BLAKEBOROUGH. Process Control Valves and Desuperheating Equipment

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1 BLAKEBOROUGH Process Control Valves and Desuperheating Equipment

2 PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Blakeborough Weir Valves & Controls The key to the success of Weir Valves & Controls is our capability to deliver engineering solutions that add value to the customer s process. We offer a total package of products to meet end-to-end project requirements. Using our own analysis and configuration system, we will design and deliver the optimum valves and controls solution to protect the value of the production process. A rigorous programme of information management means that the division is able to take a more anticipatory role in defining the future needs and expectations of the market by fully utilising the organisation's critical resources to provide whole process isolation and control valve solutions for the global Energy sector. With a comprehensive range of engineered valve products Weir Valves & Controls have developed an extensive global installed base and expertise across a wide range of industry sectors: Power Generation General Industrial Oil & Gas Production Refining Petrochemical Chemical Pulp & Paper Desalination 2 Weir Valves & Controls First choice for process protection

3 Blakeborough PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Quality assurance Weir Valves & Controls operates quality programmes to cover the full scope of their activities. Comprehensive quality systems have been developed to serve the power, oil and gas and industrial markets which they serve. The company holds approvals to: ASME Section III N, NPT, NV ASME Section I V BS EN ISO 9001:1994 API Q1 TO API LICENCES API 6D (6D-0182) AND API 6A (6A-0445) TUV - AD MERKBLATT WRD HP 0 BLAKEBOROUGH The Control Valve business unit have designed and manufactured valves for in excess of 40 years. Their control valve product range offers an extensive choice in terms of size, pressure class, body/trim materials, and includes top, top & bottom guided and cage guided valves. In addition they also supply a wide range of desuperheating equipment to satisfy power and steam conditioning applications. 6A D-0182 The Quality systems have been approved for the supply of products to meet the requirements of the Pressure Equipment Directive (PED) and compliance modules A,D1,H,B&D have been applied in categories I through IV respectively. The company is committed to compliance with legislation and has an established environment and health and safety policy. An ongoing commitment to customer care is met through the process of continuous improvement and the further development of our systems and processes towards meeting ISO 9001:2000. Valve Testing Facilities All pressure containing items are hydrostatically tested, seat leakage tested and functionally tested. In addition, gas, packing emission, cryogenic and advanced functional testing can be arranged. Material testing facilities Non-destructive examination by radiography, ultrasonics, magnetic particle and liquid penetrant. Chemical analysis by computer controlled direct reading emission spectrometer. Mechanical testing for tensile properties at ambient and elevated temperatures, bend and hardness testing. Charpy testing at ambient, elevated and sub-zero temperatures. Further technical information can be obtained from our Web site: Contents Industry applications 4 Severe service 5 Product range 6 Cage trim valves 12 X-Stream trim 16 Low flow cage trim valves 28 Top & bottom guided valves 33 Three way valves 39 Desuperheating equipment 44 Diaphragm, manual & lever operated actuators 52 Multi spring actuators 58 Actuator coding 63 Weir Valves & Controls First choice for process protection 3

4 PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Blakeborough Applications The Blakeborough range has valves for applications on process plant throughout industry where there is a requirement for automatic flow control, temperature control or pressure reducing. Power industry Fossil fired and nuclear power stations. Combined cycle power stations. Desalination plants. main uses are on boiler steam, desuperheating, feedwater, feed pump leak-off, turbine systems and oil systems. Oil and gas Blakeborough equipment has been supplied to many internationally known companies for high integrity service. Production, processing and transportation. Oil and gas offshore platforms. Compressor anti-surge valves. Part of a large order engineered for a gas plant in Abu Dhabi. Cage trim control valves supplied to a power station in China for boiler feedwater duties. Compressor anti-surge valves. Part of a large order engineered for a gas plant in Abu Dhabi. A pressure reducing and desuperheating unit operated by electrohydraulic actuator. The application was turbine bypass on a large power station. Hydraulically operated stainless steel and carbon steel valves for remotely operated offshore platforms in the North Sea. Petrochemicals and processing Hydrocracker duties. Chemical production melamine, ethylene, polyethylene, sulphuric/ phosphoric/hydrochloric/hf acids. Pulp and paper plants, Sugar industry beet and cane. A variety of control valves for oil systems and turbine duties on a combined cycle gas turbine power station. Steam heating was incorporated in these valves for handling polyethylene for a plant in Korea. 4 Weir Valves & Controls First choice for process protection

5 Blakeborough PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Three-stage ceramic trim used on pump leak-off applications. Differential pressure is 290 bar, 4205 ft/in 2. X-Stream severe service trim. Patent applied for. Seismic testing of a control butterfly valve for nuclear industry applications. Valves with low-trim outlet silencers destined for a desalination plant in the Middle East. Special/severe applications Blakeborough control valves can be used over a complete range of applications up to the most severe operating conditions. Valves can be supplied in a wide range of body and trim materials ranging from carbon steel through to exotic alloys such as Hastelloy. Trim materials and designs are selected to eliminate/minimise erosion and corrosion. Our range of special trim materials include tungsten carbide, stellite, inconel and ceramic, all of which can be supplied on liquid and gas application to greatly extend service life. In addition to standard cage trim designs which incorporate up to five stages of let-down, special designs can be provided to meet specific process requirements, such as the newly developed X- Stream trim. Blakeborough silencers, developed from the company s research into aerodynamic noise generation, can also be utilised to provide a cost effective solution to noise problems. Blakeborough can offer solutions to: Blowdown/de-pressurisation Compressor re-cycle/anti-surge Gland steam control Pump leak-off Minimum flow re-cycle valves Multi-phase fluids (including sand contamination) Oil pipeline surge relief Cryogenic valves Polyethylene service (steam jacketed valves) Research and development Blakeborough has a continuous product development policy which includes testing of new materials and components with potential benefits to the division s product range. Examples of test work conducted are, ceramic materials, valve packings and instrumentation smart positioners and most recently the X-Stream trim. In addition to the Blakeborough test facilities the extensive test services of Hopkinsons and other Weir Group companies are utilised when required. Emission testing of gland packing fitted to a valve pressurised with helium at 40 bar, 580 lb/in 2, at a temperature of 200 C, 392 F. Weir Valves & Controls First choice for process protection 5

6 PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Blakeborough Cage trim valves Low Flow Applications A range of small bore valves in globe and angle body configurations caters for small flow applications and offers accurate control. The design has a separate non-threaded seat ring held in position by a guide. Non-balanced construction allows high integrity valve shut-off. Ratings up to ANSI Class 4500 Globe pattern (BV502) Angle pattern (BV503) Forged body valve (BV504) Sizes: 15, 20 & 25 mm 1 2, 3 4 & 1 in Stepcone trim anti-cavitation trims. Medium/Large Flow Applications This range in the cage trim series offers a system of parts interchangeability. During service life valve trims can be easily changed to different performance characteristics if process control conditions alter. All essential components are easily removable without special tools whilst the body remains undisturbed in the pipeline. A cage, which incorporates the flow control element, also provides a plug guide giving stable support on hardened surfaces down to the point of seating. Ratings up to ANSI Class 600 Globe pattern (BV500 & BV502) Angle pattern (BV501 & BV503) Ratings ANSI Class 900 to 4500 Globe pattern (BV990) Angle pattern (BV992) Sizes: mm in Sizes: mm in Multiflow a low noise design for high pressure drop applications. Spine trim high rangeability for very small flow rates. Cage trim valve for small flow applications shown with the optional contour trim which is suitable for most applications. Valve with multi-flow trim (anti-cavitation/low noise) fitted as standard is suitable for general to moderately severe applications. For noise reduction/cavitation treatment cascade trim is recommended. Up to five stages of pressure let-down are fitted as standard. 6 Weir Valves & Controls First choice for process protection

7 Blakeborough PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Top & bottom guided valves Top and bottom guided valves come in two basic types, single seated and double seated. Both types feature a reversible plug which allows the fail action of the valve to be changed on site should there be a requirement to reverse the stroke direction. Double seated valves are specified for applications requiring high capacity, low to medium pressure conditions and where a tight shut-off is not essential. Low noise trims are available. Top and bottom guided valve, double seated type, arranged for pull stem to open. The valve illustrated is shown with linear contoured trim. There is a variety of other trim design options. The single seated valve design offers tight shutoff, high rangeability and can be supplied with anticavitation/low noise trim. Ratings up to ANSI Class 1500 Top and bottom guided valves double seated type: PULL stem to open (BV800) PUSH stem to open (BV801) Sizes: mm in Top and bottom guided valves single seated type: PULL stem to open (BV802) PUSH stem to open (BV803) Sizes: mm in Three way valves Valves in the three way series are most commonly used for proportional blending or splitting of two flows. There are two basic configurations: The two inlet connections with common branch outlet type (BV830) allows proportional blending of two flows into one stream. The valve can also be used for flow splitting duties with one inlet and two outlets if flow is in reverse. For proportional flow splitting the two outlet with common inlet branch type (BV831) is recommended. The valve is designed to divert a quantity of the process medium from one section of the system to another. Ratings up to ANSI Class 1500 Mixing flow type (BV830) Splitting flow type (BV831) Sizes: mm in Three way valve for flow mixing applications. The valve can also be used for flow splitting if the flow is in reverse. Weir Valves & Controls First choice for process protection 7

8 TOP & BOTTOM GUIDED VALVES BV800/1/2/3 Blakeborough Bonnet forms Standard For applications where the temperature of the controlled fluid is between -18 C and (O F) and 232 C (450 F). May be used with graphite packing up to 315 C (600 F). Although modern packagings are suitable for much higher temperatures it is recommended that the normalising bonnet be fitted in cases where the temperatures exceed the above values to accommodate lagging of the control valve body. Normalising For protection of the gland packing at temperatures above 232 C (450 F) and below -18 C (O F) down to -100 C (-150 F) The bonnet is designed with fins which dissipate the heat from process fluid and help protect the packings and actuator assembly from high temperatures. In addition the normalising bonnet is longer than the standard plain bonnet so that the valve can easily be lagged without interference with the actuator. Bellows Seal A positive leakproof stem seal for cases where gland leakage cannot be permitted. The standard bellows material is 321 stainless steel, although many other materials are available on request. The design consists of a welded flexible steel bellows which is clamped in an extended bonnet/bonnet hood. This effectively cuts out any possible leakage path around the plug stem and therefore prevents emissions from the valve packings. Packings are fitted in these valves but only act as a backup to the bellows. Cryogenic Used for temperatures below -100 C (-150 F). The bonnet designed with a long necked section which distances the packing away from the process fluid. The necked section is designed with a minimum wall section to minimise heat transfer. Cold box extension/cryogenic bonnets are also available. Packing Packings are selected based on fluid temperature and fluid type. The most common packing system materials are PTFE for low temperature and graphite to high temperature. For hydrocarbons service and where emission levels need to be controlled there are two further types of packings available. These incorporate specially selected materials and live loading to both minimise emissions and extend packing life allowing for cyclic operation. These packings are referred to as LTEP and HTEP. Packings have been tested to prove emission levels of less than 500 parts per million over 50,000 cycles and under thermal cycling conditions. PTFE Chevron is used for applications where the temperature is between cryogenic to 232 C (450 F) Grafoil is used on high temperature applications where the temperature exceeds 232 C (450 F) LTEP low emission packing, temperatures below 260 C (500 F) HTEP low emission packing, temperatures above 260 C (500 F) Other packing types can be accommodated as required. Standard Silencers Normalising Silencers/Dynamic Attenuator Bellows Seal This equipment is used on gas/vapour services to control fluid velocity and to produce dynamic attenuation. Each silencer is designed for its specific application and is considered in conjunction with the selection of the upstream control valve/trim. In selecting the silencer design all operating conditions are considered to ensure acceptable performance. PTFE Chevron Grafoil Cryogenic 8 Weir Valves & Controls First choice for process protection

9 Blakeborough LOW FLOW CAGE TRIM VALVES BV502/3/4/5 Characteristics Linear This characteristic provides a flow rate which is directly proportional to the valve lift. The proportional relationship produces a characteristic with a constant slope, so that with constant pressure drop the valve gain will be the same at all flows. The linear valve plug is commonly specified for liquid level control and for flow control applications requiring constant gain. Equal Percentage Equal increments of valve lift produce equal percentage changes in the fluid flow. The change in flow rate is always proportional to the flow rate just before the change in plug position is made. The equal percentage characteristic is generally used on pressure control applications, and on other applications where a large percentage of pressure drop is normally absorbed by the system itself. Valves with this characteristic should also be considered where highly varying pressure drop conditions occur or high rangeability is required. Quick Opening This provides for maximum change in flow rate at low valve lifts with a fairly linear relationship. Additional increases in valve lift give sharply reduced changes in flow rate, when the valve plug nears the wide open position, the change in flow rate approaches zero. Intermediate Other intermediate or special characteristics are available on request to meet specific control requirements. Weir Valves & Controls First choice for process protection 9

10 PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Blakeborough Desuperheating equipment Blakeborough offers an unsurpassed range of desuperheating equipment developed to meet all duties. A complete package is offered including the related control systems required for efficient desuperheating. Combined Pressure Reducing Desuperheating Units For the safe handling of very high drops and the control of high velocities associated with steam power generation, the combined pressure reducing and desuperheating unit is the ideal solution. A major use is with back-pressure turbines supplying exhaust steam to process. Should the turbine be shut down for any reason the steam rejected is bypassed through the valves, which serve to reduce it to the required process conditions. The unit comprises a valve body with special outlet branch incorporating a spray water injection system for steam cooling and a combined mixer/silencer device. The actuator operated valve is automatically positioned by instrument control according to downstream pressure, while the spray water supply is governed by a separate small bore control valve responding to a downstream temperature controller. Variable Orifice Desuperheaters The variable orifice desuperheater is designed to inject several finely atomised jets of spraywater into the steam flow. The head of the desuperheater is mounted into the steam pipe, and the unique design of the spray nozzles ensures that water is easily absorbed by the steam. Control of the spraywater is achieved by a conventional actuator mounted on the spraynozzle body. Ratings up to ANSI Class 2500 Variable orifice (BV985) Sizes: 25 & 40 mm 1 & in Ratings up to ANSI Class 4500 Globe pattern (BV994) Angle pattern (BV995) Mini Desuperheating Equipment Sizes: Inlet 15 & 600 mm 1-24 in The mini desuperheater is used in low capacity applications where steam demand is relatively low. It consists of a spray ring with radially drilled holes which is mounted in the steam pipe where spray water is injected into the steam as a fine jet. Ratings up to ANSI Class 1500 Mini desuperheater (BV986) Sizes: 15 & 200 mm in 10 Weir Valves & Controls First choice for process protection

11 Blakeborough PROCESS CONTROL VALVES & DESUPERHEATING EQUIPMENT Actuators and instrumentation Pneumatic Diaphragm actuators are suitable for most applications and are available in direct acting or reverse acting models. Piston actuators are used where a high thrust is needed to operate the valve. Blakeborough manufactures two types of pneumatic actuators, diaphragm and piston. There is a choice of mechanical handwheel and limit stops to suit all units. Pneumatic diaphragm Direct acting (A40) Sizes: cm 2 Reverse acting (A41) in 2 Pneumatic piston Direct acting /spring return(a30) Sizes: cm 2 Reverse acting /spring return (A31) in 2 Double acting/valve positioner (A36) Electric The Autotork Division of Hopkinsons Limited manufactures a full range of rotary electric actuators in modulating and on-off/regulating types. Thyristor drives and custom designed control systems up to nuclear industry standards are also produced. Other types Most other forms of actuation, such as electrohydraulic (bottom right), can be fitted to Blakeborough valves as required. Valves fitted with Autotork modulating actuators supplied for installation on a combined cycle gas turbine power plant. Instrumentation Blakeborough will select/design instrumentation to meet the needs of the most exacting process requirements. One of a large consignment of valves with fast operating control for duties on a gas plant in Abu Dhabi. Instrumentation required to give onesecond open/close on modulating and trip conditions. The cage trim type valves, supplied for steam condensate dump applications, were arranged with 125mm, 5in, travel. Weir Valves & Controls First choice for process protection 11

12 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Description The Blakeborough cage trim series of control valves BV500 and BV990, is designed to meet the requirements of most process control applications. These ranges of control valves have been developed by Blakeborough to meet the ever increasing demands of modern day processing plant. The valves incorporate high integrity features of previous designs together with a highly flexible philosophy of trim design options. There is a wide range of standard and high duty trims available which can be fitted within the same valve body. The options include Multi-Flow, Cascade (2 to 5 stages of letdown) and various designs which can be manufactured to suit the specific application. At the enquiry stage Blakeborough will consider the most suitable combination of valve components for each application. Pressure drop, noise, potential for cavitation are all considered to give the most cost effective solution for the particular application. Design features Cage guided Wide range of trim options High stability Easy maintenance Pressure rating Class 150lb to 4500lb PN10 to PN640 Sizes 40mm to 750mm 1 1 2" to 30" Travels 28.5mm to 300mm 1 1 8" to 12" End connections Flanged (all current standards) Butt weld Socket weld Screwed Clamped ends Cage Trim Valve with Multi Flow cage. Cage Trim Valve with Cascade Cage. 12 Weir Valves & Controls First choice for process protection

13 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 Body Materials The Cage Trim series valves can be produced in most forms of castable alloys. Standard body materials are:- Carbon steel; Grade WCB Stainless steel; Grade 316/304/ /4% chrome moly. steel; Grade WC6 2.1/4% chrome moly.steel; Grade WC9 Monel Aluminium Bronze Hastelloy B/C Duplex/Super duplex Most other materials can be cast in the on site foundry Trim Options Multi-Flow (MF) standard Cascade (CS) severe service duties Soft faced for tight shut off Variable Stage Cascade (VS) Single stage Multi-Flow (SS) Flash cone Pilot balanced X-Stream Versatility Blakeborough Cage Trim Valves offer a wide choice of options to meet most system requirements, eliminating or greatly reducing the multiplicity of valve designs that would otherwise be required. This flexible range of valves offers an extensive selection of trim designs, materials and sizes, and is therefore able to meet the ever increasing demands of modern day plant. All parts are interchangeable between globe and angle style valves in a given size and pressure rating. Parts substitution, internal inspection and maintenance are effected with minimum trouble, the essential working components being removable while the body remains undisturbed in the pipeline. Simple, low cost, in line maintenance Comprehensive interchangeable parts systems High-stability plug guiding High flow capacity Main design standards ASME B16.34 Valves-Flanged, Threaded & Welding End ANSI FCI 70-2 Control Valve Seat Leakage ASME B16.25 Butt Welding Ends ASME B16.5 Pipe Flanges & Flange Fittings NACE MR Valve Materials (option) BS1560 Circular Flanges for Pipes, Valves & Fittings BS4504 Circular Flanges for Pipes, Valves & Fittings Features Pressure Ratings ANSI Class 150lb to 600lb (BV500 Series) ANSI Class 900lb to 4500lb (BV990 Series) Equivalent metric pressure ratings Body A choice of globe or angle patterns available BV500 & BV990 Globe body BV501 & BV992 Angle body Weir Valves & Controls First choice for process protection 13

14 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Cage designs Multi-Flow (MF) - Single stage of pressure drop This form of trim design is fitted as standard and is suitable for most flow control applications (refer to front cover detail). In this design the flow is broken up into multiple jets by a number of radical holes in the cage. The flow is conventionally from outside to inside the trim so that jet impingement/high turbulence levels are controlled within the confines of the valve cage. Impingement of the jets within the valve cage produces a more stable downstream flow, reduces the effect of large scale separation and produces a smaller scale turbulence structure in the valve outlet. This in turn leads to a reduction in acoustic efficiency and changes the power spectrum of the generated noise, both of which contribute to a noise level reduction of between 15 and 20 dba compared to a contoured or ported trim valve. Further noise reduction in this style of trim can be achieved by reducing the size of the jets in the cage by drilling smaller holes, this design is referred to as the Single Stage Multi-Flow (SS), and can lead to a further 5 dba reduction in noise level. Cascade (CS) (Refer to front cover for details) The Cascade valve trim is a further advancement over the standard Multi-flow valve cage. It is used in control applications where high noise levels or cavitation would be predicted, with a standard trim design. Noise, flow erosion and/or vibration can result in a high pressure drop/ratio application if attention to controlling the pressure drop is not considered. The cascade trim has been specifically designed to eliminate these problems at source by controlling the pressure drop through a number of discrete stages of let-down. The Cascade cage is manufactured to close tolerances and consists of a series of sleeves. The number of sleeves (stages of let-down) required depends upon the amount of treatment necessary for the particular application. Each successive sleeve, has a number of radial holes, and a carefully calculated increase in flow area to ensure correct apportionment of the pressure drop. Thus, the small radial jets pass through a tortuous flow path resulting in high frictional and impingement losses. At the same time the impingement of the jets onto the outer radially drilled sleeves control the shock wave formation which has a major influence on overall noise reduction in gas/vapour applications. Variable Stage Cascade (VS) Is available when multiple stages of pressure letdown are required at low valve openings. This design particularly suits applications where there is a high-pressure drop at low flows, and a reduced pressure drop at normal to maximum flow-rates. The design philosophy of the Cascade and Multi- Flow Trims designs is combined within this trim. Variable Stage Cascade Body Protection Unit This design option is utilised on flashing liquid, multi-phase fluids, and on contaminated gas/vapour flows. The unit is designed to prevent erosive outlet flow, from the valve seat, directly impinging onto the pressure containing body walls. It is manufactured from hardened or hard-faced material to reduce erosion rates. The design breaks the erosive fluid flow into small jets and directs the bulk of the flow towards the valve outlet. Body Protection Unit 14 Weir Valves & Controls First choice for process protection

15 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 Plug designs Balanced The balanced plug design is utilised to greatly reduce fluid forces acting on the valve plug allowing economical actuation and stable control. The cylindrical plug head is drilled with balancing ports to admit pressure above the plug head. The annular leakage flow between the valve plug and cage is minimised by a sealing ring retained within a plug groove. The standard sealing rings are carbon graphite which give Class III leakage. Alternatively a U seal can be fitted to give either Class IV or Class V leakage dependent on seating load applied by the actuator. Solid (Unbalanced) The design is used on relatively low-pressure drop and/or on-off applications. It generally requires the use of much larger actuators than would be required on the balanced plug design and in all but small valve sizes is not suited to control applications. Pilot Balanced Trim The pilot balanced plug design incorporates two plugs, the main larger diameter plug used for control and the smaller pilot situated inside the main plug significantly reduces fluid forces acting on the main plug. This design produces a high integrity metal temperature where a resilient seal would be unsuitable. Opening of the valve is by the pilot plug, which lifts from its seat prior to the main plug head. This produces a flow passage to equalise the pressure above and below the valve plug, thereby significantly reducing the fluid forces acting on the valve plug. in the closed position the inlet pressure is admitted above the plug to produce a high downward seat load and the only leakage path is across metal to metal seating. Flash-cone This plug design is specified on applications requiring a very high rangeability. At low openings the conical plug nose fits inside a matching conical seat. The plug nose has a number of circumferantial grooves, which produce a staging of the pressure drop as the flow passes between the small annular passage between the plug and the valve seat. In addition to the increased rangeability this trim also allows the valve to handle higher-pressure drops at low valve openings than can be adequately handled by a standard plug design. Soft seat Is specified on applications where it is desirable to have a maximum closure on the control valve. The soft seat design consists of a resilient seal ring clamped into the plug by a face ring. When the soft seal contacts the valve seat, a lip on the seat bites into the face of the seal and effectively prevents leakage through the seat. The soft seat design can be specified in both balanced and un-balanced designs. Seal Rings On balanced design valves the valve plug is designed to incorporate a seal ring which prevents leakage around the periphery of the valve plug. Depending upon the desired leakage and temperature through the valve a variety of seal rings are specified. Carbon Ring Triple Seal Ring U Seal Weir Valves & Controls First choice for process protection 15

16 X-STREAM CONTROL VALVE TRIM Blakeborough A new, technologically advanced valve trim for extreme process conditions The new Weir Valves & Controls X-Stream trim has been specifically developed to eliminate the problems of erosion, cavitation and noise on both your severe and problematic services. Through it s unique flow path design, consisting of a multitude of staggered cylinders, the X-Stream is the first of its kind to provide 3D-flow control which stems from the understanding and control threedimensionality within the fluid flow as it passes through the valve. This is important because it is in these highly three dimensional areas where problems first start to occur. The X-Stream trim itself is the product of an extensive research and development programme which has used a combination of proven computational fluid dynamics (D) and actual flow visualisation techniques to evaluate and eliminate problematic areas within the design of the trim. This means that the X-Stream trim is able to ensure superb fluid control and continued reliability through a more accurate and thorough prediction of the fluid flow through the valve. As well as providing complete 3D flow control, the X- Stream is available in the usual variety of materials and has been designed with long term reliable service and ease of maintenance in mind. The disc stack is designed to be separable, increasing ease of on-site maintenance and keeping spares costs to a minimum. A leak resistant seal is achieved using integral, three-ringed metal seals. However, the trim is also available in a welded version if required. Features 3D flow control leading to reduced noise, cavitation, erosion and vibration problems on severe service/high-pressure applications. Trim design equated to up to 40 stages of pressure letdown, keeping extreme velocities and fluid turbulence to a minimum. Reduced maintenance due to natural self cleaning/anti-clogging capabilities reducing possibility of trim blockage on contaminated services which would result in poor flow control and expensive maintenance costs. Suitable for liquid, steam and gas applications as a solution to potentially excessive noise, cavitation, vibration and erosion problems. Custom designed to meet individual application needs, incorporating linear, equal percentage and custom characterised flow characteristics. On-site maintainable due to single unit, cageguided trim design allowing quick installation and removal. Disc stack is separable for ease of handling. Available for retrofit or as complete control valve package by incorporation into both the BV500 and BV990 range of Blakeborough globe and angle valves. Recommended applications Turbine Bypass Choke Valves Minimum Pump Flow Recirculation Anti Surge Boiler Feedwater Attemperator Spray Valve Overboard Dump 16 Weir Valves & Controls First choice for process protection

17 Blakeborough X-STREAM CONTROL VALVE TRIM How it works! The X-Steam's unique flow path is a multi-stage design, which has been specifically designed using modern analysis equipment, to safely control stage pressure drops and fluid velocity through the trim. Therefore reducing and eliminating the effects of such problems as noise, cavitation and erosion within the control valve. The strong relationship between pressure drop and fluid velocity means that the less pressure drop taken across the valve trim, the lower the fluid velocities through it. As it is not practical to have several valves in series to achieve large pressure drops, the X-Stream trim works by dividing this pressure drop over several stages of pressure letdown within the trim itself. This allows velocities to be controlled to within desired levels, and problems related to high velocities, such as noise and erosion can be reduced, see Figure 1. This pressure drop / velocity control also means that the X-Stream trim is ideally suited for controlling cavitation which is caused by the static fluid pressure falling below the vapour pressure of the liquid, therefore causing it to vapourise and form tiny bubbles of gas. These bubbles then implode as the static pressure subsequently rises back above the vapour pressure, and it is this implosion which creates most of the damage and noise problems associated with cavitating applications. By using several stages of pressure letdown as with the X- Stream trim, the minimum static pressure in the valve can be increased so that it does not fall below the vapour pressure, hence eliminating cavitation, see Figure 2. The X-Stream's flow path design of using several rows of flow obstructions to impede the flow has the effect of controlling the energy dissipation, cause by the drop in pressure, by forcing the fluid to impinge on itself rather than on the inner surfaces of the valve and trim. Trim designs using a torturous path to dissipate energy relay heavily on the impingement of the fluid on the inner surfaces of the trim and may therefore be prone to erosion in these areas on severe applications. The flow path design also provides the X-Stream trim with its unique self-cleaning ability. As part of the customised design process the spacing between flow obstructions will be sized to allow free passage of any expected line debris and once any particles have entered the trim there is nowhere for them to become lodged. However, should and unexpected debris become wedged between the flow obstructions the individual flow paths in the X-Stream trim are designed to offer several alternative routes for the fluid so as to minimise the effect on the valves performance. By working in conjunction with The University of Manchester UK, Hopkinsons has used modern computational fluid analysis in conjunction with traditional design methods to develop the X-Stream control valve trim and to ensure that it can meet the high performance demands of modern day, extreme process applications. Patent applied for. Pressure drop profile Velocity Profile Fig 1 Fig 2 Weir Valves & Controls First choice for process protection 17

18 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Table 1 Materials of construction Cage Plug Plug Stem Seat Service 420 ST.ST. Hardened 17-4PH ST.ST. Hardened / Integral with Cage/ -35 C to 399 C 17.4 PH / -30 F to 750 F 420 ST.ST. Hardened with Stellite 400 C to 565 C Stellite face & Guide 750 F to 1050 F / with Chrome Plated NACE MR PH ST.ST. Guide Diameter -35 C to 232 C -30 F to 450 F 420 ST.ST. Hardened 17-4PH ST.ST. -35 C to 232 C Hardened with PTFE Face -30 F to 450 F Monel K500 Monel 400 Monel 400/ Integral with Cage/ -35 C to 500 C Monel K500 Monel K F to 932 F Hastelloy C Hastelloy C Hastelloy C Integral with Cage/Hastelloy C Duplex Duplex Duplex Integral with cage/duplex Ceramic/420 ST.ST. + Ceramic + Ceramic *options for Stellite face or full Stellite available for most materials. Table 2 Leakage glass Leakage Class Seal Ring Material Temperature Class 111 Carbon Graphite -35 C (-30 F) to 565 C (1050 F) Class IV & V Carbon PTFE U Seal -35 C (-30 F) to 260 C (500 F) Class IV & V High temp U Seal 260 C (500 F) to 350 C (660 F) Class IV & V Virgin PTFE U Seal Cryogenic to -35 C (-30 F) Class IV Carbon Triple Seal 350 C (660 F) to 565 C (1050 F) Class V & MSS-SP-61 Pilot Balanced -35 C (-30 F) to 565 C (1050 F) Class VI Soft Face Seat -35 C (-30 F) to 232 C (450 F) Class III, IV & V None (un-balanced) Cryogenic to 565 C (1050 F) 18 Weir Valves & Controls First choice for process protection

19 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 Table 3 Recommended limiting velocities Metric Units US Units Body Size (MM) Liquid (M/S) Steam or Gas (M/S) Body Size (IN) Liquid (FT/S) Steam or Gas (Ft/S) 40, , , , , 200, 250, , 8, 10, , 400, 450, , 16, 18, Note: Maximum outlet velocity (steam or gas) = 0.65 x sonic Table 4 Rangeability Body Size MF1 & MF2 MF3 & MF4 MF5 & MF6 MF7 & MF8 MM IN SS1 & SS2 SS3 & SS4 SS5 & SS6 SS7 & SS8 40 to to 3 50:1 45:1 30:1 20:1 100 to to 8 65:1 55:1 45:1 35:1 250 to to 16 70:1 65:1 55:1 45:1 450 to to 30 80:1 70:1 60:1 50:1 Note: Maximum outlet velocity (steam or gas) = 0.65 x sonic Weir Valves & Controls First choice for process protection 19

20 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Table 5 - BV500 & BV501 series valves - multi-flow trim design CV SIZE TRAVEL MF1 MF2 MF3 MF4 MF5 MF6 MF7 MF8 (mm) =% LIN =% LIN =% LIN =% LIN =% LIN =% LIN =% LIN =% LIN mm 28.5mm mm 28.5mm mm 38mm mm 38mm 180* mm 57mm 410* mm 89mm 760* 760* mm 89mm mm 89mm mm mm 152mm mm mm mm 178mm mm mm mm mm 254mm mm mm mm mm 254mm mm mm mm mm 305mm mm mm mm *Indicates modified =% trim 20 Weir Valves & Controls First choice for process protection

21 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 Table 6 BV500 series valve - cascade trim design CV VALVE SIZE CS 2 CS 3 CS 4 CS 5 YOKE VALVE MOD LINEAR MOD LINEAR MOD LINEAR MOD LINEAR MOUNTING TRAVEL =% =% =% =% mm & 2 50mm mm mm mm mm 3 80mm mm mm mm mm 4 100mm mm mm mm mm 6 150mm mm mm mm mm 8 200mm mm mm mm 5 127mm mm 6 152mm mm mm mm mm 5 127mm mm 6 152mm mm mm mm mm 6 152mm mm 7 178mm Weir Valves & Controls First choice for process protection 21

22 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Table 7 BV990 and BV992 series valve - multi-flow trim design CV VALVE SIZE MF1 MF2 MF4 MF6 VALVE =% LINEAR =% LINEAR =% LINEAR =% LINEAR TRAVEL mm mm 2 50mm mm 3 80mm mm 4 100mm mm 6 150mm mm mm 8 200mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm = Consult factory. Table 8 BV990 and BV992 series valve - cascade trim design CV VALVE SIZE RATING CS 2 CS 3 CS 4 CS 5 VALVE MOD LINEAR MOD LINEAR MOD LINEAR MOD LINEAR TRAVEL =% =% =% =% mm ALL mm 2 50mm 900, 1500 & 2000LB mm 2500LB & 4500LB mm 3 80mm 900, 1500 & 2000LB mm 2500LB & 4500LB mm 900, 1500 & 2000LB mm 2500LB & 4500LB mm 4 100mm 900, 1500 & 2000LB mm 2500LB & 4500LB mm 6 150mm ALL mm ALL mm 8 200mm 900, 1500 & 2000LB mm mm 2500LB & 4500LB mm mm mm ALL mm ALL mm mm ALL mm ALL mm ALL mm 22 Weir Valves & Controls First choice for process protection

23 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 L M L N F/2 F Table 9 BV500 series valves dimensions BV500 F/2 BV501 BV500 Extension Bonnet Valve Size 1 1 2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 40mm 50mm 80mm 100mm 150mm 200mm 250mm 300mm 350mm 400mm 450mm 500mm 600mm 750mm Up to ANSI Class RF and BS Up to ANSI Class RTJ Class 300 Butt Weld F BS, PN64, PN100, ANSI Class RF Flanged & Butt Weld ANSI 600 Class RTJ Plain Bonnet (L) Plain Bonnet (M) Norm Bonnet (L) Norm Bonnet (M) Bellows Bonnet (L) Bellows Bonnet (M) Extension Bonnet (L) Extension Bonnet (M) N Standard Travel min 3 1 2min (Also refer to Table 8) Bonnet Mount Dia Extended Travels for Cascade Trim Valves Extended travel (Refer Table 9) Bonnet Mount Dia Plain L Norm L RF = Raised Face. RTJ = Ring Type Joint. Face-to-Face and Face to Centre Line Dimensions are generally in accordance with ISA = Consult Factory. Weir Valves & Controls First choice for process protection 23

24 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Table 10 BV990 series valves dimensions VALVE SIZE mm 50mm 80mm 100mm 150mm 200mm 250mm 300mm 350mm 400mm 450mm 500mm 600mm 750mm RATINGS UP TO AND INCLUDING ANSI CLASS 1500lb ANSI RF & PN ANSI 900 RTJ ANSI 1500 RF & PN250 F ANSI RTJ ANSI 900 & 1500 PN & PN250 Butt Weld Plain Bonnet L Norm Bonnet v N Standard Travels REFER TO TRIM SELECTION Bonnet Mount Dia ANSI CLASS 2000lb ANSI 2000 F Butt Weld Plain Bonnet L Norm Bonnet N Travel REFER TO TRIM SELECTION Bonnet Mount Dia ANSI CLASS 2500lb ANSI 2500 F Butt Weld Plain Bonnet L Norm Bonnet N Travel REFER TO TRIM SELECTION Bonnet Mount Dia = Consult Factory Consult factory for ANSI Class 4500lb Rated Valves 24 Weir Valves & Controls First choice for process protection

25 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 L N M F/2 BV990 F BV992 F/2 Table 11 BV992 series valves dimensions VALVE SIZE mm 50mm 80mm 100mm 150mm 200mm 250mm 300mm 350mm 400mm 450mm 500mm 600mm 750mm RATINGS UP TO AND INCLUDING ANSI CLASS 1500lb ANSI RF & PN ANSI 900 RTJ ANSI 1500 F RF & PN ANSI RTJ ANSI 900 & 1500 PN & PN250 Butt Weld Plain Bonnet M Norm Bonnet Standard Travels REFER TO TRIM SELECTION Bonnet Mount Dia ANSI CLASS 2000lb ANSI 2000 F Butt Weld Plain Bonnet M Norm Bonnet Travel REFER TO TRIM SELECTION Bonnet Mount Dia ANSI CLASS 2500lb ANSI 2500 F Butt Weld Plain Bonnet M Norm Bonnet Travel REFER TO TRIM SELECTION Bonnet Mount Dia = Consult Factory Consult factory for ANSI Class 4500lb Rated Valves Weir Valves & Controls First choice for process protection 25