CARRARO DS1525 User manual

I N S T R U C T I O N S
For the installation and maintenance of DS1525 - DS1550 -
DS2525 - DS2550 desuperheaters
IMI0030E.doc
Rev.4 20/08/12
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 1 of 17

I N S T R U C T I O N S
For the installation and maintenance of DS1525 - DS1550 -
DS2525 - DS2550 desuperheaters
IMI0030E.doc
Rev.4 20/08/12
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 2 of 17
MAIN INDEX
Pag.
1 General information ..............................................................................................3
2 Guarantee .............................................................................................................3
3 Validity of instructions............................................................................................3
4 Safety indications ..................................................................................................4
5 Safety warnings .....................................................................................................5
6 Safety precautions.................................................................................................6
7 Transport, handling and storage............................................................................7
8 Inst. and ass. instructions for DS1525 - DS1550 - DS2525 - DS2550
8.1 Cross-section drawings .......................................................................................8
8.2 Removing the packaging.....................................................................................9
8.3 Installation ...........................................................................................................9
8.4 Start-up................................................................................................................12
9 Maintenance ..........................................................................................................12
9.1 Removal ................................................................................................................13
9.2 Disassembly ..........................................................................................................13
9.3 Spray cylinder........................................................................................................13
9.4 Body extension ......................................................................................................14
9.5 Piston assembly ....................................................................................................14
9.6 Packing gland ........................................................................................................14
9.7 Re-assembly..........................................................................................................14
9.8 Welding..................................................................................................................15
9.9 Re-installation........................................................................................................15
10 Replacement parts ................................................................................................16
10.1 Inspection procedure .............................................................................................16
10.2 Storage ..................................................................................................................16
11 Repairs ..................................................................................................................17

I N S T R U C T I O N S
For the installation and maintenance of DS1525 - DS1550 -
DS2525 - DS2550 desuperheaters
IMI0030E.doc
Rev.4 20/08/12
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1. GENERAL INFORMATION:
1.1. - RIGHT TO MAKE MODIFICATIONS AND "COPYRIGHT"
The regulations, standards etc. quoted in these instructions are valid at the time of preparation of this
document and are not subsequently updated. It is the duty of the user to take full responsibility for
applying the most up-to-date version of the standards and regulations in question.
The supplier reserves the right to make changes and technical improvements to data and information
whenever it sees fit to do so. The user shall on no account be entitled to claim a right of modification or
improvement in relation to desuperheaters already supplied.
2. GUARANTEE
The extent and duration of the guarantee are defined in the manufacturer's “General Conditions of Sale”.
The applicable conditions are those stipulated in the most up-to-date version in existence at the time of
delivery.
The guarantee does not cover, amongst other cases, damage to valves caused by the following:
° Ignorance of or non-compliance with these instructions for use!
° The work of personnel insufficiently qualified to undertake fitting, use or maintenance;
° Normal wear;
° Erroneous or negligent use of the desuperheaters.
The guarantee shall not be valid and the manufacturer shall accept no responsibility in the event of:
° Non-compliance with regulations for the prevention of accidents and/or safety standards;
° Imperfect installation, poor commissioning and incorrect use;
° Improper or incorrect use, inappropriate application or work conditions differing from those agreed.
The user shall bear sole responsibility in the event of physical and/or material damage deriving from
failure to observe the above.
3. VALIDITY OF INSTRUCTIONS
These instructions relate to variable area desuperheaters:
•DS1525 - DS1550 -DS2525 - DS2550 SEE PARAGRAPH 8) (Fig.1)

I N S T R U C T I O N S
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4. PRODUCT SAFETY INDICATIONS AND TAG SYSTEM
If and where appropriate, safety indications have been put inside tags on the sides of the pages of this
manual.
These rectangular tags are placed vertically (as shown in the following examples) and contain four
different messages communicating:
- The level of risk;
- The nature of the risk;
- The effects of the risk on people or products;
- Instructions, if necessary, on how to avoid the risk.
The box at the top contains a warning word (DANGER – WARNING – CAUTION – ATTENTION) which
indicates the level of risk.
The box in the middle contains a drawing indicating the nature of the risk and its possible effects on
people and property. In some cases, the drawing may suggest what preventive measures can be taken,
such as wearing safety clothing.
The box at the bottom may contain a message with instructions on how to avoid the risk. In the event of
risks for people, the message may also contain a more precise definition of the risk and its effects on
people.
1) DANGER – Immediate risk which will certainly cause serious
injury or death.
2) WARNING – Risk or hazardous behaviour which may cause
serious injury or death.
3) CAUTION – Risk or hazardous behaviour which may cause
minor injury.

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5. SAFETY WARNINGS
Thorough maintenance operations and overhauls are important for the safe and reliable operation of all
desuperheaters.
The service procedures recommended by CARRARO and described in this manual are effective methods
for carrying out maintenance operations. Please note that this service manual contains various warning
and caution notices which should be read carefully in order to minimise the risk of injury to people or the
possibility of using incorrect work methods which may damage the desuperheaters or make them unsafe.
It is important to realise, however, that these warnings cannot be exhaustive.
CARRARO is unable to know, assess and inform customers or users of all the conceivable methods of
performing maintenance operations and all the risks deriving from the use of such methods.
Consequently, CARRARO has not even attempted to start such a task. Therefore, whoever uses a
service method or piece of equipment which is not recommended by CARRARO must make sure that
neither his own or other people's safety, nor desuperheater safety and performance are jeopardised by
the chosen method.
In case of doubt about the method used, please contact CARRARO.
Take all safety precautions while testing, installing or dismounting the product; these include, wearing ear
plugs, goggles and safety clothing, such as gloves, both in or near the work area.
Given the large number of conditions and circumstances that may arise while working on the products
and the consequent risks deriving from the way this is done, CARRARO is not able to prevent all risks of
injury to people and damage to property and can only help by asking you to take the utmost care and
giving you the following safety suggestions.
Users of CARRARO products are responsible for training the staff that will use the product.
It is most important for these people to acquire a thorough knowledge of the instructions relative to the
product, especially the ones contained in this manual.

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6. SAFETY PRECAUTIONS
Always follow the safety regulations applicable to the plant and observe the
following precautions:
° Wear protective clothing. Hot water causes burns and superheated
vapour is invisible.
° Before starting disassembly, make certain that the desuperheater is
isolated from any source of pressure that may exist within the system.
° Carry out checking/maintenance of desuperheaters at least once two
years.
° The outer surfaces of desuperheaters reach temperatures approximately
equal to the temperature of the fluid flowing through them. For this reason,
if fitting a desuperheater in a potentially explosive atmosphere, check that
the explosion point of the atmosphere surrounding the desuperheater is
sufficiently higher than fluid temperature inside the desuperheater itself,
and prevent deposits of dust from forming on its outer surfaces.
° In the connection between the desuperheater and line, ensure the
equipotentiality of the system in order to prevent the accumulation of
electro-static charges on the outer surfaces of the plant, which could act as
an effective trigger in a potentially explosive atmosphere.
° Before carrying out any work on desuperheater components, consult
CARRARO.

I N S T R U C T I O N S
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DS2525 - DS2550 desuperheaters
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7. TRANSPORT, STORAGE AND HANDLING
Transport
Carraro DS desuperheaters are packed with the utmost care in wooden
crates or cardboard boxes so that they are protected during handling and
transport to their place of installation. The connections are protected to
prevent the entry of dirt. Follow any directions marked on the packaging.
ATTENTION!
Personnel assigned to load-handling activities must take
all the necessary safety precautions.
Storage
The desuperheaters must be stored in a dry environment and protected
against atmospheric conditions. They must not be removed from their
crates or packaging until immediately before installation.
The protective materials on the connections must be left in place until the
last minute. Whether packed or not, the desuperheaters must not be
subject to violent impacts.
Whether packed or not, the desuperheaters must always be stored in an
upright position, i.e. never laid on one side, in order to prevent distortion
or damage to internal components.
Handling
When removing desuperheaters from their packaging and removing the
protective materials from the connections immediately prior to installation,
take the utmost care to prevent foreign matter from entering inside the
desuperheater.
ATTENTION!
When handling desuperheaters, keep the work area clear
in order to prevent damage to property
or injury to persons.

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DS2525 - DS2550 desuperheaters
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8 INSTALLATION AND ASSEMBLY INSTRUCTIONS DS1525 – DS1550 – DS2525 – DS2550
8.1 Cross-section drawings
•DS1525 – DS1550:
Pos. Part name Material
1+ 2 •Spray nozzle assembly AISI 410
3 •Piston ring AISI 431 Nitrided
4 •Piston AISI 420
5 •Tightening ring A-182 F11-F22
6 Seat Stellite 6
7 •Plunger AISI 431
8 Seat housing A-182 F11
9 Body pipe A-335 P11 / P22
10 Water flange A217 WC6 oA182 F11/F22
11 • Gasket Graphite
12 Stud A-193 B7
13 • Packing gland AISI 431
14 Nut A-194 2H
15 Gland plate AISI 304
16 Name plate AISI 304
17 Central body A-217 WC6 / WC9
• RECOMMENDED SPARE PARTS
• DS2525 – DS2550:
Pos. Part name Material
1+ 2 •Spray nozzle assembly AISI 410
3 •Piston ring AISI 431 Nitrided
4 •Piston AISI 420
5 •Tightening ring A-182 F91
6 Seat Stellite 6
7 •Plunger AISI 431
8 Seat housing A-182 F91
9 Body pipe A-182 F91
10 Water flange A-182 F91
11 • Gasket Graphite
12 Stud A-193 B7
13 • Packing gland AISI 431
14 Nut A-194 2H
15 Gland plate AISI 304
16 Name plate AISI 304
17 Central body A-182 F91
• RECOMMENDED SPARE PARTS
Fig.1

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8.2 REMOVING THE PACKAGING
Carraro DS desuperheaters are packed with the utmost care in wooden crates or cardboard boxes so that
they are protected during handling and transport to their place of installation. After hydrostatic testing, the
desuperheater is flushed through with an protective agent formulated to protect the internal surfaces
against corrosion. Should any damage occur during transport, however, the transport company or a
representative of Carraro must be notified immediately. Remove the packaging with care, then check that
the surfaces of the flanges, threads, actuators, connection pipes, etc. are not damaged (see Fig. 1).
8.3 INSTALLATION
Before installation, visually inspect the desuperheater, the actuator and any accessories, to make certain
that they are not damaged. Check that the information given in the documentation and on the data plate,
and the tag number correspond to the specifications of the order. Remove the desuperheater from its
package by lifting it with slings (for heavy loads) wrapped round its body. Do not lift the unit by the water
inlet connection, the actuator or other accessories. Do not remove the flange coverings until immediately
before installation.
During installation of the desuperheater, use gaskets and fasteners which comply with the appropriate
standards. Position the gasket on the mounting flange and gently insert the nozzle into the secondary
pipe. Before tightening the studs, check that the spray cylinder is directed in the same direction as the
vapour flow (see Fig. 2).
The desuperheater must not be installed in such a way that it is subject to tensions, forces and torque.
- Water flange positions -
PFAn PFAe PFAs PFAw
- Handwheel positions -
PVn PVe PVs PVw
Fig. 2
The DS desuperheater has a standard body length as specified in the contractual drawings, whereas the
mounting trunk of the vapour pipe must be made to measure. The length of this secondary pipe must be
such that the central axis of the spray cylinder corresponds with the central axis of the vapour line
(±5 mm). The nominal diameter of the mounting trunk must be as follows: for DS1525/DS2525 25 m3/h
version - 3” (DN 80), with maximum tube schedule of 160; for DS1550/DS2550 50 m3/h version - 4” (DN
100) with maximum tube schedule of 160.

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DS2525 - DS2550 desuperheaters
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The minimum length of tube required downstream varies according to application and is specified in the
respective quote. This length without bends is necessary to prevent erosion caused by drops of water
deposited on the walls of the pipes, the valves and the fittings, and is normally a minimum of 4, 6 m
(a straight length of pipe is not generally necessary upstream). The distance that separates the
desuperheater from the temperature sensor is between 12 and 15 m, although the specific distance for
the application is generally specified in the quote.
Longer distances ensure complete evaporation of the water at lower vapour speeds. The temperature
sensor must be positioned in the top half of the pipe. Avoid fitting branches of the vapour pipe between
the desuperheater and the sensor (see Fig. 3).
1) Temperature sensor
2) Temperature transmitter
3) Temperature control
4) H.T. Desuperheater
5) Air regulator filter
6) Safety valve
7) Filter
8) Check valve
9) Flange
10) Pneumatic positioner
Fig. 3
The unit can be fitted on either horizontal or vertical pipes. The direction of water injection must
correspond to the direction of vapour flow. The desuperheater can be fitted at 90° to the vapour pipe,
regardless of direction of flow. The possible variations are illustrated in Fig. 4. If installed horizontally, the
unit must be mounted with a weight-compensation system.
Fig. 4

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The supply water must be clean filtered and of excellent quality (e.g. boiler supply water) and must be at
constant pressure at all times, as specified in the order documents. Each water supply line must be
protected by its own filter with maximum mesh size of 0.1 mm (0.4 mm acceptable for nozzles from ‘E’
upwards). On request Carraro can supply a supplementary filter. The mainly application of Carraro’s filter
is to clean water from particles during the start up operations. If no other filter system is installed this filter
can be left and periodically inspected.
If closure components are envisaged in the water supply line, fit a safety valve of approved type. As for the
vapour pipe, use gaskets and fasteners which comply with the codes of the respective pipes. Flush the
water supply line before connecting the mounting flange of the desuperheater (see Fig. 5).

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Fig. 5
8.4 START-UP
Make certain that all the components are installed correctly. The supply for the instrumentation air pipes
must be connected as indicated in the instruction manual, together with the filter regulators and valve
positioners. Similarly, calibrate the temperature control unit/transmitter in such a way that it responds
automatically to temperature variations.
Heat the main vapour line and open the valve of the water supply line. Check the water pressure in the
desuperheater and the operation of the transmitter and temperature control unit by manually increasing
and reducing the output signal and observing the temperatures shown and recorded. Once there is
satisfactory correspondence between the signals sent by the instruments and the actual temperature, it is
possible to set the regulation point and activate the system in automatic mode.
You are advised to record the various coordinates of the vapour over a sufficiently long period, in order to
check the operation of the system and make the necessary modifications.
9MAINTENANCE
Maintenance of the desuperheater is extremely simple and does not require specific instruments or
knowledge. Take extreme care when carrying out maintenance work, especially if using honing machines,
compressed air and rotary machinery. It is imperative to wear goggles, gloves and other protective
equipment, in accordance with the applicable safety procedures.

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9.1 REMOVAL
Before removing the desuperheater from the system, check that the vapour and water pipes are
completely depressurised, drained and bled. Bleed and remove the air supply line to the instrumentation.
Slacken the studs on the water and vapour flange and remove the desuperheater from the system. It is
advisable to move the unit to a workshop equipped with workbench and vice. Lift the unit using suitable
slings wrapped round its body. Do not attempt to lift it by the actuator or any of the other accessories. The
coupling of the plunger varies according to the type of actuator installed.
9.2 DISASSEMBLY
The desuperheater can be disassembled more easily if it is positioned horizontally with the section of the
body extension firmly gripped in the vice. Grind the weld points on the nozzle, with a standard angle
grinder. Check that the weld has been sufficiently removed to allow unobstructed rotation of the tightening
ring. Unscrew the tightening ring by turning it anti-clockwise. Note that the body extension has a right-
hand thread. To facilitate removal of the ring, tap it gently with a hammer. Note that the spray cylinder has
a left-hand thread. In the event of difficulty in removing the tightening ring, grind it at two diametrically
opposed points. Take care not to damage the thread of the body and of the cylinder (see Fig. 6).
Fig. 6
9.3 SPRAY CYLINDER
Once removed, inspect the inside of the cylinder and check for any surface scratches of marks, which can
be removed by polishing or grinding. The bore of the cylinder must not exceed 32 mm for the
DS1525/DS2525 model and 45 mm for the DS1550/DS2550 model, with maximum out-of-round of 0.25
mm. Any debris must be removed from the nozzles with a compressed air jet. Inspect the nozzle outlet
holes. These must show no signs of elliptical wear, roughness or damage that could adversely affect their
performance. Thoroughly clean the thread of the cylinder, filing it with a small file where necessary.

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9.4 BODY EXTENSION
Examine the thread of the body extension and file it, if necessary, with a small file. If carried out regularly,
scheduled maintenance and repair will ensure the correct operation of the valve.
9.5 PISTON ASSEMBLY
Extract the piston and plunger. The piston and plunger are always supplied as a single assembly. If the
piston shows no signs of wear, it can be re-used. Replace the piston rings each time the unit is
disassembled, taking care not to overload the rings during fitting. The rings have a mark on the top and
must always be oriented in the direction of the gland for correct operation. Examine the condition of the
plunger at the point at which it slides inside the gland, and remove any traces of graphite by polishing
lengthways with fine emery cloth.
9.6 PACKING GLAND
Remove all the rings and components of the sealing system from the valve body. Thoroughly clean the
gland with a rotary metal brush and/or a honing tool. The area must be kept clean in order to ensure that
the valve seals correctly. Do not use grease or lubricants in the area of the sealing system. Always use
genuine Carraro components supplied as a set (see Fig. 7).
Fig. 7
9.7 RE-ASSEMBLY
Before refitting the valve, lubricate all the threads with a high-temperature-resistant nickel compound.
Do not use grease or other oily lubricants because they could cause disassembly problems. Apply a thin
layer of compound to the piston rings to prevent scoring. Position the grooves in the piston rings in such a
way that they are at 120° to each other. Re-assemble the spray cylinder to the body extension. Use a fine
abrasive paste to hone the seat of the cylinder and the body extension. As the seal is metal on metal, a
perfectly concentric area of the seat is essential. Always use a new tightening ring. Position the spray

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cylinder so that it is correctly oriented (the nebulised water must be in the same direction as the vapour
flow), then tighten the tightening ring.
9.8 WELDING
Once re-assembled, weld the spray cylinder for improved safety. It is imperative that this operation be
undertaken by a competent welder. A welding procedure specification is available from Carraro on
request. Both TIG and ARC welding are acceptable, and the recommended electrode material is ER
NiCrMo3. At least 4 welds are necessary for the DS1525/DS2525 and at least 8 for the DS1550/DS2550.
They must be 8 mm in length and diametrically opposed. One weld must secure the tightening ring to the
body extension, and the other must secure the spray cylinder to the tightening ring. On completion, check
the welding using appropriate penetrating liquids. There must be no cracks. If necessary, grind and check
again until the weld is satisfactory (see Fig. 8).
Fig. 8
9.9 RE-INSTALLATION
Refit the actuator to the desuperheater, referring to the data noted during disassembly when repositioning
the plunger. Before re-installing the desuperheater check that the surfaces of the unit connection flanges
are completely clean. Insert the desuperheater in the vapour pipe and check that the nozzle is correctly
oriented, with the spray in the direction of the vapour flow. Lubricate the nuts and studs with a suitable
lubricant for high temperatures and tighten uniformly, in accordance with the manufacturer’s instructions.
Before connecting the water supply line, flush the pipe and check that there are no restrictions and no
contamination.

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10 REPLACEMENT PARTS
When ordering replacement parts, check and specify the identification number of the unit (shown on the
data plate). For a cross-section drawing, see Fig. 1.
10.1 INSPECTION PROCEDURE
The spray nozzles (1) and (2), the tightening rings (5), the piston (4) and the piston rings (3) are
components subject to wear. The materials selected must be suited to the conditions of service of
applications on vapour/water. It is also advisable to bear in mind that the temperature changes that take
place at the desuperheaters are generally the largest in the whole plant. After the first year of service, you
are advised to check the condition of the spray nozzle assembly, the integrated injection nozzles, the
tightening ring and the welds. At the time of inspection, use penetrating or fluoride analysis liquids to
check that these components are not cracked. Components with signs of cracking must not be re-used.
Every two years of service, make certain that the heads are free from defects.
It is recommended that your replace the above components in any event, at least every five years of
service.
It has been shown that observance of these precautions keeps the system reliable at all times.
Note: After each maintenance operation, replenish your stock of replacement parts, with all parts that you
have used. The spray nozzle assemblies may have been specifically designed for a particular type of
service. The delivery time for special components is 8 weeks.
10.2 STORAGE
At the time of receipt, check that the crate and the desuperheater are free from damage. If you find
damage to either the product or the package, notify a Carraro representative immediately. Before
stocking the equipment, repair any superficial damage to the packaging in order to prevent the entry of
dust or water. Check the information shown on the data plate and in the documentation, then return the
units to their respective boxes/crates with the protective materials in place. In the event of short-term
storage (up to 6 months), no additional conservation measures are necessary. Store the units in their
original packing in a clean, dry, closed place. If it is necessary to store the valves outdoors, wrap the
crates with a waterproof tarp.
In the event of long-term storage, use a dry, indoor area. Check that the desuperheater is completely dry
and free from humidity. Apply a layer of lubricant, such as Cosmo, to machined surfaces, to the valve
plunger and to the gland. Store the desuperheaters in their original packing and inspect them every
3 months to check their condition. Before bringing the desuperheaters into service, replace the sealing
system and check the soundness of all components, such as the actuator seals, etc. in order to ensure
correct operation. Follow the installation procedure shown in the use and maintenance manual.
Note: DS desuperheaters are classified as category I by European Directive 97/23/EC, and are marked
with the CE mark.
ATTENTION!
Should it be necessary to weld the pipes, avoid connecting the
earth connection to the valve, as this could cause damage to
important sliding parts.

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11 REPAIRS
11.1 If it is not possible to eliminate the problems, send faulty desuperheaters to the
supplier/manufacturer, together with a description of the problem.
11.2 In order to receive spare parts or information, always indicates the serial number shown on the
name plate attached to the desuperheater.
11.3 Name plate (example)
MODEL.
NO: YEAR
TAG.
NO:
S/N:
WATER
CONN.
NOZZLE
CV
STROKE
MOUNTING
CONN.
20090 SEGRATE - MI (ITALY) - Via Fermi 22
TEL [phone] - FAX [phone]
www.carrarovalvole.it
11.4 To ensure the desuperheaters treated in this manual work correctly, they should be serviced by
Carraro engineers or by Carraro-authorised Service Centres using original spare parts.
ATTENTION!
The manufacturer accepts no responsibility if modifications to the
product or operations not described in this manual are carried out.