This document discusses details of a CCI Drag 100DR 4x4 globe valve used in a boiler feed pump (BFP) recirculation system. It notes the valve's specifications and operating parameters. It describes issues caused by a damaged valve, like high feed flow, motor amperage, and pump vibrations. The valve was dismantled and repaired by replacing the seat ring, plug, and other spare parts. This reduced the power consumption and feed flow of three BFPs. The payback period for purchasing the spare parts was within 4 months due to reduced energy losses. Proper performance of the recirculation valve is important to prevent pump damage and unit offline events.

1. Prepared by
KODANDAPANI VUDUGUNDLA
ADE/TURBINE MAINTENANCE/RTPP

2. ,
RC Valve Details
Type : CCI Drag 100DR
4X4 GLOBE VALVE
Pr class 2500 ANSI
Design pr -320kg/cm2, Temp-180C
Max seat leakage-5cc/min
valve Trim -24 stage disc stack

3. MAINTAIN LIQUID LUBRICATION INSIDE PUMP
INTERNALS
MAINTAIN MINIMUM FLOW(125T) THROUGH
PUMP TO
AVOID FLASHING OF WATER
AVOID PUMP SEIZURE
VALVE OPENS AT 100 T BFP SUCTION FLOW
VALVE CLOSES AT 220T BFP SUCTION FLOW
IMPORTANCE OF
RECIRCULATION VALVE

4. NRV
At 6 mts
At 21 mts

5. FEED WATER
INLET TAPPING
FROM BFP
DISCHARGE
FEED WATER OUTLET TO
DEAERATOR

6. HIGH FEED FLOW
HIGH MOTOR AMPERAGE
PUMP VIBRATIONS
DAMAGING OF NRV IN RC LINE
OUTAGES OF PUMP

7. Dismantled all RC valves
Found damaged Seat Ring & Plug
Replaced with new one & Reassembled
Spare parts used
Plug assembly ,Seat ring ,Guide bushing
balance seal and soft goods.

8. DAMAGED PLUG
DAMAGED PORTION

9. DAMAGED SEAT
DAMAGED PORTION
FLEX GASKET
SEAT RING

10. PLUG ASSEMBLY
GUIDE BUSHING
BALANCE SEAL
STEM
PLUG

11. BONNET METAL SEAL

12. DISK STACK

13. BALANCE SEAL

14. FLEX GASKET

15. SET OF RC VALVE INTERNALS

16. PERFORMANCE OF PUMPS
AFTER RECTIFICAION AT FULL LOAD
BFP-5A BFP-5B BFP-5C
FEED FLOW
T/HR
CURRENT
AMPS
FEED FLOW
T/HR
CURRENT
AMPS
FEED FLOW
T/HR
CURRENT
AMPS
PREVIOUS 364 306 370 315 355 310
PRESENT 342 297 332 292 344 300
CURRENT
SAVING
9 A 23 A 10 A
ENERGY
SAVING Per
Day
2099 KWH 5363 KWH 2322 KWH
SAVING
COST/Day
@ Rs 5/-
10,494.00 26,818.00 11,658.00

17. REDUCTION IN POWER CONSUMPTION
REDUCTION IN FEED FLOW
REDUCTION IN PUMP VIBRATIONS
REDUCTION OF NOISE IN RC PIPE LINE
ELIMINATING DAMAGING OF NRV

18. Purchase of Spares including service charges
Rs 40 Lakhs
Average Energy Loss/Year in Rupees
Rs 120 Lakhs
Pay Back period is with in 4 Months
Guarantee period of spares is one year

19. CONCLUSION
The BFP recirculation valve is one of the
most severe duty valve in the plant.
If this valve does not perform up to
expectations, it can cause severe pump
damage, degraded unit performance or
even bring a unit offline