Case Study: Turbine Condenser Air Ejector

In the demanding environment of power generation, control valve performance is essential for maintaining efficiency and safety. Kentucky Utilities, a longstanding energy provider, encountered significant challenges while managing steam for their turbine condenser’s air ejector. With steam pressures reaching 1450 psi and temperatures up to 1000°F, precise control was critical to keep operations running smoothly. 

The existing system needed a valve solution that could handle these extreme conditions reliably while minimizing downtime and maintenance, ensuring consistent performance under high load variations and fluctuating operating demands.

What was the main challenge for Kentucky Utilities?

The plant's operations required reducing high-pressure steam to 300 psi to supply the air ejector effectively. The system handles varying loads, supplying 750 pounds per hour with one set of jets and 1500 pounds per hour with two sets. The existing control valve needed to offer flexible performance without frequent maintenance or failure.

What was Trimteck’s solution?

Trimteck provided a severe-duty socketweld valve, initially equipped with a ¼” orifice. After installation, performance evaluation showed that with two jets in service, the valve was opening more than 90%, indicating a suboptimal match for the application. Trimteck's responsive engineering team then resized the orifice to 3/8”, balancing the valve's operation to approximately 40% open with one jet and 60% with two, optimizing control and efficiency.

When the Kentucky Utilities team received the valve, they conducted preliminary tests in their shop. They encountered an issue with the positioner orientation, but Trimteck’s tech support quickly guided them in resolving it. With their assistance, they rotated the actuator 180° to fit the plant's layout seamlessly.

Maximum performance, easy maintenance

The valve's performance post-installation allowed the regulation of steam flow within a precise 4-5 psi range shortly after adjustments in the plant’s Distributed Control System (DCS). This level of control was notable during plant startup, where the valve adjusted from full open to the required operational state effectively.

About 10 months into operation, the team noticed a leak at the stem packing. Initial attempts to tighten the packing were unsuccessful. However, the valve continued to perform until the scheduled annual outage, when both the upper and lower packings were replaced without issue. Inspection during this maintenance revealed no wear on the plug, seat, or stem, indicating exceptional durability and build quality.

The chief electrician at Kentucky Utilities highlighted the ease of disassembly and reassembly, praising the valve's design its ease of maintenance. This feature allowed less experienced technicians at the facility to manage repairs internally, enhancing operational independence and confidence.

The result

“I am overall very happy with the performance of the valve. The ease of disassembly to me surpasses any valve that I have worked on (including Fisher).” - Chief Electrician, Kentucky Utilities

Control valve solutions for critical power applications

Trimteck stands as a proven leader in delivering high-performance valve solutions designed for the rigorous demands of power generation. We are committed to engineering excellence and responsive customer service, ensuring that our clients receive not just products but complete solutions that enhance their operations.

Contact us today for a consultation with our Applications Engineers or specify the right control valve for your needs using our AccuValve™ software. Let us help you achieve optimal performance and reliability in your energy systems.