mm/ 150-400 mm 4-8/6-8 100-200 mm/ 150-200 mm 6-12/8-14 150-300 mm/ 200-355mm 8-24/10-30 200-600 mm/ 255-760 mm 4-8/6-12 100-200 mm/ 150-300 mm 4-16/6-24 100-400 mm/ 150-600 mm 8-24/10-24 200-600 mm/ 25-600 mm 12-24/18-32 300-600 mm/ 450-800 mm 4-8/6-10 100-200 mm/ 150-250 mm 6-16/8-16

Air LNG Propane Material refrigerant Olefins Syngas

Propane

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DRAG
0.34-1 Mpa Ethylene Multicompo nent 100-500 psi 0.69-3.4 Mpa 50-300 psi 0.34-2.1 Mpa

Anti-surge valve
10-65C 20-50F -6-10C 100-150F 37-65C 150-400 mm/ 200-400 mm 4-16/6-10 150-200 mm/ 200-300 mm 6-8/8-12 150-200 mm/ 200-300 mm

Valve Specifications:

Trim Specifications:

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DRAG

Anti-surge valve

Materials:
No. 1 2 3 4 5 6 7 Description Body Bonnet Disk Stack Seat Ring Plug Stem Balance Seal Standard A105/WCB A105 316 SS 316 SS 316 SS 17-4 PH Teflon Optional A182-F316 A182-F316 316 SS 316 SS/Stellite 316 SS 17-4PH Teflon

Standard dimensions:

54

DRAG

100DR

Boiler feed pump recirculation valve


Type: 100DR Sizing Tools: Valve Size Design Location: Application:
Boiler Feedwater pump recirculation valves are used to provide the minimum flow required for the protection of the boiler feed pump. They reduce water pressure from high pressure to deareator or condenser pressure and maintain tight shut off for long period of time. They may operate as on/off valve or modulate automatically.

Description:
The 100DR is available in angle and globe configuration and in six trim sizes (1.5, 2, 2.5, 3, 3.5 and 4). It is designed for up to ASME 2500 rating. The trim is an equal-percentage, over the plug flow disk stack design. The standard is a spring fail-open diaphragm actuator

Features: Performance
Improves plant performance, feed pumps operate without efficiency losses from valve leakage.

55

DRAG
Reduces system cost

100DR

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

Stops costly Maintenance Cycles


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

Valve Specifications:

56

DRAG
Trim Specifications:

100DR

Material:

Standard Dimensions:

57

DRAG

100DR

58

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

800D

Velocity control prevents cavitation and erosion damage. High shut-off capability Class IV, class V & Class VI with soft seat. Standard design allows fast turnaround of orders while maintaining CCIs multistage trim to meet individual operating conditions.

Quality Specifications:

59

DRAG

800D

Valve Specifications:

Trim Specifications:

Material:

Standard Dimensions:

60

DRAG

800D

61

DRAG
Type
: 100 DLC.

100DLC

BOILER FEEDWATER CONTROL VALVE


Sizing Tool: Valsiz Design Loc: CCI-RSM
CCI-Vienna

Application:
Boiler Feedwater Control Valve has a critical application in power plant operations. It regulates the feedwater level within required limits in a boiler drum. CCIs Feedwater Control Valve is suitable to achieve a smooth startup and maintain required drum level for safe, reliable and efficient plant operation. Other Severe service applications for CCI DRAG 100DLC Drum Level Control of conventional fossil fired plants (combined and start-up). Start-up Feedwater Regulator valve on large sub critical and supercritical Boilers. Boiler Circulation valves used on supercritical once-through boilers to maintain minimum flow through the boilers.

Description:
Boiler level control is a crucial factor in a power plant. If the boiler level is too high or too low, the plant may be forced to trip. Most of the plants use two valves for this application, a main feed water regulator and a start-up feed water regulator. The main valve is designed to flow 100% of the Maximum Continuous Rated (MCR) boiler flow with a pressure drop

62

DRAG

100DLC

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

63

DRAG

100DLC

Comparison between Two valve Combined DRAG Control Valve

configuration

and

Features: Eliminate Cavitation and Erosion with DRAG Combined solution


The DRAG trim forces the flow to travel to through paths of turns. Each turn causes a pressure loss to the fluid so the pressure gradually reduces over the turns without falling below the vapour pressure and so avoids cavitation. Also, it eliminates problems with trim erosion by limiting the trims fluid exit velocities and corresponding kinetic energy.

64

DRAG
Reliable long-term shutoff:

100DLC

The DRAG control valve uses hard seat, which resists cutting, and a very high seat loading to provide reliable and repeatable long-term shutoff for very high pressure differentials. The DRAG velocity control trim design owing to control of velocity and high seat force for shut-off protects the seat ring and plug surfaces from cutting or pitting due to the erosion.

Reduced Capital and Maintenance costs:


By eliminating one valve from the system, associated hardware is eliminated, providing cost savings in the system purchased. Also, with two valve solution there is a potential risk of transferring from the start-up to the main valve too soon. This exposes the main valve to the differential pressures it is not designed for, causing costly damage and contributing significantly to maintenance costs. .

Quality specifications:

Valve Specifications:

65

DRAG

100DLC

Trim Specifications:

66

DRAG

100DLC

Standard dimensions:

67

DRAG
: 100DPC

100DPC

Wellhead Production Choke Valve


Type Sizing Tool: Valsiz Design Loc: CCI- Vienna

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

Principle of Operation:
.

Features:

68

DRAG

100DPC

69

DRAG
Quality Specifications:

100DPC

Valve Specifications:

Material:

Standard Dimensions:

70

DRAG

100DPC

71

KOREA

840G/H

CONVENTIONAL VALVES
Type : 840 G/H.

Sizing Tool: Valsiz. Design Loc: CCI- Korea.

Applications: 840G
The 840 G cage-guided valve is used to control a wide variety of relatively clean liquids and gases at high pressure differentials configured with either flow-toopen or flow-to-close trim. The valve is well suited for steam, gas or liquids, where flow-to-close is typically used for liquid service and flow-to-open for steam and gas.

840H
The design of 840H (drilled-hole-cage) valve is primarily used for severe service applications requiring anti-cavitation or low-noise trim. In most cases, high pressure drop process conditions may cause erosion, noise or vibration, which can affect process control. The 840H is a good solution to this severe service. The valve is well suited for steam, gas or liquids, where flow-to-close is typically used for liquid service and flow-to-open for steam and gas.

72

KOREA
Description:

840G/H

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

Cage-guided design, Balanced Trim, Metal/Soft Seat

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

73

KOREA

840G/H

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

840H Drilled-Holed-Cage trim

74

KOREA
Features: Tight shutoff:

840G/H

A Variety of shutoff classes from ANSI IV through VI are available to meet application requirements.

Sour gas/Corrosive fluid capable:


The wide choice of body and trim materials allows these valves to be applied to corrosive/sour gas services with full compliance to NACE requirements.

Simple to change capacity and characteristics:


A simple cage change is all that is required to change between reduced and full-sized capacity trims or between linear and equal percentage characteristics.

Easy maintenance:
Top-entry design and a cage-retained seat ring allow for quick inspection or trim change. No internal components are screwed or welded into the valve body or bonnet.

Quality Specifications:
All Series 840 Valves meet the ANSI B16.34 standard for Valves~Flanged, Threaded and Butt~welding End. This encompasses the dimensions, construction, testing and rating of all valves supplied. CCI also performs ANSI standard seat leakage and hydrostatic tests on every valve we build, and operability tests are run on each valve and actuator leaving our factory. Special tests are readily available to meet the specific project needs, including non-destructive testing of valve components and performance testing of actuator controls.

75

KOREA
Valve Specifications:
Body Configuration Valve Size Ratings End Connections Flow Characterization Seat Leakage Trim

840G/H

Globe(casting, forging) under/over flow, RF, BW, SW, RTJ 1 through 20 ANSI Class 150-2500(DIN and JIS available) Raised Face Flange, Weld Ends (BW and SW ) Linear or equal percentage Standard ANSI Class IV, Option-ANSI Class V or VI Quick Change Trim (Single Port, WindowCage, Drilled-Hole-Cage)

Temperature Range series 840 valves


Valve Trim ~ 4 ANSI Class #150 through #900 #150 through #2500 #150 through #600 #150 through #2500 Seat Type Soft Bonnet Type Standard Extended -30C ~ -196C ~ 230C 230C -30C ~ 300C -30C ~ 230C -30C ~ 300C -196C ~ 565C -196C ~ 230C -196C ~ 565C Seat Leakage VI

Metal Soft

IV, V VI

6 ~ 20

Metal

IV, V

76

KOREA
Material:

840G/H

Contoured Plug 840G Type

Drilled Holed Cage 840H Type

77

KOREA
NO. PART NAME Body Bonnet

840G/H
MATERIAL 260 ~ 425 C 425 ~ 565 C A 105 WCB A 216 WCB A 351 CF8M A 217 WC6 A 217 WC9 A217 C 12 A A 182 F11 A 182 F22 A 182 F11(5) Inconel 718 A 182 F11(5) A 182 F11(6) 316 SS Graphite 316 SS TFE(Filler) & SS Or Graphite(Fille r) SS Graphite

1 2

-26 ~ 260 C A 105 WCB A 216 WCB A 351 CF8M 410 SS 410 SS 410 SS 316 SS 410 SS

3 4 5 6 7 8 9 10 11

Plug Stem Seat Cage Packing Gland Balance Seal Packing Spacer Body/Bonnet Gasket Seat Gasket

410 SS 410 SS 410 SS 410 SS 316 SS

Teflon 316 SS TFE(Filler) & SS Or Graphite(Fil ler) SS Teflon

Graphite 316 SS TFE(Filler) & SS Or Graphite(Fille r) SS Graphite

12

Packing Set

Standard Dimensions:

78

KOREA
830T THREE WAY VALVE Type : 830 T.

830T

Sizing Tool: Valsiz. Design Loc: CCI- Korea.

Applications:
The series 830T three-way valve is designed for diverting service or mixing service applications. A diverting service valves takes common stream and splits it into two outlet ports. A mixing service valve combines two fluid streams and discharges the mixed fluid to a common outlet port.

Description:
The 830T three-way valve actually performs the function of two opposite acting standard two-way valves. So the use of one valve instead of two is very economical. Various trim types and end connections of the 830T valves gives the design flexibility that can satisfy the system requirements. The 830T valve is available in size ~ 10 and ANSI 150 and 300 classes. The M-type configuration features an unbalanced plug for simple maintenance and economical installation. The large size valves are often used with motor operators. Designed with two side and one bottom pipeline connections. The B-type configuration features a balanced plug design, to minimize the actuator forces and provide stable control in large valve sizes, with pneumatic actuators. The quick change trim with the plug accessible from the bonnet

79

KOREA

830T

allows for easy maintenance. Designed with two side and one bottom pipeline connections. The U-type configuration features an unbalanced plug with a Top-Entry Quick Change Trim. Designed with three side pipeline connections, the design simplifies piping installation.

Features: Durability:
Rugged structure and smooth operation. Guarantee a long maintenance-free service valves.

High Capacity:
Broad and streamlined fluid passage can pass later amount of fluid than other three-way valves.

Stable Operation:
Port and top guiding or cage guiding makes the operation of the plug stable regardless of plug travel. .

Flexibility:
Various body and trim types provide design versatility for your needs.

Quality Specifications:
All Series 830T Valves meet the ANSI B16.34 standard for Valves~Flanged, Threaded and Butt~welding End. This encompasses the dimensions, construction, testing and rating of all valves supplied. CCI also performs ANSI standard seat leakage and hydrostatic tests on every valve we build, and operability tests are run on each valve and actuator

80

KOREA

830T

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

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

81

KOREA
Matrix of Standard Material
Temp. Range Liquid, Steam, Gas -26~260 (Non-corrosive) Fluid Valve Type

830T

3 Way valve

Item
1. Body 2. Bonnet 3. Bonnet studs 4. Bonnet nuts 5. Seat (Hard) 6. Plug 7. Cage 8. Stem 9. Balance Cylinder 10. Packing 11. Bottom Flange 12. Bal. Seal

Material
A216 WCB / A351 CF8M A193-B7 / A193-B8M A194-2H / A194-8M 316SS A351 CF8M or 316SS 316SS Teflon A216 WCB / A351 CF8M O-Ring

Standard Dimensions:

82

KOREA
Type: Sizing Tools: 840/860 TBS Valve Size

840/860 TBS

Design Location: CCI Korea Manufacuturing : CCI Korea

Application:
This valve is also referred as Low Low Pressure Valve or LLP valve. The LLP by CCI is the leading low pressure turbine bypass valve for combined cycle and process steam plants. Featuring an integrated spring-loaded spraywater nozzle desuperheating manifold at the valve outlet, the The LLP minimizes the downstream desuperheating distance, making it extremely compact for all types of low pressure steam conditioning applications including advanced turbine bypass to condenser applications with short pipe runs.

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

83

KOREA

840/860 TBS

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

Features:
Pressurized seat Trim design to achieve repeatable Class V shutoff in service and improved plant efficiency through elimination of lost steam. High-performance, reliable, fast stroking pneumatic or hydraulic actuation with many years of documented service. Accurate control and resolution to less than one second stroke time with pneumatics. Small drilled holed cage design reduces noise levels to below 85 dBA. Low maintenance costs with quick change trim, No trim parts are welded or screwed into the body. Lightweight, compact and flexible in design, easily fits into most existing piping arrangements in both globe and angle configurations.

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

84

KOREA
Valve Specifications:
Trim Size Max Capacity (Cv) Angle Config Globe Config Valve Characterization Steam Valve Rangeability Desuperheater Shutoff Class Actuator Type and Model Number Fail Mode Stroke Time Low Noise Cage Open Port Cage Low Noise Cage Open Port Cage

840/860 TBS

8 640 1030 590 840

10 830 1410 775 1200

Design Pressure Temperature

Linear, Equal % or Modified Equal % Up to 30:1 50:1 ANSI/FCI Class V is Standard Spring diaphragm actuator size 500 Closed Less than 10 sec, modulating mode Less than 2 sec, trip[ mode standard Less than 1 sec, trip mode optional 29 bar/425 C

Trim Specifications:

85

KOREA
Material:

840/860 TBS

Item no. 1 2 3 4 5 6 7

Component

Body Bonnet Cage Main plug Pilot plug Stem Seat ring

Materials of construction A216-WCB A216-WCB 400 Series Stainless Steel 400 Series Stainless Steel 400 Series Stainless Steel 400 Series Stainless Steel 300 Series Stainless Steel

Standard Dimensions:

86

KOREA

840/860 TBS

87

KOREA

840/860 TBS

88

FLUID KINETICS
Type: Sizing Tools: Desuperheater Optimize rev G.2

DAM

Design Location: Ventura, California Manufacuturing : Winfield, Kansas

Application:
Main steam attemperation is the process whereby subcooled water is injected into superheated steam along the plant main steam line for the purposes of temperature control. It is typical in both combined cycle and combined heat power plants.

Description:
Main steam attemperation consists of a Spring Loaded Water Nozzle(SLSN), spray water enters the nozzle assembly at a pressure greater than the downstream steam, compresses a helical spring which opens the nozzle. As the pressure drop across the nozzle increases, the spring os further compressed and the flow rate of spray water through the nozzle increases. SLSNs are pre-set woth a given loaf on the helical spring. In this configuration, the nozzle will not open until a predetermined pressure drop, designed the cracking pressure, is achieved across the nozzle.

Features:
Spray nozzles, connected by a common manifold are mounted circumferentially around a cross steam flow, are the primary components of DAM style desuperheater. The DAM desuperheater can have three basic configurations: DAM, DAM-D and DAM-E.

89

FLUID KINETICS
DAM Style Desuperheater

DAM

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

(DAM Style Desuperheater)

DAM-D Style Desuperheater


The DAM-D desuperheater differs from the DAM in that it includes a Pressure Reducing (or PR) device immediately upstream of the spray injection point. The PR device pressure serves the following functions: Improves spray water mixing by generating a low pressure zone at the center of the steam flow, drawing a portion of the injected water into the center of the flow. Generates backpressure to reduce the upstream steam velocity. Breaks up the high velocity jet flowing through the seat bore into multiple small jets. Reduces the noise associated with expansion at the outlet of an upstream control valve.

90

FLUID KINETICS

DAM

(DAM-D Style Desuperheater)

DAM-E Style Desuperheater


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

(DAM-E Style Desuperheater)

91

FLUID KINETICS
Quality Specifications:

DAM

As a standard practice, the design code ASME Section I shall be used for the high temperature steam pressure boundary parts. Design code ASME B31.1 (or EN 13480) for the water piping arrangement. Maximum pressure class of Standard Manifolds is ASME 1500#. However in special cases it is ASME 2500#. Thermal stress cycle analysis shall be as per EN 12952.

92

FLUID KINETICS
Material:

DAM

93

FLUID KINETICS
Standard Dimensions:

DAM

94

FLUID KINETICS

DAM

95

FLUID KINETICS
Type: Sizing Tools: Design Location: Manufacuturing :

SILENCERS

Blow Off Silencer Optimize rev G.2 Ventura, California Winfield, Kansas

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

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

96

FLUID KINETICS
Features: Superior acoustic pack

SILENCERS

Long loomed glass fiber is used for operating upto 1000F. This premium material is selected for its superior acoustic absorptivity, chemical resistance and ability to withstand high grazing velocity without fiber loss and is spooled into the cores, rather than filled from one end. This assures predictable performance by eliminating the risk of voids and varying fill density.

Expansion chamber
Expansion chamber acts as a transition zone from the high velocity of the diffuser orifice to the reduced velocity appropriate for flow through the acoustic core. Constrains noise generated at the diffuser as well as that created by expansion turbulence. Additional resistance to direct noise radiation through the silencer walls.

Diffuser
Reduces noise effectively while providing a distributed expansion pattern for the flow into the expansion chamber. Shifts the frequency of the unsilenced noise into higher active bands where the acoustic pack material functions most effectively.

Quality Specifications:

Standard Dimensions:

97

FLUID KINETICS
Type: Sizing Tools: Design Location: Manufacuturing :

SILENCERS

Control Valve Silencer Optimize rev G.2 Ventura, California Winfield, Kansas

Application:
For stringent silencing requirements Fluid Kinetics has designed a Control Valve Silencer which includes a high performance diffuser and an absorptive section. This combination silencer is capable of providing fluid-borne noise reduction up to 50 dB.

Description:
Each CVS silencer is custom engineered for the particular installation. The diffuser drilling pattern is selected to provide a reshaped noise spectrum and optimum back pressure for the valve. The packed section is designed so that slot width and length can be varied to provide the correct attenuation of the diffuser noise spectrum.

98

FLUID KINETICS
Features: Custom Acoustic Performance:

SILENCERS

The optimal combination of process conditions, performance requirements, slot width and packed length is used for each application to provide the required noise reduction.

Custom Flow Performance Design: The diffuser and packed section are designed to provide the exact amount of pressure drop required for each application. For high pressure and high noise application the diffusers can be designed to efficiently share pressure drop with the control valve. For low pressure drop requirements the silencers can be designed to minimize pressure loss. Triple Layer Pack Protection:
The long strand glass fiber acoustic packing material is protected by heavy gauge perforated facing, a layer of fiberglass cloth and a stainless steel screen. This triple protection prevents loss of packing into the gas stream.

Annular Core Construction:


The packed section consists of a series of annular cores with the long strand fiberglass spooled into place and anchored in a place by the packing support studs. This construction guarantees packing density and prevents shifting of packing.

Quality Specifications:

Standard Dimensions:

99

FLUID KINETICS

SILENCERS

Type: Gas Diffuser Silencer Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas

Application:
High pressure drop across a valve creates excessive noise and deterioration of valve components. The function of the Fluid Kinetics Gas Diffuser Silencer is to share pressure drop with the valve, thereby substantially reducing this noise and wear. BOS silencer used at Safety relief valve Start-up valve Blow down valve Compressor station Blow-down

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

Features:
Can be used in conjunction with any manufacturer's valve Creates a quieter noise environment Reduces requirements for expensive valve trim

100

FLUID KINETICS
Quality Specifications:

SILENCERS

Standard Dimensions:

101

FLUID KINETICS
Type: Sizing Tools: Design Location: Manufacuturing :

SILENCERS

Compressor Silencer Optimize rev G.2 Ventura, California Winfield, Kansas

Application:
The Fluid Kinetics Model CIS Compressor Silencer is an absorptive type silencer designed for the short acoustic wave lengths produced by centrifugal and axial compressors. CIS is used to silence the inlet or outlet of high speed dynamic compressors handling gas at any pressure.

Description:
The CIS internal configuration consists of a series of packed annular cores spaced in accordance with the needs of the application. The packing consists of long strand glass fiber which would onto the annular cores, providing a continuous blanket effect. Support studs are welded to the facing at regular intervals to act as anchor points for the packing. Layers of fiber glass cloth and stainless steel screen are applied and enclosed with a heavy perforated metal facing. The triple protection assures against loss of packing into the gas stream.

102

FLUID KINETICS

SILENCERS

Features:
Provides 20 to 40 dB attenuation Heavy, perforated metal facing

Custom Engineered Packing:


Sound is absorbed by viscous drag in the interstices of the glass fiber packing. It is important to match the packing resistance which creates this drag to the characteristic resistance of the gas handled at its operating condition. To adjust the pack resistance, Fluid Kinetics changes packing density, thickness and fiber diameter.

Custom Engineered Slot Width:


A high speed dynamic compressor produces a certain noise signature. The silencer must be engineered specifically to handle this frequency spectrum. In the Fluid Kinetics design, the silencer slot width or distance between the annular packed sections is adjusted for each application.

103

FLUID KINETICS
Quality Specifications:

SILENCERS

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

Standard Dimensions:

104

FLUID KINETICS
Type:

SILENCERS

Reactive Silencer/ I/C Engine Diffuser Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas

Application:
The Model RCS silencer provides high performance flow path pulsation and noise control for compressors or blowers running at constant RPM. The RCS silencer is well suited for use with lobe type blowers and positive displacement compressors that produce high amplitude, low frequency pulsations in critical environments with stringent noise control requirements.

Description:
The process flow stream enters the silencer through the silencer inlet connection at a tangential orientation to the vessel shell. As the flow stream follows a swirling path along the inside diameter of the vessel, any water that may be entrained in the flow stream is separated by centrifugal force and falls to the bottom of the vessel where it can be piped away to a drainage location The RCS silencer design utilizes a tuned series of reflective internal discontinuities to filter undesirable pressure pulsations from the flow stream. In the most stringent noise requirements, final stage absorptive technology can be applied for further treatment of broadband noise generated by rotating equipment. For blowers that use a liquid injection sealing/cooling system, the RCS silencer can be designed with optional water and mist separating capability. .

105

FLUID KINETICS
Features:

SILENCERS

The heaviest construction in the industry, designed to eliminate vibration and/or acoustic fatigue failures Multiple reactive chambers, computer tuned to reduce pulsations a minimum of 95 percent at the blower fundamental frequency Special reactive design providing effective pulsation control over the first three harmonics (multiples) of the fundamental frequency Pressure drop reducing features to insure maximum performance with minimum blower efficiency impact Absorptive discharge module with multiple stages to attenuate residual broadband noise Computer assisted custom designs to match the silencer design to the project/site requirement.

Quality Specifications:

Standard Dimensions:

106

FLUID KINETICS

SILENCERS

Type: Hydraulic Acoustic Filter Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas

Application:
The Fluid Kinetics Hydraulic Acoustic Filter is designed to reduce by 15 to 20 dB noise and pulsation emanating from high speed hydraulic pumps. It is designed to block fluid-borne noise and pulsation from entering the connected piping. To prevent noise radiation from the pump and motor casing, a commercially available acoustic shroud should be used. This combination treatment is necessary only if there is a requirement to quiet the immediate environment of the hydraulic package. The Hydraulic Acoustic Filter effectively reduces all downstream piping noise.

Description:
The Hydraulic Acoustic Filter is of all carbon steel construction with no bladder to fill or replace. Working pressure up to 5000 psig are standard. Higher pressures and stainless steel materials are available upon request. The multichambered acoustic filter act analogously to an electrical filter network. It is designed to filter or attenuate the predominate frequency and significant harmonics of the pump. This reactive type of filter does not require resistance or pressure drop to function. However, since there is flow through the filter some pressure drop is imposed. Filter overall size is an inverse function of pressure drop. A computer simulation response curve allows Fluid Kinetics engineers to check the selected AFC performance for each application.

107

FLUID KINETICS
Features:

SILENCERS

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

Standard Dimensions:

108

FLUID KINETICS

SILENCERS

Type: Liquid Pulsation Dampener Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas

Application:
All power pumps produce pulsation. Whether or not the pulsation is severe enough to create problems depends upon many system variables. A few of these variables are the fluid handled, the type of pump and the pump speed. As a general guide, Fluid Kinetics engineers recommend using the Liquid Pulsation Dampener on any multi-plunger pump service having a discharge pressure over 500 psig, or on any service, regardless of pressure, whether pulsation problems are expected and a maintenance-free device is required The Fluid Kinetics Liquid Pulsation Dampener reduces discharge pressure pulsation by approximately 75%. Actual performance depends on the type of pump, connected piping system, and liquid handled.

Description:
The dampener is all steel construction, with no bladders to fill or replace, and virtually no temperature limitation. With nozzles beveled for weld, the unit becomes a part of the piping. Carbon steel construction is standard, but other materials are available Completely liquid filled, with no moving parts, this dampener does away with maintenance and gas charging requirements. The stationary internals guide the incoming flow into a rotating path within the spherical shell. The spinning liquid mass creates a system smoothing effect. Viscous drag on the

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SILENCERS

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

Features:
Reduces discharge pressure pulsation by approx. 75% Handles up to 6000 psi Maintenance free - permanently weld in pipeline, saving flange costs and potential flange leaks. Inline configuration eliminates special support problems Liquid filled - no moving parts All steel construction Virtually no temperature limitation

Quality Specifications:
.

Standard Dimensions:

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SILENCERS

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SILENCERS

Type: SSC Stabilizer/ Separator Sizing Tools: Optimize rev G.2 Design Location: Ventura, California Manufacuturing : Winfield, Kansas

Application:
The Fluid Kinetics Stabilizer/Separator is an inline device to eliminate Pulsation, Cavitation and entrained gas in power pump suction lines. It can be used in any system where: There is an NPSH problem. A gas-rich fluid is being handled. There is other evidence of suction cavitations (i.e., excessive vibration or excessive pump maintenance).

Description:
Flow enters and leaves the Stabilizer/Separator tangentially, forming a low-velocity vortex. This vortex and the increased path length created by the elevation difference between inlet and outlet stimulates the release of any entrained gas. The freed gas moves through the perforated center tube to the gas or air pocket maintained at the top of the unit. In highly corrosive service, the stabilizer can be supplied with non-corrodible internals and epoxy coating of wetted steel surfaces.

Features:
The Fluid Kinetics Stabilizer/Separator, close-coupled to the pump suction flange, provides three basic functions necessary for smooth, low-maintenance operation. Volume Effect - Acting as a mini-storage tank, the Stabilizer/Separator provides a full charge of liquid when

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the pump valves open. In systems with marginal available net positive suction head (NPSH), it prevents cavitations. Also, because of its location, it acoustically uncouples the pump from the line eliminating acceleration head consideration. Dampening Effect - The gas charge provides a capacitance or spring effect to absorb pulsation created by the abrupt flow change as the valves open and close. Separation Effect - Entrained gas or vapor is removed before it can enter the pump suction manifold where the sudden pressure changes can cause gas to break out of solution and create partial cavitation.

Quality Specifications:
. The Stabilizer/Separator is of welded steel construction. Standard models are rated 100 psig in accordance with ANSI B31.3 Code. Inlet and outlet connections are ANSI 150-lb raised face flanges sized to match the pump suction flange. ASME Code construction is available.

Standard Dimensions:

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Type: Sizing Tools: Design Location: Manufacuturing :

SILENCERS

Steam Vent Silencer Optimize rev G.2 Ventura, California Winfield, Kansas

Application:
FKs EVO silencer is used to reduce noise from a gas pipeline discharging directly into the atmosphere through a safety relief valve or a control valve. This noise is generally as a result of high turbulence inside the valve during pressure reduction. The primary release of this noise energy in a safety relief system is via the open stack exit. The EVO silencer is installed either within the stack or at the stack outlet to intercept this noise before it escapes into the environment.

Description:
Our EVO silencer makes use of the passive silencer design. There are two fundamental noise reduction principles involved in passive silencer design. Dissipative noise reduction: dissipative components made of sound absorbing material provide balanced noise reduction over a broad frequency range. Reactive noise reduction: reactive components using resonant reflections within tuned chambers and passages provide peak noise reduction in a more concentrated frequency band. In addition, the Fluid Kinetics EVO Silencer uses small size passage geometry for shifting frequency and eliminating any shock waves.

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HOW DOES IT WORK? As the gas enters the silencer, the inlet diffuser with an array of small diameter holes acts as a reflective barrier to the noise energy carried within the stream from the safety relief valves. A controlled combination of diffuser hole size and spacing are used to maximize the effectiveness of this barrier. The EVO Silencer uses a QUIETPAK to further break down the jets into smaller sizes thereby increasing the noise frequency and eliminating any potential for shock wave formation from pressure reduction at the inlet diffuser. The result as you can guess is a net decrease in system vent noise! Next, the silencer expansion chamber serves as a reactive volume within the flow path, to further reduce low frequency noise. The resulting expanded flow continues at a much reduced velocity through the annular passages of the acoustic core. Final treatment of the noise is achieved through the sound absorbing characteristics of the acoustic pack, combined with the resonant properties of the perforated facing material

Features:
These vent silencers are a combination of our field-proven, time-tested diffusers and our QUIETPAK. These EVO silencers provide dramatic improvements in acoustic performance and offer significant reductions in overall silencer height and weight. Furthermore the design incorporates minimal pressure drop to the system.

Quality Specifications: Standard Dimensions:

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POWER Boilers/HRSG Safety Relief Valve Silencers

SILENCERS

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

Control/Start-up Valve Silencer EVO ( Steam Vent / Gas blow down ) BOS ( Blow-off Silencer ) GDS ( Steam / Gas Diffuser Silencer ) Blow-down Valve Silencers BOS ( Blow-off Silencer ) HRSG Stack CTS ( Gas turbine / HRSG exhaust ) Engine Exhaust Silencers EES ( Combustion Engine Silencer )

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PETROCHEMICAL Safety Relief Valve Silencers

SILENCERS

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

Blow-down Valve Silencers BOS ( Blow-off Silencer ) EVO ( Steam Vent / Gas blow down ) HRSG Stack CTS ( Gas turbine / HRSG exhaust ) Engines EES ( Combustion Engine Silencer ) CTS ( Gas turbine / HRSG exhaust ) RCS ( Positive displacement Compressor / Blower Silencer ) Compressor Station Blow-down EVO ( Steam Vent / Gas blow down ) BOS ( Blow-off Silencer ) Compressor CIS ( Compressor Inline Silencer ) Liquid Pulsation Dampener PDS (Pulsation Dampener ) Hydraulic Acoustic Filter

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SILENCERS

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

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STI
Type: Sizing Tools: Design Location: Manufacuturing : SC Series Valsiz STI, Italy STI, Italy

ACTUATORS

Application & Description:


The SC actuators are available in eight different sizes, from diameter 63 mm to 420 mm, and are therefore able to satisfy small to high thrust requirements. Manufactured with fabricated steel cylinder (except for the sizes 63 and 100 which are made of corrosion resistant aluminum alloy), they are suitable for service in harsh environment such as desert areas, power stations, petrochemical plants and steel industries. Their light and functional design assures an easy installation. Furthermore, due to the built in lubrication system, typical of all STI actuators, they are virtually Maintenance free. SC actuators are integrated by a complete line of pneumatic and electro-pneumatic positioner and accessories to meet the most various service requirements.

Technical Data:
Thrust Standard Sizes Stroke Operating temperature Supply Pressure Standard Pressure 1400 to 68,000 N Diameter 63,100,125,160,200,260,330,420 mm 150 to 450 mm -20 to +80o C max1,000 kPa NPT F (1/2 NPT F for sizes 330 and 420)

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Quality Specifications: Standard Dimensions:


Actuator size mm 63 100 Stroke mm 150 200 150 200 250 300 150 200 250 300 200 250 300 200 300 300 400 400 450 Unit Weight Kg 4 4.5 8 9.5 11 12.5 13 14 15 16 24.5 25.5 27.5 27.5 32 45 55 155 278

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160 200 260 330 420

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STI
Materials:
Component Cylinder Cover Piston Shaft Tie rod and Clevis

ACTUATORS
Material Of Construction Aluminium alloy for 63 to 100 Carbon steel for 125 to 420 Aluminium alloy for 63 to 260 Carbon steel for 330 to 420 Aluminium alloy for 63 to 100 Carbon steel for 125 to 420 Chromium plated alloy steel. Tropicalized zinc-plated carbon steel.

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Type: Sizing Tools: Design Location: Manufacuturing : SC/V Series Valsiz STI, Italy STI, Italy

ACTUATORS

Application & Description:


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

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ACTUATORS

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

Features: Quality Specifications: Materials:


Part Cylinder Cover Piston Shaft Actuator Material Small-med thrust High thrust Aluminium alloy Carbon steel Aluminium alloy Carbon steel Aluminium alloy Carbon steel Stainless steel Stainless steel

Standard Dimensions: Technical data:


Specifications Thrust Standard Sizes Stroke Operating temperature Supply Pressure Supply Media Standard Connections Actuator Type Small-med thrust High thrust 880-4000 daN 2600-30000 daN 150, 200, 250, 300 260, 330, 420, 520, mm 600, 650, 800, 850 mm 40-150 mm 100-400 mm -26C to 80C -26C to 80C Max 1000 KPa Dry instrument air or Clean gas NPTF Max 1000 KPa Dry instrument air or Clean gas NPTF

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Type: CML/CMV Series Sizing Tools: Valsiz Design Location: STI, Italy Manufacuturing : STI, Italy

ACTUATORS

Application:
The increase of the unit capacity of modern power stations requires for the control of final elements (dampers, hydraulic converters, ect.) the use of high power actuators able to develop torque up to 20000 Nm (14,760 lb.ft). CMV actuators meet these requirements as they can guarantee properly sized actuators.

Actuator Selection:
The selection of the actuator is possible by referring to table (a) which shows the torque values referred to the supply pressure of 100 Psig and operating times (without load) relating to the positioner SA/CL-1 ND or ND . The torque values are referred to an operating angle of 70o which is the standard operating angle of the lever in the CMV series. This angle of 70 o is considered as the most suitable for an efficient control of dampers, butterfly valves and other final control elements. It is therefore recommendable, when performing the coupling to the final control device, not to amplify this angle. Only for ON-OFF actuators, it is suggested to use for the final control devices a larger operating angle corresponding to about 80/90o.

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Actuator type Min. torque (1) Angle 70 90 CMV1 125/250 CMV1 160/200 CMV1* 200/200 CMV2 160/300 CMV2 200/300 CMV2 260/300 CMV3 260/400 CMV3 330/400 CMV4 420/450 140daNm 99 1033lb.ft.727 185daNm 130 1363lb.ft.961 188daNm 132 1386lb.ft.976 277daNm 195 2045lb.ft.1443 438daNm309 3234lb.ft.2278 745daNm 525 5496lb.ft.3873 993daNm 700 7330lb.ft.5163 1627daNm1146 10206lb.ft.8454 3026daNm2113 40997lb.ft.2862 7

ACTUATORS
Max. torque (1) Operating time (2)with positioner 70 angle 90 SA/CL SA/CL1 1 171daNm 139 2.5 1265lb.ft.1030 226daNm 184 3 1668lb.ft.1360 230daNm 187 5.5 1699lb.ft.1380 340daNm 278 4.5 sec 2 sec 2510lb.ft 2040 537daNm 436 7 sec 3.5 sec 39625lb.ft.3221 913daNm 742 12 sec 6 sec 6736lb.ft.5476 1217daNm989 16 sec 8 sec 8983lb.ft.7302 1993daNm1620 27 sec 13 sec 14707lb.ft.1195 5 3695daNm2996 65 sec 27 sec 50061lb.ft.4059 0 Weight

Kg153 Lb337 Kg163 Lb359 Kg183 Lb403 Kg260 Lb574 Kg280 Lb618 Kg305 Lb673 Kg520 Lb1148 Kg620 Lb1363 Kg1600 Lb7100

Description: Features: Quality Specifications:

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Materials of Construction:
Bearing Frame Housing Shaft Lever Shaft Support Manual Control Screw Standard Connections Painting

ACTUATORS
Carbon steel Carbon steel Alloy steel 38 NiCrMo4 heat treated Carbon steel Bronze fro CMV2 and CMV3; Spherical joints for CMV1 and CMV4 Alloy steel 38 NiCrMo4 heat treated Brass fittings and copper tubing Epoxydic

Standard Dimensions:

Technical data:

Torque Sizes Angles Air supply Operating temperature Control Signal

100 to 34000 Nm 63 to 520 mm 90 for CML Series and 70 for CMV Series Dry instrument air 35/100 Psig -25 C to 80 C Standard 3 to 15 Psig

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STI
Type: Sizing Tools: Design Location: Manufacuturing : APL Series Valsiz STI, Italy STI, Italy

ACTUATORS

Application & Description:


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

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Features:

ACTUATORS

3 Sizes (APL 150/200/250) available in torque ratings from 490 to 3000 Nm Piston with permanent built-in-fabrication system Lever arm with regularly spaced holes for linkage flexibility Integrated positioner with custom-shaped control cam, force-balance type, insensitive to vibrations and supply air pressure variations Excellent response times without use of boosters Hand wheel manual control with enclosed gear elements, suitable also for stroke limitation.

Quality Specifications:

Materials of Construction:
Cover Sleeve and Piston Stem Lever Stand (Yoke) Tubes Fittings Lubrication Sealing Paint Aluminium alloy Aluminium alloy Stainless steel Carbon steel Aluminium alloy Copper Brass Mineral grease Buna N TM Epoxy

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Standard Dimensions: Technical data:
Torque Sizes Angles Supply Pressure Supply Air Temperature Connections

ACTUATORS

250 to 3000 Nm 150 to 250 mm 45 to 90 200 to 665 KPa Dried and oil-less air -25 C to 80 C NPTF

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Positioner DE/3M

POSITIONERS

DE/3M is a series of liner positioner purposely designed by STI to control small to medium size SC actuators and usable for strokes from 60 to 300mm. it can be supplied either with a pneumatic or an electro-pneumatic inlet signal. The positioner is normally provided with low flow spool valve bit a special suitable for high flow service is also available on option. The DE/3M assures am easy installation and maintenance like all STI positioners. Operating Principle: The operation of the DE/3M positioners is based on the force-balance principle. The force generated by an increase of the control electric signal to the Electro-Pneumatic converter (1) produces an increase of the signal pressure on the diaphragm (2) which stretches the feedback spring (3) and cause a displacement of the spool valve. (4) The increase of the air pressure in chamber A allows the actuator shaft and consequently the feedback spring (3) Connected through the rod (5) to extend. The actuator shaft reaches a stable position only when the spool valve (4) is in equilibrium; that means when the load on the feed back spring equals the force produced by the signal pressure on

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the

POSITIONERS
diaphragm.

Air Features: Air quality according to ISO 8573-1


Size and density of particulates Pressure dew point CLASS 2 CLASS 3 (min 20 K below ambient temperature) Oil Concentration CLASS 1

Positioner Data:
Inlet/outlet connections Signal Connection NPT F NPT F (1/2 NPT F for electric signal) Flow Capacity 18 Nm3/h

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Air Consumption Input Signal Air Supply Operating Temperature Storage Temperature Sensitivity Max. Deviation Air Lock Trip Range

POSITIONERS
0.4 Nm3/h 20 to 100 kPa / 3 to 15 Psi or 4 to 20 mA Max 700 kPa -20 to +70oC -40 to +80oC 0.2% of full range 1% (linearity + hysteresis) 150 to 500 kPa (special ranges available on request)

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POSITIONERS

SA/CL-1 Series Positioner:


Application:
SA/CL series are linear cam positioners suitable for application on actuators with stroke from 100 mm to 700 mm (longer strokes are available on request). It offer a wide range of solutions and are is usable for the most various applications. Two different sizes are available ( and connection), which may be supplied either with a pneumatic or an electro-pneumatic inlet signal, also a directly mounted an emergency lock up system may be available. A position transmitter directly connected to the positioner is available on option.

Operating Principle: Also the operation of the SA/CL-1 positioners is based on the force-balance principle but, in this case the mechanical feed back is obtained by a compression spring. The force generated by the signal pressure produced by the ElectroPneumatic converter on the diaphragm opposes the feed back spring and displaces the double acting spool valve enabling the actuator shaft to move. The shaft motion is transferred to the feedback spring through the cam and the square lever. The actuator shaft reaches a stable position only when the spool valve is in equilibrium that means when the force produced by the feedback spring.

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POSITIONERS

The action of the SA/CL-1 positioners is reversible. The action reversal can be made at site by turning the cam of 180 and rotating the change-over plate of 90o.

Positioner Data:
Positioner size Inlet/outlet connections Signal Connection Flow Capacity Air Consumption Input Signal Air Supply Operating Temperature Sensitivity Max. Deviation NPT F NPT F 26 Nm3/h 1 Nm3/h NPT F NPT F 62 Nm3/h 1.3 Nm3/h

(1/2 NPT F for electric signal)

(at balance with 400kPa Supply) 20 to 100 kPa / 3 to 15 Psi or 4 to 20 mA Max 700 kPa -20 to +70oC

Storage Temperature -40 to +80oC 0.15 % of full range 1.5 % (linearity + hysteresis) (special ranges available on request)

Air Lock Trip Range 150 to 500 kPa

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STI
Type: Sizing Tools: Design Location: Manufacuturing : SR/CCK Valsiz STI, Italy STI, Italy

POSITIONERS

Application:
The SR/CCK positioner is designed for the proportional operation of quarter turn rotary single or double acting actuators, to actuate butterfly, plug, ball valves etc. It is usually located in the control circuit between the regulator and the actuator of the final control element. It is a compact design positioner with a low cost for general purpose application.

Description:
A pneumatic diaphragm generating a force proportional to the pneumatic signal (20-100 kPa) sent by the regulator. A spring generating a force opposite to that of the diaphragm, the intensity of which depends upon the position of the actuator stem. A cam operated by a actuator producing the calculated relation between the position of the actuator stem and control signal. A 4-way spool valve feeding or exhausting the two chamber of the actuator. Its position depends upon the resultant of the forces operated by diaphragm and feed-back spring. The shifting of the diaphragm to the left is due to an increase in the signal pressure. Spool valve shifts and consequently more air is conveyed to the front of the stem. While its back side is exhausted. The stem moves to the right and compresses the spring through cam. The stem stops when the load of feed-back spring equals the force generated by the signal pressure of diaphragm.

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POSITIONERS

When this occurs, Spool valve returns to the balanced position. The position of the stem results from the control signal and from the cam characteristic law. A decrease in instrument air pressure reverses the sequence described and the stem shifts to the opposite direction. This operating principle applies also to single acting actuators. For this application you will close connection E or F on the positioner, because it will not be used. The cam can be shaped to produce a linear or logarithmic action between signal pressure and stem position. Connections between positioner and actuator can be set in advance so that to move the stem in one of the two actions (direct or reverse action) according to the increase of the signal pressure.

Features:
Amplification of the transmitted pneumatic signal to eliminate the functional or parasite drag of the final control element and increase its speed of response Determining the actuator position according to the linear or non-linear function of the control signal Checking the functional sequential different actuators using a single control signal. Linear feed back cam, 3-shapes, with split range Compact design Directly and axially coupled to the actuator stem. Direct or reverse action from positioner with no additional parts. No external springs, all operating completely enclosed. Convoyed discharge creates a slight purging pressure in the positioner box and protects it from dust, humidity and corroding gases. Stable positioning characteristics are provided for full range of actuators Usable for double-acting or single-acting service.

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Quality Specifications:

POSITIONERS

Materials of Construction: Part


Body Manifold Cover Cam Spool Valve Diaphragm

Material
Anodized Aluminium Alloy Aluminium Polycarbonate HostaformTM Stainless Steel Neoprene Rubber

Standard Dimensions:
Dry Instrument Air supply Supply Signal Output Signal Pressure gauge Operating temperature Storage temperature Air consumption Actuator times Capacity Sensitivity Accuracy Hysteresis Zero suppression Range adjustment 200 kPa to 665 kPa NPTF 1/8 NPTF 1/8 NPTF 1/8 NPTF -26 to +74C -40 to +90C 1.02 Nm3/h in balanced condition with air supply at 400 kPa 1.3 sec/liter without load 26 Nm3/h with air supply at 565 kPa 0.25% better than the considered signal range 1% of the full range 0.5% 0-60 kPa 6.66 kPa

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STI
Type: Sizing Tools: Design Location: Manufacuturing : UP1/R Valsiz STI, Italy STI, Italy

POSITIONERS

Application:

Description:
Positioner UP series operation is based on the forcebalancing principle, and it consists mainly of: - a pneumatic diaphragm (10), generating a force proportional to the pneumatic signal 21 105 kPa (3 15 psi) sent by the regulator a spring (25) generating a force opposite to that of the diaphragm, the intensity of which depends upon the position of the actuator stem a cam (41) operated by the actuator stem a spool valve (43) feeding or exhausting the two actuator chambers. Its position, through lever (5), depends upon the resultant of the forces operated by diaphragm (10) and feed-back spring (25).The shifting of spool valve (43) to the right through lever (5) is due to an increase in the signal pressure on diaphragm (10). Consequently pressure raises in "S chamber of actuator , and decreases in "I" chamber. The positioner shaft integral to cam (41) moves counterclockwise. Cam rotation stretches feed-back spring (25) through lever (6). Cam rotation stops when the load of feedback spring (25) equals the force generated by the signal pressure on diaphragm (10). When this occurs spool valve (43) returns to the balanced position. Whenever the spool valve is in a balanced position, the position of the stem of the actuator is proportional to the control signal and to the cam characteristic law (i.e. : with linear cam with 50% control signal, the actuator stem will be positioned to 50% of its stroke).

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Features: Quality Specifications:

POSITIONERS

Materials of Construction: Part Material


Body Manifold Cover Cam Spool Valve Diaphragm Levers Aluminium die-cast Aluminium die-cast Polycarbonate HostaformTM Stainless Steel Nitrilic gasket Aluminium die-cast

Standard Dimensions:
Dry Instrument Air supply Supply Signal Output Signal Pressure gauge Operating temperature Storage temperature Air consumption 200 kPa to 665 kPa NPTF NPTF NPTF 1/8 NPTF -26 to +75C -40 to +90C 1.02 Nm3/h in balanced condition for standard model with NPTF connection 1.3 sec/liter without load 26 Nm3/h with air supply at 565 kPa 0.20% better than the considered signal range With linear cam 1% of the full range 0-60 kPa 30% of the range

Actuator times Capacity Sensitivity Accuracy Zero suppression Range adjustment

139

STI
Type: Sizing Tools: Design Location: Manufacuturing : CRP/SS Valsiz STI, Italy STI, Italy

POSITIONERS

Application:
Years of control experience have enabled STI to develop the CRP/SS a positioner with the features by instrument engineers in the hostile environment found in todays chemical processing, pulp and paper, nuclear, marine and food industries.

Description:
The unit utilizes a force-balance principle providing accurate positioning of an actuator stem. The CRP/SS positioner consists of a diaphragm exposed to the regulating signal pressure, of a feedback spring and a double acting spool valve connected to the diaphragm and feedback spring by the rod. An increase in signal pressure on the diaphragm stretches the feedback spring and thus determines the displacement of the spool valve and consequently of the piston in the turn actuator The piston position is linked to the cam and the hinged lever transmitted onto the feedback spring thus balancing the signal air pressure The actuator stem therefore will remain in a stable position only as long as the feedback springs force is equal to the air signal force on the diaphragm.

Features:
Force balance feed-back principle Double acting or single acting in one unit Totally enclosed, protected from harsh environment Suitable for high vibration installations

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POSITIONERS

Unaffected by supply pressure variations(no need of supply pressure regulation) Simple zero and span adjustment Three lobe cam with split range Highest reliability One single sensitive annular diaphragm on control signal High flow spool valve Easy maintenance

Quality Specifications: Materials of Construction: Part


Body Manifold Cover Cam Spool Valve Diaphragm Levers Shaft Shaft bushing Fasteners and external parts

Material
Stainless steel sheet Stainless steel section Stainless steel sheet Plastic composite Stainless Steel (HP type) Nitrile rubber Nickel plated Die-cast aluminium Stainless steel Teflon Stainless steel

Standard Dimensions:

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STI
Application:

ACCESSORIES
Position transmitter

High performance, wear-free position transmitter. Ideal for installation in hazardous areas. Available with mechanical or inductive limit switches for the end position monitoring of the control element. The electronic position transmitter STI mod. 2030 is suitable for installation on rotary motion devices with angles up to 90. It has been designed to meet the most various industrial application requirements, i.e. on board of pneumatic actuators. For use in potentially explosive atmospheres, an explosion proof certification EExd IIC T6 (ATEX) is available. Besides, the enclosure has the capability to house a wide range of either mechanical or inductive limit switches (up to 4). A shaft with manually-adjustable cam is used for the accurate and easy setting of the limit switches. Limit switches are prewired to a terminal strip.

Features:
High precision and reliability Contactless sensors-no wear Low consumption electronic circuit Several application options Easy installation

Quality Specifications:

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STI
Materials of Construction: Part
Housing Cylinder Cover Lever Shaft

ACCESSORIES

Material
Aluminium G-Al Si 9 Mn Mg UNI 3051 Aluminium alloy 2011 UNI 9002/5-anodized Aluminium G-Al Si 9 Mn Mg UNI 3051 Aluminium alloy 2011 UNI 9002/5-anodized Stainless steel AISI 303

Standard Dimensions:
Supply Output signal Calibration angle Operating temperature Operating angle Response time . 12-32 Vdc 4-20 mA Direct or reverse, field reversible -25 to +70C 30 to 90 0.2 sec

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Air lock device
Application:

ACCESSORIES

An air-lock pressure static device is mounted on pneumatic actuators when they are to be isolated from control devices(positioners, electropneumatic distrubutors, etc.) whenever air pressure falls below operating safety point. The pressure switch device AL type has been designed to meet different air-lock systems, to guarantee a specific safety position of actuators, as required by the final control element.

Description:
The air-lock device consisits mainly in a pneumatic pressure switch with a set point calibration. The air-lock operating one or more 3-way synchronous commutators,depending upon the function required. Switching device operates immediately, also in case of a gradual air pressure decrease to the set value. The hysteresis avoids a continuous, innoportune commutation when air pressure swings around the set point.

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Features: Quality Specifications:

ACCESSORIES

Materials of Construction: Pneumatic pressure switch: Part Material


Lower and upper body Plug Calibration spring Piston Aluminium Stainless steel Steel for springs Aluminium

Switching assembly: Part


Body ND Spool valve Gaskets

Material
Aluminium Hard oxided aluminium Buna NTM

Standard Dimensions:
Supply Output signal Calibration angle Operating temperature Operating angle Response time Setting range Inlet maximum pressure Connections Pressure switch connections 12-32 Vdc 4-20 mA Direct or reverse, field reversible -25 to +70C 30 to 90 0.2 sec 15 70 psi 145 psi , , 1, 11/2 NPT Pilot signal: ND 1/8 NPT

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ACCESSORIES
Derivative Booster

Application:
The STI booster is used in conjuction with a positioner on a control valve to increase stroking speed. It has been designed to pressurize one cylinders chamber and discharge the other simultaeneously. In this way, an high stroking speed increase in one direction can been obtained using just one device.

Description:
The derivative booster is activated by the exhaust flow rate of the positioner. For small input signal changes, the BD doesnt work. In case of a large, sudden change in the input signal the positioner would vent the upper side of the BD to the atmosphere. The differential pressure between the upper and lower side of the derivative booster piston would force it to move, thus venting the b side of the cylinder to the atmosphere trough the large exhaust port. The movement of the piston would also cause the supply air to flow to the a side of the cylinder. The port remains open until the pressure difference returns to within the dead band limits of the derivative booster The pilot flow rate required to active the booster is adjustable by regulating the orifice D1 which determines the pressure difference between the top and the bottom of the piston. Once it is activated, the BD is not able to modulate its flowrate. To obtain a good working of the booster is advisable to use a pilot with a CV value at discharge not less than 0.5 .

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ACCESSORIES

Cylinder overshooting can be reduced by adjusting the control valve D2.

The STI booster is used in conjunction with a positioner on a control valve to increase stroking speed. It has been designed to pressurize one cylinders chamber and discharge the other simultaneously. In this way, an high stroking speed increase in one direction can been obtained using just one device

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Features: Quality Specifications: Materials of Construction:

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Standard Dimensions:

Operating pressure Working temperature Storage temperature Body, cover, piston Indicative operating time Air consumption Connections

7 bar -10 to 70C -40 to 80C Anodised alluminium brass 0.05 sec. per each cylinders volume liter Not present Plug-in for direct mounting 1 NPT connections for supply, pilot and cylinders ports.

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Manual over ride:

All STI actuators may be equipped with a manual override to allow operation of the control element when control air is not available or when its desirable to by pass the controller to manually operate the actuator. Several sizes are available (GR1, GR2, GR2.5 and GR3) according to the type of actuator required. For actuator series SC/V the gear box is mounted between the actuator and the yoke, for SC series it is mounted in front of the actuator. The internal worm gear is mounted on ball bearings for long operating life. The manual override can be used as an adjustable stroke limitator

Application:
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Description: Features: Quality Specifications: Materials of Construction:

Standard Dimensions:

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Derivative unit:

The derivative unit is a specific device used in conjunction with STI positioners whenever a quick opening and/or closing function is required. It increases the speed of the actuator without hunting as the air to be discharged from the actuator is exhausted to the atmosphere directly from the large derivative unit outlet and not through the positioner. Whenever a very high actuator speed is required, two derivative units can be installed in parallel on the same line.

Housing material Diaphragm material Size Inlet/ outlet connections Exhaust connection Operating temperature Design pressure

Aluminium Polyurethane NPT F NPT F -20 to 80C 10 bar

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