Pressure Control and Steam

Conditioning Systems
Integrated Solutions for Process Efficiency

Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

Forbes Marshall Forbes Marshall Arca Forbes Marshall Codel J N Marshall Krohne Marshall Spirax Marshall Forbes Vyncke
For over six decades, Forbes Marshall has been building steam engineering and control instrumentation solutions that work
for process industry. Today we have evolved into a leader in process efficiency and energy conservation through technology
tie-ups and focused investments in manufacturing and research. Our joint ventures with the world’s leading names enable us
to deliver quality solutions in 14 countries. Forbes Marshall is probably the only company in the world to have extensive
expertise in both steam and control instrumentation. The dual expertise has allowed us to engineer industry specific systems
that focus on energy efficiency and utilities management for sectors as diverse as textiles, food processing, paper, power
and chemicals.

Our teams are peopled by some of the finest engineers in the land. These highly trained professionals have developed
innovative solutions and saved millions of rupees in process costs for our clients. Our business practices and processes have
combined into a singular philosophy of being trusted partners who provide innovative solutions. It’s a philosophy we are
proud to live up to.

For decades, we have partnered with some of the best names in the control instrumentation industry such as Arca, Codel,
Krohne and Shinkawa, to develop, design and supply innovative solutions for measurement and monitoring of process
parameters. With a combination of specialist knowledge and the latest technology, we provide products and solutions to
achieve optimum efficiency. Our products are a unique combination of hardware and software that make them reliable and
accurate.

For nearly three centuries steam has been used to transport energy in the form of heat from the place of its origin- the
boiler- to its usage point a steam engine, a turbine, a heat exchanger or any other process. For this reason steam is
generated in boilers at high pressure and temperature and subsequently expanded in equipments to obtain thermal and
mechanical energy. In condensers this reduced steam is converted back in to liquid phase and by means of boiler feed water
pump this condensate is pressurized again and transported to the boiler. The water/steam cycle is closed.

Hence, Pressure and Temperature reduction is inevitable. The reasons for pressure and temperature reduction can be
summarized as:

• Steam boilers are usually designed to work at high pressures. Working it at lower pressures can result in carryover
of water.

• Steam at high pressure has a lower specific volume which means that a greater weight can be carried by a pipe of given
size. Forbes Marshall recommends distribution of steam at high pressure and reduction at point of usage. This reduces
capital costs or piping / insulation and also reduces distribution losses.

• Steam pressure may be reduced to save energy. Steam at lower pressures has higher latent heat. Reduced pressure of
steam also leads to reduced heat loss and lower flash steam formation from open vents.

• Since the pressure and temperature of steam are related, controlling the pressure enables us to control the temperature
in the heating process.

• Pressure must be reduced so that they are within the within the rated safety limits.

• In plants where steam usage takes place at many different pressures, pressure reduction allows generation of steam at a
single high pressure and subsequent reduction to the desired pressure at the point of usage.

• Temperature control is necessary to control superheat temperatures.

• Temperature control is necessary to protect piping systems and components from excessive temperatures and/ or to
provide process steam at required temperatures.
The Forbes Marshall Advantage
Forbes Marshall has the knowledge and expertise to enable you to select the right pressure and temperature control solution for
your specific need. Forbes Marshall Pressure control valves and Desuperheaters are available with various options to suit a client’s
requirement.

We offer customized solutions with total system end to end station with all necessary mechanical and instrumentation components
and take guarantee of entire control system

Pos. Part Name 19 Elbow

1 Pressure Gauge 20 Flange
2 Pressure Gauge 21 Expander
3 Dial Thermometer 22 Flange
4 Dial Thermometer 23 Condensing Pot
5 Stop Valve 24 Equal Tee
6 Bypass Valve 25 Expander
7 Strainer 26 Tee
8 Pressure Reducing Cum Desuperheating Valve 27 Additional Spray Nozzle Insert
9 Elbow
10 Stop Valve
11 Safety Valve
12 Stop Valve
13 Pressure Control Loop
14 Temperature Control Loop
15 Non-Return Valve (Loose Supply)
16 Stop Valve
17 Water Flow Control Valve
18 Strainer

Total PRDS System along with Control Loop

Recommendations for efficient working of PRDS

• Minimum straight length at outlet should be 4 mtrs.
• Minimum distance of Temperature Sensor from the point of water injection should be 10 to 12 mtrs.
• Minimum distance of Pressure Sensor from PRDS Valve should be 1.5mtrs.
• It is recommended to install a strainer of 0.8 mm mesh before water control valve.
• Spray water should be very clean (equivalent to boiler feedwater).
• Instrument quality air is required.

Minimum water pressure requirement for Combined PRDS:

• Top entry : Pw = [(P1+P2)/2 ] + 7 BAR
• Bottom entry through stem : Pw = P2 + 7
• Bottom entry through nozzle : Pw = [P1 / 2 ] + 7 BAR

Notes
1 Minimum controllable temperature is Saturation Temperature + 7°C.
2 The above are based on a specific set of parameters. These guidelines may change.
Features:
• All stations are engineered and factory assembled.
• Most of the PRDS stations are supplied with ‘Combined PRDS’ valves which give the advantage of pressure reduction and
temperature control in a single unit.
• If a Combined PRDS unit is not suitable; we offer separate PRV and DSH unit.
• Even with Combined PRDS valve, separate redundant Desuperheater can be included incase of bypass operation when main
valve is under maintenance.
• The Water flow control valve and Waterline are also offered with the steam line, which ensures correct design and one to one
matching of pressure and temperature control stations.
• It is designed inline with good steam engineering practices using our proprietary software.
• Forbes Marshall manufactures most of the components of pressure reducing and desuperheating stations in-house which,
enables quality control as per our standards.
• The entire assembly is hydro tested.
• Various options and makes are available for isolation valve and bypass valves.
• We ensure availability of steam to the process of the right quantity, quality, pressure and temperature.
• For low sizes we maintain same pressure class at the inlet and outlet which allows high robustness and strength for the station.
This ensures reliability of station even in case of any malfunction or failure.
• Stations are available in various sizes from 25mm upto 1500mm or more. Pressure class available from ANSI 150# upto 2500# in
A106 Gr. B / A335 P11 / A335 P22 materials.
Pressure Reducing Valve
Pressure control valve which, is the ‘Heart of the Station’ is designed, engineered and manufactured in house which ensures high
quality.
Strainer
This ensures clean steam going into station and avoids burrs, foreign particles entering in main valve.
Isolation Valves
Zero leakage Gate / Piston valves prevent inline leakage. Helps to isolate the main pressure control valve in case of maintenance
activities.
Bypass Valve
This can be supplied with manual or actuated operation. This is a Globe type valve and ensures reduced steam pressure and
uninterrupted supply in case the main pressure control valve is under maintenance.
Desuperheater
Fixed or Variable Nozzle Desuperheaters are provided for accurate temperature control. These are designed, engineered and
manufactured in house which ensures high quality.
Safety Valve
A good quality safety valve is essential in the event of a sudden steam pressure increase. Forbes Marshall safety valves are the most
reliable and proven safety valves.
Gauges
Good quality pressure and temperature gauges are essential at inlet and outlet of station. These ensure correct parameters at the
inlet and measure the result of the pressure reducing station at the outlet.
Instrumentation
High accuracy instrumentation for pressure and temperature control like transmitters, controllers, DCS system are offered as per
client’s requirement with options of various makes and models.

Notes:
• Special materials are offered as per clients requirement.
• Same pipe material is maintained throughout station as per design temperatures.
• Entire assembly is provided with IBR Certificate.
• Option of Self Regulating valve is also available.
• We recommend minimum 4mtrs. straight length from the point of water injection.
• We recommend minimum 10 mtrs. distance of temperature sensor from the point of water injection.
• Interconnecting pipe between water and steam line, supporting pads, supporting structures, any other item which is not
specified in line diagram is not a part of standard package but can be supplied upon request.
• Pneumatic testing can be offered for the entire assembly on request.
• Multilayer redundancy for critical applications is also available.
Various other Options:
• Pressure Reducing Station - We also offer pressure reducing stations with pressure control systems. High quality
components are used which ensure reliability of the system. These are also engineered, designed and fabricated at
Forbes Marshall and duly hydrotested before dispatch.

Pressure Reducing Station with Instrumentation

Bill of material 7. Safety valve 14. Unequal Tee

1. Pressure Gauge 8. Stop Valve 15. Pressure control loop
2. Pressure Gauge 9. Inline Strainer 16. Dial thermometer
3. Stop valve 10. Elbow 17. Expander
4. Bypass valve 11. Flange 18. Expander
5. Stop valve 12. Condensing Pot 19. Expander
6. Pressure Control valve 13. Flange

Pressure Reducing Station with Self-Regulating Valve TS

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Bill of material 7 Safety valve 14 Expander

1 Pressure gauge 8 Stop valve 15 Flange
2 Pressure gauge 9 Elbow 16 Flange
3 Stop valve 10 Flange 17 Expander
4 Bypass valve 11 Inline Strainer 18 Dial Thermometer
5 Stop valve 12 Flange
6 Pressure Control valve 13 Tee

Note:
• Entire assembly is offered with IBR Certificate.
• Combined angle type pressure reducing and desuperheating station

These are suitable for High pressure Turbine bypass and HP / LP bypass applications. We offer the same with various sizes,
material and pressure class. This ensures required pressure and temperature drop.

Requirements of Turbine Bypass System:

• Protection of Condenser against excessive Pressure & Temperature.

• Partial Bypass to maintain steady upstream pressure when Turbine runs back to house load.
• Efficient matching of steam & turbine metal temperatures during cold, warm & hot start up cycles.
• To prevent boiler pressure fluctuations in case of Turbine trip or load rejection.
• To avoid the lifting of HP safety relief valve & condensate loss.
• Cooling of final superheating in case of falling pressure application.
• Controlled pressure build up during start up operation or in the event of Turbine Trip.

Features:

• Angle type Combined PRDS valves with various stages on pressure and temperature reduction.
• Customized designs to accommodate complete performance needs.
• Tailor made multi stage Trims for Dynamic noise control.
• Cast / Forged body selection available.
• End connections to meet existing piping sizes & materials.
• Bolted Bonnets for easy serviceability.
• Trim removable thru’ bonnet, In Line.
• Installation in any orientation.
• Shut off in accordance with ANSI / FCI 70.2, Class V.
• Dump Tubes can be designed & supplied on request
• Suitable for Feedforward as well as conventional control strategies.

Notes:
• As this system itself acts as bypass system for turbine, no bypass is required for this system again.
• If condensers are equipped with safety devices like rupture discs then no extra safety devices like safety valves are necessary.
Desuperheating stations
Forbes Marshall offers various range of Desuperheating stations with fixed nozzle or variable nozzle options to suit customer
requirements. These are offered with temperature control instrumentation of various makes and models.

A) Fixed nozzle Desuperheating station

10
AIR SUPPLY Bill of Material
4 11
1 Dial Thermometer 6 Strainer
3 4 2 Dial Thermometer 7 Pid Controller
AIR SUPPLY WATER

5 6
4 INLET 3 Non-return Valve 8 Spray Nozzle Insert
STUB WITH SORF FLANGES 4 Stop Valve 9 Temperature Sensor
7
(LOOSE SUPPLY)
5 Water Flow Control 10 I/P Convertor
8
1 9 2 Valve
11 Piping

STEAM STEAM
Note:
INLET OUTLET • Applicable for steam pipe size 100mm (4”) and above
• Separate spray water valve required
• Also offered with pipe shell with stub
• IBR certificate provided for individual components.
IBR for entire assembly offered on request

B) Minicooler Desuperheating station

11 AIR SUPPLY Bill of Material
12
4
1 Dial Thermometer 7 Temperature Controller
3 4 2 Dial Thermometer 8 Minicooler
AIR SUPPLY WATER
Desuperheater
4
INLET 3 Non-return Valve
5
6 7 9 Steam Pipeline
4 Stop Valve
10 Temperature Sensor
2
5 Water Control Valve
1 8
10 11 I/P Convertor
6 Strainer
9 12 Piping
STEAM STEAM

OUTLET
Note:
INLET
• Applicable for steam pipe size below 100mm (4”)
• Separate spray water valve required
• Separate pipe shell with stub not required
• IBR certificate provided for entire assembly

C) Variable nozzle Desuperheating station

Bill of Material

1 Dial Thermometer
5 2 Dial Thermometer
3 Temperature Sensor
AIR SUPPLY

4
4 PID Controller
WATER INLET 5 I/P Convertor
1 2 6 Air Filter and Regulator
3

STEAM STEAM
Notes:
INLET OUTLET • Applicable for steam pipe size 100mm (4”) and above
• Separate spray water valve not required
• Also offered with pipe shell with stub
• IBR certificate provided for entire assembly
Parameters required:

For PRDS Station: For PRS Station: For DSH Station:

• Inlet pressure in bar (g) • Inlet pressure in bar (g) • Pressure in bar (g)
• Outlet pressure in bar (g) • Outlet pressure in bar (g) • Inlet temperature in deg.C
• Inlet temperature in deg.C • Temperature in deg.C • Outlet temperature in deg.C
• Outlet temperature in deg.C • Existing pipe size in mm • Water pressure in bar(g)
• Water pressure in bar(g) • Water Temperature in deg.C
• Water Temperature in deg.C • Line size in mm
• Existing pipe size in mm

www.forbesmarshall.com

Forbes Marshall Pvt. Ltd.

A-34/35, MIDC, Industrial Estate, ‘H’ Block, Pimpri, Pune - 411 018. India.
Tel.: 91(0)20 - 27442020
Fax: 91(0)20 - 27442040 E-mail: [email protected]

Domestic:
Ahmedabad, Alibag, Bangalore, Bhopal / Indore, Chandigarh, Chennai, Coimbatore, Delhi, Hyderabad, Jamshedpur, Kolkata, Mumbai,
Nagpur, Navi Mumbai, Surat, Trichy, Vadodara, Visakhapatanam
International Operations: [email protected]
Bangladesh, Canada, Egypt, Indonesia, Iran, Kenya, Malaysia, Nepal, Sri Lanka, Thailand, U.A.E. (Instrumentation) (Boilers & Boiler Accessories)USA,