Valves

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Committed to making a better world

PRESENTATION PRESENTATION ON ON

VALVES ENGINEERINGVALVES ENGINEERING



Globe ValveGate Valve Check Valve Blow-down Valve

Gate Valve Check Valve Reheating Isolating Device

Gate Valve Check Valve Elbow type Blow-down Valve

Forged Steel Valves

Cast SteelMedium Pressure Valves

Cast SteelHigh Pressure

Valves

Globe Valve

Globe Valve

VALVE PRODUCTS



Silencer

High Pressure By-pass Valve

Quick Closing Non-Return Valve

Soot Blower

VALVE PRODUCTS

Safety ValveSafety Relief Valve



X-Mas Tree Assembly

VALVE PRODUCTS

Full Bore Gate Valve

Well-Head Assembly



TECHNOLOGY BASETECHNOLOGY 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



Technology Up gradation

• Cost competitiveness• Competitive Technological edge• Advanced technology



IMPROVEMENT PROJECTSIMPROVEMENT PROJECTS

Technology Improvement

Business Improvement.

Cost and cycle time reduction

IT initiatives

Future plans



Technology Improvement.Technology Improvement.

Angle type bypass valve, MOU project completed.

(Approval obtained from M/S DVC for installation

of Angle HP Bypass valve in MEJIA 4)

Improved Design Of HP Bypass Valves.

Metal seal full bore gate valves for oil field equipment.

Development of Proportional Valve.

@

@

@

@



Business Improvement.Business Improvement.(Market requirement)(Market requirement)

Development of:Development of:

Economic series 150 Class Gate Valves.

Choke and Kill Manifold Units for 5,000 and 10,000 psi rating for OIL India , Duliajan

11”-10000 PSI Tubing Spool Assembly and 11”-10000 PSI Tubing Hanger

32”/ 600 Class Gate valve for 500 MW.

32”/ 150 Class SCNRV for 500 MW.

@

@

@





Main steam stop valve of size 14” / 2500Class

with A217-C12A material for 210 / 250 MW

32”& 36” class 150 Gate valves.

4-1/16”-10000 PSI Double Acting Type Hydraulic Actuator

@

@

@





6” & 8” 900 class Gate Valves.

2” to 4” 600 Class Globe valves.

¾” &1” 3500 Class Globe valves

Hand Operated 8”,10” 600 Class Gate Valves.



Cost and cycle time reductionCost and cycle time reduction

E-Type Compact High Pressure Gate valves.

Variety reduction of QCNRV body castings from 114 numbers to 34 numbers.

Improved Design of “A” Type Swing Check Valves.

NTPC approval for High Torque indigenous actuators

@

@

@



IT initiativesIT initiatives

Created Valve Home Page and provided engineering information.

Drawings are being released as SOFT copy.

Drawings, IBR approvals and other technical documents are attached in SAP system

Technical directives and maintenance instructions on valves in Valves Home Page

O&M Manuals & Catalogues released through CD.



TURN OVER FROM IN HOUSE DEVELOPMENTTURN OVER FROM IN HOUSE DEVELOPMENT

PROJECTS Value(Lakhs)Introduction of Economic Series Silencers with SS internals 18Introduction of Dual completion tubing spool, tubing hanger and dual block Xmas tree. 1947Weight energised design tubing hanger 7-1/16"-10m, tubing spool for oil india requirement 52Development of Angle type HP Bypass Valves 20Development of NRV 14" Class 300 19Development of NRV 16" Class 300 41Development of NRV 20" Class 150 20Development of Gate Valves 32"-150 Class 74




PROJECTS Value (Lakhs)Development of Double acting Hydraulic actuated FBVs 45Development of Choke and kill manifold With hydraulic actuated choke

223

Development of 6", 8"& 12" C150 Economic series Gate valves.

61

Development of Gate Valves 36" Class 150 22Double disc Flexible Disc Gate Valves for Hindalco 148Valves developed for NPCIL, TAPP 2 x 500MW 900



FUTURE PLAN - DEVELOPMENTSFUTURE PLAN - DEVELOPMENTS

Improved design of “A” type Gate valves of sizes 5”, 6” and 16” in 2500 class.

Improved design of “A” type Globe valve of sizes 2.5”, 3”,4”and 6” in 2500 class.

Value Engineering of 150 Class Check Valves.

Value Engineering of 150 Class Globe Valves.

Hydraulic Power Unit for HP Bypass System.

26” and 28” Class 300 Gate valves.




Interface Panel for Proportional Valve and Hydraulic Power Pack for HP Bypass system.

Replacement set for oil supply unit pump for HP By pass system.

4”/ 900 class Quick Closing Non Return Valve.

18”/ 150 class Quick Closing Non Return Valve.

Wall Blower Design Modification.

Development of Rack Type LRSB.




• Development of surface safety valve.

• Data Base for Soot Blower Contract Information.

• Mandrel Casing Hanger 13-5/8x9-5/8” and 11x7”

• X-Type Bushing for 11x5-1/2” and 13-5/8x9-5/8”

• Unitised Well Head (Oil Field Equipment)

• Introduction of control Valves.



PREVENTIVE ACTION FOR GENERIC PROBLEMSPREVENTIVE ACTION FOR GENERIC PROBLEMS

As a measure of preventive action , write-ups issued to site and process improved for:

Causes for frequent Problems in HPBP Oil System.

Recommendations for Servicing of HP Bypass System. Causes and Recommendations for Accumulator bladder Failure.

Valve Actuator settings.



PREVENTIVE ACTION FOR GENERIC PROBLEMSPREVENTIVE ACTION FOR GENERIC PROBLEMS

HP Bypass valve body downstream inner surface cracks

HP Bypass Valve Stem Thread Damages.

Safety Valves - Servicing and Floating of Valves at site.

Electromatic Relief Valves – Problems and Solution.

Safety & Safety Relief Valves - Set pressure Tolerances

and Blow down Limits.





ANGLE TYPE HP BYPASS VALVEANGLE TYPE HP BYPASS VALVEPRODUCT: Pressure reducing and de super- heating valve,

for bypassing the steam during turbine trip and to achieve quick start up of the unit.

OBJECTIVE:To eliminate erosion of seat and valve passing, which occurs due to inadequate piping drain arrangement, during cold start up.In angle type valve, wet steam flow through the valve is totally eliminated due to vertical entry of steam. Hence this development is taken up.



ANGLE TYPE HP BYPASS VALVEANGLE TYPE HP BYPASS VALVEFEATURES :

Vertical inlet to avoid wet steam entry . Gland is shifted to the lower pressure side. Pressure seal plug made into two pieces for ease of

assembly and replacement.

PROJECT COMPLETEDPROJECT COMPLETED

Commercialisation Commercialisation

Technical presentation made, discussed with M/s Technical presentation made, discussed with M/s DVC and APPROVAL obtained for installation in DVC and APPROVAL obtained for installation in MEJIA unit 4MEJIA unit 4



EXISTING HPBP VALVE ANGLE TYPE HPBP EXISTING HPBP VALVE ANGLE TYPE HPBP VALVEVALVE

Back



Development of 36” 150 Class Gate ValveDevelopment of 36” 150 Class Gate Valve

Requirement for Gate Valves of size 36” 150 class rating were received from various process industries.

Valve designed as per BS 1414 standard, manufactured and tested as per BS 6755 part 1 successfully.

Three numbers supplied to HPCL, MUMBAI and one number supplied to IOCL, PANIPAT. Order value 30 Lakhs



36” / 150 Class Gate valve36” / 150 Class Gate valve

DESIGN STD. = BS1414

TESTING STD.=BS 6755-Part1

OVEALL HEIGHT = 4 Mtrs

TOTAL WEIGHT = 3.8 Tons

BACK



CHOKE & KILL MANIFOLD .CHOKE & KILL MANIFOLD .

Customer : M/s OIL India Limited, Duliajan

Quantity : 4 Sets of CKM rated for 5000 psi. 1 Set of CKM rated for 10,000 psi.

Order received against Stiff Global Competition from Reputed Manufacturers abroad.

Requested Customer for Plant Visit & convinced them on our capabilities in Design, Manufacture &Testing of CKMs.

One set each of 5,000 psi & 10,000 psi CKM have been

Successfully Assembled, Tested & Despatched.

Order Value : 588,510 US Dollars [ Rs. 285.42 Lakhs ]



Back



Economic Series Gate ValvesEconomic Series Gate Valves Class 150Class 150

Sizes DevelopedSizes Developed

6 inch 8 inch & 12 inch



Reduction in machining scope in Body and Wedge

leading to reduced machining cost.

Reduction in the machining allowance to optimum level

leading to reduced casting weight and machining cost.

Revisit of material specification and Procurement to

commercially available ASTM grades, thereby

reduction in cost of castings.

Aspects towards reduced costAspects towards reduced cost



Competitor data ComparisonCompetitor data Comparison

BHEL(EXISTING)BHEL(NEW)AUDCO KITZ RAIMONDIFOURESS

Height(open)mm 805 744 787.4 762 795 890

HW Dia mm 400 315 304.8 300 350 356

Weight Kg 91.5 78 86 85


Height(open)mm 995 932 985.5 960 1015 1120

HW Dia mm 450 450 355.6 350 350 356

Weight Kg 141 106 139 128


Height(open)mm1421 1345 1397 1370 1465 1470

HW Dia mm 450 450 457.2 450 450 508

Weight Kg 337 290 304 310

6"-C150-GV

8"-C150-GV

12"-C150-GV



Gate Valve – Class 150

Sizes : 6”,8” & 12”

SizeOld New Old New

6 805 760 91 76 168 995 932 140 106 2412 1421 1360 336 290 14

Height(open) mm Weight(Kg.) % Reductio

Range of Valves Range of Valves



COMMERCIALISATION OF ECONOMIC SERIES COMMERCIALISATION OF ECONOMIC SERIES VALVESVALVES

VALVE TYPE ORDER RECD Rs.LAKHS

6”/ 150 CL.GATE VALVE

17.55


21.68


21.85

Back



E-type Compact High Pressure Gate E-type Compact High Pressure Gate ValvesValves..

Salient Features

Revisiting the process and machining time is 20%

reduced (Stainless steel inlay eliminated in body, bonnet

and Split ring design in place of screwed retaining ring)

Weight reduction to the extend of 15 to 20%

Improved features (Grafoil gasket in place of soft iron

gasket)

Back



Unification of QCNRV body Unification of QCNRV body castings.castings.

To use the same valve body for different Actuator size & its orientation.

Total 114 nos. of existing castings were brought down to 34 nos.

BONNET

BODY

ARMDISC

AIR/OIL CY LINDER

SEAT(STELLITED)

(STELLITED)

GASK ET

NUT

Back



Improved design Swing Check ValveImproved design Swing Check Valve

A - TYPE C – Type

SIZES DEVELOPED : 6”,8”,10”,12” & 14” RATING : 1500 CLASS



Swing Check ValveSwing Check Valve

A - TYPE C - Type

Back



IMPROVED DESIGN OF HP BYPASS IMPROVED DESIGN OF HP BYPASS VALVEVALVE

SALIENT FEATURES:

Pressure seal plug split into two parts enabling replacement of only the damaged portion , easy assembly and lesser spares cost.

Jet cage holes reoriented, to avoid direct impingement of spray water to valve seat, which can lead to thermal stress and seat crack.

Inclined spray holes is changed as straight holes in pressure seal plug for manufacturing easiness.



EXISTING IMPROVEDEXISTING IMPROVED



EXISTING IMPROVED

Back



Development of 32”/ 600 Class Gate valveDevelopment of 32”/ 600 Class Gate valve for 500MW Projects. (Line to De-aerator) for 500MW Projects. (Line to De-aerator)

This valve development was taken as an import substitute.

Design development completed .

Casting and forging, Sub delivery and Manufacturing drawings released.



32”/ 600 Class GATE 32”/ 600 Class GATE VALVEVALVE

Back



Main steam stop valve 14” / 2500ClassMain steam stop valve 14” / 2500Class with A217-C12A material for 210 / 250 with A217-C12A material for 210 / 250

MWMW

Why this project was taken.Presently Main steam stop valve with F91

ends are supplied to suit SA 335 P91 pipes.Valves with A217 C12A casting equivalent to

P91 material.The valve weight is less by 25%

Foundries are identified.Back





VALVES •1963 VALVES FOR IN HOUSE REQUIREMENT

AS PER CZECH DESIGN TO DIN STANDARD

•1972 VALVES OF ANSI / API / BS STANDARDS

DEVELOPED IN HOUSE

•1973 TECHNOLOGY TIE UP FOR SOOT BLOWERS

•1976 TECHNOLOGY TIE UP FOR HP BY PASS SYSTEM

•1978 TECHNOLOGY TIE UP FOR FORGED STEEL

AND SAFETY / SAFETY RELIEF VALVES

•1984 TECHNOLOGY TIE UP FOR HIGH PREESSURE

CAST STEEL VALVES AND QCNRV.

•1985 TECHNOLOGY TIE UP FOR OIL FIELD EQUIPMENTS

2001-20022001-2002 2002-20032002-2003

Identi- fiedIdenti- fied Comp- Comp- letedleted

Under Under ProgressProgress

Identi-Identi-fiedfied

Comp-Comp-letedleted

Under Under ProgressProgress

TOTALTOTAL 207207 123123 7575 1818 -- 1818

DETAILSDETAILSBIPBIP 1818 77 44 88 -- 88

TIPTIP 44 33 11 55 -- 55

CIPCIP 6060 3232 1818 -- -- --

QIPQIP 3232 2828 1111 -- -- --

DIPDIP 9292 5252 3636 22 -- 22

SIPSIP -- -- -- 22 -- 22

EIPEIP 11 11 11 -- 11

Some of the improvement projects focus on more than One area of Some of the improvement projects focus on more than One area of improvementimprovement..

Improvement Projects - MappingImprovement Projects - Mapping

Index



Year BudgetLakhs

ActualLakhs

2000-01 600 609

2001-02 550 551

2002-03 560 629

2003-04 650




METAL SEAL FULL BORE GATE VALVES METAL SEAL FULL BORE GATE VALVES Presently manufacturing Full Bore Gate Valves with

Elastomeric Seat to Body seal.

Specific Customer require Seat to Body seal to be of Metal to Metal type.

OBJECTIVE : Develop Design, Procure Materials, Manufacture and perform Test on Metal to Metal seal Full Bore Gate Valves.

SALIENT FEATURES >> Design development of Metal to Metal Seal Feature>> Procurement of Valve Castings / Forging, Metal seals. >> Manufacture and Testing of Valves



GATE

SEAT RING

BELLEVILLESPRING

SEALINGPROFILE

METAL TO METAL SEAL



METAL SEAL FULL BORE GATE METAL SEAL FULL BORE GATE VALVESVALVES

STATUS : PROJECT COMPLETED • Assembly and Testing taken up at shop as per SIP.

• Valve tested on either side for Seat leak tightness, as per API – 6A Standard.

• Valve checked for leak tightness at 5000 psi as well as for Low pressure sealing at 500 psi. and also at further increments of 500 psi Upto 5000 psi.

• Valve successfully withstood the test and found leak tight.



METAL SEAL FULL BORE GATE METAL SEAL FULL BORE GATE VALVESVALVES

BENEFITS ENVISAGED :

Achieve complete compliance to Customer’s Technical Specification.

Approach towards State of Art Technology.

Enhance product capability towards high temperature Service application.



back



DEVELOPMENT OF PROPORTIONAL VALVEDEVELOPMENT OF PROPORTIONAL VALVE• HP Bypass system valve actuators are operated with the help of servo valve and blocking element, which require high level of cleanliness (<3 microns).

• Frequent field problems of servo valve were reported, which are mainly due to inadequate cleanliness of the hydraulic system.

• Proportional valves, which can be substituted in place of servo valves and blocking elements, can function satisfactorily at a lesser level of cleanliness (<10microns) hydraulic system.

• Order placed on YUKEN and supply effected.



DEVELOPMENT OF PROPORTIONAL VALVEDEVELOPMENT OF PROPORTIONAL VALVE

• Servo valve control signal requirement is ± 11.5 V DC and Blocking element solenoid voltage is 48V DC. • HPBP valve’s travel speed is proportional to servo valve’s input signal. Blocking unit ensures stay-put position on power failure and loss of oil pressure.

• Proportional valve control signal requirement is ± 10V DC and blocking solenoid coil voltage is 24V DC.

• Sample proportional valve installed at test bench and travel speed checked for various control signal voltages. Open / close time and stay-put position established.

• Project completed. Requirement of interface with Control system taken up with EDN.

back



PRODUCT SPECIFICATION :

Type : Double acting Hydraulic actuatedMax. Act.Control Pr. : 1500 psiStroke : 127.4 mmSpecification : As per API-6AProduct Spec.Level : 3Material Class : EETemperature rating : U

Double Acting Type Double Acting Type Hydraulic ActuatorHydraulic Actuator

4-1/16”-10000 PSI 4-1/16”-10000 PSI



DESIGN FEATURES :• Adjustable Stroke Feature enables setting of Actuator Travel precisely.

• T-Slot Connection between Steam and Piston ensure proper alignment and leak tight operation.

• Clamp connection enable ease of Dismantling and re-assembly.

• Hard Chromium Plating of Cylinder ID and Piston OD.

• Manual over ride facilitate opening of Valve by Manual means in case of Hydraulic fluid failure.

Double Acting Type Hydraulic Double Acting Type Hydraulic ActuatorActuator

4-1/16”-10000 PSI 4-1/16”-10000 PSI



ANTICIPATED BENEFITS :Foreign Exchange savings to the tune of US $ 4000 / Actuator.

BHEL make Actuators are now being offered against Customer enquiries to make our offers competitive.

C U R R E N T S T A T U S

Actuator Components have been manufactured and are under Assembly.

Back

Double Acting Type Hydraulic Double Acting Type Hydraulic ActuatorActuator

4-1/16”-10000 PSI 4-1/16”-10000 PSI

Valves

Documents