Baker Hughes Masoneilan SteamForm 84003 Series User manual

Baker Hughes Data Classication : Public
Masoneilan™
84003 Series SteamForm™
Steam Conditioning Control Valve
Installation Guide (Rev. B)

ii | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
About this Guide
All information contained herein is believed to be accurate at the time of publication and is subject to change without
notice.
Changes to specications, structure, and components used may not lead to the revision of this manual unless such
changes affect the function and performance of the instrument.
In no case does this manual guarantee the merchantability of the hardware or the software or its adaptability to a
specic client needs.
Please report any errors or questions about the information in this manual to your local supplier or visit
valves.bakerhughes.com
Disclaimer
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE
INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE
PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BAKER HUGHES COMPANY (AND ITS
SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC
LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN
CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR
REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO
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REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.
Copyright
The complete design and manufacture are the intellectual property of Baker Hughes.
All information contained herein is believed to be accurate at the time of publication and is subject to change without
notice.
Document Changes
Version/Date Changes
Rev.A - 05/2015 Original Release
Rev.B - 11/2020 Baker Hughes rebranding

Masoneilan 84003 Series SteamForm Installation Guide | iii
Copyright 2020 Baker Hughes Company. All rights reserved.
Contents
Masoneilan 84003 Series SteamForm Installation ................................................................................................. 1
Piping system layout............................................................................................................................................... 1
Upstream pipe recommendations .................................................................................................................... 1
Downstream pipe recommendations ............................................................................................................... 2
Straight pipe length .................................................................................................................................... 2
Temperature sensor location ..................................................................................................................... 3
Pressure sensor location ........................................................................................................................... 4
Pipe size and selection .............................................................................................................................. 4
Material break point ................................................................................................................................... 6
Piping material transition recommendations .............................................................................................. 6
Spray water system requirements .......................................................................................................................... 7
Water pressure ................................................................................................................................................ 7
Water temperature ........................................................................................................................................... 8
Strainers .......................................................................................................................................................... 9
Valve installation ..................................................................................................................................................... 9
Valve support ................................................................................................................................................... 9
Actuator support .............................................................................................................................................. 9
Orientation ....................................................................................................................................................... 11
Drains and pipe slopes .................................................................................................................................... 12
Warm-up and preheating steam ...................................................................................................................... 13
Insulation ................................................................................................................................................................ 14
Accessibility ..................................................................................................................................................... 14
Temperature control methods ................................................................................................................................. 14
Temperature – feedback control ...................................................................................................................... 14
Temperature – feedforward control .................................................................................................................. 14
Response time and stroke speed .................................................................................................................... 15
Start-up and commissioning ................................................................................................................................... 15
System blow down and cleaning ..................................................................................................................... 15
Trim Installation Device (TID) .......................................................................................................................... 16
Post weld heat treatment and hydro-testing .................................................................................................... 16
SteamForm assembly ...................................................................................................................................... 16
Commissioning spares .................................................................................................................................... 16
Turbine bypass to condenser applications ............................................................................................................. 16
Bypass system requirements .......................................................................................................................... 16
Process control ................................................................................................................................................ 16
Back-pressure dump tubes .............................................................................................................................. 17
System noise evaluation .................................................................................................................................. 17
Final recommendations .......................................................................................................................................... 17

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Table of Figures
Figure 1
Recommended upstream straight pipe length ........................................................................................................ 2
Figure 2
Typical downstream piping installation ................................................................................................................... 3
Figure 3
Recommended pipe length prior to the temperature sensor. ................................................................................. 5
Figure 4
Evaporation process of a water droplet .................................................................................................................. 6
Figure 5
SteamForm water spray control valve Installation .................................................................................................. 10
Figure 6
Recommended orientation of the SteamForm........................................................................................................ 11
Figure 7
Improper orientation of the SteamForm.................................................................................................................. 11
Figure 8
Vertical ow down outlet orientation, should be located at low point downstream ................................................ 12
Figure 9
Drain vertical ow up inlet orientation, drain should be located at low point upstream .......................................... 12
Figure 10
Vertical ow down inlet orientation, drain should be located at low point of SteamForm valve body. .................... 13
Figure 11
Horizontal inlet and horizontal outlet orientation, drain should be located at low point of
SteamForm valve body. .......................................................................................................................................... 13
Figure 12
Start-up trim. ........................................................................................................................................................... 15
Figure 13
Trim Installation Device .......................................................................................................................................... 16

Masoneilan 84003 Series SteamForm Installation Guide | 1
Copyright 2020 Baker Hughes Company. All rights reserved.
Masoneilan 84003 Series Steamform
Installation
Installation of the Masoneilan 84002 series SteamForm
products requires a thorough understanding of the
surrounding operating environment. Product selection
and evaluation must extend upstream and downstream to
ensure proper design for successful long-term operation.
Baker Hughes’s installation guidelines are intended to
provide recommendations and warnings for the various
design elements of the steam conditioning system.
Enhancements to the overall performance of the system
are tested and documented through years of installed
experience and proven eld-tested methods.
Piping System Layout
The design and layout of the piping system are
important factors for a successful installation of a steam
conditioning valve. Several performance factors are
highly dependent upon the proper arrangement of the
piping system. Without the correct design in place,
the steam conditioning valve becomes ineffective in
achieving temperature control and stability. Additional
Design requirements including selecting pipe size, laying
out upstream and downstream piping, and positioning of
control elements are explained throughout this document.
Upstream Pipe Recommendations
Adjacent pipe bends such as pipe elbows and tee
connections are known to cause high levels of rotational
forces and excessive vibration when installed in close
proximity to a valve body. Long-term exposure to this ow
induced vibration results in problems such as damaged
trim and excessive noise during operation.
To reduce these risks, a uniform and stable ow prole
must be achieved prior to admission of the steam into
the SteamForm valve body. This is accomplished by
supplying a length of straight pipe, L1, upstream of the
valve inlet as shown in Figure 1. A straight pipe section
allows the inlet steam to recover its uniform ow prole
after passing through the turbulent path of an elbow.
In the case of an upstream elbow installation, the
recommended distance of ve pipe diameters of straight
pipe must be mounted upstream of the valve. Longer
lengths of straight pipe are also desirable.
Minimum upstream straight pipe length:
L1 = 5 x Nominal Pipe Diameter
Upstream tee connections involve further consideration,
as higher levels of turbulence are present in these
applications. These systems must supply a longer
length of upstream straight pipe, as higher levels of
instability exist. Consult your local Baker Hughes sales
ofce or factory for the recommended distance for these
applications.

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Downstream Pipe Recommendations
Downstream considerations are more complex due to
a larger number of variables that are introduced in the
outlet of the SteamForm. The most signicant of these
variables includes the addition of spray water into the
steam ow and the expansion of steam as the pressure is
reduced. The following sections describe the necessary
features for properly designing the downstream piping
layout.
Straight Pipe Length
To avoid phase separation and downstream problems,
such as erosion or poor process control, it is necessary
to extend the straight pipe length exiting the SteamForm
to allow for water vaporization prior to the installation of a
pipe elbow. This distance ensures that a sufcient mass
of the water droplets is vaporized in order to prevent
water fallout and insufcient mixing. While this length
varies with each set of design conditions, a conservative
design downstream of the valve prior to installation of the
rst pipe elbow is L2, as per the equation below:
Minimum downstream straight pipe length:
L2 = Greater of 10 ft (3m) OR 7 x Nominal Pipe
Diameter
Once a minimum straight distance is obtained, Baker
Hughes recommends installing downstream elbows to
enhance ow turbulence. The downstream elbows assist
in the mixing of spray water within the steam ow and
help achieve an evenly distributed temperature prole. It
is suggested to design the rst pipe bend using a long-
radius, chrome-moly elbow to protect against wear and
erosion. An example installation is shown in Figure 2.
Figure 1: Recommended upstream straight pipe length

Masoneilan 84003 Series SteamForm Installation Guide | 3
Copyright 2020 Baker Hughes Company. All rights reserved.
Temperature Sensor Recommendations
Baker Hughes recommends a minimum of three (3)
temperature sensors to be mounted at the downstream
of the desuperheater. The sensors should be installed
at 120 degree angle, with 2 out of 3 voting failure, and
average logic.
The temperature sensor must be located at a point far
enough downstream to ensure 100% vaporization of the
water droplets. For control stability, single-phase steam
ow must be achieved. If high-energy water droplets
exist within the steam ow, the temperature element
recognizes sub-saturated conditions and reduces the
capacity of water injection. This misplacement of the
temperature element results in uncontrollable operation
requiring re-engineering to correct the errors of the
improperly designed steam conditioning system.
The proper location of the temperature sensor is
application specic. Benets from a properly designed
downstream pipe system allow for a greatly reduced
distance. Flow induced benets are achieved with the
proper placement of pipe elbows that allow high-energy
turbulence to assist in the mixing of spray water upon
passage through the elbow. For the sensor location
of a specic application, a piping layout along with
operating conditions must be provided to your local Baker
Hughes representative. However, the general direction
for minimum distance required for temperature sensor
location is per the equation below, and shown in Figure 3.
Temperature sensor distance, L3 = Minimum 33 ft
(10m)
Figure 2: Typical downstream piping installation

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In some cases, the required distance prior to a
temperature sensor cannot be provided by the plant
due to a lack of real estate or specic application
requirements. In these cases, the use of a feed forward
temperature control algorithm is required for control. See
the temperature control methods that are explained later
in this document for further explanation.
The radial location of the temperature sensor can be
a concern for applications that do not pass through a
pipe bend. Long lengths of straight pipe along with large
quantities of water injection can result in spray water
fallout. Thermal sensors located at or near the lower pipe
wall can measure lower temperatures as water fallout
reduces the temperature of the lower boundary layer at
a faster rate than the pipe core. Temperature sensors
must be placed in the middle to upper portion of the pipe
cross-section to ensure the maximum steam temperature
is observed.
As previously noted, the addition of at least one pipe
elbow within a system is extremely benecial in assisting
with the mixing of spray water with the steam. These
installations must always mount the temperature sensor
downstream of the elbow by at least ve pipe diameters.
Close coupling of the sensor with an elbow can result in
poor temperature control.
Pressure Sensor Recommendations
The pressure sensor must be located at a point
downstream where there is a relatively stable ow prole.
The recommended installation point is ve pipe diameters
downstream of the valve connection and any pipe
elbows. See Figure 3.
Minimum Pressure Sensor location:
L4 = 5 x Nominal Pipe Diameter
Pipe Size and Selection
Prior to laying out the piping system, the appropriate
pipe sizes must rst be determined. This is accomplished
by following velocity limitation guidelines. These
guidelines are usually established by the customer or
by the engineering standards of the design rm. These
guidelines are typically practical for the upstream
design; however, with the addition of spray water some
guidelines become conservative and impractical for the
downstream design of a steam conditioning system.
The ideal environment for water injection is a high
velocity and highly turbulent ow operating between
the ranges of 250 ft./sec and 300 ft./sec. A high velocity
steam jet creates an effect that shears across water
droplets and increases the surface area that is exposed
to steam. By creating more surface area, the diameter
or thickness of the water droplets is decreased. This
drastically decreases the amount of time that is required
for a water droplet to vaporize.
Conversely, a low velocity ow stream does not assist
in breaking down the water droplet. As a result, larger
diameter water droplets are injected into low velocity
applications. Because these larger diameter droplets
carry more mass, it becomes difcult at low velocity for
the steam to suspend the heavier droplet in the ow
stream.
This can result in water fallout and insufcient
evaporation at the temperature sensor location.

Masoneilan 84003 Series SteamForm Installation Guide | 5
Copyright 2020 Baker Hughes Company. All rights reserved.
It is important to design the pipe around the most
critical operating scenarios. For example, it is common
to design a maximum ow rate scenario that is rarely
ever experienced. For this case, it is benecial to allow
short durations of high velocity (in excess of 300 ft/
sec) to obtain a tradeoff of better performance at lower
ow rates. There is a direct relationship between pipe
size and turndown that must be evaluated for each
installation.
After selecting the pipe size, the next step is to
correctly design the pipe wall thickness and material
to follow the appropriate codes of the country or state
of the installation. The design of the downstream wall
thickness and material depends on the upstream design
temperature as a possible limit. This temperature limit is
set because the water is introduced in the outlet of the
valve, thus, does not effectively cool the steam until a
signicant distance downstream.
Figure 3: Recommended pipe length prior to the temperature sensor

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Material Break Point
As previously mentioned, temperature reduction does
not occur immediately at the outlet of the SteamForm.
Spray water injected into the steam must rst heat-up to
the saturation point, and then evaporate into steam for
cooling. This phase change is shown in Figure 4. The
SteamForm valve can be used as a material breakpoint
provided the lower grade material is designed to accept
the full upstream temperature.
Heat-up Time, t1Evaporation Time, t2
Temperature = T water Temperature = T saturation
The material break point, in the case where temperature
reduction is a required design factor, is application
specic and is not possible to advice as a rule of thumb
process. The complexity of this calculation stems from
the fact that the evaporation rate is a function of the
following three variables.
• The enthalpy differential between the water and the
saturation point determines the amount of time required,
t1, for heating the water to its saturation point.
• The droplet diameter, which is a function of nozzle
design and injection velocity, inuences the amount
of time required, t2, to evaporate the water once it
becomes saturated.
• The length for proper evaporation is determined by
multiplying the steam velocity by the sum of t1 and t2.
Multiple variables are presented in the calculation
and are applied through indirect relationships. For
applications where a temperature reduction must take
place prior to the material downgrade, a Baker Hughes
representative should be contacted to provide the best
location for the material transition.
Figure 4: Evaporation process of a water droplet
Warning: Steam exiting the SteamForm valve exhibits high temperature. Complete cooling of the steam
temperature does not occur until the spray water evaporates and mixes with the steam. Therefore, the nal
outlet set point is not achieved until reaching the factory specied temperature sensor location.
Piping Material Transition
Recommendations
SteamForm valves are often manufactured with high alloy
cast material body such as C12A Grade 91, specially for
steam temperatures exceeding 1000°F. The End Users
typically maximize lower grade material piping at the plant
for cost savings. Lower grade materials cannot withstand
the higher temperatures steam conditions. Therefore,
before transitioning piping material from higher grade to
lower grade at downstream of the SteamForm valves,
specic distance guidelines must be followed. Please
contact factory for evaluation and minimum distance
recommendations.