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Design DVG/AF Variable Geometry Desuperheater
Contents
Introduction 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principle of Operation 2 . . . . . . . . . . . . . . . . . . .
Installation 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Instructions 4 . . . . . . . . . . . . . . .
Servicing 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 . . . . . . . . . . . . . . . . . . . . . . . . .
DVG/AF Parts Ordering 6 . . . . . . . . . . . . . . . . . .
Parts List 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Scope of Manual
This instruction manual includes installation, mainte-
nance, and operation information for the Design DVG/
AF variable orifice desuperheater. Refer to separate
instruction manuals for information on the actuator and
accessories.
Only personnel qualified through training or experience
should install, operate, and maintain a Design DVG/AF
desuperheater. If you have any questions about these
instructions, contact your Fisher Controls sales office
or sales representative before proceeding.
Figure 1. Design DVG/AF Variable Geometry Desuperheater
with Pneumatic Actuator
W6981/IL
Description
The Design DVG/AF variable orifice desuperheater
(figure 1) provides a convenient and efficient method
of reducing superheated steam, and some other va-
pors, to desired temperature levels. The variable ori-
fice design allows precise temperature control under
widely fluctuating process conditions.
The DVG/AF assures:
1. Fine atomization over a wide range of operating
conditions assuring rapid and complete vaporization of
injected water.
2. No pipe liners, atomizing steam, or separate spray-
water control valves are required.
3. Temperature control to within 10 - 15F (6 - 8C) of
saturation.
Instruction Manual
Form 5295
August 1998 Design DVG/AF
Design DVG/AF
2
Table 1. Specifications
Steam Line Sizes
J8 to 60-inch
Steam Line Connection Sizes
J3, J4, and J6-inch ANSI Class J150, J300,
J600, J900, and J1500 raised-face flange (con-
sult factory for higher ratings)
(1)
Spraywater Connection Sizes
J1, J1-1/2, and J2-inch ANSI Class J150,
J300, J600, J900, and J1500 raised-face
flange (consult factory for higher Ratings)
(1)
Maximum Inlet Pressures
(2)
Consistent with applicable Class 150, 300, 600,
900, and 1500 (consult factory for higher ratings)
pressure-temperature ratings per ASME B16.34
Inherent Rangeability
(3)
Up to 25:1
Spraywater Pressure Required
50 to 500 psig (3.5 to 35 bar) greater than steam
line pressure
Minimum Steam Velocity
(4)
30 feet per second (9.1 meters per second)
Yoke Boss Sizes and Valve Stem Diameters
2-13/16 inch (71mm) yoke boss diameter with 1/2
inch (12.7mm) stem diameter
Valve Travel (Standard)
1-1/2 inch (38mm)
1. Alternate pressure classes may be available. Consult factory.
2. Do not exceed the pressure or temperature limits in this instruction manual, nor any applicable code or standard limitations.
3. Ratio of maximum to minimum controllable C
v
, dependent on available water pressure differential.
4. Minimum steam velocity is a function of several application parameters and may be adjusted upward or downward from this standard.
W6982-1/ IL
Figure 2. Detail of Design DVG/AF Desuperheater
4. Simple in line installation is accomplished through a
standard flange connection. Installation can be in a
vertical-up or horizontal pipe.
5. High turndown capability.
Principle of Operation
The Design DVG/AF desuperheater reduces steam
temperatures by introducing cooling water directly into
the hot steam. Heat transfer accomplishes the desired
temperature reduction. The cooling water absorbs
heat by conduction and forced convection until the wa-
ter absorbs sufficient heat for vaporization. By regula-
tion of the water quantity, the degree of heat absorp-
tion can be controlled and a specified final steam
temperature maintained.
The linear positioning of the plug regulates water flow
to the sprayhead of the DVG/AF. The main body di-
ameter controls the flow of water, via radially drilled
orifices, in the guide cage. A cross sectional drawing
of the DVG/AF appears in figure 2.
The Design DVG/AF desuperheater utilizes the prov-
en, spring-loaded AF (Anti-Flash) nozzle to provide a
uniform hollow cone spray pattern over a wide range
of flow conditions (see figure 3). The water is injected
through holes drilled at a compound angle to induce
spin as the AF nozzle plug is opened with increasing
water pressure. The design of the AF nozzle is such
that water flows only after sufficient backpressure is
available to provide a good spray pattern. The full
opening of the AF nozzle is limited by a travel stop to
ensure that the spring is kept within its proper working
range and the water film thickness is maintained at the
necessary thickness for proper atomization.
Design DVG/AF
3
Figure 3. AF Nozzle Cross Section
STEM
SPRING
NUT
PIN
WATER INJECTION HOLES
PLUG
BODY
A7191 / IL
Installation
WARNING
Personal injury or equipment damage
caused by sudden release of pressure
may result if the desuperheater is
installed where service conditions could
exceed the limits of the pressure class
noted on the nameplate. To avoid such
injury or damage, provide a relief valve
for over pressure protection as required
by government or accepted industry
codes and good engineering practices.
CAUTION
When ordered, the desuperheater con-
figuration and construction materials
were selected to meet particular pres-
sure, temperature, pressure drop, and
fluid conditions. Do not apply any other
conditions to the desuperheater without
first contacting your Fisher Controls
sales office or sales representative.
1. Insert the Design DVG/AF desuperheater into the
flanged pipe stud on the steam pipe (see table 2 and
figure 4 for the proper T length dimension). Bolt the
unit to the pipe stud flange in accordance with stan-
dard piping practice.
Table 2. T Dimensions
D T
(1)
Nominal Pipe Size,
Inches
Inches mm
8
10
9-3/4
8-1/2
248
216
12
14
16
18
11
10-1/2
9-1/2
8-1/2
279
267
241
216
20
22
24
>24
10-1/2
9-1/2
8-1/2
8-1/2
267
241
216
216
1. For the 6-inch mounting flange, add 2-3/4 inches (70 mm) to the T dimension.
2. Clean and flush out the cooling water line before
connecting to the desuperheater. Use only clean
sources of cooling water. Use of clean water de-
creases wear to the valve trim and prevents clogging
of desuperheater orifices by solid particles.
Note
Fisher Controls recommends installa-
tion of a strainer and isolating valve on
the waterline leading to the desuper-
heater. Failure to do so may result in
clogging of the desuperheater by solid
particles, thus hampering temperature
control of the steam.
3. A straight run of pipe is required downstream of the
desuperheater to ensure complete vaporization of
cooling water. Consult the desuperheater certified
drawing for the required distance of straight pipe.
4. Typically, a temperature sensor should be mounted
at a minimum distance of 30 feet (9.1 m) downstream
of the desuperheater. This distance will vary depend-
ing on steam velocity and percentage of spraywater.
Consult the installation drawing provided with the unit
for this distance or call your Fisher Controls sales of-
fice or sales representative.
5. The steam line should have no branch lines be-
tween the desuperheater and the downstream temper-
ature sensor.
6. A typical control loop is illustrated in figure 5. A
temperature sensor (TE) measures changes in tem-
perature and transmits a signal to a remote tempera-
ture-indicating controller or distributed control system
(DCS). The output signal from the controller is sent to
the positioner on the desuperheater. The positioner
output signal is piped to the actuator, which strokes
the stem/plug of the desuperheater. A rising stem
opens the desuperheater to allow additional water
flow.
Design DVG/AF
4
Figure 4. DVG/AF T Location
WATER
FLANGE
MOUNTING
FLANGE
T HEIGHT
NOMINAL
PIPE SIZE
A7192 / IL
WARNING
Personal injury could result from pack-
ing leakage. Valve packing was tight-
ened prior to shipment; however it
should be checked for possible loosen-
ing due to shipping and handling.
Maintenance Instructions
Servicing
Due to the care Fisher Controls takes in meeting all
manufacturing requirements (heat-treating, dimension-
al tolerances, etc.), use only replacement parts
manufactured or furnished by Fisher Controls.
WARNING
Avoid personal injury from sudden re-
lease of pressure or uncontrolled pro-
cess fluid. Before starting disassembly:
D Disconnect any operating lines pro-
viding air pressure, electric power, or a
control signal to the actuator. Be sure
the actuator cannot suddenly open or
close the valve.
D Use bypass valves or completely
shut off the process to isolate the valve
from process pressure. Relieve process
pressure on both sides of the valve.
Drain the process media from both
sides of the valve.
D Vent the power actuator loading
pressure and relieve any actuator spring
precompression.
D Use lock-out procedures to be sure
that the above measures stay in effect
while you work on the equipment.
Shut off water and steam flow and vent all system
pressure before removal of the desuperheater from
the steam line. Disconnect the desuperheater from the
flanged pipe stud and water flange. Withdraw the unit
from the line.
Temporarily connect the desuperheater to the air sup-
ply and verify proper action. To check for seat leak-
age, connect a water line to the unit and pressurize to
service conditions.
Disassembly
CAUTION
Residual system pressure may be re-
leased during the following steps if the
system was improperly isolated or
vented. Use extreme care to prevent per-
sonal injury while loosening any fasten-
ers in the pressure boundary.
1. Disconnect all field connections to the positioner
and actuator. Remove the mounting and water flange
bolting and remove the DVG/AF from the steam line.
2. Remove the actuator from the DVG/AF using the
actuator manufacturers removal instructions. Refer-
ence figure 6 for assistance in disassembly in the fol-
lowing steps.
3. Slowly loosen the bonnet nuts (key36) approxi-
mately 1/16 in a uniform manner.
4. Break the bonnet (key 13) loose from the body (key
01).
5. After ensuring that the system is depressurized
remove the bonnet nuts (key 36) and washers (key
35).
6. Remove the bonnet (key 13) from the body (key
01) taking care to avoid damage to the stem (key 17).
7. Remove the plug/stem assembly (keys 8, 17 and
18), cage guide (key 15) and seat (key14) for inspec-
tion.
8. Examine the removed parts for unusual wear and
replace if necessary.
9. Remove and discard the seat gasket (key 30), bon-
net gasket (key 31) and stem packing (key 24).
Design DVG/AF
5
Figure 5. Typical DVG/AF Installation
SPRAYWATER
DESIGN DVG/AF DESUPERHEATER
WITH TYPE 667 ACTUATOR
STEAMFLOW
TC
TE
C0817/IL
10. Remove the spray nozzle(s) (key 9) by unscrew-
ing them from the nozzle holder after removing the
anti-rotation tab(s).
11. Inspect the spray nozzles. The nozzles should be
completely closed with no evidence of foreign debris
or uneven action when opened and closed. If this is
not the case and the nozzle(s) cannot be disas-
sembled for cleaning; the nozzle(s) must be replaced
to correct the problem.
12. Flush the desuperheater to remove any debris.
Clean all gasket and part mating surfaces.
Assembly
1. Reassemble the unit with new gaskets and packing
following a reverse sequence of the disassembly. Lu-
bricate all sliding surfaces and the bonnet studs and
washers with a quality high temperature lubricant. The
nozzle antirotation tabs can be replaced with any simi-
lar sized SA182-F22 (2-1/4 Cr1 Mo) material or
9018 weld rod if required. Take care to avoid over-
heating the nozzle or getting weld spatter on the
nozzle opening surface.
2. Tighten the bonnet bolts in a multi-step uniform
cross pattern. It is recommended that the bonnet bolt
torquing be carried out in a minimum of four torque
levels until the final torque is achieved. Torquing val-
ues are shown in table 3.
3. Reinstall the packing ring, a new packing set, pack-
ing follower, flange and nuts.
4. Mount the actuator. When mounting the actuator it
is critical to ensure that the stroke is set to ensure that
proper seating load is available. Follow the guidelines
set forth by the manufacturer in setting up the actua-
tor. In general, position the plug on the seat, move the
actuator to full open position, close the actuator for the
length of the DVG/AF stroke and then connect actua-
tor and DVG/AF stems. If more complete information
is required, consult the actuator documentation.
5. Tighten the packing nuts as required. Torquing val-
ues are shown in table 4. Recheck the stem packing
for leakage after the system is returned to service and
retighten the packing nuts if required.
Troubleshooting
The following guide (table 5) is intended as a basic
first line troubleshooting guide. Contact your Fisher
Controls sales office or sales representative for assis-
tance if you are unable to resolve your field operation
problem.
Design DVG/AF
6
Table 3. Troubleshooting Guide
Problem Corrective Action
Stem packing is leaking Tighten stem packing nuts
Stem packing is leaking after tightening stem packing nuts Repack and replace worn parts as needed
Actuator cannot open desuperheater Check actuator calibration.
Actuator cannot open desuperheater Check for over-tightening of the packing nuts
Actuator action is sticky Check for alignment between actuator and DVG/AF
Actuator action is sticky Check positioner calibration
Actuator action is sticky Replace plug, cage, stem guide and/or packing follower
Temperature setpoint is not reached Check water source availability and pressure
Temperature setpoint is not reached Check nozzle(s) for plugging
Temperature setpoint is not reached Make sure that steam saturation pressure is not above setpoint
Temperature setpoint is not reached Check to ensure full actuator stroke is reached
Temperature setpoint is not reached Check for proper orientation of nozzle in steam flow
Temperature is below setpoint Check temperature control loop reset
Temperature is below setpoint Check nozzle for fouling/poor spray pattern clean/replace
Temperature is below setpoint Check temperature sensor location relocate per guidelines.
Temperature is below setpoint Check for proper orientation of nozzle in steam flow
Water in steam line Check that steam traps are functioning properly
Water in steam line when steam line isolated Check for proper desuperheater actuator installation
Water in steam line when steam line isolated Replace desuperheater seat and plug assembly
Bonnet gasket is leaking
Inspect body/bonnet mating surfaces, replace bonnet gasket. Ensure
bonnet bolts are properly torqued.
Table 4. Recommended Bonnet Bolt Torque
Bolt Size, Inch Threads per Inch
Recommended Bolt
Torque, LbfSft
(1)
5/8 11 125
3/4 10 200
1. Torques for studs with heavy hex nuts.
DVG/AF Parts Ordering
Each desuperheater assembly is assigned a serial
number which can be found on the mounting flange of
the desuperheater. The serial number will have the
form ATL-XX-YYYY-Z, where XX is the project year,
YYYY is the specified sequence of numbers and/or
letters identifying the project, and Z is the item number
identifying the desuperheater on that project. Refer to
the serial number when contacting your Fisher Con-
trols sales office or sales representative for technical
assistance. When ordering numbers for each part re-
quired, the key numbers on figure 6 can be used to
help in part identification.
Table 5. Recommended Packing Nut Torque
Stem
Diameter, Inch
ANSI Pressure
Class
Maximum
Torque,
LbfSft
Minimum
Torque,
LbfSft
150 6 4
300 7 5
1/2
600 10 7
1/2
900 13 9
1500 16 11
2500 18 13
150 12 8
300 15 10
3/4
600 22 15
3/4
900 30 20
1500 37 25
2500 45 30
Design DVG/AF
7
Figure 6. Design DVG/AF Assembly
B2603 / IL
Parts List
Key Description
1 Valve Body
2 Valve Body Pipe
3 Water Flange
4 Water Pipe
5 Valve Body Flange
7 Nozzle Mount
8* Plug
9* Spray Nozzle
13 Bonnet
14* Seat
15* Cage Guide
17* Stem
Key Description
18* Stem Pin
23 Gland Ring
24* Packing Set
25 Gland Follower
26 Gland Flange
27 Gland Stud
28 Gland Nut
30* Seat Gasket
31* Bonnet Gasket
34 Bonnet Stud
35 Bonnet Stud Washer
36 Bonnet Stud Nut
*Recommended spare parts
Design DVG/AF
8
For information, contact Fisher Controls:
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 128461
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express
or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Printed in U.S.A.
EFisher Controls International, Inc. 1990, 1998; All Rights Reserved
Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc.
All other marks are the property of their respective owners.