Modern production at HORA: optimized processes through cell ...

PRODUCT INNOvATION
Fascination and challenge:
Newly developed PT products for emerging markets
Dierk Joachim of the Product Innovation team with three of more than 60 minimum flow valves that
wait in the PT Assembly to be delivered to India.
Power plants in India and China are designed differently
than comparable plants in Europe, and that’s why HORA
developed special valves for this market. The PT product
portfolio has been expanded to include two new products
– minimum flow control valves and low-pressure turbine
bypass valves – so that HORA could take on two orders
from India in 2010 that will be delivered this year. “These
projects have a volume of several million euros,“ says Matthias
Dirbach, Director Sales PT. “But since such project packages
can only be commissioned as a whole, we wouldn‘t
have received the order for our existing products without
our new ones.”
The new minimum flow control valves represent an extension
of PT’s product portfolio in the direction of cus-
Construction engineer Horst Seidlitz and welder Ulrich Mickan inspect the
progress of welding on the new low-pressure turbine bypass valve.
tomized high-end solutions: Chinese
and Indian power plants with unit
output in excess of 500 megawatts
increasingly plan a straight-through
installation of these globe valves.
With the new globe valve body, the
modular minimum flow control valve
series is complete, and HORA can now
offer its customers a large selection of
tailored combinations of valve body
designs and inner trims.
Currently, HORA is working on a new
series of low-pressure turbine bypass
valves (TBV) for steam temperatures
of over 600°C. These valves are destined
for power generation units with
outputs in excess of 600 megawatts –
a type of large power plant that will
be built especially in Asia in the coming years. And with the
order it received in April 2010 for two units each with two
high-pressure and two low-pressure turbine bypass valves,
HORA qualified as a supplier for one of the first supercritical
800 megawatt power plants in India. Because of the
high temperatures, the valve bodies will be manufactured
in forged steel instead of cast steel.
Through the further development of its injection nozzle,
HORA can now expand its market share in the low-pressure
turbine bypass valve segment. These new injection nozzles
deliver a significantly finer spray of water in the partialload
range and thus improve steam desuperheating. The
most important goal of this development was the optimization
of droplet size.
velocity dispersion in the new pressure-controlled injection nozzle.
PRODUCT DETAILS
Heavy Duty Control valves now available
The HORA Heavy Duty Control Valve is a versatile, modular
globe valve designed for severe duties. This type of valve
can be utilized to regulate and control the flow of gases,
steams or liquids in all industrial applications. “It is particularly
suitable for the water-steam cycle in high pressure/high
temperature power plant applications,” explains
Franz Hansknecht, Director Product Innovation PT. “Working
in close cooperation with end-user facility engineers
and technical staff, we identify common problems. Due to
our long-standing expertise in valve design we are able to
eliminate them.” The result is the HORA Heavy Duty Control
Valve, which incorporates a number of sophisticated
design improvements:
• For optimum flow, the internal geometry of the valve
body has been designed and validated using FEM and
CFD techniques.
• Operating and maintenance costs are minimized by the
use of quick-change trims and highly wear-resistant
materials.
• A modular design with an extensive array of standard
trims as well as tailor-made solutions provides optimum
performance in flow control.
• An exchange of trims is possible so the valve can be
adapted to meet revised process conditions, e.g. plant
upgrades.
• A wide range of actuators is available: manual, pneumatic,
electric and electro-hydraulic.
• HORA maintains a stock of valve bodies and modules,
so product lead times are short, which in turn makes
planning for maintenance and plant outages easier.
Careful material selection and proven design eliminate
common issues associated with control valves such as erosion,
corrosion, cavitation, vibration, noise and poor controllability.
By combination of optimized design and costefficiency,
the HORA Heavy Duty Control Valve is an ideal
choice for severe service operating conditions.
The HORA Heavy Duty Control Valves can be combined
with all types of actuators. Electric or pneumatic actuators
are used by default, however, other types are available on
request. For applications in pressure classes lower than PN
63 or Class 600, please refer to the HORA Standard Duty
Control Valves.
The interior geometry of the valve has purposely designed
large spaces to allow easy access with serviceability in
mind. The body can accommodate various trim designs and
exhibits high flow coefficients as well as low turbulence.
Depending on pressure class and valve size, end connections
are available as socket-weld, butt-weld or flanged.
For gas and steam applications involving high pressure
drops or high velocities, outlet extensions with integrated
perforated discs can be supplied.
“The temperature distribution of insulated valves is analyzed
by extensive CFD simulations,” says Franz Hansknecht.
“At temperatures above 400°C (752°F), an intermediate
yoke is utilized to protect the actuator and any optional
accessories from overheating and resulting damage.”
The Heavy Duty Control valve is
available now. Please contact
pt@hora.de for more information.
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