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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WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE
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THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,
TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
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

iv | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
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.

2 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
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

4 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
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

6 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
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.

Masoneilan 84003 Series SteamForm Installation Guide | 7
Copyright 2020 Baker Hughes Company. All rights reserved.
Spray Water System Requirements
When selecting a spray water source the impact on both
system turndown and operation cost must always be
considered. Tradeoffs exist, especially when debating
the added expense of a water pump verses using low-
pressure spray water. The pressure differential between
the water and the outlet steam dictates the operating
range of the nozzle. The low pressure water source
severely limits the turndown and performance of a
steam conditioning system, regardless of the upstream
equipment supplied. The design goal is to provide a
water source that achieves the required turndown of the
system, while minimizing the cost of operation. Some
guidelines are provided in the following sections.
Water Pressure
When evaluating performance of a spray water source,
it is important to remember that water passes through
two stages of pressure drops. The rst stage is the spray
water control valve. This valve controls the amount of
water that is injected into the steam ow. The second
stage is the spray nozzle. At this point, the spray water
is broken down into a ne aerosol spray mist and
introduced into the steam.
The availability of water pressure is paramount in the
selection of the appropriate spray nozzles. This is
because each nozzle design has a critical point where
the pressure differential becomes too low and yields large
slugs of water as opposed to the desired aerosol effect.
Large slugs of water are ineffective in cooling the steam
because their mass exceeds the limit of what the steam
ow is capable of suspending. This results in poor cooling
of the steam and severe water fallout.
Other types of nozzles, such as variable orice nozzles,
require a minimum differential pressure that must be
present to overcome the force on the nozzle and allow
the ow passage to open.
When the minimum pressure limitations are satised the
spray nozzle becomes effective in injecting a ne aerosol
of water into the steam. When the minimum pressure
limitations are surpassed, the nozzle is able to supply a
larger capacity of spray water and supplies a larger range
of turndown. The amount of available pressure differential
above the minimum limit dictates the turndown range
of the spray nozzle. This is explained in the following
example application. In the example below, assume
the use of a spray nozzle with Cv = 1.0. Also assume
the specic gravity of the water is 1.0. This example
compares two operating scenarios, the rst uses a water
source with an available pressure differential of 400 PSI,
and the second uses a water source with an available
pressure differential of 100 PSI. In both scenarios,
assume the minimum effective pressure differential of the
nozzle is 25 PSI.
The equation to calculate the Cv of an incompressible
uid such as water is:
This can be rearranged to calculate the volume ow rate, Q (GPM):
Scenario 1: 4:1 Turndown Application

8 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
Scenario 2: 2:1 Turndown Application
This quantity is measured by ow rate, and the heat is measured by enthalpy, H.
From the law of conservation of mass, we can substitute outlet with the combination of inlet + water.
This equation can then be rearranged to solve for the water mass ow rate, water.
The water source used for steam conditioning should
be more than 150 PSI (11.5 Bar) above the outlet steam
pressure. This range ensures proper atomization and
a good range of performance. A higher water pressure
differential is also desirable. Water pressure below 150
PSI is also acceptable; however, low-pressure differential
limits the amount of turndown the system is able to
provide. The minimum operating differential pressure is
typically between 20 PSI and 45 PSI, depending on the
nozzle design that is being used.
Each spray nozzle also has a maximum rated pressure
differential. However, this is not a concern because the
excess pressure differential is distributed across the
water control valve.
Water Temperature
The temperature of the water source is a variable that
directly impacts the amount of water required to reduce
the steam to a specied outlet temperature. The water
temperature also has a direct effect on the amount
of downstream pipe that is required and dictates the
efciency of evaporation.
Cold water sources, such as condensate and makeup
water, require less mass ow to sufciently cool the
steam to the outlet set point. The exact amount of water
required can be determined through a heat balance
calculation. This calculation is a balance of the quantity
of heat entering the valve in the forms of inlet steam and
spray water, to the quantity of heat exiting the valve as
the outlet steam.
Hot spray water, such as boiler feed water, requires a
larger quantity of ow, but evaporates at a faster rate
because less heat transfer is required to reach the
saturation point. High temperature water also reduces
thermal shock by minimizing the differential temperature
between the steam and water.
For the majority of the cases, hot water is benecial to
steam conditioning as it minimizes the downstream pipe
requirements and helps protect against water fallout.
However, in low-pressure steam applications, hot water
can sometimes result in ashing as the pressure is
reduced through the control valve or nozzle orice. If the
ashing occurs upstream of the nozzle, special valve trim
is required to prolong the active life of the equipment. If
the ashing occurs upon injection into the outlet pipe, it
will be benecial in assisting with evaporation and mixing
of the water with the steam. The water temperature
is a design condition that typically cannot be modied
for a particular application. However, it is important to
understand the impact the water source has and design
the system to suit the condition.
x
x
x
x x
x x

Masoneilan 84003 Series SteamForm Installation Guide | 9
Copyright 2020 Baker Hughes Company. All rights reserved.
Strainers
The SteamForm spray water injection system is made up
of a variety of nozzle types and sizes to ensure optimum
results in a variety of applications. Available nozzle types
include at spray pattern nozzles, hollow-cone spray
pattern nozzles, and variable orice nozzles. Each nozzle
is selected based on water quantity required and the
available water pressure differential. These nozzles all
possess a unique spray pattern and droplet size, which
dictates the performance capabilities of the SteamForm.
To prevent blockage of these small orice nozzles, an
inline strainer is strongly recommended on all spray water
lines. Regardless of the quality of the water source, the
possibility always exists that scale, debris, or other pieces
of particulate can be found in the water system. This
particulate can be large enough to clog or block the ow
exiting the nozzle.
The strainer must always be installed as close to the
nozzles as possible to collect any possible scale or
debris that can be in the water system. Baker Hughes
recommends minimum 100 MESH screen strainer
at upstream of the water spray control valve. Strainers
must be monitored and maintained regularly to ensure
blockage does not occur. See gure 5 on next page for
strainer location, and general water injection control valve
recommendation.
Valve Installation
The steam conditioning valve is an instrumental piece
of equipment used to prolong the active life of the plant
and critical pieces of equipment. When properly used,
the steam conditioning valve keeps a plant on-line during
load rejections and allows the system to return to normal
operation with minimized delays. It can also be used to
protect sensitive downstream equipment from heat and
pressure excursions or during the plant start-up phase.
To protect the plant and its equipment, it is important
not to overlook the necessary steps that prolong the
life of the steam conditioning valve. Several steps can
be taken to ensure the valve is installed in the best
possible orientation, and it is easily accessible for routine
maintenance. The guidelines below are suggested to limit
exposure to undesirable scenarios and prolong the useful
life of the valve.
Valve Support
All valve supports must be mounted to xed points
within the piping system. Excess strain on the valve
components must be avoided whenever possible. The
SteamForm can never be used as a xed point at which
a system is mounted on. Supports must not be welded to
the SteamForm valve body.
Actuator Support
Actuation support can become a concern in the case of
horizontal actuation installations. When large actuators
are mounted horizontally, a spring-loaded saddle support
system must be used to cradle the actuator and minimize
stress applied to the valve plug and stem. The saddle
support system must be periodically monitored to verify
the support is not out of its original tuning. If not properly
maintained, the support system can become a source of
additional stress on the actuator, plug, and stem.
Warning: Failure to install a strainer can result in
blockage of the nozzle, damage to heat sensitive
equipment, and plant shutdown.

10 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
SPRAY WATER
ISOLATION VALVE
CONTROL VALVE
SPRAY WATER
100# MESH
STRAINER
L1
L2
Figure 5: SteamForm water spray control valve Installation
Note:
• The desuperheater nozzle has variable plug to
prevent superheated steam back ow to the spray
water control valve.
• Strainer to be provided by OTHER.
• Strainer must be monitored and maintained to
prevent any blockage

Masoneilan 84003 Series SteamForm Installation Guide | 11
Copyright 2020 Baker Hughes Company. All rights reserved.
Orientation
The proper orientation of the SteamForm valve is
important to ensure efcient vaporization and mixing
of the spray water. For best results, the recommended
orientation is to install the valve with a horizontal inlet
and a vertical ow down outlet, as shown in Figure 6.
In this orientation, the vertical run of outlet pipe assists
in mixing of the spray water by creating a ow path that
is parallel to gravitational ow direction that the water is
naturally pulled towards. This parallel direction assists by
suspending the water within the steam ow while heat
transfer is taking place and the water is evaporating.
On the contrary, in a horizontal outlet ow path heavier
water droplets are encouraged by gravity to fallout of the
steam ow and run along the bottom of the pipe. This
results in ooding of the downstream steam lines and
poor temperature control. This is particularly important
for applications that need a wide range of turndown
capability, as low velocity steam ows cannot maintain
enough momentum to properly suspend the water during
this process.
When determining the orientation, it is important to
address future maintenance considerations and the
effects of condensate build up. If the SteamForm is
mounted with a vertical ow up outlet as shown in Figure
7, the removal of trim and maintenance on the valve
becomes extremely difcult. Another drawback is, the
SteamForm valve body now acts as a condensate trap,
being that the valve body is the low point of this system.
Water fallout, in this system, becomes detrimental to the
long-term success of the valve as water build-up occurs
inside the trim and results in premature erosion.
Figure 6:
RECOMMENDED ORIENTATION
of the SteamForm
Figure 7:
IMPROPER ORIENTATION
of the SteamForm
CAUTION:
Orientation not
recommended

12 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
Drains and Pipe Slopes
The SteamForm valve must never be used as a
condensate trap for the steam line. When condensate
is passed through the trim of the SteamForm, ashing
occurs as the condensate reacts to the pressure
reduction. The ashing of the condensate erodes the
surface of nished parts and can fragment the surface
of the valve’s diffuser. This is avoided by properly
designing the piping system to slope away from the valve
and installing drain connections at all low points of the
piping system. Figures 7 through 10 show four possible
installation scenarios and the desired location of drain
connections to protect the SteamForm from passing
condensate.
Drain connections can also be supplied by the factory
for installation that results in the body of the SteamForm
acting as the low point of the piping system. The
locations of the SteamForm valve body drains are shown
in Figures 9 and 10.
Drain connections must also be located at all
downstream low points of the piping system to remove
excess water that has fallen out of the steam ow during
service. This preventative design will reduce the risk of
water hammer induced damage.
Figure 8:
Vertical ow down outlet orientation, should
be located at low point downstream
Figure 9:
Drain vertical ow up inlet orientation, drain should
be located at low point upstream
D
D

Masoneilan 84003 Series SteamForm Installation Guide | 13
Copyright 2020 Baker Hughes Company. All rights reserved.
D
Figure 10: Vertical ow down inlet
orientation. drain should be located at
low point of SteamForm valve body.
D
Warning: Failure to install a condensate drain at all piping low points can result in ashing and water hammer
damage to the SteamForm valve and surrounding system.
Warm-Up and Preheating Steam
SteamForm valves that are designed for intermittent
operation, such as turbine bypass applications, can be
installed with a warm-up system to minimize the effects of
thermal shock on the valve body and downstream piping.
Thermal shock can occur when the valve sits idle for long
periods of time and is instantly shocked when full load
conditions of high temperature steam are forced through
the valve upon an upset condition, such as a turbine trip.
These thermal shock scenarios occur when the steam
conditioning valve is mounted farther than ten feet away
from the main header. In this case, heat transfer to the
valve is reduced making it possible for the valve body to
cool to a large temperature differential compared to the
live steam passing through it. To counter this condition,
the SteamForm can be designed with warm-up bypass
connections to allow a minimal amount of live steam to
ow through the valve body and maintain a consistent
heat level at all times during non-operation of the valve.
By bleeding small quantities of steam from an upstream
source, such as the main header, the possibility of
thermal shock on the valve and system can be greatly
reduced.
Figure 11: Horizontal inlet and horizontal outlet
orientation, drain should be located at low point
of SteamForm valve body.

14 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
These proactive measures require additional system
costs; however they extend the active life of the steam
conditioning valve and the surrounding system.
The design of this system can be exible to meet the
constraints of the plant. A Baker Hughes representative
can be contacted for an in depth evaluation of
various design options and warm-up steam quantity
recommendations. For general preheating guidelines
assuming 1000°F steam temperature, Baker Hughes
recommends following:
ṁ (kg/s) = 0.0104 x D(m) x L(m)
ṁ (pph) = 0.052 x D(in) x L(in)
Where:
D = O.D. of upstream pipe
L = Pipe length up to the header upstream
of the valve
Insulation
All SteamForm valves should be surrounded with thermal
insulation. The SteamForm bonnet and spray nozzle
anges must be accessible through the insulation for
routine maintenance reasons.
Accessibility
Larger SteamForm valves require two or more
maintenance personnel to service the installation. To
properly service and maintain the valve, adequate space
must be provided. If the valve is not accessible from the
ground level, a working platform must be provided around
the valve as a safe workable area for maintenance
engineers. A safe route must be carefully planned out
in advance to satisfy the needs of a proper start-up and
routine maintenance.
Temperature Control Methods
The SteamForm must always be designed around
the most critical operating scenario. This can include
intermittent operations such as plant start-up and load
rejection scenarios or may be a steady-state operation
such as a continuous application of a process plant.
Regardless of the operating technique, the SteamForm
temperature control methods must be considered along
with the design of the valve for best control performance.
The spray water control valve must not be opened before
steam conditioning valve is opened. Temperature set
point for the spray water control valve to be provided by
OTHER.
Temperature – Feedback Control
Temperature feedback control is the most common
method for controlling the amount of spray water that is
injected into the steam ow. This method requires the use
of a downstream temperature sensor that relays a signal
to a separate water control valve, to adjust the amount of
water injected and achieve the desired downstream set
temperature.
When using the feedback control method, it is essential
that the temperature sensor is located downstream
at a distance greater than or equal to the minimum
required distance that is specied by the factory for
the application. For more information on the proper
location of the temperature sensor, please refer to
the temperature sensor location section under the
downstream pipe recommendations of this document.
Temperature – Feedforward Control
The temperature sensor is a proven method of control,
but this method requires a longer lag time as a signal
must travel from a sensor to the control valve and
must also allow for response time. Feedback control
also requires a signicant length of downstream pipe
to ensure spray water is vaporized and has achieved
an evenly distributed temperature prole. These
requirements are not available for all SteamForm
installations. For these instances, a feedforward control
method is suggested.
The feedforward control method is achieved with a
control algorithm and inherent steam tables that are
programmed into the Distributed Control System (DCS).
This algorithm is a heat balance calculation used to
calculate the required amount of spray water based on
upstream conditions and a specic downstream set point.
The algorithm is programmed directly into the DCS to
provide fast response temperature control. Baker Hughes
customizes an algorithm to the Masoneilan SteamForm
valve ow characteristics for each application requiring
this control technology.
Warning: Noise insulated within a system remains
within a system and propagates downstream. To
reduce the effects of downstream noise, sufcient
downstream attenuating equipment must be
designed within the system.
Warning: Failure to provide adequate downstream
pipe length prior to the temperature sensor will result
in instability and inability to control temperature.

Masoneilan 84003 Series SteamForm Installation Guide | 15
Copyright 2020 Baker Hughes Company. All rights reserved.
Response Time and Stroke Speed
Response time is critical in preventing steam and
condensate losses from the system due to lifting of safety
valves. These system requirements are specied during
the early stages of the plant design and must account for
both the lag time of the temperature control system and
the opening speed of the SteamForm valve.
The lag time resulting from the response of the
temperature sensing system can be reduced through the
use of a dual method control system. This dual method
system uses a feedforward control algorithm to determine
the amount of water required and provides faster acting
temperature response. The addition of a temperature
sensor to this system improves the accuracy of the
temperature control by “trimming” the variability once the
downstream prole stabilizes.
Stroke speed must be considered in this system, as rapid
response time cannot be achieved with all methods of
actuation. Stroke speeds using a pneumatic controller
are often limited to the 2–3 second ranges. For faster
response time, the use of electrohydraulic actuation
can be considered. Please consult a Baker Hughes
Masoneilan Certied Technician for a recommendation
for each application.
Start-Up And Commissioning
In addition to specifying the steam conditioning valves,
a start-up procedure must also be dened up front in the
design process. Proper cleansing of the steam line and
water lines is essential to ensuring performance when the
plant becomes operational. Debris left in line can remove
the machined nish from a shutoff surface or block the
orice of a control element or spray nozzle. To protect the
integrity of the operational trim, Baker Hughes strongly
encourages the purchase of sacricial start-up trim, which
is used to divert debris away from all critical surfaces.
Installation of the start-up trim is shown in Figure 12.
Figure 12: Start-up trim
System Blow Down and Cleaning
With the SteamForm start-up trim installed and the spray
nozzles removed, all debris, scale, and unintended
substances must be ushed from the steam and water
lines.
Conducting this cleaning procedure with operating trim
installed can result in several possible scenarios requiring
components replacement or repair. For instance, damage
to a nished surface can result in premature erosion
that eventually leads to unwanted leakage and unstable
control. Debris lodged in the operating trim can also
result in loss of ow capacity or plug sticking because
of debris induced galling of the plug against a control
surface.
See SteamForm Instruction Manual GEA31013A for
detailed instructions for valve installation and cleaning
process.
CAUTION : Any damage caused to the valve during
cleaning or installation process is not Baker Hughes’s
responsibility. Failure to follow instructions provided in
the Manual GEA31013A will violate the valve warranty
agreement.

16 | Baker Hughes Copyright 2020 Baker Hughes Company. All rights reserved.
Warning: Do not install operational trim and spray
nozzles until the pipelines have been completely
blown down and thoroughly cleaned. All debris must
be removed to protect the trim from damage.
Trim Installation Device (TID)
A xture to facilitate the safe and successful installation
or removal of trim from a valve body in the horizontal
orientation must be utilized. A local representative should
be contacted for information regarding the tool as trim-size
specic adaptors are required to mount the lifting tool.
For larger SteamForm valves installed in horizontal
orientation, special tool and care is required. Please
contact the Factory for recommendations.
Post Weld Heat Treatment and
Hydro-Testing
SteamForm valves are manufactured with either anged
or butt weld end connections. For valves that require
welding into line, select welding rod that is compatible
with the valve connection material. Check the valve
specication sheet data for the body and end connection
material that is being supplied.
The applicable codes of the country or state of
installation specify welding and post weld heat treatment
requirements that must be followed. Verication of
localized welding temperatures by thermocouples is
advised.
Hydro-testing procedures can require a factory designed
test xture, depending on whether or not the SteamForm
is used as a material or pressure class break point. In
this type of installation, isolation of the inlet section from
the outlet section is necessary to test each component
individually against its unique code required testing
conditions.
SteamForm Assembly
The SteamForm must be installed in line so the ow
through the valve follows the direction indicated on by the
ow arrow on the valve body.
After the steam lines are thoroughly cleaned and
hydrotested, it is safe to install the operating trim. For
start-up assistance from a certied technician, please
contact your local Baker Hughes Masoneilan sales ofce
or factory. For the complete installation procedure, please
refer to the SteamForm instruction manual.
Commissioning Spares
A full set of commissioning spares should be available on
site at all times to minimize the amount of downtime for
the SteamForm. Commissioning spares must include, at
a minimum, a full set of gaskets and packing to provide
the required soft-parts for reassembly.
Soft-parts such as gaskets and packing should never
be reused once they are removed from a valve. Do not
interchange components with parts supplied for other
valves.
Contact your regional Baker Hughes Sales ofce,
Aftermarket center or Channel Partner for spare parts
requests.
Turbine Bypass To Condenser
Applications
Several internal and external factors are introduced within
the turbine bypass applications, specically in the bypass
to condenser application. The role of the SteamForm
becomes critical in ensuring equipment is protected
during the high pressure and temperature excursions.
Another major concern is for the limitation of noise as
high-energy steam is injected into a thin wall duct that
acts similar to a noise amplier. These concerns are
addressed in more detail in the following sections.
Bypass System Requirements
The bypass to condenser design requires a signicant
reduction in the heat level of the steam to reach an
enthalpy limit that is within the condenser design
limitations. Heat limits require the SteamForm to reduce
the steam temperature to the saturation range prior
to admission into the condenser. This application also
requires fast response to ensure safety valves remain
closed and prevent steam from venting outside of this
closed loop system.
Figure 13: Trim installation device
Warning: Removing the operational trim during
these procedures is recommended to ensure the trim
is not damaged.