CCI DRAG

100DLC for Boiler

Feedwater Control
Applications

Demanding Feedwater Control Requirements

High Reliability

It is critical within power plant operations in drum boilers (or ow in

Faster Plant Start-up

Considering drum type boilers, if the drum level is too high or too low,

Improve Plant Efciency

at plant start-up, when the pressure differential between the Boiler

Eliminate Erosion and

Cavitation

Feedwater Control Valves must achieve a smooth start-up and maintain

once-through boilers); the level of feedwater is within required limits.

the plant may be forced to trip. Drum or boiler level control is crucial
Feed Pump (BFP) and boiler is very high and control is difcult. Boiler
required drum level for safe, reliable and efcient plant operation. The
high pressure differential at start-up/low-load, and sensitive control
requirement, requires a high-performance severe service control valve.

Reduce Required Hardware

Reduce Maintenance Costs

Feedwater Control Valve Requirements

During Start-up and Low-load Operation

Operate at high pressure differentials of up to 240 bar (3500 psid)

maintaining good control (Figure 1)

CCI DRAG 100DLC for Boiler Feedwater Control Applications

(Drum Boilers), without damaging the trim components, and

Smooth and quick transition from start-up to normal operation

Consistent and reliable operation

Tight shut-off to prevent leaks and subsequent valve erosion

During Normal Operation

A valve with a high capacity is required at normal operation to

minimize frictional losses in the system to minimize Boiler feed

Pump power requirements (Figure 1).

During Load Change (assuming xed speed boiler feed pump)

Figure 1: Typical Start-up Pressures

Load changes are often experienced and this will result in a lower
Plant
Load

steam pressure and drum pressure, but feedwater pressure will remain
1GT Operating

2 GT Operating

similar, resulting in a higher pressure differential. Figure 2 shows that

the P, and so Cv requirements, at full load on a 2 x 2 x1 Combined

Cv

P (psi)

Cv

P (psi)

9%

2.0

2750

2.0

2750

14%

3.0

2740

3.0

2700

18%

4.0

2675

4.1

2575

36%

8.4

2430

8.8

2230

55%

13.4

2160

14.6

1810

73%

19.7

1780

22.6

1350

82%

23.8

1545

29.2

1025

91%

29.3

1260

42.4

600

Consequences of Feedwater Control Valve Problems

100%

38.1

900

114.4

100

Figure 2: Cv requirements at various plant loads.

Both represent same 2x2x1 CCPP conguration.
Also note that the units for P are psi.

Cycle Power Plant (CCPP) are signicantly different depending on

whether one GT (Gas Turbine) or two GTs are in operation, and
so the control valve used must be able to meet a wide range of Cv
requirements to provide full exibility to the plant.
With once through boilers there can be similar issues, particularly at
start-up when Boiler regulator valve is used before the main variable
speed pumps (usually steam turbine driven) go into operation.

Cavitation/ashing: Insufcient pressure reducing stages will

cause high velocity ows, leading to valve/trim damage owing to
cavitation/ashing

Feedwater Control Valve Solutions

Lost production: Poor control at low ows can lead to plant trips
and/or an extended start-up process

High maintenance costs: Frequent replacement and repair of valve

components adds to maintenance costs

Symptoms of Feedwater Control Valve Problems

Erosion damage: Caused by:

- Insufcient number of trim stages, creating excessive trim
velocities
- Poor seat design and insufcient seat force

Plug or stem breakage: Typically caused by high trim velocities, and

subsequent trim vibration and fatigue failure

Vibration and noise: Caused by cavitation and excessive internal

DRAG Reduces Costs and Improves Performance

CCI is able to offer a one valve solution with the 100DLC DRAG valve,
which meets both the high and low Cv requirements as an alternative to
the two valve system (Figure 3). This conguration is only possible due
to DRAG high rangeability trim providing excellent controllability at
all ows, from start-up through to normal operation. There are distinct
benets to the combined solution:

The change is eliminated providing a quick, smooth start-up

At start-up and increasing from low-load conditions, the transition
from the start-up to main valve is difcult to control and maintain
stability. At this stage in the process, plant trip is at risk and

Figure 3; Combined feedwater control valve

conguration instead of two

undesirable as there will be penalties incurred owing to increased

maintenance, lost generating revenue and fuel costs. Considering

two valve solution, to avoid a plant trip, start-up is done gradually

owing to limitations at the feedwater control valve system, and

Smooth increases provides

quick, stable start-up

this can signicantly extend the start-up time. Extended start-up

times translate into lost revenues, and penalties (many government
environmental control bodies may apply penalties to a utility when
the start-up times exceed certain limits and may also require more

Severe fluctuations
increase plant-trip potential

frequent maintenance of Gas Turbine as a result of trips)

Using a combined valve, the transition is eliminated and the
limitation of pressure drop across the main valve is eliminated

Figure 4: Before and after DRAG combined

solution was installed at a CCPP

resulting in a smoother, quicker start-up. Figure 4 shows a clear

example of this for an 815MW Combined Cycle Power Plant (CCPP)
in the U.S. The plant now consistently achieves a 60-90 minute

CCI DRAG 100DLC for Boiler Feedwater Control Applications

velocities

More than a Feedwater Control Valve

faster start-up and enjoys the fastest dispatch in its region and eet.

Insufficient Staging and leaks at shutoff

The smoothing of the transition also provides peace-of-mind that the

likelihood of a costly plant-trip has been minimized.
Cavitation or
flashing

High
velocities

Maintenance costs are reduced

With the two valve solution, there is the potential risk of transferring
from the start-up to the main valve too soon. This exposes the main
valve to differential pressures it is not designed for, causing costly

Noise & Vibration

Trim &
body wear

Poor control

damage. For the 815MW CCPP, this problem resulted in the trimsets requiring replacement on at least a yearly basis, contributing
signicantly to maintenance costs.
Using the two valve solution, the start-up valve was not able to

CCI DRAG 100DLC for Boiler Feedwater Control Applications

Lagging/ silencing
required

High maintenance
costs

withstand the severe and erratic conditions of start-up, and for the

Lost production

815MW CCPP this meant regular additional maintenance costs.

The plant has not experienced any of its original problems since

Figure 6: Web of problems caused by applying the

wrong Boiler Feedwater Control Valve

the Combined DRAG valves have been installed, providing them

with signicant maintenance cost savings and improved plant

System Components

performance.

Your Savings

2 x Start-up line
isolation valve
2 x Tee (e.g. 10 SCH160)
2 x Elbow (e.g. 3 SCH160)
Pipework (e.g. 10ft)
4 x large welds (e.g. 24hrs)
12 x small welds
(e.g. 24hrs)

Capital costs of additional hardware are reduced

By eliminating one valve from the system, associated hardware is
eliminated, providing cost savings in the system purchased (and
associated maintenance costs).
CCI estimates for a Feedwater Control System on a 500MW 2x2x1
Combined Cycle Power Plant, the hardware savings could amount
to at least $20,000 per unit with two units per Plant. Heres what

Start-up control valve

CCI have identied savings sources; ll in the table (Table 1) to see

Control loop

what yours would be.

Total Capital Cost

Table 1: System Components/Savings

Severe Service Applications for CCI DRAG 100DLC

The CCI DRAG 100DLC are not solely used for Drum Level Control
of Combined Cycle Power plants, but can be equally applied to the
following applications:
Drum Level Control of conventional fossil red plants (Combined
and start-up)
Start-up Feedwater Regulator valve on large sub critical and
supercritical Boilers
Boiler Circulation Valves, used on supercritical once-through boilers
to maintain minimum ow through the boilers.

Control erosion by controlling velocity!

DRAG Combined Solution Controls Fluid Velocity

CCI has designed DRAG to operate within the ISA Guide, Control
Valves, Practical Guides for Measurements and Control, to provide
sufcient velocity control.
Velocity (H2O)

Service Conditions

Figure 7: Multiple pressure reducing stages

eliminates erosion

m/s

ft/s

Continuous service single phase uids

30

100

Cavitating & multi-phase uid outlet

23

75

High trim exit velocities are commonly responsible for erosion damage
in control valves (erosion increases to the power of 2 to 4 with velocity
increase).
The Velocity Control DRAG trim eliminates problems with trim erosion
by limiting the trims uid exit velocities and corresponding kinetic energy.

control this kinetic energy, eliminating erosion, vibration and noise.

With one pressure stage, the water ows over the edge of the dam with
high energy, resulting in erosion. With numerous steps to ow over in
the stepped dam, the water has much less energy as it reaches the base,
eliminating erosion.
Fluid Velocity

Figure 8: CCI 100DLC multi-path, multi-stage trim

designs are characterized to provide optimal
valve performance at all ow conditions.

vs. Stages of

Recommended

Recommended

Velocity

Stages

Pressure Drop
Bar

psi

130

1885

4 Stages

Multi-stage

m/s

ft/s

m/s

ft/s

54

177

30

98

Stages
16

By eliminating this destructive energy source, positioners, air sets and

other actuator components will not be as susceptible to damage or
calibration shift. Piping will also no longer be subject to fatigue failure
from valve-induced vibration.
Eliminate Cavitation with DRAG Combined Solution
The DRAG trim forces the ow to travel through paths of turns
(Figure 8). Each turn causes a pressure loss to the uid (Figure 9), and
so the pressure gradually reduces over the turns. This series of multiple

Figure 9: Each turn in the DRAG trim provides a

pressure drop

CCI DRAG 100DLC for Boiler Feedwater Control Applications

Figure 7 illustrates an analogy of how multiple pressure stages can

DRAG 100 DLC - proled to maximize

feedwater control performance

pressure drops allows the pressure to reduce without falling below the

P1
pressure

vapor pressure (Figure 10) and so avoids cavitation (Figure 11). As

cavitation is destructive to the valve and trim, the DRAG multistage
pressure drop provides a clear benet in terms of performance, and
P2 outlet pressure

V1
inlet velocity

V2 outlet velocity

Pv
vapor pressure

maintenance costs.
Accurate Control and Reliable Operation at all Flow
Conditions with the CCI DRAG Disk Stack
DRAG disk stacks can be customized to provide the required Cv
throughout the valve stroke; this is done by conguring disks of varying

Figure 10: The DRAG staging stops erosion and

cavitation.

numbers of turns within the stack (Figure 12). The DRAG control
valve disk stack features an equal percentage characteristics. These trim
characteristics provide very ne ow control. The disk stacks use disks
with more pressure letdown stages near the seat end of the trim (up to 20

CCI DRAG 100DLC for Boiler Feedwater Control Applications

Vvc
P1
inlet pressure

stages or more), and fewer stages near the full-open end of the trim. This

Vvc

provides critical protection of the seat ring while allowing superior ow

Vvc

control throughout stroke of the valve. Independent and isolated ow

paths are utilized to eliminate short circuits between the ow paths.
V2 outlet velocity

V1
inlet velocity

P2 outlet pressure

Pvc
Pv vapor pressure

bubbles collapse,
cavitation occurs

Pvc

Reliable Long Term Shutoff

The DRAG control valve uses a hard seat, which resists trash cutting,
and a very high seat loading to provide reliable and repeatable long-

Pvc
cavitation bubbles form here

term shutoff for very high pressure differentials. The actuator is sized
to provide a minimum seat ring loading of 500lbf per circumferential

Figure 11: Insufcient stages can lead to

cavitation

inch (9 kg/mm) as recommended by ISA. The DRAG velocity control

trim design owing to control of velocity and high seat force for shut-off
protects the seat ring and plug surfaces from cutting or pitting due to
erosion.
Custom Design Meets Plants Needs
As well as 100DLC standard DRAG valve, CCI also provides custom
DRAG valves. Options such as anged ends, expanded butt-weld ends,
high temperatures seals, and forged body is available. CCI can also
provide a 2 valve solution (see Figure 3) if required. Please contact your
CCI representative for further details on non-standard options.

% Flow
100
90
80
70
60
50
40
30
20
10
0

Linear

Modified
Linear
Modified
Equal %
0

10

20

30

40

50

60

70

80

90

100

% Stroke

Figure 12: Characterized Equal Percentage disk stack

DRAG 100 DLC features

Stem Packing
Multiple Teon packing design with
graphite guide spacer for low packing
friction and long term leak free service.
Graphite packing available for higher
temperature feedwater (after economizer).

High Integrity Balance Seal

The spring energized Teon balance seal is
specially packaged in a split gland design for
easy assembly and long service life. Other
seal designs are available to meet hightemperature requirements.

Multiple Cv Trims Throughout

Disk Stack

Multi-Stage DRAG Disk

Stack Technology

Allows characterized design for optimum

control throughout start-up and normal
operation conditions.

Limits uid velocities, controls

vibration and erosion. Multiple
Cv trims throughout disk stack

Class V Shut-off

This section of the disk stack

has no ow passages; in their
place labyrinth grooves break
up clearance ow, preventing
seat ring damage.

A metal seat is standard,

with a 500 PLI (9 kg/mm)
loading force to achieve
tight shut-off.

Valve Performance Characteristics (% Cv vs. % Stroke)

Modied Equal
Percentage

CCI DRAG 100DLC for Boiler Feedwater Control Applications

Disk Stack Labyrinth

Grooves

Equal Percentage

Use this check list to evaluate the benets of

CCIs DRAG 100DLC valve

Benets
Provides the Valve Doctor Solution. CCI works with

plant operators to improve plant performance, reliability

and output.

CCI DRAG 100DLC for Boiler Feedwater Control Applications

Prevents Cavitation Damage. CCI works to ISA guidelines

to ensure solutions prevent potential for cavitation.

Eliminates Erosion Damage. By controlling uid

velocities, erosion is eliminated.

Noise Eliminated. Noise eliminated through velocity

control, eliminating need and cost for lagging/silencing.

Stops Costly Maintenance Cycles. CCI valves are

designed and sized to provide longer intervals between

maintenance and allows easy access to all components.

Assists Quick Start-up. CCI valves are designed to handle

the severe start-up conditions to provide good control and

avoid plant-trips at start-up.

8
9

Avoids Plant Shutdowns. Valves are designed and sized

to handle severe conditions and provide excellent control.

Further Assists Quick Start-up. Combined valve provides

smooth, quick start-up.

Efcient Start-up. Stable start-up avoids plant-trips.

Ownership Cost of Additional Equipment Eliminated.

10

Additional instrumentation and hardware not required,

eliminating signicant associated costs.

DRAG 100DLC

Competition

Technical Specications

Specications shown are for the 100DLC DRAG valve; the standard 100D DRAG valve offered.
Other 100D DRAG valves are available where this specication is not suitable.

1500 ANSI
Globe

Angle

Trim
Size

Buttweld

2.0

Use 2500
ANSI

Use 2500
ANSI

4, 6

21.50
(546 mm)

25.50
(648 mm)

6, 8

27.75
(705 mm)

10

33.00
(838 mm)

5.0

8, 10

42.50
(1080 mm)

6.0

10, 12,
14

50.00
(1270 mm)

7.0

10, 12,
14

50.00
(1270 mm)

9.0

12, 14,
16

63.40
(1610 mm)

2.5
or
3.0

4.0

2500 ANSI

13.00
(330 mm)

Globe
Height

Weight

50
(1270 mm)

400 lbs
(180 kg)

13.75
(330 mm)

65
(1650 mm)

800 lbs
(360 kg)

16.25
(413 mm)

65
(1650 mm)

1000 lbs
(450 kg)

Contact
CCI for
these
options

Angle

Buttweld

3, 4

22.75
(578 mm)

24.00
(610 mm)

4, 6

26.50
(673 mm)

29.25
(743 mm)

6, 8

36.00
(914 mm)

10

38.50
(978 mm)

54
(1370 mm)

2500 lbs
(1150 kg)

8, 10

42.50
(1080 mm)

74
(1880 mm)

5000 lbs
(2300 kg)

10, 12,
14

50.00
(1270 mm)

74
(1880 mm)

5000 lbs
(2300 kg)

10, 12,
14

50.00
(1270 mm)

76
(1920 mm)

7500 lbs
(3400 kg)

12, 14,
16

63.40
(1610 mm)

Height

Weight

13.00
(330 mm)

50
(2030 mm)

450 lbs
(200 kg)

17.88
(454 mm)

65
(1650 mm)

1100 lbs
(500 kg)

20.00
(508 mm)

65
(1650 mm)

2000 lbs
(900 kg)

54
(1370 mm)

2500 lbs
(1150 kg)

74
(1880 mm)

5000 lbs
(2300 kg)

74
(1880 mm)

5000 lbs
(2300 kg)

76
(1920 mm)

7500 lbs
(3400 kg)

Contact
CCI for
these
options

CCI DRAG 100DLC for Boiler Feedwater Control Applications

Throughout the world, companies rely on CCI to solve their severe service control valve
problems. CCI has provided custom solutions for these and other industry applications for
nearly half a century.
CCI sales ofces worldwide.

Oil & Gas

CCI Australia
Phone: 61 2 9918 4094
21 Catalina Crescent
Avalon, NSW 2107
Australia

CCI Italy - Florence

Phone: 39 0571 5953203
Via DellIndustria 13
50056 Montelupo Fiorentino (Fl)
Italy

CCI Austria

CCI Italy Milan

Phone: 39 02 4671 2274
Via Vincenzo Monti 8
20123 Milano
Italy

(Formerly Spectris Components GmbH)

Phone: 43 1 869 27 40
Fax: 43 1 865 36 03
Lembockgasse 63/1
AT-1233 Vienna
Austria

Nuclear

CCI China - Beijing

Phone: 86 10 6501 0350
Fax: 86 10 6501 0286
Fortune Plaza, 7 Dong San Huan
Zhong
Room 606 Ofce Tower
Chao Yang District 100020
Beijing
China
CCI China Shanghai
Phone: 0086 21 64851331
Fax: 0086 21 64851328
Room 1003-1004 Xinyuan
Technology Tower
No. 418 Guiping Road
Shanghai 200233
China

Fossil Fuel

CHP

CCI RSM World Headquarters

Phone: 949 858 1877
Fax: 949 858 1878
22591 Avenida Empresa
Rancho Santa Margarita, CA
92688
USA
CCI Russia
Phone: 7 495 941 8660
Europe Square 2, Ofce 611
Moscow 121059
Russia

CCI KK Kobe City

Phone: 81 78 991 5910
6-2-2 Takatsukadai, Nishi-ku
Kobe City
Hyogo 651-2271
Japan

CCI South Africa

Phone: 27 13 690 3305
Shop 4, 14 Arnhem Singel
Die Heuwel
Witbank 1035
South Africa

CCI Japan - Tokyo

Phone: 81 3 5402 3100
4th Floor Terada Bldg.
2-3-3 Shibakoen
Minato-ku, Tokyo 105-0011
Japan

CCI Sweden

(Formerly BTG Valves)

Phone: 46 533 689 600

Fax: 46 533 689 601
Industrigatan 1-3, Box 603
SE-661 29 Safe
Sweden

CCI Korea Seoul

Phone: 82 (0)31 980 9960
10F, Sinwon B/D,
210-1, Hangangno-2GA
Yongsan-Gu
Seoul Korea

CCI Houston (Repair Center)

Phone: 713 869 5233
3409 Brinkman
Houston, TX 77018
USA

CCI Korea Gimpo City

Phone: 82 31 980 9800
# 26-17, Pungmu-Dong
Gimpo-Si, Gyeonggi-Do
Korea

CCI India
Phone: 0091 80 4190 3000
6th Floor, Warp Tower
Plot No. 13, 14 & 15, EPIP Zone
Phase 1, Whiteeld Road
Bangalore East
Bangalore 560 066
India

CCI Middle East - Dubai

Phone: 9714 886 1477
Light Industrial Unit: BJ04
Jebel Ali Free Zone, Dubai FZS1
UAE

CCI Switzerland
(Formerly Sulzer Valves)

Phone: 41 52 264 95 00
Fax: 41 52 264 95 01
lm Link 11, P.O. Box 65
8404, Winterthur
Switzerland
CCI Technology Centre UK
Phone: 44 (0) 161 655 1690
Unit A3, Brookside Business
Park
Greengate, Middleton
Manchester M24 1GS
UK

Contact us at:info@ccivalve.com
Visit us online for sales and service locations at: www.ccivalve.com

DRAG is a registered trademark of CCI.

2006 CCI
560 12/06/06