Valves

Bharat Heavy Electricals Limited TIRUCHIRAPALLI
PRESENTATION ON VALVES ENGINEERING
Committed to making a better world
VALVE
Forged Steel Valves
PRODUCTS
Gate Valve
Globe Valve
Check Valve
Blow-down Valve
Cast Steel Medium Pressure Valves

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

Gate Valve Globe Valve Check Valve Elbow type Blow-down Valve
VALVE
PRODUCTS
Quick Closing Non-Return Valve
High Pressure By-pass Valve
Soot Blower
Safety Relief Valve

Safety Valve
Silencer
VALVE
PRODUCTS
Well-Head Assembly
X-Mas Tree Assembly
Full Bore Gate Valve
TECHNOLOGY BASE
High Pressure Gate, Globe and Non-Return Valves Toa Valve Co. Ltd., Japan
Quick Closing Non-Return

valve
Toa Valve Co. Ltd., Japan
Safety & Safety Relief Valves Dresser Ind. Inc., USA
Forged Steel Valves

Soot Blowers HP-LP Bypass Systems
Dresser Ind. Inc., USA

Copes Vulcan, USA SULZER (CCI), Switzerland
Oil Field Equipments
Kvaerner National, USA
Cost competitiveness Competitive Technological edge Advanced technology
Technology Up gradation
IMPROVEMENT PROJECTS
Technology Improvement
Business Improvement. Cost and cycle time reduction IT initiatives Future plans
Technology Improvement.
Angle type bypass valve, MOU project completed. (Approval obtained from M/S DVC for installation
of Angle HP Bypass valve in MEJIA 4)

Improved Design Of HP Bypass Valves.
@ @
Metal seal full bore gate valves for oil field equipment. @ Development of Proportional Valve.
Business Improvement.
Development of:
(Market requirement)
Economic series 150 Class Gate Valves.
Choke and Kill Manifold Units for 5,000 and 10,000 psi @ rating for OIL India , Duliajan 11-10000 PSI Tubing Spool Assembly and 11-10000 PSI Tubing Hanger 32/ 600 Class Gate valve for 500 MW. 32/ 150 Class SCNRV for 500 MW.
Development of:
Main steam stop valve of size 14 / 2500Class with A217-C12A material for 210 / 250 MW 32& 36 class 150 Gate valves.
4-1/16-10000 PSI Double Acting Type Hydraulic Actuator @
Development of:
6 & 8 900 class Gate Valves. 2 to 4 600 Class Globe valves. &1 3500 Class Globe valves
Hand Operated 8,10 600 Class Gate Valves.

Cost and cycle time reduction

E-Type Compact High Pressure Gate valves. @
Variety reduction of QCNRV body castings from 114 @ numbers to 34 numbers. Improved Design of A Type Swing Check Valves. NTPC approval for High Torque indigenous actuators @
IT initiatives
Created Valve Home Page and provided engineering information.
Drawings are being released as SOFT copy. Drawings, IBR approvals and other technical documents are attached in SAP system Technical directives and maintenance instructions on valves in Valves Home Page O&M Manuals & Catalogues released through CD.
TURN OVER FROM IN HOUSE DEVELOPMENT

PROJECTS Value(Lakhs) Introduction of Economic Series Silencers with SS internals 18 Introduction of Dual completion tubing spool, tubing hanger and dual block Xmas tree. 1947 Weight energised design tubing hanger 7-1/16"-10m, tubing spool for oil india requirement 52 Development of Angle type HP Bypass Valves 20 Development of NRV 14" Class 300 19 Development of NRV 16" Class 300 41 Development of NRV 20" Class 150 20 Development of Gate Valves 32"-150 Class 74
PROJECTS Development of Double acting Hydraulic actuated FBVs Development of Choke and kill manifold With hydraulic actuated choke Development of 6", 8"& 12" C150 Economic series Gate valves. Development of Gate Valves 36" Class 150 Double disc Flexible Disc Gate Valves for Hindalco Valves developed for NPCIL, TAPP 2 x 500MW
Value (Lakhs) 45 223 61 22 148 900
FUTURE PLAN - DEVELOPMENTS

Improved design of A type Gate valves of sizes 5, 6 and 16 in 2500 class.
Improved design of A type Globe valve of sizes 2.5, 3,4and 6 in 2500 class.
Value Engineering of 150 Class Check Valves. Value Engineering of 150 Class Globe Valves. Hydraulic Power Unit for HP Bypass System. 26 and 28 Class 300 Gate valves.

Interface Panel for Proportional Valve and Hydraulic Power Pack for HP Bypass system.
Replacement set for oil supply unit pump for HP By pass system.
4/ 900 class Quick Closing Non Return Valve. 18/ 150 class Quick Closing Non Return Valve. Wall Blower Design Modification.
Development of Rack Type LRSB.

Development of surface safety valve.
Data Base for Soot Blower Contract Information.
Mandrel Casing Hanger 13-5/8x9-5/8 and 11x7

X-Type Bushing for 11x5-1/2 and 13-5/8x9-5/8 Unitised Well Head (Oil Field Equipment)
Introduction of control Valves.

PREVENTIVE ACTION FOR GENERIC PROBLEMS

As a measure of preventive action , write-ups issued to site and process improved for: Causes for frequent Problems in HPBP Oil System. Recommendations for Servicing of HP Bypass System. Causes and Recommendations for Accumulator bladder Failure. Valve Actuator settings.
PREVENTIVE ACTION FOR GENERIC PROBLEMS

HP Bypass valve body downstream inner surface cracks
HP Bypass Valve Stem Thread Damages. Safety Valves - Servicing and Floating of Valves at site. Electromatic Relief Valves Problems and Solution. Safety & Safety Relief Valves - Set pressure Tolerances
and Blow down Limits.
ANGLE TYPE HP BYPASS VALVE

PRODUCT: Pressure reducing and de super- heating valve, for bypassing the steam during turbine trip and to achieve quick start up of the unit.
OBJECTIVE: To eliminate erosion of seat and valve passing, which occurs due to inadequate piping drain arrangement, during cold start up. In angle type valve, wet steam flow through the valve is totally eliminated due to vertical entry of steam. Hence this development is taken up.
FEATURES : Vertical inlet to avoid wet steam entry . Gland is shifted to the lower pressure side. Pressure seal plug made into two pieces for ease of assembly and replacement. PROJECT COMPLETED Commercialisation Technical presentation made, discussed with M/s DVC and APPROVAL obtained for installation in MEJIA unit 4
ANGLE TYPE HP BYPASS VALVE
EXISTING HPBP VALVE
ANGLE TYPE HPBP VALVE
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Development of 36 150 Class Gate Valve

Requirement for Gate Valves of size 36 150 class rating were received from various process industries.
Valve designed as per BS 1414 standard, manufactured and tested as per BS 6755 part 1 successfully. Three numbers supplied to HPCL, MUMBAI and one number supplied to IOCL, PANIPAT. Order value 30 Lakhs
36 / 150 Class Gate valve

DESIGN STD. = BS1414 TESTING STD.=BS 6755-Part1
OVEALL HEIGHT = 4
Mtrs
TOTAL WEIGHT = 3.8 Tons
BACK
CHOKE & KILL MANIFOLD .

Customer : M/s OIL India Limited, Duliajan Quantity : 4 Sets of CKM rated for 5000 psi. 1 Set of CKM rated for 10,000 psi. Order received against Stiff Global Competition from Reputed Manufacturers abroad. Requested Customer for Plant Visit & convinced them on our capabilities in Design, Manufacture &Testing of CKMs. One set each of 5,000 psi & 10,000 psi CKM have been Successfully Assembled, Tested & Despatched. Order Value : 588,510 US Dollars [ Rs. 285.42 Lakhs ]
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Economic Series Gate Valves Class 150 Sizes Developed 6 inch 8 inch & 12 inch
Aspects towards reduced cost
Reduction in machining scope in Body and Wedge
leading to reduced machining cost.

Reduction in the machining allowance to optimum level
leading to reduced casting weight and machining cost.

Revisit of material specification and Procurement to commercially available ASTM grades, thereby reduction in cost of castings.
Competitor data Comparison

6"-C150-GV BHEL(EXISTING) BHEL(NEW)AUDCO 744 787.4 Height(open)mm 805 HW Dia mm Weight Kg 400 91.5 315 78 304.8 86 KITZ RAIMONDIFOURESS 762 795 890 300 350 85 356
8"-C150-GV BHEL(EXISTING) BHEL(NEW)AUDCO 932 985.5 Height(open)mm 995 HW Dia mm Weight Kg 450 141 450 106 355.6 139 KITZ RAIMONDIFOURESS 960 1015 1120 350 350 128 356
12"-C150-GV BHEL(EXISTING) BHEL(NEW)AUDCO 1345 1397 Height(open)mm 1421 HW Dia mm Weight Kg 450 337 450 290 457.2 304 KITZ RAIMONDIFOURESS 1370 1465 1470 450 450 310 508
Range of Valves
Gate Valve Class 150 Sizes : 6,8 & 12
Size Height(open) mm Old New 6 805 760 8 995 932 12 1421 1360
Weight(Kg.) % Old New Reductio 91 76 16 140 106 24 336 290 14
COMMERCIALISATION OF ECONOMIC SERIES VALVES

VALVE TYPE 6/ 150 CL.GATE VALVE 8/ 150 CL.GATE VALVE 12/ 150 CL.GATE VALVE ORDER RECD Rs.LAKHS 17.55 21.68
21.85 Back
E-type Compact High Pressure Gate Valves.

Salient Features
Revisiting the process and machining time is 20% reduced (Stainless steel inlay eliminated in body, bonnet
and Split ring design in place of screwed retaining ring)

Weight reduction to the extend of 15 to 20% Improved features (Grafoil gasket in place of soft iron
gasket)
Back
Unification of QCNRV body castings.

GASKET BONNET
To use the same valve body for different Actuator size & its orientation. Total 114 nos. of existing castings were brought down to 34 nos.
ARM
DISC (STELLITED)
NUT SEAT (STELLITED) BODY
AIR/OIL CYLINDER
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Improved design Swing Check Valve
A - TYPE C Type SIZES DEVELOPED : 6,8,10,12 & 14 RATING : 1500 CLASS

Swing Check Valve
A - TYPE
C - Type
Back
IMPROVED DESIGN OF HP BYPASS VALVE

SALIENT FEATURES: Pressure seal plug split into two parts enabling replacement of only the damaged portion , easy assembly and lesser spares cost.
Jet cage holes reoriented, to avoid direct impingement of spray water to valve seat, which can lead to thermal stress and seat crack. Inclined spray holes is changed as straight holes in pressure seal plug for manufacturing easiness.
EXISTING
IMPROVED
EXISTING
IMPROVED
Back
Development of 32/ 600 Class Gate valve for 500MW Projects. (Line to De-aerator)
This valve development was taken as an import substitute. Design development completed . Casting and forging, Sub delivery and Manufacturing drawings released.
32/ 600 Class GATE VALVE
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Main steam stop valve 14 / 2500Class with A217-C12A material for 210 / 250 MW
Why this project was taken.
Presently Main steam stop valve with F91 ends are supplied to suit SA 335 P91 pipes.
Valves with A217 C12A casting equivalent to P91 material. The valve weight is less by 25% Foundries are identified.
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VALVES
1963 VALVES FOR IN HOUSE REQUIREMENT AS PER CZECH DESIGN TO DIN STANDARD 1972 VALVES OF ANSI / API / BS STANDARDS DEVELOPED IN HOUSE 1973 TECHNOLOGY TIE UP FOR SOOT BLOWERS 1976 TECHNOLOGY TIE UP FOR HP BY PASS SYSTEM 1978 TECHNOLOGY TIE UP FOR FORGED STEEL AND SAFETY / SAFETY RELIEF VALVES 1984 TECHNOLOGY TIE UP FOR HIGH PREESSURE CAST STEEL VALVES AND QCNRV. 1985 TECHNOLOGY TIE UP FOR OIL FIELD EQUIPMENTS
Improvement Projects - Mapping

2001-2002
Identi- fied Completed Under Progress Identified
2002-2003
Completed Under Progress
TOTAL
207
123
75
18
18
DETAILS
BIP 18 7 4 8 8
TIP
CIP
4
60
3
32
1
18
5
-
5
-
QIP
DIP SIP EIP
32
92 1
28
52 1
11
36 -
2 2 1
2 2 1
Some of the improvement projects focus on more than One area of improvement.
Index

Year 2000-01 2001-02 Budget Lakhs 600 550 Actual Lakhs 609 551
2002-03
2003-04
560
650
629
METAL SEAL FULL BORE GATE VALVES

Presently manufacturing Full Bore Gate Valves with Elastomeric Seat to Body seal. Specific Customer require Seat to Body seal to be of Metal to Metal type.
OBJECTIVE : Develop Design, Procure Materials, Manufacture and perform Test on Metal to Metal seal Full Bore Gate Valves.
SALIENT FEATURES >> Design development of Metal to Metal Seal Feature >> Procurement of Valve Castings / Forging, Metal seals. >> Manufacture and Testing of Valves
GATE SEAT RING BELLEVILLE SPRING
SEALING PROFILE
METAL TO METAL SEAL


STATUS : PROJECT COMPLETED
Assembly and Testing taken up at shop as per SIP. Valve tested on either side for Seat leak tightness, as per API 6A Standard. Valve checked for leak tightness at 5000 psi as well as for Low pressure sealing at 500 psi. and also at further increments of 500 psi Upto 5000 psi. Valve successfully withstood the test and found leak tight.

BENEFITS ENVISAGED :
Achieve complete compliance to Technical Specification. Customers
Approach towards State of Art Technology. Enhance product capability towards high temperature Service application.
back
DEVELOPMENT OF PROPORTIONAL VALVE

HP Bypass system valve actuators are operated with the help of servo valve and blocking element, which require high level of cleanliness (<3 microns).
Frequent field problems of servo valve were reported, which are mainly due to inadequate cleanliness of the hydraulic system. Proportional valves, which can be substituted in place of servo valves and blocking elements, can function satisfactorily at a lesser level of cleanliness (<10microns) hydraulic system.
Order placed on YUKEN and supply effected.

DEVELOPMENT OF PROPORTIONAL VALVE

Servo valve control signal requirement is 11.5 V DC and Blocking element solenoid voltage is 48V DC. HPBP valves travel speed is proportional to servo valves input signal. Blocking unit ensures stay-put position on power failure and loss of oil pressure. Proportional valve control signal requirement is 10V DC and blocking solenoid coil voltage is 24V DC. Sample proportional valve installed at test bench and travel speed checked for various control signal voltages. Open / close time and stay-put position established.
Project completed. Requirement of interface with Control system taken up with EDN. back
Double Acting Type Hydraulic Actuator 4-1/16-10000 PSI

PRODUCT SPECIFICATION : Type : Double acting Hydraulic actuated Max. Act.Control Pr. : 1500 psi Stroke : 127.4 mm Specification : As per API-6A Product Spec.Level : 3 Material Class : EE Temperature rating : U
Double Acting Type Hydraulic Actuator

DESIGN FEATURES : Adjustable Stroke Feature enables setting of Actuator Travel precisely.
T-Slot Connection between Steam and Piston ensure proper alignment and leak tight operation. Clamp connection enable ease of Dismantling and re-assembly. Hard Chromium Plating of Cylinder ID and Piston OD. Manual over ride facilitate opening of Valve by Manual means in case of Hydraulic fluid failure.
4-1/16-10000 PSI
Double Acting Type Hydraulic Actuator
4-1/16-10000 PSI
ANTICIPATED BENEFITS : Foreign Exchange savings to the tune of US $ 4000 / Actuator. BHEL make Actuators are now being offered against Customer enquiries to make our offers competitive. CURRENT STATUS Actuator Components have been manufactured and are under Assembly. Back

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Bharat Heavy Electricals Limited TIRUCHIRAPALLI

PRESENTATION ON VALVES ENGINEERING

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Cast Steel Medium Pressure Valves

Cast Steel High Pressure Valves

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Quick Closing Non-Return Valve

High Pressure By-pass Valve

Safety Relief Valve

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

X-Mas Tree Assembly

Full Bore Gate Valve

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Quick Closing Non-Return

Toa Valve Co. Ltd., Japan

Safety & Safety Relief Valves Dresser Ind. Inc., USA

Forged Steel Valves

Dresser Ind. Inc., USA

Oil Field Equipments

Kvaerner National, USA

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Cost competitiveness Competitive Technological edge Advanced technology

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

of Angle HP Bypass valve in MEJIA 4)

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Economic series 150 Class Gate Valves.

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

4-1/16-10000 PSI Double Acting Type Hydraulic Actuator @

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Hand Operated 8,10 600 Class Gate Valves.

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Cost and cycle time reduction

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

TURN OVER FROM IN HOUSE DEVELOPMENT

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

TURN OVER FROM IN HOUSE DEVELOPMENT

Value (Lakhs) 45 223 61 22 148 900

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FUTURE PLAN - DEVELOPMENTS

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FUTURE PLAN - DEVELOPMENTS

Development of Rack Type LRSB.

Committed to making a better world

FUTURE PLAN - DEVELOPMENTS

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Data Base for Soot Blower Contract Information.

Mandrel Casing Hanger 13-5/8x9-5/8 and 11x7

Introduction of control Valves.

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

PREVENTIVE ACTION FOR GENERIC PROBLEMS

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI