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

26 CAGE TRIM VALVES BV500/1 & BV990/2 Blakeborough Table 12 Approximate weight Kg with multi-flow cages SIZE BONNET UP TO 300LB 600LB RATING 900 & 1500LB RATING 2000LB RATING 2500LB RATING STYLE (PN 40) (PN 100) (PN150 & PN250) (PN 330) (PN 420) FLG BW FLG BW FLG BW FLG BW FLG BW 40mm Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 50mm 2 Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 80mm 3 Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 100mm 4 Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 150mm 6 Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 200mm 8 Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 250mm 10 Plain N/A 1670 Norm N/A 1789 Bellow N/A N/A N/A N/A N/A N/A 300mm 12 Plain N/A 2098 Norm N/A 2199 Bellow N/A N/A N/A N/A N/A N/A 400mm 16 Plain N/A Norm N/A Bellow N/A N/A N/A N/A N/A N/A 500mm 20 Plain 3370 N/A Norm 3440 N/A Bellow N/A N/A N/A N/A N/A N/A 600mm 24 Plain 5010 Norm 5090 Bellow = Consult factory 26 Weir Valves & Controls First choice for process protection

27 Blakeborough CAGE TRIM VALVES BV500/1 & BV990/2 Table 13 End connection details for butt weld end valves (mm) VALVE SIZE BV500 ALL RATINGS BV990 UP TO & INCLUDING BV LB RATING BV LB RATING 1500LB (PN 250) (PN 330) (PN 420) ID OD ID OD ID OD ID OD 40mm (1 1 2 ) mm (2 ) mm (3 ) mm (4 ) mm (6 ) mm (8 ) mm (10 ) mm (12 ) mm (16 ) mm (20 ) 600mm (24 ) 750mm (30 ) Weir Valves & Controls First choice for process protection 27

28 LOW FLOW CAGE TRIM VALVES BV502/3/4/5 Blakeborough Description This versatile range of globe and angle valves available in sizes 15mm to 25mm ( 1 2" to 1") offer a wide variety of trim selections to suit all flow conditions in a nonbalanced construction. The body design can be supplied in cast or forged materials. There is a wide range of standard and high duty trims available that can be fitted within the same valve body. Flow characterisation is determined by the shape of the valve plug, or in the Multi-flow trim, a radial pattern of holes in the cage is arranged to give the required valve characteristic. 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. Parts substitution, internal inspection and maintenance can be performed with minimum trouble, the essential working components being removable while the body remains in the pipe line. Body A choice of globe or angle patterns is available BV502 Globe Body (cast) BV504 Globe Body (forged) BV503 Angle Body (cast) BV505 Angle Body (forged) Body materials The valves can be produced in most alloys. Standard cast body materials are:- Carbon steel; Grade WCB Monel Stainless steel; Grade 316/304/347 Aluminium Bronze Chrome moly steel; Grade WC5, WC6 & WC9 Hastelloy B/C Duplex Most other materials can be produced Main design standards ANSI B16.34 Valves-Flanged, Threaded & Welding End ANSI FCI 70-2 Control Valve Seat Leakage ANSI B16.25 Butt Welding Ends ANSI B16.5 Pipe Flanges & Flange Fittings NACE MR Valve Materials BS1560 Circular Flanges for Pipes, Valves & Fittings BS4504 Circular Flanges for Pipes, Valves & Fittings Design features Top cage guided Wide range of trim options High stability Easy maintenance Pressure rating Class 150LB to 4500LB Equivalent metric ratings Sizes 15mm to 25mm 1 2" to 1" End connection sizes 40mm (1 1 2") & 50mm (2") can be supplied Travels 10mm to 25mm 3 8" to 1" Features Flanged Butt weld Socket weld Screwed BV502 series valve fitted with contour trim and normalising bonnet 28 Weir Valves & Controls First choice for process protection

29 Blakeborough LOW FLOW CAGE TRIM VALVES BV502/3/4/5 Trim design Contour The contour trim is suitable for most flow applications and is provided as standard in most valves. The valve characteristic is determined by the contour of the plug head. The contour trim is available in eight trim sizes with equal percentage, linear or quick opening characteristics. The trim is available as a metal to metal or for tight shut off a soft face design is available. Spline The spline trim is designed specifically for accurate control of very small flows. The design consists of a long parallel nosed plug with a accurately cut V notch cut down the centre. The linear movement of the valve plug exposes a variable amount of the notch to the flow. The plug head shank is usually made from stellite or other hard wearing materials for galling resistance and to prevent erosion of the plug tip. The actual characteristic derived from the V notch is modified equal percentage. The spline trim is available in either metal to metal design or where bubble tight shut off is required a soft face is fitted. Multi-flow (single stage of pressure drop) In this design flow is broken up into multiple jets by a number of radial holes drilled in the cage. The flow is conventionally from outside to inside the cage so that jet impingement/high turbulence levels are controlled within the confines of the valve cage. The flow jets impinge together in the centre of the cage bore producing a more stable downstream flow which in turn reduces the effect of large scale separation thus producing a smaller scale turbulence structure in the valve outlet. This results in a reduction in acoustic efficiency, changes the power spectrum of the generated noise both of which contribute to noise level reduction of between 15 and 20 dba, compared to a contoured trim valve. Step cone This design is offered where a high degree of pressure breakdown is required on low flows. The plug head is designed with an extended shank having a number of stepped grooves down its length. As the flow medium passes the plug head the pressure drop is broken down in stages across the labyrinth steps of the plug. The plug head shank is usually made from stellite or other such hard wearing materials to prevent erosion of the plug tip. Contour trim Spline Multi-flow trim 2 & 3 Stage Pressure Letdown Trim Soft face contour trim Spline with diffuser Step cone trim These trim designs are suited to applications where a high degree of pressure letdown is required to eliminate cavitation on low flow applications. The trim is designed so that flow passes through each stage of the trim. The design requires a very tight tolerance between the plug and seat to eliminate anular flow between the plug and seat. Body Protection Unit (Diffuser) Is specified on globe valves where a high pressure across the valve leads to high velocity jet flow from the trim impinging directly onto the valve body wall. The seat diffuser deflects the jet away from the body wall towards the valve outlet. The seat diffuser is constructed of hardened steel which is more resistant to the effects of jet impingement than the valve body wall. This feature is particularly useful on flashing flows where high velocity two phase flows can lead to body erosion. 2-stage trim with diffuser 3-stage trim with diffuser Weir Valves & Controls First choice for process protection 29

30 LOW FLOW CAGE TRIM VALVES BV502/3/4/5 Blakeborough Valve selection guideline Valve flow co-efficient All valves are sized using the valve flow co-efficient, CV, in accordance with ISA as detailed in the Blakeborough sizing and selection manual. Design CV values are given in table 5. Body Selection The valve body size and style is selected on the basis of supporting the selected trim design and design CV. In addition consideration is made of the velocity and the required pressure drop application. Liquid velocities are limited mainly due to erosion considerations, whereas gas/vapour flow velocities are limited for trim stability noise and vibration considerations. Trim Selection The selection criteria of the valve trim ranges from valve flow co-efficient, rangeability, pressure drop, cavitation, flashing and noise consideration. Blakeborough sizing and selection manual details the various calculation methods and selection limitations for each trim design. TABLE 1 Standard trim material combinations TRIM TYPE PLUG SEAT CAGE CAGE TEMP 400 C (750 F) TEMP 400 C (750 F) & MAX ABOVE CONTOUR WITH STELLITE FACE WITH STELLITE FACE SPLINE WITH FULL STELLITE WITH FULL STELLITE STEP CONE 316 ST. ST. WITH STELLITE 316 ST. ST. WITH STELLITE MULTIFLOW WITH STELLITE FACE INTEGRAL WITH GUIDE 17-4PH ST.ST. 420 ST.ST. SOFT FACE WITH PTFE HARDENED HARDENED STAGED TRIM WITH STELLITE FACE WITH STELLITE FACE ALL TRIMS CERAMIC WITH ST.ST. CERAMIC WITH ST.ST. For services below -3.5 o C (-30 o F), all 316 ST. ST. construction with PTFE seals. The above table shows standard ST. ST. combination. Many other materials can be used depending on the application. TABLE 2 Recommended limiting inlet velocities for control valves VALVE SIZE LIQUID M/S LIQUID FT/S STEAM OR GAS M/S STEAM OR GAS FT/S MAX OUTLET (STEAM OR GAS) 15,20 & 25MM 1 2, 3 4 & X SONIC Note: 0.3 sonic for low noise applications TABLE 3 Rangeability for control valves VALVE SIZE CONTOUR (METAL & SOFT FACED) SPLINE (METAL & SOFT FACED) STEP CONE MULTI-FLOW STAGE TRIM 15,20 & 25MM , 3 4 & 1 Note: Control at openings of less than 5% is not recommended for prolonged periods 30 Weir Valves & Controls First choice for process protection

31 Blakeborough LOW FLOW CAGE TRIM VALVES BV502/3/4/5 TABLE 4 Control valve leak rates in accordance with ANSI/FCI ANSI LEAKAGE CLASS TRIM STYLE MAXIMUM ALLOWABLE LEAKAGE CLASS IV METAL FACED 0.01% OF RATED CAPACITY CLASSES V METAL FACED-LAPPED SEATS ML/MIN OF WATER PER INCH OF PORT PER PSI PRESSURE DROP CLASS VI SOFT SEAT BUBBLE TIGHT TABLE 5 Design CV values CONTOUR TRIM SPLINE/M SPLINE STEP CONE MULTIFLOW VALVE TRIM QUICK LINEAR TRAVEL VALVE TRIM MOD=% TRAVEL TRIM LINEAR TRAVEL TRIM =% LINEAR TRAVEL SIZE SIZE OPEN & =% SIZE SIZE SIZE SIZE DC MC SC4 4.5 MF (1 ) 25 MM 20 MM 15 MM DC2 DC3 DC4 DC5 DC6 DC mm (1 ) ALL SIZES MC00 MC0 MC1 MC2 MC3 MC4 MC STANDARD SPLINE 25mm (1 ) MULTI STAGE SPLINE 19mm ( 3 4 ) SC5 SC6 SC7 SC8 SC9 SC mm (1 ) MF2 MF3 MF mm (1 ) 25mm (1 ) 19mm ( 3 4 ) DC9 0.4 MC MC MC NOT AVAILABLE AS M/SPLINE MC9 MC10 MC11 MC12 MC MC MC TABLE 6 Valve weights (Kg) VALVE SIZE BONNET TYPE UP TO 600LB UP TO 1500LB UP TO 2500LB UP TO 4500LB AND (PN100) RTG (PN250) RTG (PN420) RTG RTG BODY STYLE FLG B.W FLG B.W FLG B.W FLG B.W UP TO 25MM PLAIN NA NA NA NA (1 ) CAST NORMALISING NA NA NA NA BV502 & BV503 BELLOWS NA NA NA NA CRYOGENIC NA NA NA NA UP TO 25MM PLAIN (1 ) FORGED NORMALISING BV504 & BV505 BELLOWS NA NA NA NA CRYOGENIC Weir Valves & Controls First choice for process protection 31

32 LOW FLOW CAGE TRIM VALVES BV502/3/4/5 Blakeborough L M N F/2 F BV502 valve F/2 BV503 valve TABLE 7 Valve dimensions BV502/503 CAST BODIES NOMINAL VALVE SIZE UP TO ANSI 300 LBR.F. (BS PN40) ANSI 600 LB R.F. & RTJ (BS PN 64 & 100) ANSI 900 LB & 1500 LB R.F. & RTJ (BS PN 160 & 250) BUTT WELD UP TO ANSI 600 LB (BS PN 250) BUTT WELD ANSI 900 & 1500 LB (BS PN 160 & 250) PLAIN NORM BELLOWS CRYOGENIC N (MAX) F F F F F/2 F F/2 L M L M L M L M 15mm / x 25 x x 1 x x 25 x x 1 x TABLE 8 Valve dimensions BV504/505 FORGED BODIES NOMINAL VALVE SIZE UP TO INCL. ANSI 1500 LB R.F. RTJ (BS PN40) ANSI 2500 LB R.F. & RTJ (BS PN 420) BUTT WELD UP TO ANSI 2500 LB (BS PN 420) BUTT WELD ANSI 4500 LB PLAIN NORM N (MAX) F F F F/2 F F/2 L M L M x 25 x x 1 x x 25 x x 1 x Weir Valves & Controls First choice for process protection

33 Blakeborough TOP & BOTTOM GUIDED VALVES BV800/1/2/3 Description The Blakeborough range of top and bottom guided valves are suited to a wide range of general process applications, such as water, steam, oil, gases and the majority of chemical services. The basic design incorporates a standard contour or V Port plug form as the control element, however, the valves construction allows more specialised trims to be fitted. The BV800 and BV801 double seated valve offers high capacity on low to medium pressure drop applications. The design is inherently balanced allowing the use of diaphragm actuators for the majority of applications. For higher pressure drop conditions the valve can be supplied with multi-flow sleeves to give low pressure recovery. The design is not suited for tight shut-off applications. The BV 802 and BV 803 series are single seated valves. They offer high rangeability, tight shut-off capability and can also be fitted with anticavitation/low noise trims. Design features 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. Top and bottom guided valve, single 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. Top and bottom guided Wide range of trim options High capacity (BV800/1) Excellent rangeability Action is field reversible High integrity closure (BV802/3) Inherently characterised trim Pressure rating Class 150LB to 1500LB PN10 to PN250 Sizes 40mm to 600mm (BV800/1) to 24 (BV800/1) 40mm to 250mm (BV802/3) to 10 (BV802/3) Travels 28.5mm to 152mm to 6 End connections Flanged Butt weld Socket weld Screwed Weir Valves & Controls First choice for process protection 33

34 TOP & BOTTOM GUIDED VALVES BV800/1/2/3 Blakeborough Trim options Contour/ V Port Several trim options are available as standard in the top and bottom guided series of valves. The contour V port trim presents a smooth profile to the flow leading to relatively high pressure recovery which is ideal for low pressure drop flow control applications. These designs are suitable for the majority of control applications. Characteristics Equal percent Linear Quick open Multi-flow Trim Seat Options Metal to metal Resilient seal Hard faced The multi-flow trim is designed for applications where customers require the top and bottom guided style of valve associated with the benefits of the traditional cage guided valve (listed right.) Low noise Anti cavitation Low pressure recovery The trim option can also be inverted if it is desired to change the actuator action. BV802/BV803 Valves with soft face trim The soft face trim option is specified on applications where bubble tight closure is required. As such it is only available on the single seated valves where the un-balanced nature of the valve allows a better class of seat closure. The soft seal is fitted into the plug head and retained by a shroud. The seat is designed with a lip so that when the plug head contacts the seat the seat face is deformed to produce a high integrity seal. Standard contour trims. Plugs can be inverted to change the fail action of the valve. BV800/1 valve with multi-flow trim. BV802/3 valve with multi-flow trim. BV802/3 valve with soft face trim. 34 Weir Valves & Controls First choice for process protection

35 Blakeborough TOP & BOTTOM GUIDED VALVES BV800/1/2/3 Valve selection guidelines Valve flow co-efficient All valves are sized using the valve flow co-efficient, CV, in accordance with ISA as detailed in the Blakeborough sizing and selection manual. Design CV values are given in table 5. Body Selection The valve body size and style is selected on the basis of supporting the selected trim design and CV. In addition consideration is made of the velocity and the required pressure drop application. Liquid velocities are limited mainly due to erosion considerations, whereas gas/vapour flow velocities are limited for trim stability noise and vibration considerations. Trim Selection The selection criteria of the valve trim ranges from valve flow co-efficient, rangeability, pressure drop, cavitation, flashing and noise consideration. Blakeborough sizing and selection manual details the various calculation methods and selection limitations for each trim design. TABLE 1 Standard material combinations Body Bonnet Bottom Flange Carbon Steel Cast or Wrought Chrome Moly Steel 304 or 304L ST.ST. 347 ST.ST. Hastelloy B or C Monel Alloy 20 Duplex Body Gasket PTFE PTFE PTFE PTFE Body Studs/Nuts B7/2H B7/2H or B16/7 B8/8 B8/8 B8/8 B8/8 B8/8 B8/8 B8/8 TABLE 2 Trim material combinations Plug 316 Stellite Faced 316 Full Stellite Hastelloy B/C Monel 400 Alloy PH ST.ST. NACE Duplex Seat 316 Stellite Faced 316 Full Stellite Hastelloy B/C Monel 400 Alloy PH ST.ST. Duplex Stem Hastelloy B/C Monel 400 Alloy 20 Duplex Guide Bush 440C ST.ST. 440C ST.ST. Stellite Stellite Monel K500 Stellite 440C ST.ST. Stellite Stellite Packing Parts Hastelloy B/C Monel 400 Alloy 20 Duplex PTFE gaskets are suitable for temperatures up to 232 o C (450 o F), above this material specifically considered. Materials listed are standard combination only. Any other material combination can be accommodated. Trim materials specified can be supplied to conform to NACE Spec. MR Material can be supplied to UOP spec. Other material combinations are available. TABLE 3 Recommended limiting inlet velocities for control valves VALVE SIZE 40 & 50mm (1 1 2 & 2 ) LIQUID m/s 12 LIQUID ft/s 40 STEAM or GAS m/s 105 STEAM or GAS ft/s 350 MAX OUTLET (STEAM or GAS) 80 & 100mm (3 & 4 ) x SONIC 150 & 200mm (6 & 8 ) to 600mm (10 to 24 ) Note: 0.3 sonic for low noise applications Weir Valves & Controls First choice for process protection 35

36 TOP & BOTTOM GUIDED VALVES BV800/1/2/3 Blakeborough TABLE 4 Rangeability for control valves BV800 & BV801 DOUBLE SEATED BV802 & BV803 SINGLE SEATED VALVE SIZE FULRATE MIDRATE LORATE FULRATE MIDRATE LORATE 40 & 50mm (1 1 2 & 2 ) 30:1 30:1 20:1 40:1 40:1 30:1 80 & 100mm (3 & 4 ) 40:1 30:1 30:1 60:1 50:1 40:1 150 & 200mm (6 & 8 ) 45:1 40:1 30:1 70:1 60:1 50:1 250 to 600mm (10 to 24 ) 50:1 45:1 30:1 80:1 70:1 60:1 Note: Standard/inherant rangeability of linear characteristic trims is 20:1 corresponding to a valve opening of 5%. Control at openings less than 5% is not recommended for prolonged periods. TABLE 5 Design CV values BV800 & BV801 DOUBLE SEATED BV802 & BV803 SINGLE SEATED TRIM TYPE BODY SIZE FULRATE MIDRATE LORATE FULRATE MIDRATE LORATE 40mm (1 1 2 ) mm (2 ) mm (3 ) mm (4 ) LINEAR 150mm (6 ) mm (8 ) mm (10 ) mm (12 ) mm (16 ) mm (20 ) mm (24 ) mm (1 1 2 ) mm (2 ) mm (3 ) mm (4 ) EQUAL % 150mm (6 ) mm (8 ) mm (10 ) mm (12 ) mm (16 ) mm (20 ) mm (24 ) mm (1 1 2 ) mm (2 ) mm (3 ) mm (4 ) QUICK OPEN 150mm (6 ) mm (8 ) mm (10 ) mm (12 ) mm (16 ) mm (20 ) mm (24 ) = Consult factory 36 Weir Valves & Controls First choice for process protection

37 Blakeborough TOP & BOTTOM GUIDED VALVES BV800/1/2/3 TABLE 6 Control valve leak rates in accordance with ANSI/FCI VALVE STYLE TRIM STYLE ANSI LEAKAGE CLASS MAXIMUM ALLOWABLE LEAKAGE BV800 & BV801 Double Seated Valves Metal Faced Class III 0.1% of Rated Capacity BV802 & BV803 Single Seated Valves Unbalanced Metal to Metal Class IV 0.01% Rated Capacity BV802 & BV803 Single Seated Valves Unbalanced Metal to Metal Lapped Seats Class V ml/min of water per Inch of Port Diameter per PSI differential BV802 & BV803 Single Seated Valve Unbalanced Resilient Seat Class VI Bubble Tight J L N N F BV800 valve F BV802 valve TABLE 7 Valve dimensions 40mm (1 1 2") 50mm (2") 80mm (3") 100mm (4") 150mm (6") 200mm (8") 250mm (10") 300mm (12") 400mm (16") 500 mm (20") 600 mm (24") Up to ANSI 300lb and PN40 (F) 235 (9 1 4) 267 (10 1 2) 317 (12 1 2) 368 (14 1 2) 473 (18 5 8) 568 (22 3 8) 717 (28 1 4) 775 (30 1 2) 940 (37) 1410 (55 1 2) 1470 (57 7 8) ANSI 600lb and PN100 (F) 251 (9 7 8) 286 (11 1 4) 337 (13 1 4) 394 (15 1 2) 508 (20) 610 (24) 762 (30) 820 (32 1 4) 990 (39) 1413 (55 5 8) 1600 (63) Up to ANSI 300lb Ring Joint (F) 248 (9 3 4) 283 (11 1 8) 333 (13 1 8) 384 (15 1 8) 489 (19 1 4) 584 (23) 733 (28 7 8) 791 (31 1 8) 956 (37 5 8) 1425 (56 1 8) 1486 (58 1 4) ANSI 600lb Ring Joint (F) 251 (9 7 8) 286 (11 1 4) 340 (13 3 8) 397 (15 5 8) 511 (20 1 8) 613 (24 1 8) 765 (30 1 8) 823 (32 3 8) 993 (39 1 8) 1425 (56 1 8) 1616 (63 5 8) Up to 300lb Butt/Socket/SCW (F) 251 (9 7 8) 286 (11 1 4) 337 (13 1 4) 394 (15 1 2) 508 (20) 610 (24) 762 (30 1 8) 775 (30 1 2) 1108 (43 5 8) Up to 600lb Butt/Socket/SCW (F) 251 (9 7 8) 286 (11 1 4) 337 (13 1 4) 394 (15 1 2) 508 (20) 610 (24) 762 (30) 820 (32 1 4) 1108 (43 5 8) BV 800/ Plain (J) 191 (7 1 2) 197 (7 3 4) 235 (9 1 4) 251 (9 7 8) 356 (14) 381 (15) 464 (18 1 8) 502 (19 3 4) 689 (27 1 8) 902 (35 1 2) 1220 (48) BV 801 Normalising (J) 311 (12 1 4) 323 (12 7 8) 352 (13 7 8) 400 (15 3 4) 464 (18 1 4) 530 (20 7 8) 705 (27 3 4) 791 (31 1 8) 1041 (41) 1260 (49 5 8) 1441 (56 3 4) Bellows (J) 365 (14 3 8) 378 (14 7 8) 464 (18 1 4) 476 (18 3 4) 660 (26) 673 (26 1 2) 895 (35 1 4) 910 (35 7 8) BV 802/ Plain (L) 159 (6 1 4) 165 (6 1 2) 203 (8) 194 (7 5 8) 311 (12 1 4) 376 (10 7 8) 349 (13 3 4) BV 803 Normalising (L) 283 (11 1 8) 295 (11 5 8) 321 (12 5 8) 343 (13 1 2) 419 (16 1 2) 422 (16 5 8) 591 (23 1 4) Bellows (L) 337 (13 1 4) 346 (13 5 8) 432 (17) 422 (16 5 8) 578 (22 3 4) 578 (22 3 4) 778 (18 5 8) BV800/1 (N) 156 (6 1 8) 168 (6 3 8) 210 (8 1 4) 222 (8 3 4) 330 (13) 356 (14) 438 (30 5 8) 473 (18 5 8) 660 (26) 839 (33) 965 (38) BV802/3 (N) 127 (5) 137 (5 3 8) 178 (7) 165 (6 1 2) 238 (9 3 8) 245 (9 5 8) 311 (12 1 4) Valve Travel 28.6 (1 1 8) 28.6 (1 1 8) 38.1 (1 1 2) 38.1 (1 1 2) 57.2 (2 1 4) 57.2 (2 1 4) 88.9 (3 1 2) 88.9 (3 1 2) 88.9 (3 1 2) 152 (6) 152 (6 ) = Consult factory. Consult factory for dimensions of 900 & 1500 LB rated valves Weir Valves & Controls First choice for process protection 37

38 TOP & BOTTOM GUIDED VALVES BV800/1/2/3 Blakeborough TABLE 8 Weights (flanged valves - Kg) 40mm (1 1 2") 50mm (2") 80mm (3") 100mm (4") 150mm (6") 200mm (8") 250mm (10") 300mm (12") 400mm (16") 500mm (20") 600mm (24") BV800 & BV801 CLASS 300LB (NP40) CLASS 600LB (NP100) Plain Norm Bellows Plain Norm Bellows BV802 & BV803 CLASS 300LB (NP40) CLASS 300LB (NP100) Plain Norm Bellows Plain Norm Bellows NA NA NA NA NA NA NA NA NA NA NA NA = Consult factory 38 Weir Valves & Controls First choice for process protection

39 Blakeborough THREE WAY VALVES BV830 & BV831 Description The BV830/831 valves are designed for either blending two different flows or for dividing a flow into two proportional amounts. The valves can be used on a wide range of process applications for air, water, steam, oil, gases and chemical services. The BV830 has two inlets and a common outlet branch. It is used for proportional blending of two flows into one stream, on such applications as control of process fluid temperature downstream of heat exchangers, or as mixing valves to control the composition of service media. It can also be used for flow splitting duties. The total capacity is constant irrespective of plug position. The BV831 series valves are used for proportional control on flow splitting applications. This valve has two outlets and a common inlet branch. They are used for proportional flow splitting, diverting a portion of the process medium from one part of a system to another. A typical application is on the upstream side of heat exchangers to control the temperature of the process fluid. Design features Top and skirt guided BV830 three way valve for flow mixing applications. The valve can also be used for flow splitting if the flow is in reverse Wide range of trim sizes High capacity High stability Balanced Pressure rating Class 150LB to 1500LB PN10 to PN250 ANSI 2500 Sizes 40mm to 400mm to 16 Travels 28.5mm to 89mm to End connections Flanged Butt weld (on special request) Socket weld (on special request) Screwed (on special request) BV831 three way valve for flow splitting applications Weir Valves & Controls First choice for process protection 39

40 THREE WAY VALVES BV830 & BV831 Blakeborough Trim options V Port Standard Trim The standard trim design for three way applications is the V port plug. This design provides high flow capacity, high rangeability and good leakage capability (ANSI class IV). Other trim options are available as semi-special in the three way valve. Characteristics Linear Equal percentage (special applications) Linear cascade (multi-stage) Seat Options Metal to metal Soft face Hard faced BV830/BV831 Valves with soft face trim The soft face trim option is specified on applications where bubble tight closure is required. The soft seal is fitted into the plug head and retained by a shroud. The seat is designed with a lip so that when the plug head contacts the seat high integrity of valve closure is achieved. Severe Service Trim Specialist severe service trims can be accommodated within the BV830 body design. The cascade trim is normally used for applications where the flow requires treatment at source to prevent cavitation and high noise levels on high pressure drop liquid and gas applications. Low noise Anti cavitation Low pressure recovery BV830 valve standard contour trim BV831 valve standard contour trim BV830 valve with soft face trim FLOW DIRECTION BV830 Normal Flow Mixing (Blending) BV830 Reverse Flow Splitting (Diverting) BV831 valve with soft face trim BV831 valve with cascade trim BV831 Normal Flow Splitting (Diverting) 40 Weir Valves & Controls First choice for process protection

41 Blakeborough THREE WAY VALVES BV830 & BV831 Valve selection guidelines Valve flow co-efficient All valves are sized using the valve flow co-efficient, CV, in accordance with ISA as detailed in the Blakeborough sizing and selection manual. Design CV values are given in table 4. Body Selection The valve body size and style is selected on the basis of supporting the selected trim design and design CV. In addition consideration is made of the velocity and the required pressure drop application. Liquid velocities are limited mainly due to erosion considerations, whereas gas/vapour flow velocities are limited for trim stability noise and vibration considerations. Trim Selection The selection criteria of the valve trim ranges from valve flow co-efficient, rangeability, pressure drop, cavitation, flashing and noise consideration. Blakeborough sizing and selection manual details the various calculation methods and selection limitations for each trim design. TABLE 1 Standard material combinations Body Bonnet Bottom Flange Carbon Steel Cast or Wrought Chrome Moly Steel 304 or 304L ST.ST. 347 ST.ST. Hastelloy B or C Monel Alloy 20 Duplex Body Gasket PTFE PTFE PTFE PTFE Body Studs/Nuts B7/2H B7/2H or B16/7 B8/8 B8/8 B8/8 B8/8 B8/8 B8/8 B8/8 TABLE 2 Trim material combinations Plug 316 Stellite Faced 316 Full Stellite Hastelloy B/C Monel 400 Alloy PH ST.ST. NACE Duplex Seat 316 Stellite Faced 316 Full Stellite Hastelloy B/C Monel 400 Alloy PH ST.ST. Duplex Stem Hastelloy B/C Monel 400 Alloy 20 Duplex Guide Bush 440C ST.ST. 440C ST.ST. Stellite Stellite Monel K500 Stellite 440C ST.ST. Stellite Stellite Packing Parts Hastelloy B/C Monel 400 Alloy 20 Monel 400 Duplex PTFE gaskets are suitable for temperatures up to 232 o C (450 o F), above this material specifically considered. Materials listed are standard combination only. Any other material combination can be accommodated. Trim materials specified can be supplied to conform to NACE Spec. MR Material can be supplied to UOP spec. Other material combinations are available. TABLE 3 Recommended limiting inlet velocities for control valves VALVE SIZE 40 & 50mm (1 1 2 & 2 ) LIQUID m/s 12 LIQUID ft/s 40 STEAM or GAS m/s 105 STEAM or GAS ft/s 350 MAX OUTLET (STEAM or GAS) 80 & 100mm (3 & 4 ) x SONIC 150 & 200mm (6 & 8 ) to 300mm (10 to 16 ) Note: 0.3 sonic for low noise applications Weir Valves & Controls First choice for process protection 41

42 THREE WAY VALVES BV830 & BV831 Blakeborough TABLE 4 Flow coefficients CV (US units) TABLE 5 Normal control valves leak rates BV830 BV831 TRIM TYPE BODY SIZE FULRATE FULRATE TRIM STYLE ANSI LEAKAGE CLASS MAXIMUM ALLOWABLE LEAKAGE 40mm (1 1 2 ) Unbalanced Metal Class IV 0.01% Rated Capacity 50mm (2 ) to Metal 80mm (3 ) LINEAR 100mm (4 ) 150mm (6 ) 200mm (8 ) Unbalanced Metal to Metal Lapped Seats Class V ml of water per inch of port diameter per PSI differential 250mm (10 ) mm (12 ) Unbalanced Class VI Bubble Tight 400mm (16 ) Soft Face J L G H F F BV830 valve BV831 valve TABLE 6 Valve dimensions 40mm (1 1 2 ) 50mm (2 ) 80mm (3 ) 100mm (4 ) 150mm (6 ) 200mm (8 ) 250mm (10 ) 300mm (12 ) 400mm (16 ) Up to ANSI 300lb and PN40 F 235 (9 1 4) 267 (10 1 2) 317 (12 1 2) 368 (14 1 2) 473 (18 5 8) 568 (22 3 8) 718 (28 1 4) 775 (38 1 2) 940 (37) G 157 (6 3 16) 168 (6 5 8) 200 (7 7 8) 216 (8 1 2) 273 (10 3 4) 306 ( ) 413 (16 1 4) 433 (17) 508 (20) H 187 (7 3 8) 200 (7 7 8) 232 (9 1 8) 273 (10 3 4) 319 ( ) 379 ( ) 540 (21 1 4) 562 (22 1 8) 635 (25) ANSI 600lb and PN100 F 251(9 7 8) 286 (11 1 4) 337 (13 1 4) 394 (15 1 2) 508 (20) 610 (24) 762 (30) 820 (32 1 4) 990 (39) G 164 (6 7 16) 178 (7) 229 (9) 267 (10 1 2) 319 ( ) 368 (14 1 2) 440 ( ) 455 ( ) 533 (21) H 195 ( ) 210 (8 1 4) 260 (10 1 4) 324 (12 3 4) 367 ( ) 435 (17 1 8) 562 (22 1 8) 584 (23) 660 (26) Up to ANSI 300lb Ring Joint F 248 (9 3 4) 283 (11 1 8) 333 (13 1 8) 384 (15 1 8) 489 ( ) 584 (23) 733 (28 7 8) 791 (31 1 8) 956 (37 5 8) G 160 (6 5 16) 172 (6 3 4) 204 (8) 220 (8 5 8) 277 (11) 310 (12 1 8) 417 (16 3 8) 437 (17 1 4) 515 (20 1 4) H 190 (7 1 2) 204 (8) 236 (9 1 4) 277 (10 7 8) 323 ( ) 383 ( ) 565 (22 1 4) 565 (22 1 4) 638 (25 1 8) ANSI 600lb Ring Joint F 251 (9 7 8) (39 1 8) G 167 (6 9 16) 181 (7 1 8) 332 (9 1 8) 270 (9 1 4) 322 ( ) 371 (14 5 8) 443 ( ) 458 (18) 536 (21 1 8) H (7 3 4) (8 5 16) ( ) ( ) (14 1 2) ( ) ( ) ( ) ( ) Plain (J) J 159 (6 1 4) 165 (6 1 2) 203 (8) 194 (7 5 8) 311 (12 1 4) 376 (10 7 8) 349 (13 3 4) Normalising (J) J 283 (11 1 8) 295 (11 5 8) 321 (12 5 8) 343 (13 1 2) 419 (16 1 2) 422 (16 5 8) 591 (23 1 4) Plain (L) L 191 (7 1 2) 197 (7 3 4) 235 (9 1 4) 251 (9 7 8) 356 (14) 381 (15) 464 (18 1 8) 502 (19 3 4) 689 (27 1 8) Normalising (L) L 311 (12 1 4) 323 (12 7 8) 352 (13 7 8) 400 (15 3 4) 464 (18 1 4) 530 (20 7 8) 705 (27 3 4) 791 (31 1 8) 1041 (41) Bellows (L) L 365 (14 3 8) 378 (14 7 8) 464 (18 1 4) 476 (18 3 4) 660 (26) 673 (26 1 2) 895 (35 1 4) 910 (35 7 8) Valve Travel 28.6 (1 1 8) 28.6 (1 1 8) 38.1 (1 1 2) 38.1 (1 1 2) 57.2 (2 1 4) 57.2 (2 1 4) 88.9 (3 1 2) 88.9 (3 1 2) 88.9 (3 1 2) = Consult factory 42 Weir Valves & Controls First choice for process protection

43 Blakeborough THREE WAY VALVES BV830 & BV831 TABLE 7 Weights (flanged valves - Kg) BV830 CLASS 300LB (NP40) CLASS 600LB (NP100) Plain Norm Plain Norm 40mm (1 1 2") mm (2") mm (3") mm (4") mm (6") mm (8") mm (10") mm (12") 400mm (16") BV831 CLASS 300LB (NP40) Plain Norm Bellows CLASS 600LB (NP100) Plain Norm Bellows = Consult factory Weir Valves & Controls First choice for process protection 43

44 DESUPERHEATING EQUIPMENT & SYSTEMS Blakeborough Pipeline desuperheaters BV985 - Variable Probe Spray Nozzle Large range of design Cv options High rangeability Swirl chambers and conical nozzles for optimum atomisation Pipe sizes 150mm (6 ) and above Interchangeable nozzles BV986 - Fixed Area Spray Ring Pipe sizes 25mm (1 ) and above CV designed for each application Simple and inexpensive system BV987 - Desuperheater Pipe Desuperheater pipe and optional liner BV988 - Fixed Area Probe Multi nozzle for optimum dispersion in steam flow Combined temperature & pressure reducing equipment BV994 - Globe Design BV995 - Angle Design These units offer an excellent combination of pressure and temperature control in one costeffective unit. Pressure Ratings ANSI Class 150 to ANSI 4500 PN10 to PN640 Sizes Inlet - 40mm (1 1 2 ) to 500mm (20 ) Outlet - 40mm (1 1 2 ) to 1000mm (40 ) Design Features Large range of trim design options - standard to low noise Outlet section for improved mixing and noise control Spray water injection away from control/seat faces to eliminate problems of thermal shock and erosion Optional pilot balanced design for tight shut off Proven design 44 Weir Valves & Controls First choice for process protection

45 Blakeborough DESUPERHEATING EQUIPMENT & SYSTEMS BV985 - Variable spray unit General The BV985 multi nozzle desuperheater is a proven design used in thousands of installations throughout the world. The latest version offers increased CV ratings and improved rangeability with the option of modified characteristics. Design Details The standard model incorporates 12 carefully spaced spray nozzles for optimum dispersion in the steam flow, and to minimise coalescence of the droplets. Nozzles arranged so that at low steam flows water is injected into high turbulence zone of the vortices shed from the desuperheater probe. Nozzle design incorporates swirl chambers and conical nozzle for optimum atomisation even at low superior pressures. Nozzle assemblies can be characterised to suit process requirements and nozzle selection can be changed after installation. Standard Design Options Water inlet connection size 25mm, 40mm and 50mm (1, and 2 ) Connection - flanged, socket weld Ratings - ANSI 150 to ANSI 2500 Nozzle sizes (see table 1) Superior Pressure 1 bar to 50 bar (15psi to 740psi) Nozzle Rangeability - up to 40:1 TABLE 1 Nozzle design CV MN1 MN2 MN3 MN4 MN5 MN TABLE 2 Branch height & actuator mount dimensions BV987 Branch Height Act. Mount Pipe Size mm L K Optional Handwheel K Air supply Filter regulator M L Diaphragm actuator N Positioner Refer to Actuator catalogues for dimensions. Standard Travel 57mm(2 1 4 ) Yoke Mtg 89.5mm ( ) Water inlet flange Desuperheater Pipe (optional extra) Steam flow Pipe to fall towards drain port. Inclination approx 20 mm per m under working conditions. 1 metre Rating M N 600lb lb & 1500lb lb Typical arrangment using BV985 Mark II Main steam supply Shown with manually operated isolating valve Hopkinsons parallel slide valve Filter regulator Positioner BV500 control valve pressure reducing Filter regulator From temperature loop Positioner Water supply BV985 Mark II Variable orifice multi-nozzle Reduced/Desuperheated steam BV987 Desuperheater pipe From pressure loop Water Flange Orientation The pipework inlet flange can be arranged to suit customer s pipework configurations. C Steam flow SPRAY UNIT B D A Weir Valves & Controls First choice for process protection 45

46 DESUPERHEATING EQUIPMENT & SYSTEMS Blakeborough BV986 - Fixed area spray ring General This unit offers a relatively simple and inexpensive solution for applications which have low rangeability and stable steam demand. The system consists of a spray ring together with a separate spray water control valve. The spray water control valve regulates the flow into an annular feed within the spray ring body. This annular feed passes water into a number of holes to produce a series of radial jets into the steam flow, which assist in the mixing process. Standard Design Options Body size - 25mm to 200mm (1 to 8 ) Ratings - ANSI 150 to ANSI 2500 Nozzle size designed for specific application Superior Pressure 1 bar to 50 bar (15psi to 740psi) Rangeability - up to 8:1 on steam flow BV987 - Pipeline desuperheater pipe The BV987 desuperheater pipe offers a convenient method to install either the BV985 or the BV988. It is available in sizes from 150mm to 900mm (6 to 36 ). An 80mm (3 ) branch flange is provided for mounting the desuperheater. The desuperheater pipe can be supplied in carbon steel or chrome moly. Desuperheater pipes can be supplied with protective liners when the service conditions indicate the possibility of thermal shock or to increase the steam velocity. BV988 - Fixed area probe General This multi-nozzle desuperheater can be fitted into line sizes >= 6. The nozzle head is the same as used in the BV985 incorporating up to 12 nozzles. The spray water is regulated by a separate spray water control valve. Standard Design Options Refer to BV985 section Rangeability - up to 8:1 on steam flow FACE TO FACE DIMENSIONS Bore (mm) Dimn (mm) DESIGN CV MD1 MD2 MD3 MD4 MD5 MD6 MD7 MD8 MD9 MD TABLE 3 Pipeline desuperheater standard materials Component BV985/BV988 BV986 Body <=427 C Carbon Steel Carbon Steel Body >427 C Chrome Moly Chrome Moly Spray unit head 316 L st.st. Seat 316 L st.st. Plug/Stem 316 L st.st. + stellite face Nozzles 316 L st.st. Swirl Inserts 316 L st.st. Spraywater BV988 Mark II Fixed orifice type BV987 Desuperheater Pipe (optional extra) Superheated steam Desuperheated steam Pipe to fall towards drain port. Inclination approx 20 mm per m under working conditions. 1 metre 46 Weir Valves & Controls First choice for process protection

47 Blakeborough DESUPERHEATING EQUIPMENT & SYSTEMS Standard Design Options Pressure Ratings ANSI Class 150 to ANSI Class 4500 PN10 to PN640 Sizes Inlet - 40mm to 500mm (1 1 2 to 20 ) Outlet - 40mm to 1000mm (1 1 2 to 40 ) Trim Options Multi-flow, Cascade 2/3/4/5 Valves with low noise trim and outlet silencers destined for a desalination plant in the Middle East. Combined steam reducing & desuperheating unit BV994 & BV995 units Application The BV994 and BV995 range of valves have been designed specifically for the control of process steam to meet the various pressures and temperatures required throughout the plant. It can also be specified to work in parallel with a turbine to supplement the supply of steam to process, also on turbine by-pass duties where the valve dumps the flow directly to the condenser or to cold reheat. Design The unit consists of a steam pressure reducing valve, either of angle or globe body configuration, with a specially designed outlet incorporating a spray water injection system and a combined mixer/silencer. Conditions usually associated with this service are high pressure drop in the critical flow regime leading to sonic conditions across standard trim designs. The BV994 and BV995 units can be fitted with either multiflow or cascade trims. These trims are able to handle the severe service conditions of this application without the by products of vibration, erosion and high noise levels. The type of plug generally used in this valve series is a balanced design to reduce the actuator load requirements. This design equalises the pressure above and below the plug in the open position thereby significantly reducing actuator loads. A further advancement on this design is the pilot balanced plug, which enables ANSI Class V shutoff to be achieved without the need of high thrust actuators. This design incorporates two plugs (one within the other), which creates a high integrity sealing system. The spray system consists of either a spray ring and separate spray water control valve, or a probe type variable spray unit, BV985, depending on steam turn down requirements. The spray water is normally injected before a series of baffle plates, which act to improve desuperheating efficiency. The baffle plates are carefully calculated to produce further stages of pressure drop and improved mixing of the steam and spray water. The main steam valve and the spray water valves are commonly fitted with pneumatic diaphragm or piston actuators, fitted with positioners for accurate response. Weir Valves & Controls First choice for process protection 47

48 DESUPERHEATING EQUIPMENT & SYSTEMS Blakeborough Turbine bypass systems Blakeborough have over 40 years of experience in design and manufacturing valves and desuperheaters. Equipment has been supplied throughout the world ranging from small process applications through to large power generating installations. Typical Scope of Supply High pressure by-pass control valve High pressure desuperheater High pressure spray water control valve IP by-pass control valve IP desuperheater IP spray water control valve Low pressure isolation valve LP by-pass control valve LP desuperheater LP spray water control valve Design Features Angle or globe designs. Tight shut-off with pilot operation to maximise efficiency. Cage guided plugs to eliminate vibration potential. Multi-stage low noise trims. Erosion resistant trim materials selected which also prevent galling and the effects of thermal cycling. Pneumatic or electro-hydraulic actuation. Variable spray designs. Ancillary instrumentation to give fast response, whilst maintaining stable operation. HP turbine bypass desuperheater for combined cycle power plant LP turbine bypass desuperheater for combined cycle power plant SEC. SUPER- HEATER COMBUSTION CHAMBER ATTEMPERATOR DRUM SUPERHEAT SPRAY PRIM. SUPER- HEATER ECONMS H.P. STEAM BY-PASS DESUPER- HEATER REHEAT ECONMS REHEAT SPRAY ATTEMPERATOR MAIN FEED & START-UP REGULATING VALVES H.P. HEATERS DISTRIBUTION DAMPERS H.P. TURBINE N.R.V. P FEED PUMPS I.P. & L.P. TURBINE L.P. STEAM BY-PASS DEAERATOR L.P. STEAM ISOLATING VALVE GENERATOR L.P. HEATERS DUMP TUBE L.P. SPRAY VALVE ELECTRICAL OUTPUT CONDENSER P FUEL FLUE GASES TO STACK Schematic of Turbine Bypass System 48 Weir Valves & Controls First choice for process protection

49 Blakeborough DESUPERHEATING EQUIPMENT & SYSTEMS Initial sizing of desuperheaters Information required at enquiry stage P 1 Inlet Pressure Bara (Psia) T 1 Inlet temperature C ( F) P 2 Required outlet pressure Bara (Psia) T 2 Required outlet temperature C ( F) P W Available spraywater pressure Bara (Psia) T W Spraywater temperature C ( F) W S Maximum inlet steam flow kg/hr (lb/hr) Controlled temp. should be higher than 5 C (9 F) above saturation point. Initial calculations Calculate the required flow of water W W, kg/hr (lb/hr), needed to control the steam temperature at the outlet, by the heat balance method. W W = W S (h 1 - h 2) (h 2 - h F) where h 1 = enthalpy of superheated steam at inlet where h 2 = enthalpy of steam mixture at outlet where h F = enthalpy of spraywater at inlet values in kj/kg (Btu/lb) Total outlet steam flowrate W M = W S + 2 W kg/hr (lb/hr) Sizing of low pressure pipeline This is the recommended pipe size for BV985, BV986 and BV988 pipeline types, or the outlet size for the BV995 design for efficient desuperheating. The pipe is sized so that the steam velocity does not exceed 90m/s (300ft/s) or, for BV985, BV986, BV988 types, fall below 4.5m/s (14ft/s). The preferred velocity is 75m/s (250ft/s). The minimum pipe diameter is calculated using the following formulae. W D = 18.8 M x V S W M x V S mm or D = in. Velocity Velocity where W M = outlet steam flowrate kg/hr (lb/hr) where V S = outlet specific volume m 3 /kg (ft 3 /lb) Velocity m/sec (ft/sec) For BV985, BV986 and BV988 desuperheaters there is a selection of standard trim sizes available BV995 units are often associated with outlet silencer sections depending upon the ratio of inlet and outlet pressures and the maximum permissible sound pressure. For these reasons each unit receives individual considerations based upon customer requirements. Distance to temperature sensing point Depending upon the amount of superheat required in the steam after desuperheating, the minimum recommended distance to the temperature sensing point can be determined from the graphs shown. To ensure complete mixing and absorption of the injected water the recommended distance increases as the steam saturation temperature is approached. kj/kg Enthalpy 250 Change 200 Graphs Btu/lb Final required degrees of superheat, degrees C. Minimum distance 7.5m metres Final required degrees of superheat, degrees F Minimum distance 25 feet feet Graphs based upon 300mm pipe size. For other sizes multiply distance by d (d = pipe dia. mm) 300 Should the recommended location for the temperature sensing point coincide with a pipe bend, then the sensing point should be moved a further two metres downstream. Examples on use of the above graphs Steam pressure 10 bara. Saturation temperature 180 C. Required outlet temperature 200 C Steam Inlet enthalpy 3253kJ/kg Enthalpy change Steam Outlet enthalpy 2829kJ/kg } 424 kj/kg Final required degrees of superheat = = 20 C Draw line from enthalpy change to intercept degrees of superheat line, read off minimum distance = 15.2 metres. Spraywater Temperature Effective desuperheater operation depends upon the correct amount of spraywater introduced into the steam flow. If the steam or water temperature conditions dictate a water addition of greater than 20% of the steam mass flow under normal conditions then a two stage nozzle system may be necessary. To limit the amount of water entering the steam to an acceptable level a maximum water temperature can be calculated using the following formulae. Tmax = (P + 0.5DS Δh + 630) C Metric Tmax = (0.125P + 0.5DS - 6.1Δh ) F Imperial where P = absolute steam pressure bara (psia) D S = final required degree of superheat C ( F) Δh = enthalpy change from inlet to outlet kj/kg (Btu/lb) Ideally the water temperature should be within the following range for satisfactory operation:- (T SAT - 100) C < T WATER < (T SAT - 5) C Metric (T SAT - 210) F < T WATER < (T SAT - 10) F Imperial also applying the maximum water temperature limitations when applicable (T SAT is the stream saturation temperature) Weir Valves & Controls First choice for process protection 49

50 DESUPERHEATING EQUIPMENT & SYSTEMS Blakeborough Design & installation of pipeline desuperheater systems Location in pipework The desuperheater should be installed so that the spray nozzle is located at the steam inlet of the tube (if supplied). A filter should be fitted in the spray water inlet line to prevent ingress of dirt. Pipe Joints Owing to the severe expansion strains which may be imposed on the joints when starting up it is essential that all flange joint bolts are manufactured from high tensile alloy steel irrespective of the steam pressure. These remarks also apply to the water joint flanges which are also subject to sudden temperature changes. Drainage and drainage systems Efficient drainage of the pipework following the desuperheater is essential. To ensure that water cannot accumulate at any point the pipe should be arranged to fall in the direction of flow approximately 20mm per metre ( 1 4 per foot) under actual working conditions and be provided with an efficient large capacity trap (10% of maximum flow to facilitate start-up and shut down of plant) at the lowest point. To prevent the trap becoming airbound the drain pipe should have ample capacity to deal with the drainage and be fixed as near to vertical as possible. There must be sufficient space in the drain pipe for water to flow down and air to pass up the pipe. When starting up the plant it is advisable to open the trap by-pass valve to deal with any excess water. If a by-pass valve is not fitted the trap should be inspected to ensure that it is passing water and has not become airbound. When the pipework has warmed through to working temperature and a reasonable amount of steam is flowing the drainage of water should practically cease and the trap by-pass valve can then be closed. Successful operation of a desuperheater depends to a large extent on the injection of water being hot, preferably near to the saturation temperature of the steam to be cooled so that it is mainly the latent heat which is extracted from the steam to evaporate the injected water. This minimises the time of the suspension of the water particles in the steam so that all the water is evaporated and none falls to the inside walls of the pipework. As mentioned below the pipes connecting the water supply to the injection nozzle should be efficiently lagged to minimise the loss of heat. The water pressure and temperature should be no less than the values originally specified at the enquiry/order stage since these figures are used for design purposes in sizing the injection nozzle. The pipes connecting the water supply to the injection nozzle should be no less in diameter than the water isolating valve flange connections indicate. Condensate supply should be free from debris and effectively filtered to less than 0.25mm. Lagging of pipes The fact that a desuperheater is a device for reducing the steam temperature sometimes leads to the mistaken impression that the lagging of steam and water pipes is not important. Unlike the absorption of heat by the spray water, any loss of heat should be avoided. Unless the pipework can be maintained at the proper temperature successful desuperheating may not be possible and a preliminary trial of a plant before it has been lagged may prove disappointing. 50 Weir Valves & Controls First choice for process protection

51 Blakeborough DESUPERHEATING EQUIPMENT & SYSTEMS Design & installation of pipeline desuperheater systems SELECTION CHART 1 Is inlet pressure rating less than PN250? 2 Is inlet pressure rating greater than PN100 and outlet pressure rating less than PN100? 3 Is outlet pipe size greater than 100mm? 4 Is steam flow variable? PRESSURE REDUCING AND DESUPERHEATING 1 YES 2 YES 3 NO YES NO 4 YES NO 5 DESUPERHEATING ONLY NO 5 Is outlet pipe size greater than 100mm? 6 Is steam flow variable? YES 6 YES NO NO 7 7 Is pipe size greater than 100mm? 8 Is steam flow variable? YES 8 YES NO NO RECOMMENDED SYSTEM BV985 MARK II BV988 MARK II BV986 BV994/5 USED IN CONJUNCTION WITH CONTROL VALVE OF SERIES STATED BV 990 BV 990 BV 990 BV 500 BV 500 BV 500 NOTE:- This chart is for guidance only. Other factors, such as customer conditions or special requirements may result in a different system than recommended by this chart. Weir Valves & Controls First choice for process protection 51

52 DIAPHRAGM, MANUAL & LEVER ACTUATORS Blakeborough Description The Blakeborough range of diaphragm actuators is designed to suit the majority of control applications and offer an economical solution to valve control. The diaphragm actuator is available in two basic forms, the direct acting type (A40 series) and the reverse acting type (A41 series). Both ranges are suitable for modulating applications when used in conjunction with a suitable control device. Alternatively they can be used for On/Off applications. A number of optional features can also be specified such as manual handwheels or travel limit stops. The simplicity of design of the actuator enables routine maintenance in the field without the need for removal of the actuator to the workshop. All actuators in the Blakeborough range are produced in the same range of travels and bonnet mount diameters and are interchangeable size-forsize on any Blakeborough valve body. Design Features Economical design Side and top mounted handwheels A40A Diaphragm Actuator (200 in 2 ) Range adjustable limit stops High stability Low hysteresis Pressure/temperature rating Pressures Bar (45-75 PSI) Temp -40 C - 80 C (-40 F F) Sizes 50 in 2 (320 cm 2 ) 100 in 2 (640 cm 2 ) 200 in 2 (1290 cm 2 ) 300 in 2 (1935 cm 2 ) Travels 19mm to 178mm 3 4" to 7" A41A Diaphragm Reverse Acting Actuator (100 in 2 ) 52 Weir Valves & Controls First choice for process protection

53 Blakeborough DIAPHRAGM, MANUAL & LEVER ACTUATORS A40 & A41 series piston actuator - general description The Blakeborough, spring return diaphragm actuators come in two basic forms, the type A40 which is direct acting and the A41 which is reverse acting. Both are designed with a cast iron yoke (carbon steel on request) and a high integrity carbon steel diaphragm case. The A40 actuator is designed with an air tight upper chamber and when air is applied the pressure pushes the actuator stem downwards. When air is released the spring force lifts the actuator stem upwards. The A41 actuator has a pressure tight lower chamber and when air is applied pressure lifts the actuator stem. When air is released the actuator spring pushes the stem downwards. Features Manual Controls Side Mounted Handwheel (geared) Side Mounted Handwheel (clipon) 200 in 2 Direct Acting Diaphragm Actuator Top mounted handwheel Top mounted limit stop Travels 19mm ( 3 4") to 178mm (7") Mounting The actuator yoke allows easy access to the gland and stem coupling. The base is secured to the bonnet by a clamp ring (on larger yoke mountings bolts are used) and the complete unit may be removed without disturbing the gland of the valve. Stem Coupling Actuator and valve stems are connected by a steel split coupling, the halves bolted together to ensure a tight union. Position Indicator A travel indicator having pointer and graduated plate shows the position of the valve plugs at all times. Materials of Construction Yoke - Nodular cast iron (carbon steel on request) Case - High integrity carbon steel 200 in 2 Reverse Acting Diaphragm Actuator Spring - High tensile spring steel Diaphragm - Buna N nitrile rubber (other materials on request) BC Weir Valves & Controls First choice for process protection 53

54 DIAPHRAGM, MANUAL & LEVER ACTUATORS Blakeborough Features and options S Type Side Handwheel Side Mounted Handwheel Handwheels are designed to give an override facility to the operator to bypass the control signal that is controlling the valve therefore allowing manual intervention in the control system. This can sometimes be useful in such things as plant start-up to preposition the valve to a given flow. There are two forms of side mounted handwheel unit available in the Blakeborough range. The S type is of bell crank design which may be added to a basic diaphragm actuator without any need for design modifications (although re-positioning of instruments may be required). The S type unit can only be used for valve travels of up to 1 1 2" (38mm). For valve travels above 1 1 2" (38mm) the B type side mounted unit should be used. As this is a geared unit, it is purpose designed and should be selected at the order stage. The unit is built as an integral part of the actuator yoke on A40B & A41B actuators. B Type Handwheel Side mounted handwheels can also be used to limit travel in either direction (though not at the same time). The handwheel may be set in the neutral position for automatic operation through the full valve travel. In any other position valve travel is restricted. Top Mounted Handjacks Top mounted handjacks are supplied as an alternative to the side mounted handwheel where for example space may be limited or access is only available from the top. They are designed principally as a travel limit stop, however the top mounted handwheel can be used to give manual control of the valve. The handjack comes in two basic designs, when fitted with a handwheel it can be used for manual intervention. When fitted with a cover it becomes a limit stop which may be set by the valve operator to limit either the opening or closing of the valve. A41K Limit Stop Top Handjack A41F Handwheel A40J Limit Stop Top Handjack A40E Handwheel 54 Weir Valves & Controls First choice for process protection

55 Blakeborough DIAPHRAGM, MANUAL & LEVER ACTUATORS Diaphragm, manual Lever actuators The actuator is useful in applications where conditions do not justify instrument operation, but where precise control of the process is required. Valves equipped in this way can be converted at any time to pneumatic operation, since the actuators are interchangeable, size-for-size. The handwheel is keyed to a revolving nut which engages a screwed non-revolving stem connected to the plug by means of a normal split coupling. Anti-friction thrust bearings ensure ease of operation. A locking facility which, can additionally incorporate a lower travel stop, is available. Clockwise rotation of the handwheel moves the stem downwards. For thrusts greater than 200lb F geared units would be specified. Generally used for operation of the valve by existing hydraulic or pneumatic cylinder. The lever mechanism is carried on a standard cast yoke and operates a sliding stem, riding in permanently lubricated bearings. The unit can be adjustable for travel and is connected to the valve stem by the normal split coupling. The length of the lever and provision for piston rod connection is manufactured to suit customers requirements. Size Bonnet Max J1 H5 Wt Code Mount Travel (Kg) Size Bonnet Max P1 H4 Wt Code Mount Travel (Kg) MB MD MF MF MF WB WD WF WF WF WJ WJ P1 J1 H4 H5 A48/A49 yokeless diaphragm actuator The A49 style actuator is basically the same design as the standard A40/A41 diaphragm actuators, but manufactured without yoke. The design has been primarily developed for fitting to butterfly valves. Weir Valves & Controls First choice for process protection 55

56 DIAPHRAGM, MANUAL & LEVER ACTUATORS Blakeborough D D D D D D D D J1 H3 H J H1 P H2 P P H P H1 H J H1 J1 K A40A A41A A40B A41B A40S A41S A40A A41A (50in 2 & 100in 2 ) (50in 2 & 100in 2 ) L K L A40 & A41 series actuator dimensions Size Area Act r Travel Basic Weight D H H1 H2 H3 J J1 K L P Code Mount Unit with Sq in Dia Weight H/W Sq cm (kg) (kg) DB DB GB GB GD GD KD GF N/A KF KF KF KJ KJ LF N/A N/A LF N/A N/A LJ N/A N/A LJ N/A N/A LJ N/A N/A LJE N/A N/A LJF N/A N/A Weir Valves & Controls First choice for process protection BC

57 Blakeborough DIAPHRAGM, MANUAL & LEVER ACTUATORS A40 & A41 series actuator technical data Size Data Design Conditions Size Area Yoke Tra,L Max Initial Swept Total Code Mtg Work Vol Vol Vol Sq in Press in3 in 3 in 3 Sq cm PSI Bar mm 3 mm 3 mm 3 DB DB GB GB GD GD KD GF KF KF KF KJ KJ LF LF LJ LJ LJ LJE LJE Thrusts Approximate Stroke Speed (Secs) of valves with positioner Spring Pneu. Min Spring Pneu. Min Bench No Booster Range Thrust Spring Range Thrust Spring Set Booster (Norm) Thrust (Max) Thrust PSI Bar lbf kgf lbf kgf PSI Bar lbf kgf lbf kgf Apply Vent Apply Vent Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max NA NA NA NA NA NA Min Max NA NA NA NA NA NA Min Max NA NA NA NA NA NA Min Max NA NA NA NA NA NA Min Max NA NA NA NA NA NA Min Max NA NA NA NA NA NA Min Max NA NA NA NA NA NA Weir Valves & Controls First choice for process protection 57

58 MULTI SPRING ACTUATORS Blakeborough Description The Hopkinsons range of multi-spring diaphragm actuators is designed to suit the majority of control applications and offer an economical solution to valve control. The unit features a high integrity steel casing which houses the spring return mechanism. The design height of the actuator is reduced when compared to conventional single spring actuators. The multi-spring diaphragm actuator is available in either reverse acting (A61) or direct acting (A60) type. Both ranges are suitable for modulating applications when used in conjunction with a suitable control device. Alternatively they can be used for On/Off applications. A number of optional features can also be specified such as manual handwheels or travel limit stops. The simplicity of design of the actuator enables routine maintenance in the field without the need for removal of the actuator to the workshop. Design features Economical design Side and top mounted handwheels Compact design with reduced height High strength actuator case with rugged design Low volume between diaphragm and actuator case High stability Low hysteresis Diaphragm - Buna N nitrile rubber (other materials on request) Pressure/temperature rating A60A - Direct Acting (85in 2 ) Pressure 5 Bar (73 PSI) Temperature -40 C to 120 C (-40 F F) Sizes 50 in 2 (320 cm 2 ) 225 in 2 (1450 cm 2 ) 85 in 2 (550 cm 2 ) 326 in 2 (2100 cm 2 ) 147 in 2 (950 cm 2 ) Travels 19mm to 178mm 3 4" to 7" Materials of Construction Yoke - Nodular cast iron (carbon steel on request) Case - High integrity carbon steel Spring - High tensile spring steel Diaphragm - EPDM, Fabric Reinforced with Polyester (other materials on request) A61A - Reverse Acting (85in 2 ) 58 Weir Valves & Controls First choice for process protection

59 Blakeborough MULTI SPRING ACTUATORS Top mounted Top mounted handwheels are supplied as an alternative to the side mounted handwheel where for example space may be limited or access is only available from the top. They are designed principally as a travel limit stop, however the top mounted handwheel can be used to give manual control of the valve. A60B - Direct Acting (85in 2 ) A60 & A61 series The Hopkinsons, spring return diaphragm actuators come in two basic forms, the type A60 which is direct acting and the A61 which is reverse acting. Both are designed with a cast iron yoke (carbon steel on request) and a high integrity carbon steel diaphragm case. The A60 actuator is designed with an air tight upper chamber and when air is applied the pressure pushes the actuator stem downwards. When air is released the spring force lifts the actuator stem upwards. The A61 actuator has a pressure tight lower chamber and when air is applied pressure lifts the actuator stem. When air is released the actuator spring pushes the stem downwards. The spring chamber features four diametrically opposed springs which give the actuator its fail action. The compact nature of the spring design means that the actuator height is substantially reduced when compared to conventional single spring actuators. The yoke section of the actuator is designed to NAMUR standards which means that the majority of European designed positioners and instrumentation will mount, and are interchangeable, with the minimum of effort. One of the main benefits of the multi spring actuator is that the design of the air cylinder means that the unit is field reversible without the need to purchase new parts. This enables the engineer to change the fail action of the valve in the field with very little effort. Side mounted Handwheels are designed to give an override facility to the operator to bypass the control signal that is controlling the valve therefore allowing manual intervention in the control system. The side mounted handwheel is modular in construction and is secured as an intermediate section between the yoke and the diaphragm casing. When the handwheel is engaged movement of the valve is achieved by turning the handwheel. To put the valve in automatic operation the handwheel can be disengaged. A finger pointer indicated the position of the handwheel. The handwheel can also be used as a limit stop to limit travel in either direction (though not at the same time) A61B - Reverse Acting (85in 2 ) Weir Valves & Controls First choice for process protection 59

60 MULTI SPRING ACTUATORS Blakeborough A60 & A61 series actuator dimensions Size Area Act r Travel Basic Weight Code Mount Dia Unit with D H J H1 P Sq in Inch Inch Weight H/W Inch Inch Inch Inch Inch (Sq cm) (mm) (mm) (kg) (kg) (mm) (mm) (mm) (mm) (mm) D (320) (54) (25.4) (54) (28.6) (280) (440) (625) (650) (250) (71.4) (38) E (550) (54) (25.4) (54) (28.6) 14.2 (480) (665) (690) (360) (250) (71.4) (38) (90.5) (57.2) (500) (685) (710) H (950) (54) (25.4) (54) (28.6) (506) (781) (786) (71.4) (38) (450) (300) (90.5) (57.2) (570) (845) (850) (90.5) (89) (600) (875) (880) I N/A 550 (1450) (71.4) (38) (562) (962) N/A (90.5) (57.2) (630) (1030) (90.5) (89) (550) (300) (5) E.C. N/A E.C.. (125) (89) (5) (5) J 326 (5) (2100) (125) (57.2) *E.C. (Engineering Consult) (5) (125) (89) 25.6 (5) (5) E.C E.C (650) E.C E.C E.C (125) (127) (5) 6 (125) (152) (5) 7 (125) (178) 60 Weir Valves & Controls First choice for process protection

61 Blakeborough MULTI SPRING ACTUATORS A60 & A61 series actuator technical data Size Area Act r Travel Design Condition Thrusts Stroke Time (secs) Code Mount Dia Max Work Initial Vol Swept Vol Total Vol Spring Min No Booster Booster Sq in Inch Inch Press in 3 in 3 in 3 Range Thrust Apply Apply (Sq cm) (mm) (mm) psi(kg/cm2) (cm 3 ) (cm 3 ) (cm 3 ) psi (kg/cm 3 ) lbf (kgf) Vent Vent Special Notes: 1) E.C. (Engineering Consult) 2) Approximate Stroking speed of valves with positioner MIN MAX MIN MAX D (320) (54) (25.4) (710 (948) (1658) ( ) (64) (54) (28.6) (5) (710) (1068) (1778) (0.8-44) (256) (71.4) (38) (710) (1418) (2128) ( ) (384) E (550) (54) (25.4) (1360) (1643) (3003) ( ) (110) (54) (28.6) 73 (1360) (1850) (3210) (5) ( ) (440) (71.4) (38) (1360) (2458) (3818) ( ) (660) (90.5) (57.2) (1360) (3700) (5060) H (950) (54) (25.4) (2140) (2585) (4725) (54) (28.6) (2140) (2911) (5051) ( ) (190) (71.4) (38) (5) (2140) (3868) (6008) ( ) (760) (90.5) (57.2) (2140) (5822) (7962) ( ) (1140) (90.5) (89) (2140) (9060) (11200) I (1450) (71.4) (38) (3680) (6070) (9750) (90.5) (57.2) (3680) (3680) (9138) ( ) (290) (90.5) (89) (5) (3680) (14220) (17900) ( ) (1160) (5) (125) (89) (3680) (14220) (17900) (5) (5) (3680) (20290) (23970) J (2100) (57.2) (89) ( ) (420) E.C. (5) 71 E.C. E.C. E.C E.C. (127) (5) ( ) (1680) (152) ( ) (2520) 7 (178) Weir Valves & Controls First choice for process protection 61

62 ACTUATORS - TYPICAL PIPING Blakeborough The range of instrument combinations for spring return actuators is virtually endless, however, the most common combinations are shown. On/Off applications with solenoid and airset (Fig 1) The actuator is fitted with a solenoid and airset as shown. The solenoid is connected to the side of the diaphragm chamber to be pressurised depending on actuator action. The regulated air supply is connected to the solenoid through the airset. The airset pressure setting should be less than the maximum diaphragm pressure. Air can then be either applied or vented from the actuator via the solenoid thereby opening or closing the valve. Normal positioning applications (Fig 2) The actuator is fitted with positioner and airset. The positioner is linked to either the upper or lower actuator chamber depending on actuator action and increases or decreases the air pressure to the actuator thereby positioning the valve. The change in air pressure is controlled by the positioner in response to an instrument signal (normally 3 to 15 PSI or 4 to 20mA) fed to the positioner from the control system. The airset is used to both limit the maximum air pressure in the system to avoid over-pressurising the actuator, and to filter the air to remove foreign particles from the system. 3-WAY SOLENOID VALVE DA RA FIG 1 DA RA FIG 2 P0 POSITIONER 1A P1 ELECT. SUPPLY A EXHAUST B C AIR SUPPLY FILTER REGULATOR AIR SUPPLY FILTER REGULATOR INSTRUMENT SIGNAL Fast action fitted with volume boosters (Fig 3) The principle of operation of a valve fitted with volume boosters is identical to that described above except that the positioner output is piped directly to the signal connection on the booster, instead of into the diaphragm case. The booster, in relation to the control signal from the positioner either opens or closes. This allows a higher volume of air to either energise or vent from the actuator than would pass through a conventional positioner. The maximum pressure of air allowed to pass to the actuator is controlled by the setting of the airset. DA RA FIG 3 P0 POSITIONER 1A P1 61H BOOSTER RELAY FILTER REGULATOR INSTRUMENT SIGNAL AIR SUPPLY Air fail valve stays put with the positioner and airset (Fig 4) In normal operation the actuator responds to the valve positioner as described above. To achieve a fail fix condition on air failure the trip valve senses a supply failure in the air pilot line. When this condition occurs the ports of the trip valve connected to the valve positioner are deactivated and air is locked into the actuator chamber. If any air leaks occur in the pipework then the actuator will revert to the inherent fail position of the actuator. Solenoid trip valve opens or closes (Fig 5) In normal operation and fail condition this arrangement operates as described above. To operate from an electrical signal a solenoid valve is connected in the air line between the positioner and diaphragm case. Once the solenoid is tripped this vents air from the diaphragm chamber and the spring return action of the actuator returns the actuator to its relaxed state. RA DA FIG 4 P0 POSITIONER 1A P1 AC61A C A B INSTRUMENT SIGNAL AIR SUPPLY FILTER REGULATOR 3-WAY SOLENOID VALVE ELECT. SUPPLY DA B A EXHAUST C RA P0 POSITIONER 1A P1 AIR SUPPLY FILTER REGULATOR FIG 5 INSTRUMENT SIGNAL 62 Weir Valves & Controls First choice for process protection

63 Blakeborough ACTUATORS - CODING Basic Actuator Model Number A40 - Direct acting diaphragm A41 - Reverse acting diaphragm A50 - Direct acting piston A51 - Reverse acting piston A36 - Double acting piston A60 - Direct acting multi spring diaphragm M1 - Manual W1 - Lever Design Feature A - Standard B - Side Handwheel C - Top Handwheel Size (Effective Area) D - 50 in 2 (320 cm 2 ) E - 85 in 2 (550 cm 2 ) F - 75 in 2 (480 cm 2 ) G in 2 (640 cm 2 ) H in 2 (950 cm 2 ) I in 2 (1450 cm 2 ) J in 2 (2100 cm 2 ) K in 2 (1290 cm 2 ) L in 2 (1935 cm 2 ) M - Manual Actuator Yoke Mounting B (54 mm) D (71.6 mm) F (90.5 mm) J - 5 (127 mm) N - 7 (177.8 mm) A60 B G F 8 S B Stroke Stem Connector Thread Spring Range (19 mm) 4-1 (25.4 mm) (28.5 mm) (38.1 mm) (57.1 mm) (88.9 mm) 9-5 (127 mm) E - 6 (152 mm) F - 7 (177.8 mm) G - 9 (228.6 mm) M - M8 x 1 mm pitch N - M10 x 1.25 mm pitch P - M12 x 1.25 mm pitch R - M16 x 1.5 mm pitch U - M20 x 1.5 mm pitch S - M22 x 1.5 mm pitch T - M22 x 1.5 mm pitch anti-rotation V - M33 x 2 mm pitch anti-rotation W - M39 x 2 mm pitch anti-rotation A - 3 to 15 PSI or 0.2 to1.0 kg/cm 2 B - 6 to 30 PSI or 0.4 to 2.0 kg/cm 2 C - 12 to 30 PSI or 0.8 to 2.0 kg/cm 2 D - 18 to 44 PSI or 1.2 to 3.0 kg/cm 2 Modification Blank- No modification 0 - No air connection air connection air connection air connection P - Stainless steel packing box L - LCB Yoke W - WCB Yoke S - St.St. construction-std paint T - St.St. construction-spl paint Weir Valves & Controls First choice for process protection 63

64 Division head office: Weir Valves & Controls Tel: +44 (0) Fax: +44 (0) Local Representative Sales/manufacturing: Weir Valves & Controls UK Ltd Tel: +44 (0) Fax: +44 (0) Weir Valves & Controls France SAS Sebim site Tel: +33 (0) Fax: +33 (0) [email protected] Sarasin-RSBD site Tel: +33 (0) Fax: +33 (0) [email protected] Weir Valves & Controls USA Inc Tel: Fax: [email protected] Regional sales offices: Canada Tel: Fax: [email protected] China Tel: Fax: [email protected] Malaysia Tel: Fax: [email protected] Middle East Tel: Fax: [email protected] Korea Tel: Fax: [email protected] Australia Tel: Fax: [email protected] South Africa Tel: Fax: [email protected] A list of worldwide agents is available on request Weir Valves & Controls UK Ltd Britannia House Huddersfield Road Elland, West Yorkshire HX5 9JR England Tel: +44 (0) Fax: +44 (0) [email protected] Excellent Engineering Solutions