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Water Travels Mountainous Terrain with the Help of Control Valves

Posted by William Su

Oct 19, 2017 8:55:00 AM

Water Travels Mountainous Terrain with the Help of Control Valves


Originally published in Water Technology here.

The ChallengePipeline from dock

The newly constructed Zhijin power plant in China’s Guizhou province gets its water from the Hongjiadu reservoir and transports it 8.1 km over mountainous terrain with an approximate elevation of 1150 meters. The water first travels up to a water treatment plant and then on to a water tank where supply can be controlled before it is gravity fed down to the plant. The high lift and long distance of this water distribution system makes it vulnerable to surges and pipe breaks.

Our Solution 

The Design Institute called on Singer Valve to determine what technologies could be put in to place to safely transport the water and ensure a stable flow of water regardless of flow rates that vary according to power production needs.

The first stage involves pumping water from a floating dock and transporting it by two DN600 pipelines to the water treatment plant. To regulate surging when starting or shutting down the pump, two surge anticipating relief valves were installed on the dock. These two valves can be open before the surge comes and relieve the pressure from the pipe. This is especially important if there is a power failure and water rushes back down to the pump station. An added precaution to prevent surges was to install air valves on the pipeline to release any trapped air from the pipe.

Pipeline from WTP to water tankAfter the water is treated, it is pumped to a water tank. With a 340 meter pump head, a surge calculation determined the need for a control valve after the pump with a surge anticipating relief valve mounted in a tee, downstream of the pump check valve. This is designed to anticipate surges and avoid the severe water hammer often associated with power failure surges. The Anticipating Relief Valve with Flow Limiting on Solenoid Valve Opening (106-RPS-ET-HFL) was selected to do the job. This valve is a pilot operated pressure relief valve designed to open when the inlet pressure exceeds a predetermined setting. The valve also opens when the solenoid valve is energized. When the solenoid valve opens the valve, the maximum opening of the valve can be limited. The solenoid valve is typically energized by a controller that senses power failure and/or low header pressure and uses battery power to energize the solenoid valve for a short adjustable period.

After the pump, there is a pump control valve to protect the pump, and also to be used as a check valve when the flow comes back. The Booster Pump Control Valve was installed after the pump to prevent surging during opening and closing of the pump.

The water tank is 180 meters higher than the power plant which makes this final transportation gravity fed via two DN600 pipelines over 6.3 km. With this elevation and distance a pressure reducing station was required in the middle. The Design Institute selected Singer’s 106-PR with an anti-cavitation cage as the pressure drop between intake and outflow was greater than 3 to 1 ratio.

Booster Pump Control Valve

Cavitation consists of rapid vaporization and condensation within a liquid. When local pressure falls to vapor pressure (approximately 0.25 psi / 0.018 bar absolute for cold water), vapor bubbles are formed and when these bubbles travel to an area of higher pressure, the bubbles collapse with phenomenal force and great localized stress. It is the violent collapse of these vapor bubbles near valve components or downstream piping surfaces, which cause cavitation damage and subsequent performance degradation.

Singer’s Anti-Cavitation technology contains two heavy stainless steel sliding cages that maximize the full flow capacity. The first cage directs and contains the cavitation recovery, allowing it to dissipate harmlessly. While the second cage allows further control to a level as low as atmospheric pressure downstream. The cages are engineered to meet the flow / pressure differential of each application.

After the pressure reducing station, the water flows in to the power plant with one last flow regulating valve installed at the entrance gate to ensure stable flow and pressure.

The Result 

“We knew it was going to be very challenging to transport the water to the power plant safely with the elevations and distance that it needed to travel”, said Liu Zhizhao, Manager of Zhijin Power Plant.

“Singer’s surge anticipating plan and quality valves gave us the confidence to complete this project,” concluded Mr. Zhizhao.


 The power plant has capacity to produce 2X660MW that travels 150 km to power the city of Guiyang and the surrounding communities. Zhijin power plant employs around 600 people.

Author William Su is head of technical support for Singer, China and has been solving problems in the water industry for over 10 years.

Winner of the Industrial Project of the Year with Water & Waste Digest at WEFTEC in Chicago. Read more here.

SINGER ELIMINATES CAVITATION DAMAGE IN PITTSFIELD TOWNSHIP’S RESERVOIR FILLING STATION

Posted by RS

Jun 4, 2014 3:02:00 PM

Pittsfield-Web-PicSINGER ELIMINATES CAVITATION DAMAGE IN PITTSFIELD TOWNSHIP’S RESERVOIR FILLING STATION

Their Challenge 

To address cavitation damage immediately and maintain the current valve functions with controlled programming. The high pressure drop caused by fluctuation in elevation ranges was causing significant cavitation in the plug valve.

Our Solution

Single Rolling Diaphragm with Anti-Cavitation Trim

The Result

  • Cavitation damage eliminated immediately without sacrificing other valves
  • Valve consistently modulating the flow into the tank without any shut down
  • Consistent water flow for the residents of Pittsfield Township
  • SRD allowing the valve to operate steadily at both low and high flows
  • Reduced maintenance thanks to the SRD self-flushing the pilot controls

"THE SINGER VALVE IS WORKING FANTASTICALLY. IT IS A SIMPLE AND EFFICIENT SOLUTION WITH MINIMAL MAINTENANCE."

- Billy Weirich, Pittsfield Township Utilities Superintendent

 

download-pdf-article

Topics: Singer Valve Solutions, anti-cavitation trim, Anti-Cavitation

Pressure Management Reduces Water Loss & Pipe Bursts in Indonesia City

Posted by RS

Jun 4, 2014 1:29:00 PM

Malang-Web2

Pressure Management Saves Indonesian City 75% in NRW, Improves Pipe Breakage by 300%, and Reduces Power Consumption by 33%

Their Challenge 

To address high leakage rates, daily pipe bursts and insufficient water levels caused by aging infrastructure.

  • High leakage rates
  • Daily pipe bursts
  • Low reservoir levels due to leakage and pipe bursts
  • Lack of water supply
  • 30% of city's population deprived of water suppl

Our Solution 

138 units of Singer Valve’s S106-2-PR-BT ranging in size from 100mm to 500mm

The Result

  • Reduction of pressure during high demand in the daytime, and further reduction to night time pressure
  • 75% reduction in original water leakage rate 
  • 300% reduction in pipe breakage (thus saving the client money on annual maintenance and repairs)
  • 33% reduction in city power consumption  
  • City of Malang expanded water service to an additional 25,000 connections (amounts to roughly 125,000 people)

"I can sleep well at night knowing the vast majority of customers now have reliable water."

- Mr. Teguh Cahyono, Director of Non-Revenue Water, City of Malang Water Department

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Topics: Singer Valve Solutions, Singer Valve, Singer Valve S106-2PR-BT, Waterloss

SRD Valve with Anti-Cav Trim Offers Stability to Yarra Valley Station

Posted by RS

Jun 4, 2014 12:30:00 PM

yarra-valleySINGER’S SRD VALVE WITH ANTI-CAV TRIM REDUCES YARRA VALLEY STATION FROM 3 VALVES INTO 1

Their Challenge

To prevent cavitation with extreme pressure drop, address the excessive noise, severe erosion, valve damage and downstream pipeline issues - all caused by valve cavitation.

Our Solution

Singer Valve’s 150mm (6") Single Rolling Diaphragm (SRD) fitted with Anti-Cavitation trim

The Result

  • Cavitation problems addressed with the 150mm SRD fitted with Anti-Cav trim (S106-PR-AC)
  • Improved downstream pressure feeding into residential homes with better stability
  • Removed the need to protect the other two valves with Anti-Cav trim as one valve can handle entire flow range 
  • Less maintenance required in the future

"ANOTHER ADVANTAGE THAT IS SIGNIFICANT OVER TIME IS THAT WE NOW HAVE FEWER ASSETS REQUIRING LESS MAINTENANCE."

- Fiore DiPietro, Specialist Technician, Yarra Valley Water Operations

download-pdf-article

Topics: Yarra Valley, Singer Valve, SRD Valve, Anti-Cavitation

Singer Valve's Altitude Pilot Stops Malaysian Reservoir Overflowing

Posted by RS

May 12, 2014 4:08:17 PM

Malaysia301-4_tnailSINGER VALVE'S ALTITUDE PILOT STOPS MALAYSIAN RESERVOIR OVERFLOWING

 

Their Challenge

To ensure that the state's water infrastructure is reliable and effective.

Our Solution 

Singer Valve’s 301-4 Atltitude Pilot.

The Result

Singer Valve's 301-4 Altitude Pilot reduced the number of overflows in the reservoir, increased the supply of revenue-generating water and reduced repair costs because the valve body can be serviced without removing the pilot and the inner valve can be replaced without disconnecting the pilot tubing.

Topics: Singer Valve Solutions, altitude pilot, altitude