VALVE

PRODUCTS

Forged Steel
Valves

Gate Valve

Globe Valve

Check Valve

Blow-down
Valve

Cast Steel
Medium
Pressure
Valves
Gate Valve

Globe Valve

Check Valve

Reheating
Isolating Device

Globe Valve

Check Valve

Elbow type
Blow-down Valve

Cast Steel
High Pressure
Valves
Gate Valve

VALVE

Quick Closing
Non-Return Valve

Safety Relief Valve

PRODUCTS

High Pressure
By-pass Valve

Soot
Blower

Safety Valve

Silencer

VALVE

Well-Head
Assembly

PRODUCTS

X-Mas Tree Assembly

Full Bore
Gate Valve

TECHNOLOGY BASE
High Pressure Gate, Globe

Toa Valve Co. Ltd., Japan

and Non-Return Valves

Quick Closing Non-Return

Toa Valve Co. Ltd., Japan

valve
Safety & Safety Relief Valves Dresser Ind. Inc., USA
Forged Steel Valves

Dresser Ind. Inc., USA

Soot Blowers

Copes Vulcan, USA

HP-LP Bypass Systems

SULZER (CCI), Switzerland

Oil Field Equipments

Kvaerner National, USA

What is a Valve
Valves are mechanical devices specially
designed to direct, start, stop, mix or
regulate the flow, pressure, or temperature
of a process fluid, valves can be designed
to handle either liquid or gas applications.

TYPES OF VALVES FLOW , PRESSURE

FLOW CONTROL :

GATE, GLOBE & CHECK VALVES

PRESSURE CONTROL :

PRESSURE RELIEVING VALVES

CONTROL VALVES

HOW TO SPECIFY A VALVE

What Parameter?

MAIN PARAMETERS TO SPECIFY

1. TYPE OF VALVE
2. SIZE
3. MATERIAL
4. RATING (Pressure & Temperature)
5. END CONNECTION
6. OPERATION

TYPE OF CONVENTIONAL VALVES

1. GATE VALVE
2. GLOBE VALVE

REG. GLOBE
PISTON LIFT
3. CHECK VALVE

SWING CHECK

SIZE
IDENTIFIED BY
NOMINAL PIPE SIZE (NPS)
OF THE PIPING ON WHICH
VALVES ARE MOUNTED.
BHEL MANUFACTURES FROM
0.25 to 36

MATERIAL
MATERIAL

UPTO
TEMP

CARBON STEEL

425
C

ALLOY STEEL

550
C

550
STAINLESS STEEL
C

2
FORGE
A105
F 22
F316

2
CAST
WCB / WCC
WC6 / WC9
CF8 / CF8M

COMPOSITION

C-Mn-Si

Cr. - Mo
2 Cr-1-Mo
18 Cr-8 Nl
16Cr-8Nl-2Mo

A217-C12A DEVELOPED FOR SUPER CRITICAL BOILER APPLICATION

RATING

MAXIMUM PERMITTED PRESSURE OF MEDIUM

WITH RESPECT TO TEMPERATURE FOR A

MATERIAL GIVEN IN ASME B16.34
RATINGS DENOTED BY CLASS NUMBERS.
BHEL MANUFACTURES
FORGED VALVE IN
CLASS 800,1500,2500 & 3000 spl

CAST VALVES IN
CLASS 150,300,600,1500,2500,3500
ASME CLASS

ASME CLASS

END CONNECTION
VALVE ASSEMBLY MOUNTED
ON PIPELINE BY FOLLOWING MEANS
1. SOCKET WELD ENDS
2. SCREWED ENDS
3. FLANGED ENDS
4. BUTTWELD ENDS

} FOR
} FOR

OPERATION
HAND WHEEL OPERATION
GEAR OPERATION
MOTOR OPERATION

DESIGN STANDARDS
API 600
API 602
ASME B16.34
BS 1414
BS 1873
BS 1868

GATE
GATE
ALL VALVES
GATE
GLOBE
SWING CHECK

OTHER STANDARDS
ASME B16.10
ASME B16.5
ASME B16.25
ASME B16.11
ASME B16.47
ASME B1.1
ASME B36.10M

END TO END
FLANGED END
BUTT WELD END
SOCKET/THREADED
LORGE DIA FLANGES
UNIFIED INCH SCREW
STEEL PIPES

INSPECTION AND TESTING

STANDARD
API 598

BS 6755 PART 1
ASME B16.34

GATE
GATE , GLOBE &SCV
GATE, GLOBE &SCV

PRODUCT RANGE-GATE
150C
300C
600C
800C
900C
1500C
2500C
2850C

2 TO 36
2 TO 20
2 TO 12
0.25 TO 2
4 TO 8
2.5 TO 18
2 TO 18
20

PRODUCT RANGE-GLOBE
C 300
C 600
C 800
C 1500
C 2500
C 3000 Spl
C 3500

2 TO 8
3 TO 4
0.25 TO 2
2.5 TO 4
2.5 TO 6
0.25 TO 2
2.5 T0 3

PRODUCT RANGE-SCV
C 150
C 300

C 1500
C 2500

2 TO 8 &24
2 TO 12 &16
2.5 TO 14
2.5 TO 18

PRODUCT RANGE-PLNRV
C 800

0.25 TO 2
C 1500
0.25 TO 2
C 2500
0.25 TO 2
C 3000 Spl 0.25 TO 2

Forged Valve :

Forged Valve :

Medium Pressure
Gate Valves

High Pressure
Globe Valves

Globe Valves

Check Valves

Check Valves
Cast Steel Bolted
Bonnet Valves :

High Pressure PressureSeal Bonnet Valves :

Gate Valves

Gate Valves

Globe Valves

Globe Valves

Check Valves

Check Valves

Difference between Gate & Globe

GATE VALVE
CONSTRUCT OPEN/CLOSE BY A WEDGE/GATE
USAGE
FOR OCCASIONAL OPEN/CLOSE
FOR OPEN/CLOSE ONLY
LIFT

LIFT IS MORE.
OPERATING FORCE/TORQUE IS
FORCE
LESS
OPERATION OPERATION TIME IS MORE
PR.DROP
PRESSURE DROP IS LESS
POPULAR IN ALL SIZES.
SIZES
SPECIFICALLY HIGHER SIZES.

GLOBE VALVE
OPEN/CLOSE BY A PLUG/DISC
FOR FREQUENT OPERATION
REG. GLOBE VALVES USED FOR
REGULATION DUTY
LIFT IS LESS(~ D/4)
OPERATING FORCE/TORQUE IS
MORE.
OPERATION TIME IS LESS
PRESSURE DROP IS MORE
RESTRICTED TO SMALLER SIZES
ONLY.

SPECIALITIES

Sealed Gland Arrangement SG

By-Pass Valve Arrangement BPV
Pressure Relieving Arrangement PRV
Limit Switch Arrangement LS
Balance Hole Arrangement BH
Locking Arrangement LO
Indicator Arrangement INDICATOR
Drain Hole Arrangement DRAIN HOLE

SPECIALITIES
IN OPERATION
Chain Wheel Operation CHAIN
Extension Spindle Operation EXTN

ELECTRICAL ACTUATORS
For

VALVE OPERATION

Type of actuators
1.
2.
3.

Hydraulic actuators
Pneumatic actuators
Electric actuators

Hydraulic actuators
Hydraulic actuators are compact, fast acting and

delivers high torque. But these actuators require

complete hydraulic system and cleanliness.
These are used where there is a requirement of
quick response and compactness.

Pneumatic actuators
Pneumatic actuators are compact and fast acting.
But torque developed is very low, sufficient only for small
valves. For other valves need torque amplification system.
Because of fast action used for control application of small
valves.
Electric Actuators
Electric Actuators are simple, develop high torque,have
good operating speed.
With electronic controls these actuators become
robust,easy to install and operate.
These are also compatible to modern plant control
systems.

Type actuating movement

Multi turn Actuators
Part turn actuators
Linear Actuators
Multi-Turn actuator
An actuator which transmits torque to the valve
for one or more revolution.
Part-turn actuator
An actuator which transmits torque to the valve
for less than one revolution.
Linear Actuator
An actuator which transmits torque to the valve
With linear motion.

ELECTRICAL VALVE ACTUATORS

All critical valves in a power plant are operated by an electrical
Actuator from remote control room. These include :
Main steam stop valves
Feed discharge valves
HP heater isolating valves
Continuous blow down valves
Emergency blow down valve
Start up vent valve
Steam & feed water drain valve
Extraction line valve

Types of Motor Operated Valves

Motor Operated
Actuators
Actuator without
Integral Starter

Actuator with
Integral Starter
Actuator with
Electronic
Integral Starter
Actuator with
Smart
Integral Starter

CONSTRUCTION
Actuator is an electro mechanical equipment consisting
of
Motor
Gear box
Control compartment

Hand wheel and De-clutch lever

Thrust base
Terminal box

MANUAL OPERATION

For emergency manual operation of valve during power failure

the hand wheel provided in the actuator is coupled to the
output shaft by means of a declutch lever. Once power supply
is restored the hand wheel automatically gets disengaged.

Actuator without Integral starter

For Torque <= 100 Kg M

Actuator without Integral starter

For Torque > 100 Kg M

SPECIAL FEATURES

Inbuilt starter
Explosion proof / frame proof
Non-intrusive type
Two wire system

Actuator with & without Integral starter

Integral starter of an actuator

INTEGRAL STARTER
Actuator with integral starter consists of following items.
Reversing contactor
Overload relay
Stop / open / close push button
Local remote selector switch

Monitoring relay
Interposing relays for remote operation
415V / 110V step down transformer
Fuses on primary & secondary circuits.

ELECTRONIC POSITION TRANSMITTER

(EPT)
Input ->

0 - 100 ohm

Output ->

4-20mA

System ->

2 wire or 4 wire

Supply ->

24V DC

Provided for inching duty regulating valves.

Development / Supply of Two Wire Control

System for Thermal stations.
Two Wire Control system is being supplied to NTPC-Talcher

(for the first time in power plant environment in India),

comprising the following .
60 Channel Master Station with hot standby.
PakTester
PakReader
Non-Intrusive actuators with field control units
This system enables faster communication with DCS system,

quicker & accurate fault identification apart from enormous

saving in cable cost.

Two Wire Control System

Two Wire Control System

POSITION SEATING
All GATE valves of size 100mm & above and Pressure rating
1500 C and above shall be set for POSITION SEATING . i.e.,
valve closing shall be by CLOSE POSITION limit switch trip
only.
The close Torque limit switch to be connected as Back up /
Parallel connection.
Valve Opening shall be by OPEN POSITION Limit switch trip.

TORQUE SEATING

All other GATE,GLOBE and REGULATING valves shall be

set for TORQUE SEATING only. i.e., valve closing shall be by
CLOSE TORQUE limit switch trip only.

The close position limit should NOT be connected as back

up / parallel connection.
Valve Opening shall be by OPEN POSITION Limit switch trip.

For all Gate valves the during initial 5% opening, of the valve
from its close position, the OPEN TORQUE LIMIT SWITCH
should be bypassed to ensure smooth opening of the valve.
Thermostat and Over load relay (OLR) should be connected to
the motor control circuit.
Actuator setting are to be done as per the above
recommendations and set to the recommended opening and
closing torque values ,other wise it can lead to valve jamming.
For actuator wiring and torque /position limit switch setting
refer wiring diagram 4.V.MISC. 90721 Rev 11 indicated in the
O&M.

At the time of Commissioning:

All valves gland to be tightened to arrest gland leak.
Hot tightening of all High pressure valves Bonnet retainer to
arrest Self Sealing Bonnet leak after attaining Max pressure &
temperature.
Attend to all critical valves involved in Steam Blowing and Acid
cleaning.
- Check for Seat damage and re-lap.
- Replace Gland Packing
- Replace SW Gasket
- Ensure Actuator settings as per recommendation.

At the time of annual over-hauling:

Replace Gland Packings
Replace Body-Bonnet joint SW gasket, Hinge pin Gaskets
Lapping of damaged Seating surfaces in Body,Wedge/Disk.
Replace Pressure Seal Bonnet Gasket (Soft Iron/ Grafoil)
Hot tightening of all High pressure valves Bonnet retainer to
arrest Self Sealing Bonnet leak to be ensured after attaining Max
pressure & temperature.
In Motorised Valves check for settings in the actuator as per
original recommendations.
All valves are to be attended at least once in TWO years.

1. Gland leakage
Tightened Gland bolts evenly, as soon as leakage is noticed and arrest it.

Additional packing shall be added, if necessary (at the next available shut down).
If leakage persists, packing shall be replaced with new set of packing.

2. Body bonnet joint leakage. (SW gasket)

Tighten the bolts sequentially. If the leakage still persists, replace the SW gasket.
Also ensure that the sealing surface is intact.

3. Pressure seal bonnet/ Hinge Pin leak in high pressure valves.

In pressure seal design, sealing effect is achieved by the medium pressure only.

TO ensure effective sealing, self sealing bonnet nuts are to be fully tightened in
cold condition and to be retightened after achieving full operating pressure.
Also bonnet nuts are to be retightened again when maximum operating
temperature is achieved as temperature variations can cause relaxation of
bonnet nuts.

4. VALVE PASSING

Contd

Valve passing is mainly because of damaged sealing surfaces.

It is due to entrapment of foreign particle between wedge / disc and

body seat.

It is to be attended by lapping of both the body and wedge / disc seat.

It is preferable to attend the valves immediately after steam blowing,

in case the valves are involved during steam blowing operation

SPARES DESCRIPTION

GV GLV CV CATEGORY

BODY BONNET GASKET

COMMISSIONING

GLAND PACKING

COMMISSIONING

STEM/SPINDLE

MAINTAINENCE

WEDGE/DISC

MAINTAINENCE

YOKE BUSH

MAINTAINENCE

HINGE PIN GASKET

MAINTAINENCE

GV - GATE VALVE GLV - GLOBE VALVE CV - CHECK VALVE

N.A. - NOT APPLICABLE

Thank you

Quick Closing Non-Return

Valve
(QCNRV)
&
Cold Reheat Line
Non-Return Valve
(CRHNRV)

QUICK CLOSING NON RETURN VALVE

Function:
Quick Closing Non Return Valves are standard non return
valves equipped with power cylinders, ensuring rapid and
positive closing to prevent any reverse flow into the turbine.
Cold Re-Heat Non Return Valve also does the same function but
opens & closes by power cylinder as per the system
requirement.

QUICK CLOSING NON RETURN VALVE

Application
QCNRVs are used in turbine extraction lines to the heater and
deaerator.
CRH- NRVs are used in cold reheat line from HP turbine to
reheater.
Both QCNRV and CRH-NRVs are closed by power cylinders on
the initiation of turbine trip, when the forward flow ceases.

RANGE OF VALVES
CLASS RATING
VALVE TYPE

SIZE
3
6
8
10
12

QCNRV

14
16

20
24
32

CRH NRV

18
24
32

150

300

600

900

GASKET

ARM

BONNET

DISC
(STELLITED)

NUT
SEAT
(STELLITED)

BODY

AIR/OIL CYLINDER

QUICK CLOSING NON RETURN VALVE

QUICK CLOSING NON RETURN VALVE

OPERATION
Power cylinder energised through oil / air to keep the flap
free to open when there is flow.
Power cylinder de energised to forcibly close the valve by the
spring force.
The flap opening is max. 35 deg. in QCNRV and
85 deg. in CRHNRV.
Position indicators are provided to indicate the valve flap
position.

QCNRV PHOTO

QUICK CLOSING NON RETURN VALVE

QUICK CLOSING NON RETURN VALVE

210 MW

500 MW

VALVE

NB
mm

NP
class

QTY
Nos

NB
mm

NP
class

QTY
Nos

CRH NRV

450

600

800

600

QCNRV

200

300

500

300

QCNRV

300

150

500

150

QCNRV

400

150

400

300

QCNRV

600

150

GO TO

Maintenance
Maintenance Check: (Recommended per shift)
1. Disc arm assy. swinging freely.
2. On line Test operation of the cylinder.
3. Position transmitter and limit switch function.
4. Steam leakage to be checked at :
Stuffing box/ gland packing.
Spiral wound gasket area.
Annual Maintenance
1. The bushes and bearings are to checked. Any abnormality noticed requires
replacement of these components.
2. The claw portion of the Spindle and arm are to checked for any crack.
3. The stellite surface of the spindle to be checked for any abration.
4. Asbestos/Graphite packing area on the spindle are to be checked for any
pitting.
5. In the cylinder all the Orings, piston rings and packings are to be checked
for leaking .

QUICK CLOSING NON RETURN VALVE

Recommended Spares
Gaskets for valves and actuators
Packings for valves and actuators

Spiral Wound Gaskets for valves

O rings for actuators

RECOMMENDED SPARES
SPARES DESCRIPTION

CATEGORY

BODY BONNET GASKET

COMMISSIONING

SIDE BONNET GASKET

COMMISSIONING

GLAND PACKING

COMMISSIONING

SPINDLE

MAINTAINENCE

DISC, ARM

MAINTAINENCE

BUSH

MAINTAINENCE

SL No.

SAFETY
AND

SAFETY RELEIF
VALVES

SAFETY VALVES:
A valve, which automatically discharges
fluid to atmosphere so as to prevent a predetermined safe pressure being exceeded.
It is generally used for compressible fluids
such as steam and other gases which
demand quick over-pressure relief.

SAFETY & SAFETY RELIEF VALVES

SB

RB

SS

RS

PRESSURE RELIEF VALVES

CLASSIFICATION OF PRVs :

(A) SV- Safety Valves (1700 & 1811 SERIES)

(B) RV- Relief Valves
(C) SRV - Safety Relief Valves (1900&1990 SERIES)

Applications of SV, RV & SRV

Description

Safety Valve
(SV)

Relief Valve
(RV)

Safety Relief Valve

(SRV)

Compressible Media
Vapors & Gases like
steam, air etc

Incompressible
Media
All liquids like water

acts as SV in compressible
medias and acts as RV in
incompressible medias

Opening

Pop Action (Sudden

opening)

Opening is
proportional to the
excess pressure
over the set pressure

Pop action in compressible

medias and proportional
opening in incompressible
medias

Code
Requirements

ASME Sec-I & IBR

ASME Sec-VIII

ASME Sec-VIII

Operating Gap

5% Minimum

10% Minimum

10% Minimum

Blow Down

5% Maximum

15% Maximum

15% Maximum

Applications

Utility & Industrials

Boilers

Petroleum &
Fertilizer
Industries

All applications except

boiler drum, SH & RH.

Over Pressure

3% of set pressure

25% of set pressure

10% of set pressure

Applicable
Fluids

CAP
SPG.ADJUSTER
YOKE
SPRING
SPINDLE
LEVER

GUIDE
DISC HOLDER
UP.ADJ.RING
ADJ.RING PINS
LO.ADJ.RING
DISC
BODY

CAP
SPG.ADJUSTER
WASHER

SPRING
SPINDLE

GUIDE
DISC HOLDER
ADJ.RING PIN
ADJ.RING
NOZZLE
BASE

Typical Number of Valves in Power Boilers.

LOCATION

DRUM
S.H.
C.R.H.
H.R.H.
ERV-SH
ERV-RH

VALVE MODEL

1750 WB
1740 WB
1739 WD
1740 WD
1786 WB
1786 WB-10
1786 WD
1538 VX-10W
1525 VX-4
TOTAL

QUANTITY REQUIRED

210 MW

250MW

500 MW

3
1
1
3
1
9

1
2
2
1
4
2
2
14

2
4
2
4
4
5
4
25

SL

COMPONENT

PARAMETER

EFFECT OF ADJUSTMENTS

01

SPRING
ADJUSTER

SET PRESSURE

CLOCKWISE INCREASE
COUNTER CLOCKWISE - DECREASE

02

UPPER
ADJUSTING
RING

BLOWDOWN

CLOCKWISE / DOWN INCREASE

COUNTER CLOCKWISE / UP
DECREASE

LOWER
ADJUSTING
RING

SIMMER / LIFT

COUNTER CLOCKWISE REDUCE SIMMER

AND ENABLE FULL LIFT.

OVERLAP
COLLAR

BLOWDOWN

CLOCKWISE TO REDUCE.
COUNTERCLOCKWISE - INCREASE.

03

04

NOTE : ALL ROTATIONS ARE TO BE MADE AS LOOKING FROM

THE TOP OF THE VALVE

COMPONENT NAME

SV

SRV

REQUIREMENTS

DISC

COMMISSIONING

ADJ.RING PINS
(Lower & Upper)

COMMISSIONING

ADJUSTING RINGS

MAINTENANCE

SPINDLE

MAINTENANCE

DISK HOLDER

MAINTENANCE

GUIDE

MAINTENANCE

OVERLAP COLLAR
N.A - Not Applicable

N.A

MAINTENANCE

SOOT BLOWERS
&
APPLICATIONS

TYPES OF SOOT BLOWERS

WALL DESLAGGER

APPLICATION
- FURNACE WALL

* LONG RETACTABLE SOOT

BLOWER

- CONVECTION ZONE
(SH, RH, LTSH, ECO)

* HALF RETRACTABLE SOOT

BLOWER

- CONVECTION ZONE,
FLUE GAS < 600 DEG. C

* ROTARY SOOT BLOWERS

- CONVECTION ZONE,
INDUSTRIAL BOILERS,
ID FAN (IMPELLER)
BANK TUBES, ECO.
AIR HEATERS

* AIR HEATERS CLEANERS

- ROTARY AIR HEATERS.

* TRAVERSING NON- ROTATING

- TUBULER AIR HEATERS

WALL DESLAGGER

DESIGN FEATURES

- 2 MOTOR DRIVE

MODEL WBIE
- EASY ACESSIBILITY FOR
MAINTENANCE OF PARTS
- COMPLETE 360 Deg. ROTATION
- FLEXIBILITY TO VARY THE BLOWING TIME
- FLEXIBILITY TO VARY BLOWING ANGLE
- LESS NON - BLOWING TIME

OPERATION
FORWARD TRAVEL -305 MM IN 3 SECS.
ONE ROTATION IN 84 SECS.
RETRACT TRAVEL - 305 MM IN 3 SECS.
TRAVERSE SPEED - 6.1 M / MIN

ROTARY SPEED - 0.7 RPM.

ROTARY GEAR REDUCTION - 2067 : 1
TRAVERSE - 28 : 1

LONG RETACTABLE SOOT BLOWERS

MODELS
SINGLE MOTOR
(CHAIN DRIVEN)

- LRS - I

MAX. TRAVEL : 6 MTR.

DOUBLE MOTOR
( CHAIN DRIVEN )

GEAR OPERATED

- LRS - I ER MAX TRAVEL : 5 MTR

LRD - I E
LRD - I ER
LRD - I A
LRD - II E

MAX. TRAVEL : 7.6 MTR

MAX. TRAVEL : 7.6 MTR
MAX. TRAVEL : 7.6 MTR
TRAVEL : 7.7 TO 12.2 MTR

OPERATION
LANCE MOVEMENT

-TRAVERSE & ROTARY

TRAVERSE SPEED

-1.63 M/MIN (LRD IE)

ROTARY SPEED

-5.2 RPM (LRD IE)

MAX CLEANING RADIUS - 2.5 2.7M

GEAR REDUCTION (T)

-155:1

GEAR REDUCTION (R)

- 28:1

OPERATION
ROTARY SPEED

- 1.2 RPM

NO OF REVOLUTION

-1

NO OF NOZZLES

- AS MANY COILS

NOZZLE DIAMETER

- 6 / 8 / 10 MM

OPERATING TIME

- 0.82 MIN

GEAR RATIO

- 124 : 1

SOOT BLOWER CHECKS

COMMISSIONING CHECKS:

LUBRICATING OIL LEVEL.

INTERLOCKS.
HAND CRANK AVAILABILITY.
DIRECTION OF ROTATION OF MOTORS.
OPERATION OF LIMIT SWITCHES.
ENSURE STEAM CONDITIONS.
BLOWING PRESSURE.
STEAM LEAKAGES.

MAINTENANCE CHECKS
ANNUAL CHECKS

REPLACE LUBRICATING OILS.

CHAIN, CHAIN LINKS.

VALVE STEM ASSY.

ROTATION OF LANCE ROLLER ASSY.

BLOWING PRESSURE.

LANCE / NOZZLE DISTANCE.

GO To

MAINTENANCE CHECKS
SHUT DOWN CHECKS
REPEAT ANNUAL CHECKS.
VALVE HEAD SERVICING.
CHECK FOR BOILER TUBES.
BLOWER ADJUSTMENT FOR ANY

MISALIGNMENT.
GO TO

Recommended Spares
SL
01
02
03
04
05
06
07
08
09
10
11
12
13

DESCRIP[TION LR
GEAR BOX ASSY
MOTOR
SBV HEAD ASSY
VALVE STEM
LIMIT SWITCHES
BEARINGS
GLANDS
OIL SEALS
LANCE ASSY
SWIVEL TUBE ASSY NA
BLOWING ELEMENT NA
PACKINGS
GASKETS

WB

NA
NA

RB

NA
NA

TYPE OF SPARES
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
COMMISSIONING
COMMISSIONING

HPLP BYPASS
SYSTEM
VALVES

HP/LP BYPASS SYSTEM

FUNCTION:
To ensure operation of steam generator by
maintaining a minimum circulation of steam flow ,
when turbine is not in service

ADVANTAGES:

Quick start up of the unit

Reheater protection during start - up
Parallel operation of steam generator & turbine
House load operation
Limited safety valve lifting during trip outs
Dm water saving

MAINTENANCE CHECKS

EVERY MONTH

OIL LEVEL

OPTICAL PR.DROP INDICATOR (RED BUTTON) IN 3

MICRON FILTER

EVERY 3 MONTHS

NITROGEN PRESSURE IN ACCUMULATOR

SYSTEM PRESSURE

PRESSURE SWITCH SETTING

AIR FILTER ELEMENT CHECKING

MAINTENANCE CHECKS

EVERY ANNUAL OVER HAUL

CONDITION OF SEALING SURFACES OF VALVES

CONDITION OF ACTUATOR SEALS

CONDITION OF HYDRAULIC OIL

PUMP SUCTION STRAINER

DELIVERY FILTER IN OIL SUPPLY UNIT

ALL OPERATING PRESSURES IN PRESSURE

SWITCH

HP BYPASS AND SPRAY VALVE SPARES

COMPONENT NAME
HPBP SPRAY REQUIREMENT
PACKING RING
COMMISSINING
SPIRALWOUND GASKETS
COMMISSINING
VALVE SEAT
MAINTENANCE
VALVE STEM
MAINTENANCE
PRESSURE SEAL PLUG
MAINTENANCE
JETCAGE
MAINTENANCE
GLAND BUSH
MAINTENANCE
GUIDE BUSH
MAINTENANCE
N.A: NOT APPLICABLE

HP BYPASS HYDRAULIC SYSTEM SPARES

COMPONENT NAME
FILTER ELEMENTS
ACTUATOR SEALS & ORINGS
SERVO VALVE SEALS & ORINGS
BLOCKING ELEMENT SEALS & ORINGS
OIL SUPPLY UNIT SEALS & ORINGS
ACCUMULATOR BLADDER
FAST OPENING DEVICE SEALS & ORINGS

REQUIREMENT
COMMISSINING
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE

DIRECT WATER LEVELGAUGE

To indicate
the visible water level
in pressure containing vessel.

CONSISTS OF
1. GAUGE GLASS ASSEMBLY.
2. TIE BAR ASSEMBLY
3. ILLUMINATOR
4. VIEWING HOODS.

GAUGE ASSY

REPAIR PORT ASSEMBLY INSTRUCTIONS

Assy to be done in a clean atmosphere.

Glass, mica, gasket shall be handled with its
Edges; Faces shall not be touched.
Incase of leakage, all items (2-5) shall be
changed with new one.

FAST OPENING OF HP BYPASS VALVE UNDER:

1. GENERATOR CIRCUIT BREAKER OPENS
2. TURBINE TRIPS
3. TIRBINE LOAD SHEDDING REALY ACTS.

COMMISSIONING / O&M CHECKS

Acid cleaning & installation of oil lines

Setting of oil system pressure
Flushing with 25micron filter

Flushing with 3micron filter

Draining of flushed oil
Testing of oil for PARAFFIN content
Line filters should not be used for flushing
Contamination level to be checked

Accreditation
IBR
ISO 9001

: Well known Tube and Pipe Maker

: Quality Systems for Boilers,
Auxiliaries,
Valves, Heat Exchangers, Pressure
Vessels and Oil Field Equipment
ISO 9002
: Quality Systems for Manufacture of
Seamless Steel Tubes.
Lloyds Register of : Class-I Fusion Welded Pressure
Vessel Shipping Manufacture.
NABL
: National Accreditation Board for
Testing and Calibration laboratory

VALVES- EXPORT PERFORMANCE

USA

MALTA

CYPRUS
SYRIA
GHANA

BANGLADESH
KUWAIT

JAPAN

PHILLIPINES
MALAYSIA
INDONESIA

FURTHER PENETRATE into : Middle East, U.S.A., Singapore, Russia(OFE),

Iran, Iraq & Canada for enhanced business volume.

WEAR WASHERS
STEM WITH DOUBLE ACME THREAD

HAND WHEEL
STURDY SWING BOLT

TWO PIECE GLAND

DEEP STUFFING BOX
SPIRAL WOUND GASKET

POSITIVE BACK SEATING

FULLY GUIDED WEDGE

RENEWABLE SEATS.

DESIGN STD. : API-602

TESTING STD. : API-598

GATE VALVE
( FORGED STEEL - MEDIUM PRESSURE )

THREAD BUSHING
HANDWHEEL

TWO-PIECE GLAND

SPIRAL WOUND GASKET

STURDY SWING BOLT

DEEP STUFFING BOX
POSITIVE TAPERED BACKSEAT
DISC NUT

GUIDED STEM-DISC
DISC
SCREWED SEAT RING

DESIGN STD. : BS-5352

TESTING STD. : BS-6755(1)

GLOBE / REG. VALVE

(FORGED STEEL - MEDIUM PRESSURE )

FOR REG. VALVE

HIGH STRENGTH BOLT

TOP ENTRY DESIGN.
FORGED BODY & CAP
SPIRAL WOUND GASKET

CUSHIONED DISC

FLAT SEAT

FULLY GUIDED DISC

RENEWABLE SEAT
DESIGN STD. : BS-5352
TESTING STD. : BS-6755(1)

( FORGED STEEL - MEDIUM PRESSURE )

HAND WHEEL

RISING STEM

GREASE NIPPLE

EYE BOLTS
STUFFING BOX

SEAT RINGS

BODY

YOKE BUSH

GLAND

BACK SEAT

STEM

WEDGE

END CONNECTIONS

HAND WHEEL
YOKE BUSH

EYE BOLTS
DEEP STUFFING BOX

SELF ALIGNING GLAND

REGULATING DISC

STEM
BACK SEAT
BODY

END CONNECTIONS

DESIGN STANDARD : BS 1873

TESTING STANDARD : BS 6755 Part-I

BONNET JOINT
HINGE PIN
DISC STOP
HINGE

END CONNECTION
SEAT RING
BODY

DISC

DESIGN STANDARD : BS 1868 / API 6D

TESTING STANDARD : BS 6755 Part-I / API 6D

YOKE ARM
STEM

ALUMINIUM BRONZE BUSHING

RUGGED FLANGE
SPLIT GLAND

STAKE LOCKED DISC NUT

DISC PAD
INTEGRAL HARD FACING

DEEP STUFFING BOX.

FULL PENETRATION WELD

FOR REG. VALVE

DESIGN STD. : BS-5352/ANSI-B16.34

TESTING STD.: ANSI-B16.34

GLOBE / REG. VALVE

( FORGED STEEL - HIGH PRESSURE )

SEAL WELD

SCREWED AND SEAL WELDED COVER

FULLY GUIDED DISC

FULL PENETRATION WELD

HARD FACING

BODY

DESIGN STD. : BS-5352/ANSI-B16.34

TESTING STD. : ANSI-B16.34

CHECK VALVE
( FORGED STEEL - HIGH PRESSURE )

MECHANICAL
STOPPER
HAND WHEEL
YOKE SLEEVE
YOKE
BEARING
GLAND FLANGE

GREASE NIPPLE
RETAINING RING(NI-PLATING)
SOFT IRON GASKET

GLAND PACKING
STEM
YOKE CLAMP
PR. SEAL BONNET
BACK SEAT

18/8 SS INLAY
SEAT RING
DISC

BODY

DETAIL OF PRESSURE
SEAL CONSTRUCTION
LIFTING LUG
RETAINING RING
PRESSURE SEAL
BONNET
CUSHION PLATE
DISC

SOFT IRON GASKET

18/8 SS INLAY

ARM
NUT

SEAT RING

PLUG
BUSHING
SPINDLE

BODY

PRESSURE RELEIVING
VALVE ASSEMBLY

BACK

BACK

Thank you