Overview
The document provides comprehensive technical specifications and features of the Crosby H-Series Direct Spring Safety Valves, focusing on the ISOFLEX® models. These valves are designed for overpressure protection in steam applications, adhering to ASME Boiler and Pressure Vessel Code Sections I and VIII.
Key Features- ASME/NB certified capacities for steam.
- Set and tested on steam with full nozzle flanged options.
- Long service life with low maintenance requirements.
- Two-ring set pressure and blowdown control.
- ISOFLEX seat tightness up to 93%.
General Application
The H-Series valves are suitable for steam safety applications such as economizers, steam drums, superheaters, and reheaters.
Technical Data- Sizes range from 1¼” F 1½” to 6” RR 10”.
- Orifice sizes from 0.307 to 19.29 in².
- Temperature range up to 1120 °F (604 °C).
- Set pressures from 15 to 5000 psig.
Valve Selection and ApplicationsThe document includes a selection matrix for optimal valve placement in steam systems, with specific recommendations for different pressure ranges and applications such as drum, superheater outlet, reheater inlet, and economizer.
Style HE ISOFLEX®- Designed for high pressure, high capacity applications on boiler drums.
- Features include extended uptime, reduced maintenance costs, and minimized installation costs.
- Technical specifications include sizes from 2½” x 6" to 4" x 8", with maximum temperatures up to 750°F and set pressures up to 3060 psig.
Style HCI ISOFLEX®- Suitable for 300 to 3000 psig steam generators.
- Features include increased operating efficiency, reduced maintenance costs, and minimized installation costs.
- Technical specifications include sizes from 1½” x 3" to 6" x 10", with maximum temperatures up to 1120°F and set pressures up to 3000 psig.
Materials and Spare Parts
The document lists materials used for various valve components and recommends maintaining an inventory of spare parts for maintenance and repair.
Conclusion
The Crosby H-Series ISOFLEX® safety valves are engineered for reliability and efficiency in high-pressure steam applications, offering customizable features to meet specific operational needs.
Capacity
The adjustable nozzle and guide rings utilize the reactive and expansive forces of flowing steam to provide full capacity lift. Valve capacity is determined solely by the nozzle throat area. High capacity valves ensure positive overpressure protection with fewer valves.
Tight Shut-Off
The ISOFLEX® disc insert is designed for pressure and temperature equalization, ensuring the seats remain flat during service.
Two Ring Design
Blowdown control is precise with two adjustable rings, allowing adjustments from 2 to 4% under operating conditions.
Precise Popping Point
Close machining tolerances ensure precise centering of the disc insert, with special materials and finishes ensuring low friction guiding at all temperatures. The open bonnet minimizes thermal effects, ensuring valves open precisely at their set pressure.
Materials
The document lists various materials used for different parts of the valve, including carbon steel, stainless steel, Inconel®, and nickel alloy, with maximum temperature ratings provided for each material.
Specifications
The document provides detailed specifications for the Crosby H-Series Style HCI ISOFLEX valves, including valve sizes, orifice areas, maximum set pressures, and temperature limits for different materials and configurations.
Dimensions and Weights
Dimensions and approximate weights for various valve sizes and styles are provided, including details for both welded and flanged configurations.
Notes
Additional notes include recommendations for maintaining spare parts inventory and using genuine Crosby parts to ensure product performance and warranty.
Specifications:
1. The 'W' is omitted from the style designation for standard welded inlets. For optional flanged inlet valves, the 'W' is dropped.
2. An additional dismantling height of 20 inches (508 mm) is required.
3. Weld preparation must adhere to customer specifications. Safety valves should be mounted on a nozzle with an inlet diameter equal to or greater than the nominal valve inlet size, dimension A. Refer to ASME boiler and pressure code Section I and ANSI/ASME B31.1 for recommended installation.
4. Bolt holes straddle the centerline on flanged connections. Drain specifications are ½” NPT for inlet sizes 1½” to 4” and ¾” NPT for 6” inlet size.
Valve Specifications and Dimensions:
The document provides detailed specifications for various valve models (HCI-36, HCI-38, etc.) including inlet sizes, orifice areas, maximum set pressures, and temperatures for standard body materials. It also lists standard and optional flanged outlet classes, and dimensions in metric units for different valve styles.
Notes:
1. For applications exceeding ASME/ANSI B16.34 pressure/temperature limits, specified HCI-( )W (welded only) valves are designed for maximum set pressure at maximum temperature stated in the table.
2. Set pressure is limited to either the inlet pressure limit per ASME/ANSI B16.34 or the maximum set pressure, whichever is lower.
3. Style HE ISOFLEX® safety valves are recommended for high-pressure drum saturated steam service between 138-207 barg.
Restricted Lift Feature:
The HCI-R ISOFLEX® style offers a restricted lift option available on all HCI ISOFLEX® valve sizes with either flanged or weld end connections. Capacities can be adjusted from 100% to 30% of full rated capacity, allowing for economic distribution of relieving capacity and reducing reaction forces.
HSJ Direct Spring Safety Valve Features:
1. Increases operating efficiency with a FLEXI-DISC seat design for pressure and temperature equalization, ensuring a flat and tight seal.
2. Reduces maintenance costs with a replaceable full nozzle design and single bonnet design for easy set pressure changes.
3. Minimizes installation costs with a high discharge coefficient for economical valve selection.
Technical Specifications
The Crosby H-Series Style HSJ safety valves are designed for use in high-pressure and high-temperature applications, such as boilers and Dowtherm® systems. They are available in sizes ranging from 1½” x 2” to 6” x 8” with orifice areas from 0.307 to 11.045 in². The valves support inlet ratings from ANSI Class 150 to 2500, with a maximum temperature of 1000°F (538°C) and a maximum set pressure of 2700 psig (186.2 barg). They comply with ASME I and VIII codes.
Product Overview
The HSJ valves are recommended for boiler pressures from 15-600 psig and are designed for economizer and Section VIII applications up to 2700 psig and 1000°F. They feature an adjustable nozzle ring and guide ring for full lift and high capacity, ensuring overpressure protection with minimal valves. The FLEXI-DISC® ensures a tight seal at 93% of the valve’s set pressure.
Design Features
The two-ring design allows for precise blowdown control, adjustable while installed. The disc centering ensures precise opening at set pressure. Options include closed and open bonnets, with closed bonnets recommended for outdoor service under ASME Section VIII.
Style HSJ-DOW
Specifically designed for Dowtherm® service, this variant features an unvented closed bonnet and alloy steel spring for high temperatures, meeting ASME Section I requirements for organic fluid vaporizer generators.
Materials
The valves are constructed from materials suitable for high temperatures, including carbon steel, alloy steel, stainless steel, and nickel alloy. Spare parts are categorized into consumable, repair, and insurance parts, with recommendations for maintaining an inventory of genuine Crosby parts.
Specifications and Options
The valves are available in various classes (150, 300, 600, 900, 1500, 2500) with different pressure and temperature limits. Detailed specifications include valve size, orifice area, maximum set pressure, and material options.
Installation and Maintenance
Installation and maintenance instructions are available upon request, emphasizing the importance of using genuine parts and following proper procedures for optimal performance.
Specifications
The document outlines the specifications for the Model EFS drip pan elbow, which is designed to be used with safety valves. The sizes available range from 1½” to 8”, with a flange ANSI Class of 150. The material used is carbon steel, and it features a welding neck flange. The dimensions and specific requirements for installation are provided to ensure compatibility and safety.
Features and Benefits
The Crosby H-Series Style HCA-I-118W safety valves are highlighted for their ability to increase operating efficiency and reduce maintenance and installation costs. Key features include restricted lift options, seat tightness up to 93%, and two-ring control for adjusting overpressure and blowdown. These valves are suitable for ASME VIII off boiler steam applications and are designed to withstand supercritical pressure steam generator conditions.
Certification and Approvals
The valves comply with several certifications and approvals, including the ASME Boiler and Pressure Vessel Code, National Board of Boiler and Pressure Vessel Inspectors Capacity Certifications, Pressure Equipment Directive (97/27/EC), and China Manufacturing License (TS).
Technical Data
The technical data section provides detailed information on inlet sizes, inlet and outlet ratings, maximum set pressures, temperature range, orifice sizes, and blowdown percentage. The valves are designed to handle maximum set pressures of 5,000 psig and temperatures up to 1100°F.
Materials
The document lists the materials used for various parts of the Style HCA-I-118W safety valves, including ASME SA217 Grade WC9 for the body, 316 stainless steel for the nozzle ring, and NI-CU Alloy for the disc holder. The materials are chosen for their durability and ability to withstand high temperatures.
Dimensions and Weights
Detailed dimensions and weights for different valve sizes are provided, including information on inlet and outlet sizes, orifice designations, and approximate weights. This information is crucial for ensuring proper installation and compatibility with existing systems.
Saturated Steam Capacities
The document includes tables showing the saturated steam capacities for various styles and set pressures, measured in pounds per hour at 3% overpressure. These capacities are certified by the National Board of Boiler and Pressure Vessel Inspectors and are essential for determining the appropriate valve size for specific applications.
Overview: The document provides detailed information on the saturated steam capacities of Crosby H-Series valves, certified by the National Board of Boiler and Pressure Vessel Inspectors according to the ASME Boiler and Pressure Vessel Code, Section I for power boilers. It includes data for various valve styles (HE, HCI, HSJ) and orifice sizes, expressed in USCS units.
Specifications: The document lists saturated steam capacities in pounds per hour at 3% overpressure for set pressures ranging from 1650 to 3090 psig. It specifies orifice designations and areas in square inches for different valve styles.
Procedures: For superheated steam, capacities should be adjusted using a superheat correction factor (Ksh) found on pages 60-61. The document also provides a formula for calculating capacities at 10% overpressure up to an absolute pressure of 1500 psia.
Key Data: The document includes extensive tabular data showing steam capacities for various pressures and orifice sizes. It highlights the need to multiply the saturated steam capacities by specific factors for superheated steam and provides a formula for calculating rated capacity (W) based on nozzle throat area (A), set pressure (P), and a discharge coefficient (K).
Recommendations: The document advises using the capacity formula provided and adjusting for superheated steam as necessary. It also notes that HCI-R valves can adjust to a minimum of 30% of full rated capacity, with restricted capacity calculated as a percentage of restricted lift times the ASME rated capacity.
Overview: The document provides detailed information on the saturated steam capacities of Crosby H-Series valves, specifically styles HE, HCI, and HSJ, in both metric and US customary units. It includes tables of steam capacities at various set pressures and orifice sizes, certified by the National Board of Boiler and Pressure Vessel Inspectors according to the ASME Boiler and Pressure Vessel Code.
Specifications: The document lists steam capacities in kilograms per hour at 3% overpressure for set pressures ranging from 130 to 213 barg for metric units and 15 to 725 psig for US customary units. Orifice designations and areas are provided for each style, with specific capacities for each orifice size.
Procedures: For superheated steam, capacities should be multiplied by a superheat correction factor (Ksh). The document also provides a formula for calculating capacity, which involves converting valve set pressure to absolute pressure and using the ASME Section I capacity formula.
Norms and Standards: Capacities are certified in accordance with the ASME Boiler and Pressure Vessel Code, Section I for power boilers. The document emphasizes adherence to these standards for accurate capacity calculations.
Recommendations: For steam capacities at 10% overpressure, a specific ratio is provided to adjust the capacity values. The document also suggests using the superheat correction factor for superheated steam applications.
Key Data: The tables provide detailed capacity values for different orifice sizes and set pressures, both in metric and US customary units. These values are critical for selecting the appropriate valve size and ensuring safe and efficient operation under specified conditions.
Overview: The document provides detailed technical specifications and capacities for the Crosby H-Series valves, specifically focusing on saturated steam capacities in both metric and US customary units. It includes tables for steam capacities at various pressures and temperatures, as well as correction factors for superheated steam.
Key Sections:
- Saturated Steam Capacities: The document lists steam capacities in kilograms per hour at 3% overpressure for different set pressures ranging from 1.034 to 50 barg. The capacity is calculated using a formula that converts valve set pressure from barg to psig, then calculates in pounds per hour using the ASME Section I Capacity formula, and finally converts to kilograms per hour.
- Notes on Overpressure: For steam capacities at 10% overpressure, a specific ratio is provided to adjust the capacities listed in the tables. Additionally, for superheated steam, a correction factor (Ksh) is applied, which is detailed on pages 60-61 of the document.
- Set Pressures and Orifice Areas: The document provides a detailed table of set pressures in barg and corresponding orifice areas in square millimeters for different valve styles (F, G, H, J, K, L, M, N, P, Q).
- Superheat Correction Factor: A table is provided for the superheat correction factor (Ksh) based on flowing pressure and total temperature of superheated steam, ranging from 400°F to 1100°F.
- USCS Units Capacities: The document also includes steam capacities in pounds per hour for the US customary system, with specific orifice sizes (1.840 in² and 2.545 in²) and inlet pressures (P1) in psig. Capacities are certified by the National Board of Boiler and Pressure Vessel Inspectors and comply with the ASME Boiler and Pressure Vessel Code, Section I.
Critical Information:
- Capacity Calculation: The capacity is calculated by converting the valve set pressure from barg to psig, using the ASME Section I formula, and converting to kilograms per hour.
- Overpressure Adjustments: For 10% overpressure, capacities are adjusted using a specific ratio involving the set pressure in psig.
- Superheat Correction: For superheated steam, capacities are adjusted using the superheat correction factor (Ksh) provided in the document.
- Certification: Capacities are certified by the National Board of Boiler and Pressure Vessel Inspectors and comply with ASME standards.
Overview: The document provides detailed specifications and guidelines for the Crosby H-Series Style HCA-I steam capacities, focusing on safety valve sizing and requirements according to ASME Section I standards. It includes tables of steam capacities at various pressures and temperatures, as well as pressure/temperature limits for different body materials.
Specifications: The document lists steam capacities in kg/hr for different orifice sizes (M and M2) and inlet pressures (P1) at various steam relieving temperatures. It also outlines pressure/temperature limits for standard class valves made from materials like SA 216 GR. WCB, SA 216 GR. WCC, and SA 217 GR. WC6.
Procedures: The document details the sizing of ASME Section I safety valves, emphasizing the importance of proper sizing, selection, manufacturing, assembly, testing, and maintenance to ensure optimal protection of power boilers during overpressure events.
Standards and Requirements: Key requirements include:
- Boilers with more than 500 sq. ft. of bare tube must have two or more safety valves, with specific capacity requirements for each valve.
- Superheater and reheater safety valve requirements are specified, including minimum relieving capacities and placement guidelines.
- Economizer safety relief valves must have a discharge capacity based on maximum expected heat absorption.
- Organic fluid vaporizer safety valves must be enclosed and discharge vapors safely, with specific calculations for minimum relieving capacity.
Recommendations: The document suggests selecting safety relief valves with a higher maximum allowable working pressure than the desired operating pressure to minimize valve lifting frequency. It also provides sample calculations for boiler set sizing, including determining superheater safety valve set pressure and capacity requirements.
Key Data from Tables: The tables provide steam capacities for different orifice sizes and inlet pressures at various temperatures, as well as pressure/temperature limits for different valve body materials. These data are crucial for selecting appropriate safety valves based on specific boiler conditions.
Pressure/Temperature Limits Overview
This document provides detailed pressure and temperature limits for various valve styles and materials, specifically focusing on the Crosby H-Series valves. The limits are categorized based on the body material and ANSI standard class, referencing ASME/ANSI B16.34 - 1996 standards.
Valve Styles and Materials- HSJ-( )6 Valves: Body material SA 216 Gr. WCB, with pressure/temperature limits specified for ANSI classes 150, 300, 600, 900, 1500, and 2500.
- HCI-( )6 Valves: Body material SA 216 Gr. WCC, with limits for ANSI classes 300, 600, 900, 1500, and 2500.
- HSJ-( )7 and HCI-( )8 Valves: Body material SA 216 Gr. WC6, with similar class specifications.
- HCI-( )9 Valves: Body materials SA 217 Gr. WC9 and SA 217 Gr. C12A, with detailed limits for ANSI classes 300 to 2500.
Pressure/Temperature Data
The document includes extensive tables showing working pressures (psig) across a range of temperatures (°F) for each valve style and material. These tables are crucial for determining the operational limits and ensuring safety and efficiency in valve applications.
Outlet Reaction Forces
The document also discusses outlet reaction forces for valve styles HE, HCI, and HSJ. It explains the calculation of total resultant forces at the outlet elbow when the valve is open and discharging. The forces are categorized into horizontal (Fh) and vertical (Fv) components, with equations provided for determining these forces based on flow, velocity, area, and static pressure.
Key Equations- Vertical Force (Fv): Fv = (W * V + A * Pe) / gc, where W is flow, V is velocity, A is area, Pe is static pressure, and gc is the gravitational constant.
Conclusion
This document is essential for engineers and designers working with Crosby H-Series valves, providing necessary specifications to ensure compliance with safety standards and optimal performance under specified conditions.
Valve Installation and Configuration
Safety relief valves should be connected directly to the boiler, minimizing any intervening piping or fittings. The inlet piping must be robust enough to withstand discharge reactions. For piping systems, safety valves should be positioned downstream from pressure reducing valves, with nozzles designed to counterbalance discharge reactions. Multiple smaller valves are preferred over a single large valve, with staggered set pressures within ASME code limits.
Boiler Recommendations
The minimum differential pressure between valve set and operating pressure should be at least 5% to ensure seat tightness. Nozzles should match or exceed the valve nominal size, especially for off-center installations.
Discharge Piping
Discharge piping should be as direct as possible, with adequate sizing to prevent steam blowback. Flexible connections or expansion bends are recommended to accommodate thermal expansion without stressing the valve outlet.
Design Considerations
Manifold lines should be sized to accommodate all discharge lines, with independent support and adequate drainage. Discharge lines should enter the manifold at an angle to minimize back pressure.
Hydrostatic Testing
Hydrostatic test plugs are recommended for welded inlet valves, and testing should be completed before installing flanged inlet valves.
Drains
Drains should be provided for valve bodies and discharge systems to safely dispose of condensate and prevent personnel injury.
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