Desuperheating Equipment & Systems

DESUPERHEATING EQUIPMENT & SYSTEMS

Weir Power & Industrial First choice for power and industrial protection

Blakeborough

BD 1-0207

Blakeborough

DESUPERHEATING EQUIPMENT & SYSTEMS

Quality assurance

BLAKEBOROUGH

Weir Power & Industrial 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 Control Valve business unit have designed and

manufactured valves for in excess of 50 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.

The company holds approvals to:

ASME Section III N, NPT, NV
ASME Section I V
BS EN ISO 9001:2000
API Q1 TO API LICENCES API 6D (6D-0182) AND
API 6A (6A-0445)
TUV - AD MERKBLATT WRD HP 0

6A-0445
6D-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.
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: http://www.weirpowerindustrial.com

BD 1-0207

Weir Power & Industrial First choice for power and industrial protection

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 (112) to 500mm (20)
Outlet - 40mm (112) 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

Weir Power & Industrial First choice for power and industrial protection

BD 1-0207

Blakeborough

DESUPERHEATING EQUIPMENT & SYSTEMS

BV985 - Variable spray unit

Standard Design Options

General

Water inlet connection size 25mm, 40mm and

50mm
(1, 112 and 2)

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.

Connection - flanged, socket weld

Ratings - ANSI 150 to ANSI 2500
Nozzle sizes (see table 1)

Design Details

Superior Pressure 1 bar to 50 bar (15psi to 740psi)

The standard model incorporates 12 carefully

spaced spray nozzles for optimum dispersion in
the steam flow, and to minimise coalescence of
the droplets.

Nozzle Rangeability - up to 40:1

Nozzles arranged so that at low steam flows

water is injected into high turbulence zone of the
vortices shed from the desuperheater probe.

TABLE 1 Nozzle design CV

Nozzle design incorporates swirl chambers and

conical nozzle for optimum atomisation even at
low superior pressures.

Diaphragm
actuator

Positioner

Filter
regulator

Water inlet flange

Desuperheater Pipe
(optional extra)

M
K

N
L

Steam
flow

MN3

MN4

MN5

MN6

0.9

1.5

2.7

4.7

8.0

dimensions

Refer to Actuator catalogues

for dimensions.
Standard Travel 57mm(2 14)
Yoke Mtg 89.5mm (3 916)

Air
supply

MN2

0.5

TABLE 2 Branch height & actuator mount

Nozzle assemblies can be characterised to suit

process requirements and nozzle selection can be
changed after installation.

Optional
Handwheel

MN1

Pipe to fall towards drain port.

Inclination approx 20 mm per m
under working conditions.
1 metre

BV987
Pipe Size mm

Branch Height
L

Act. Mount
K

150
200
250
300
350
400
450
500
600
650
700
750
800
850
900

177
200
226
251
277
302
327
350
372
416
454
480
501
517
547

382
405
431
456
482
507
532
555
577
621
659
685
706
722
752

Rating

600lb
900lb & 1500lb
2500lb

135
184
210

133
167
200

Water Flange Orientation

The pipework inlet flange can be arranged to
suit customers pipework configurations.

Typical arrangment
using BV985 Mark II
Filter
regulator
Shown with manually
operated isolating
valve

Filter
regulator

Positioner
Positioner

Main
steam
supply
Hopkinsons
parallel slide
valve

BD 1-0207

B
From temperature loop

BV500
control valve
pressure
reducing

Water supply

SPRAY
UNIT

BV985 Mark II Variable orifice multi-nozzle

Reduced/Desuperheated
steam
BV987
Desuperheater pipe

From pressure loop

Steam
flow

Weir Power & Industrial First choice for power and industrial protection

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.
FACE TO FACE DIMENSIONS

Standard Design Options

Body size - 25mm to 200mm (1 to 8)

Bore (mm)

25

40

50

80

100

150

200

Ratings - ANSI 150 to ANSI 2500

Dimn (mm)

80

80

80

150

150

150

150

Nozzle size designed for specific application

Superior Pressure 1 bar to 50 bar (15psi to 740psi)

DESIGN CV

Rangeability - up to 8:1 on steam flow

MD1

MD2

MD3

MD4

MD5

MD6

MD7

MD8

MD9

MD10

BV987 - Pipeline desuperheater pipe

0.03

0.04

0.06

0.1

0.14

0.2

0.4

0.63

1.0

1.4

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.

TABLE 3 Pipeline desuperheater standard materials

Component

BV985/BV988

BV986

Body <=427 C

Carbon Steel

Carbon Steel
Chrome Moly

Body >427 C

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.

Standard Design Options

BV988 Mark II
Fixed orifice type

Spraywater

Refer to BV985 section

Rangeability - up to 8:1 on steam flow

BV987 Desuperheater Pipe

(optional extra)

Desuperheated
steam

Superheated
steam

Pipe to fall towards drain port.

Inclination approx 20 mm per m
under working conditions.
1 metre

Weir Power & Industrial First choice for power and industrial protection

BD 1-0207

Blakeborough

DESUPERHEATING EQUIPMENT & SYSTEMS

Standard Design Options

Combined steam reducing & desuperheating

unit

Pressure Ratings

BV994 & BV995 units

ANSI Class 150 to ANSI Class 4500

PN10 to PN640
Sizes
Inlet - 40mm to 500mm (1 12 to 20)
Outlet - 40mm to 1000mm (1 12 to 40)
Trim Options
Multi-flow, Cascade 2/3/4/5

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.

Valves with low noise trim and outlet silencers

destined for a desalination plant in the Middle
East.

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.

BD 1-0207

Weir Power & Industrial First choice for power and industrial protection

DESUPERHEATING EQUIPMENT & SYSTEMS

Blakeborough

Turbine bypass systems

Design Features

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.

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.

Typical Scope of Supply

High pressure by-pass control valve

Erosion resistant trim materials selected which also

prevent galling and the effects of thermal cycling.

High pressure desuperheater

Pneumatic or electro-hydraulic actuation.

High pressure spray water control valve

Variable spray designs.

IP by-pass control valve

Ancillary instrumentation to give fast response,

whilst maintaining stable operation.

IP desuperheater
IP spray water control valve
Low pressure isolation valve
LP by-pass control valve
LP desuperheater
LP spray water control valve

HP turbine bypass
desuperheater for combined
cycle power plant

SUPERHEAT
SPRAY

I.P. & L.P.

TURBINE

H.P.
TURBINE

L.P. STEAM
ISOLATING
VALVE

CONDENSER

REHEAT
L.P. STEAM
BY-PASS

MAIN FEED & START-UP

REGULATING VALVES

DUMP TUBE
L.P.
SPRAY
VALVE

COMBUSTION
CHAMBER

ECONMS
H.P.
HEATERS

P
FEED
PUMPS

DEAERATOR

L.P.
HEATERS

DISTRIBUTION
DAMPERS

ECONMS

ATTEMPERATOR

PRIM.
SUPERHEATER

ELECTRICAL
OUTPUT

N.R.V.

SEC.
SUPERHEATER

GENERATOR

ATTEMPERATOR

DRUM

REHEAT
SPRAY

H.P. STEAM
BY-PASS
DESUPERHEATER

LP turbine bypass
desuperheater for combined
cycle power plant

FUEL

FLUE
GASES

TO STACK

Schematic of Turbine Bypass System

Weir Power & Industrial First choice for power and industrial protection

BD 1-0207

Blakeborough

DESUPERHEATING EQUIPMENT & SYSTEMS

Initial sizing of desuperheaters

Final required degrees of superheat, degrees C.

110 90 70
100 80 60

kJ/kg

Information required at enquiry stage

50

30

10

40

20

550
500
450

Inlet Pressure
Inlet temperature
Required outlet pressure
Required outlet temperature
Available spraywater pressure
Spraywater temperature
Maximum inlet steam flow

Bara
C
Bara
C
Bara
C
kg/hr

(Psia)
(F)
(Psia)
(F)
(Psia)
(F)
(lb/hr)

T1
P2
T2
PW
TW
WS
Controlled temp. should be higher than 5 C (9 F) above saturation point.

400

Minimum distance 7.5m

P1

350
300

Enthalpy
Change
Graphs

250
200
150
100
50

10

12

14

16

18

20

metres

Final required degrees of superheat, degrees F.

200 160
120
180 140

Btu/lb

80

40

100

60

20

250

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.
D = 18.8

WM x VS
Velocity

mm or D = 0.225

WM x VS
Velocity

in.

where WM = outlet steam flowrate kg/hr

(lb/hr)

where VS = outlet specific volume m3/kg

(ft3/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.

BD 1-0207

225

Minimum distance 25 feet

Initial calculations
Calculate the required flow of water WW, kg/hr (lb/hr),
needed to control the steam temperature at the outlet,
by the heat balance method.
WW = WS (h1 - h2)
(h2 - hF)
where h1 = enthalpy of superheated steam at inlet
where h2 = enthalpy of steam mixture at outlet
where hF = enthalpy of spraywater at inlet
values in kJ/kg (Btu/lb)
Total outlet steam flowrate WM = WS + 2W 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.

200
175
150
125
100
75
50

10

25
0
20

25

30

35

40

45

50

55

60

65

feet

Graphs based upon 300mm pipe size. For other sizes

multiply distance by

300

(d = pipe dia. mm)

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 180C.
Required outlet temperature 200C
Steam Inlet enthalpy 3253kJ/kg
Enthalpy change
Steam Outlet enthalpy 2829kJ/kg
424 kJ/kg
Final required degrees of superheat = 200-180 = 20C
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 - 1.427h + 630)
C Metric
Tmax
= (0.125P + 0.5DS - 6.1h + 1190)
F Imperial
where P = absolute steam pressure
bara (psia)
DS
= final required degree of superheat C (F)
h
= enthalpy change from inlet to outlet kJ/kg (Btu/lb)
Ideally the water temperature should be within the
following range for satisfactory operation:(TSAT - 100) C < TWATER < (TSAT - 5)
C Metric
(TSAT - 210) F < TWATER < (TSAT - 10)
F Imperial
also applying the maximum water temperature limitations
when applicable (TSAT is the stream saturation temperature).

Weir Power & Industrial First choice for power and industrial protection

DESUPERHEATING EQUIPMENT & SYSTEMS

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

Blakeborough

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.

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 (14 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.

10

Weir Power & Industrial First choice for power and industrial protection

BD 1-0207

Blakeborough

DESUPERHEATING EQUIPMENT & SYSTEMS

Design & installation of pipeline desuperheater systems

SELECTION CHART
PRESSURE REDUCING
AND DESUPERHEATING

DESUPERHEATING
ONLY

1
YES
2

NO

Is inlet pressure rating less than PN250?

Is inlet pressure rating greater than PN100

and outlet pressure rating less than PN100?

Is outlet pipe size greater than 100mm?

Is steam flow variable?

Is outlet pipe size greater than 100mm?

YES
6

Is steam flow variable?

YES

Is pipe size greater than 100mm?

Is steam flow variable?

YES
3
YES
4
YES

NO
NO
NO

5
NO
NO

7
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

BD 1-0207

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.

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11

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Huddersfield Road
Elland, West Yorkshire
HX5 9JR England

Tel: +44 (0) 1422 282 000

Fax: +44 (0) 1422 282 100
Email: [email protected]
www.weirpowerindustrial.com
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BD 1-0207

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Power & Industrial
Solutions

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