crane valves for centreline fgd presentation

Crane Energy Flow Solutions - Americas

CenterLine RSCenterLine RS Butterfly ValvesButterfly ValvesCenterLine RSCenterLine RS Butterfly Valves Butterfly Valves in POWER / FGD in POWER / FGD

Werner KremerWerner KremerProduct Manager RS/MSProduct Manager RS/MS

BU Energy / PowerBU Energy / Power

The Power StationThe Power StationCRANE ENERGY POWERPOWER

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What Is Flue Gas Desulphurization?

•Process used to remove Sulfur Dioxide (SO2) gas prior to release of furnace emissions to the atmosphere

•The process is accomplished by using wet limestone FGD Scrubber technologygy

• FGD systems are commonly installed on coal fired powerinstalled on coal fired power plants

• Wet FGD Scrubber technology can also be applied to Refineries, Pulp Mills, and various other industries

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The coal fired Power StationThe coal fired Power StationA – E: Steam and boiler

houses

F: Machine house

G: Coal belt

H: Coal breaker

I: Coal belt to vessel bunker

K: Stack

L: Cooling towers

M: TransformerM: Transformer

N: Raw gas channels toFGD

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Flue Gas CleaningFlue Gas CleaningBasic Diagram of FGDBasic Diagram of FGD--SystemSystem

Fl G D l h i ti i th l f th id f l h d it d dFlue Gas Desulphurization is the removal of the oxides of sulphur and nitrogen producedduring the burning of fossil fuels from emissions to the atmosphere. A major source ofpollution is coal fired power generation which together with other coal consumptionoperations, accounts for 60% of all emissions. A further 25% is the result of oil refinery, oil

ti d th il tipower generation and other oil consumption.

Clean GasClean Gas

F G D –S

GypsumWater

i System Waste Water

air

Additive

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Raw GasRaw Gas

Wet Limestone Scrubber System for SO2 Removal

Think of SO2 as excess stomach acid

We take anti-acids to neutralize the acid

A scrubber uses limestone as the neutralizer!

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Gas flow

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A flow diagram of a FGD(Source: Penwell)

Flow diagram of a typical wet FGD plant

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Where to install Crane EnergyWhere to install Crane Energy Valves e.g. RS Butterfly Valves

in the FGD Processin the FGD Process

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Where to install(Process systems, no gas systems)

Fl di f t i l t FGD l t CenterLine RS

Saunders KB

XOMOX 108G

Flow diagram of a typical wet FGD plant

HP butterfly valve MS

And ball valvesAnd ball valves

Total circa 300 – 650 different kind of valves

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CRANE Butterfly Valves and Diaphragm Valves in FGDCRANE Butterfly Valves and Diaphragm Valves in FGD

Black Box Medium Type of valveBlack Box Medium Type of valve

Washer/ Scrubber Wash suspension RS, IDV" Process water RS IDV R 201" Process water RS, IDV, R 201" Oxidation RS, MS, 108G

Gypsum treatment Gypsum (fluid) RS IDVGypsum treatment Gypsum (fluid) RS, IDVWater treatment Waste water RS, IDV, R 201Air systems Air IDV, KVy ,Heating system Water, air RS, MS, 108G, KV

108G = Xomox Lined Butterfly Valve

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R201 = Xomox Lined Ball Valve

KV = Xomox Ball Valve

Requirements of valvesRequirements of valves

for operationfor operation

in Flue Gas Desulphurization plants

C i & Ab i- Corrosion & Abrasion -

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Requirements for Butterfly Valves in FGD Service

Material guidelines for wetted parts of the CenterLine RS Series Butterfly Valve are based on fi ld i i 1980 C E i blfield experience since 1980. Crane Energy is able to give for every existing service / operating condition a material recommendation.They meet requirements regarding:

CorrosionAbrasionVelocityTemperature

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Temperature

RequirementsRequirements

high reliabilityhigh reliabilityprotection against corrosionprotection against abrasionp gabsolute and permanent tight shut-off

Wh i k f i ?Why risk of corrosion?high chloride contents, a low ph-value, fluorides and operating temperatures of more than 40°C (104°F)

Why risk of abrasion?high contents of solid particles in form of calcium

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hydroxide or limestone in the media.


Why risk of corrosion?

Corrosion originates from FGD process conditions:

y

Chloride concentration

up to 100,000 ppm

ph values 1 6ph-values 1 ... 6Fluorides 0 ... 500 ppmTemperatures > 45° C < 72° CTemperatures > 45 C ... < 72 C

(>113° F ….<162° F)

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Why risk of abrasion?

Abrasion originates from FGD process conditions:

Why risk of abrasion?

Solid particles (Calcium Hydroxyd) up to 50 %

Operating pressures 2 ... 8 bar (29 …116 psi)

Velocities 2.3 m/s ... 3.5 m/s (7 5 f/ 11 5 f/ )(7.5 f/s…11.5 f/s)

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How to construct a butterfly valve in order toHow to construct a butterfly valve in order to guarantee best protection against corrosion?

) th b t ibl f t i la) the best possible use of materials

b) minimizing number of wetted parts

c) avoidance of pitting corrosion, contact corrosion and stress corrosion

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Are these conditions fulfilled by CRANE CenterLine RS ?Are these conditions fulfilled by CRANE CenterLine RS ?

a) best possible use of materials

Disc material: Hastelloy, Superduplex, Hostalen GUR

Lining material: EPDM (CSM)

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b) low number of wetted parts

The CenterLine RS butterfly valve has only two wetted parts

Disc

Cartridge seat with lining

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c) avoidance of pitting corrosion

Quality of disc surface according to DIN S3 eq. MSS (means smooth surface) or better Materials with hi h l bd t thigh molybdenum content

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d) avoidance of contact corrosion

minimizing metal-to-metal contact points.no use of pins or screws for connecting disc/shaft.

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e) "floating" discPrevention of wear;

Eliminates formation of deposits between disc and li i d t th lf t i di ( i )lining due to the self centering disc (no pins).

= Even compression on the entiredisc sealing surfacedisc sealing surface

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Different kinds of corrosion in FGD plantsDifferent kinds of corrosion in FGD plants

V l d i d l i f i l h bValves design and selection of materials have to be chosen, to prevent:

Pitting corrosion Pitting corrosion

Contact corrosion

Stress corrosion

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Different kinds of corrosion in FGD plants Different kinds of corrosion in FGD plants

Pitting corrosionPitting corrosion

Pitting corrosion is the most dangerous type of corrosion and requires high-quality materialsand requires high quality materials.

Deposits on disc The protective passive layer is not renewed. Pitting corrosion can spread.Actions to be taken:

Selection of a cast material with highSelection of a cast material with high chrome and molybdenum content & high quality disc surface

CRANE S d lNeedle Cavity

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CRANE uses Superduplex or Hastelloy.

Different kinds of corrosion in FGD plants Different kinds of corrosion in FGD plants Contact corrosionContact corrosion is one of the most frequent types of corrosion.

It occurs when connecting different components as well as at screwed connections, washers, etc.

Action to be taken:

Avoidance of gaps, sealings, etc.

Due to the internal power connectionbetween disc and shaft, this type of corrosion does not affect the C t Li

Crevice corrosion

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CenterLine RS.

Requirements for Butterfly Valves in FGD ServiceRequirements for Butterfly Valves in FGD Service

Corrosion

Material selection is a function of…

Recommendation in Public literature

Fi ld E i Field Experience

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Superduplex and Hastelloy in FGD ServiceSuperduplex and Hastelloy in FGD Service

Corrosion

Public literaturePitti f t (P F ) f di t i l d iPitting factor (P.F.) of disc materials used in CenterLine RS

P.F. = % Cr + 3,3x (% Mo + 0,5% W) + 2x %Co + 16 x %N

Cr Mo W Cu N Pitting Material % % % % % FactorSuper-DuplexUNS J93404 25.00 4.00 0.00 0.30 0.27 43.00Hastelloy

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yUNS N26022 21.35 13.67 2.84 0.00 0.00 71.00

Superduplex and Hastelloy in FGD ServiceSuperduplex and Hastelloy in FGD ServiceWhen to use which material in Slurry Service ?Corrosion Public literature says:

Pitting factor is a function of pH-value and Chloride levelg p

pH-value1000 5000 10000 50000

chloride level in ppm

6.5 34 35 40 454.5 35 40 45 513 0 40 45 513.0 40 45 51 -1.5 45 51 - -

Temperature: 50 to 65°C (122º F - 149º F) Blue = SuperDuplex

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Temperature: 50 to 65 C (122 F 149 F)

Literature: Materials for FGD- and Denox-InstallationsRed = Hastelloy

Corrosion

H t l GUR®Hostalen GUR®

(UHMWPE)( )

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Hostalen GURHostalen GUR®, a trend setting material !, a trend setting material !

Alternative disc material for SlurriesAlternative disc material for Slurries

With washing temperatures of more than 60° C (140°F) and a ph-value of < 3 metal cast materials turn out to bea ph value of < 3, metal cast materials turn out to be unsuitable very soon picture

Chloride concentrations up to 100,000 ppm are possible.p , pp p

An additional fluoride share of > 50 ppm reduces the lifetime of valves many times.

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Hostalen GURHostalen GUR®, a trend setting material !, a trend setting material !

Installation of HastelloyInstallation of Hastelloy disc in a FGD system with pH-value 2.5 causes in a strong corrosion after astrong corrosion after a short service time.

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Hostalen GURHostalen GUR®, a excellent material ! , a excellent material !

Alt ti t i l f l iAlternative material for slurries

Especially at lignite coal-fired power plants, medium t t t 68° C (155°F) th h l i ltemperatures are at 68° C (155°F) , the ph-value is less than 3.5;

Chloride contents of more than 55 000 ppm and fluoridesChloride contents of more than 55,000 ppm and fluorides of up to 500 ppm are normal here.

Gas cleaning plants for copper plants and for the cementGas cleaning plants for copper plants and for the cement industry operate with high acid concentrations and low ph-values.

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Hostalen GURHostalen GUR®, a excellent material !, a excellent material !

Alternative material for slurriesAlternative material for slurries

Advantages of Hostalen GUR® compressed disc Butterfly valves:valves:

no danger of corrosion, no wear, no abrasion

suitable for ph = 0p

temperature up to 80 °C (+176°F)

Competitive Valve solution vs High Alloy materialsCompetitive Valve solution vs High Alloy materials e.g. Hastelloy etc. material surchargesExample: NPS 40”/#150 cost of Valve with Hostalen Gur, app. 40% cheaper than

V l ith H t ll C22 di i l h

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same Valve with Hastelloy C22 disc incl. surcharges

Actual field experiences

RS Butterfly Valves

in an FGD plant

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After field operationAfter field operation

Deposits in washer sump in front ofDeposits in washer sump in front of closed RS Butterfly Valve

View from inside scrubber towards recycling pumptowards recycling pump impeller

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After field operationAfter field operation

Despite deposits on the disc no pitting corrosion

Removing partially hardend Slurry suspension is really a hard job.

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Our RS delivery programme

f FGD tfor FGD systems

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CenterLine RS Series Butterfly Valves for FGD application

Size range: NPS 1.50” to 54.00”

Pressure range: up to 150 psi

Pressure Class: ANSI B 16.47-A #150

Temp. range: - 30° F to 300° F

Body material: Ductile Iron

Body types: WaferBody types: WaferTappedLugFlanged

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Flanged

Face to face: All short pattern

Value and Performance

Low price E ti

Features Low price Low freight charges Low installation costs Reduced footprint

Easy operation Simple conversion from manual

to automatic operation Positive shut off

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Features of our RS design

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CenterLine RS Series Butterfly ValvesFeatures

1. Cartridge Seat design with solid backup ring

Features

g g p g

2. Square disc/shaft connection

3. Flattened disc design

4. Replaceable cartridge seat

5. Maintenance free

6. ISO top flange/square shaft

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1. Cartridge seat design withsolid backup ring

Features

solid backup ring Secures seat in position Eliminates seat distortion Minimizes stresses on rubber

seat for longer life Suitable for vacuum service Suitable for vacuum service Easier to assemble and

dismantle

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CenterLine RS Series Butterfly ValvesFeaturesFeatures

2. Square disc/shaft connectionconnection No pins Only two wetted parts O y p Corrosion free Self centering disc/uniform

seat compression Easy to assemble and dismantle

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3. Flattened vs round disc Even compression

Features

paround disc and at discbosses

C t ll d t Controlled stresses

Reduced wear

Excellent shut offperformance

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4. Replaceable Liner Maintenance friendly Easy assembly due to solid cartridge seat Easy assembly due to solid cartridge seat

No pins - interlocking assembly

Body, shaft and bushing do not contact theprocess medium

Self lubricating bushings – result in lower Self lubricating bushings result in lowertorques

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5. Low Cost of Ownership Standard spare parts

Features

Only wetted parts requiresreplacement

Cartridge Seat (rubber liner)g ( ) Disc

Service life 2.5x longer vs boot seat

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6. ISO top flange / square shaft Direct mounting of actuation possible

eatu es

Easy change of operators

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Requirements for Butterfly Valves in FGD Service

SummaryMaterial guidelines for wetted parts of the CenterLine RS Series Butterfly Valve are based on field experience since 1980. Crane is able to give for every existing service / operating condition a y g p gmaterial recommendation.They meet requirements regarding:

CorrosionAbrasionVelocity

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VelocityTemperature

References

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Products

Crane Process Flow Technologies - DusseldorfUser List for RS Series , Flowseal MS and Revo Actuators

Enduser Market segment

Continent (Enduser)

ContractorCountry Location/ProjectCLRS FSMS Revo

Electrabel Belgium Power X

Companhia Siderurgia de Tubarao Brasil Blast Furnace,Unit 2 Lurgi Lentjes Bischoff /

Ferrostahl PowerX

NB Electric Power Canada FGD Belledune Preussag Noell Power X

Beijing First Cogeneration China FGD Beijing Steinmüller Power X

Banshan Power Plant China FDG Banshan Steinmüller Power X

Chongqing Power Plant China FGD Chongqing Steinmüller Power Xgq g gq g

Guang Power Plant China FGD Guang An,Sichuan Beijing Guohua Ebara (LLB) Power X

Huaiyin Power Plant China FGD Jiangyin;Jiangsu Beijing Boqi (AE+E) Power X

GuiZhou YaXi Power Plant China FGD GuiZhou YaXi Shandong Sanrong Power X

XuZhou Huaxin Power Plant China FGD XuZhou Wuhan Kaidi Power X

HuangPu Power Plant China FGD Guang Zhou Shanghai Longking Env. Power X

JianBi Power Plant China FGD JianBi Energy & Environment Power X

Ligang Power Plant China FGD Ligang Jiangsu Beijing Longyuan (L&C S) Power X

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Ligang Power Plant China FGD Ligang,Jiangsu Beijing Longyuan (L&C S) Power X

Changzhou Power Plant China FGD Changzhou,Jiangsu Beijing Longyuan (L&C S) Power X

Products

Crane Process Flow Technologies - DuesseldorfUser List for RS , Flowseal MS and Revo Actuators


Continent (Enduser)


segment (Enduser)

CEZ Czech Republic FGD Pocerady Lurgi AG Power X

CEZ Czech Republic FGD Prunerov Lurgi Lentjes Bischoff PowerX

Elektrarna Milnik Czech Republic FGD Milnik ABB PowerXX

Elkraft DenmarkFGD Amager Block Section 3 Babcock Anlagen Power X

Elkraft Denmark FGD Aesnes Block Section 5 Flaekt PowerX

Fynsværket Denmark FGD Odense Block Section 7 Flaekt PowerX

Imatran Voima Oy Finland FGD Meri Pori Lurgi Lentjes Bischoff Power X

Imatran Voima Oy Finland FGD Inkoo L&C Steinmüller PowerX

E ON ( Preussen Elektra ) GermanyFGD Staudinger, Rostock and others Lurgi Lentjes Bischoff Power X X X

E ON ( VKR ) Germany FGD Scholven and others Thyssen Eng. PowerX

RWE Germany FGD Frimmersdorf Lurgi Lentjes Bischoff Power X X X

STEAG Germany FGD Herne,Lünen and others Babcock Anlagen Power X X X

EnBW Germany FGD Mannheim and Heilbronn Babcock Anlagen Power X X X

Vattenfall Europe Generation ( VEAG ) Germany FGD Lippendorf Lurgi Lentjes Bischoff Power X X

Vattenfall Europe Generation ( VEAG ) Germany FGD Boxberg,Schwarze

Pumpe Preussag Noell Power X X

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RWE Germany FDG Weisweiler Babcock Anlagen PowerX

RWE Germany FGD Ibbenbüren Thyssen Eng. PowerX

Products

Crane Process Flow Technologies - DuesseldorfUser List for RS , Flowseal MS and Revo Actuators


Continent (Enduser)


segment (Enduser)

Greece FGD Megalopolis Preussag Noell PowerX

Paiton Private Power Indonesia FGD Paiton Lurgi Lentjes Bischoff PowerX

Kepco ( Korean Electric Power Corp ) Korea FGD Tangjin ,Units 1 - 4 Samwhan Corp. Power

XPower Corp ) gj pX

Kepco ( Korean Electric Power Corp ) Korea FGD Hadong and TAEN Babcock Wilcox Power

X

E.P.Z. Borselle Netherlands FGD Borselle E.P.Z. PowerX

Kopaolnie i Zaklady Przetworcze Siarki Poland FGD Siarkopol Saarberg-Hölter Power

X

Poland FGD Jaworzno 3 L&C Steinmüller / Rafako PowerXX

Elektrownia Opole Poland FGD Opole Block Section 1-4 Saarberg-Hölter Power

XKingdom of Saudi Arabia Royal Commission for Jubail and Yanbu

Saudi ArabiaFGD Madinat Yanbu Al-Sinaiyah Steam Power Plant Unit 4

Lurgi Lentjes Bischoff Power X

Taiwan Power Taiwan FGD Taichung Black + Veatech Power X

TEAS ( Turkiye Elektrik AS Turkey FGD Yeniköy ,Units 1 & 2 Lurgi Lentjes Bischoff PowerXX

TEAS ( Turkiye Elektrik AS Turkey FGD Yatagan Lurgi Lentjes Bischoff Power

X

TEAS ( Turkiye Elektrik AS Turkey FGD Cayhiran Lurgi Lentjes Bischoff PowerX

TEAS ( Turkiye Elektrik AS Turkey FGD Orhaneli Babcock Borsig Power Power XNational Power UK Drax Babcock Wilcox Power X

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National Power UK Drax Babcock Wilcox Power XPower Gen UK Ratcliffe John Brown Power XSouthern Indiana G&E USA Power XSigeco USA FGD Culley Station Babcock Wilcox Power X

FGD Birlik Steuler Power XUm Pirdop Lurgi Lentjes Bischoff Power X

Pictures of Installation

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Typical situation after shut down of scubber. RS Butterfly Valves, NPS 32“

RS Butterfly Valves, NPS 32“ during shut down for inspection of the scrubber in Power Station Wilhelmshaven, EON in 1997

RS Butterfly Valve during shut down. View from inside scrubber to pump recycling valve in Power Station Hafen, Stdw. Bremen in 1999

RS Butterfly Valves, NPS 32“ in Power Station Ibbenbüren, RWE in 1994 after pump discharge

RS Butterfly Valves, NPS 48“ in Power Station Weisweiler, RWE in 1993 after 10 years in service. Babcock system with scrubber

RS Butterfly Valves, NPS 48“ in Power Station Weisweiler, RWE in 1993 after 10 years in service.

RS Butterfly Valves, NPS 48“ in Power Station Weisweiler, RWE in 1993 after 10 years in service. Typical abrasion of pump impeller

RS Butterfly Valves, NPS 48“ in Power Station Weisweiler, RWE in 1993 after 10 years in service.

Our competition…..

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RubberRubber--lined disclined discWhy no rubberWhy no rubber--lined disc?lined disc?

Rubber-lined discs (hard rubber) are ineffective in this WFGDRubber lined discs (hard rubber) are ineffective in this WFGD service.

Why does CRANE Energy not offer this option?y gy p

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Why no rubberWhy no rubber--lined disc?lined disc?

Rubber-lined discs have the following disadvantages:Rubber lined discs have the following disadvantages:

when the valve is closed, disc and rubber lining can stick together (temperature)

a rubber-lined disc is not resistant against penetration of slurry

corrosion damages of the disc surface are the reason for its rapid deteriorationits rapid deterioration.

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Knifegate Valve, Typical Installations

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Same size DN800 (32“)

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Competitive situationCompetitive situation

There are some differences between the design of theThere are some differences between the design of the CenterLine RS butterfly valve and that of competitors.

These are as follows:

two-part body

disc-shaft connection with pins or screws

body lining as a loose part

(a simple "rubber ring" without support)

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Positioning ofPositioning of

CRANE Valves

today

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Where CRANE (CPFT) stands todayWhere CRANE (CPFT) stands today

Worldwide among the "Top Five"

Number #2 in Europe

Worldwide among the Top Five

L t i i 1978Long-term experience since 1978

Flue gas cleaning plants are our center of excellenceFlue gas cleaning plants are our center of excellence(FGD, FGC, copper plants etc…….).

Here, CRANE Energy feels at home and can offer

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, gycomprehensive expertise.

crane valves for centreline fgd presentation

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