reference projects vag riko® plunger valve … · capacity of 1.2 million tonnes of waste water...
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• Watersupply• Industry• Hydropowerstations/Dams• Wastewatertreatmentplants• Edition2/11-2014
Reference ProjectsVAG RIKO® Plunger Valve
PlaceApplicationDate
Products
Project description
Withatotalareaof700,000hectaresandatreatmentcapacityof1.2milliontonnesofwastewaterperday,thewastewatertreatmentplantHangzhouQiGeisoneofChina’slargestplants.
Totreatthewater,bacteriaareusedherewhichneedoxygentodigestthesludge.Toomuchortoolittleoxygenwillreducetheperformanceofthebacteriaandthusaffectthewaterquality.
Thisiswhyapossibilityofpreciselycontrollingtheairsupplyhadtobefound.Additi-onallythecustomerwantedtoreducetheenergylostduetoairfrictiontolowertheoperationcostsoftheplant.
Toimplementtheserequire-ments,VAGRIKO®PlungerValveswereused.Thelinearflowcurveoftheplungervalvesallowsaveryprecisecontroloftheairsupplywithonlynegli-giblefrictionlosses.
DuetotheuseofVAGplungervalves,thecostsforaerationcouldbereducedby30%.
Hangzhou/ChinaWastewatertreatmentplant2002to2009
18xVAGRIKO®PlungerValvesDN400-PN1011xVAGRKVPlungerVlavesDN350-PN10
Hangzhou Qi Ge Waste Water Treatment Plant
Picture at the top: Schematic drawing of the Hangzhou Qi Ge waste water treatment plant
Picture at the bottom: Administration building and main entrance of the Hangzhou Qi Ge waste water treatment plant
PlaceApplicationDate
Products
Harbin/ChinaWatersupply2005to2009
5xVAGPlungerValvesDN1400/1600-PN10/1618xVAGEKN®ButterflyValveswithhydraulicbrake-and-liftcylinderDN700/900-PN10and1660xVAGEKN®ButterflyValveswithelectricactuatorDN400to1100-PN1048xVAGEKN®ButterflyValveswithpneumaticactuatorDN400to800-PN10
Harbin-Mopanshan Water Supply Pipeline
Project description
Intheperiodfrom2005to2009,anewdrinkingwatersupplysystemforthecityofHarbinwasestablished.ThewatertransportpipelinerunningfromtheMopanshanreservoirtothecityofHarbinwasthelongestinthenorth-eastofChinaatthattime.
Two180kmlongparallelpipelinesnowsupplythecity’s10millioninhabitantswithdrinkingwater.
EachofthepipelinesrunsfromtheMopanshanreservoirthroughawatertreatmentplantanddirectlytothecity’ssupplynetwork.
Thedifferenceinaltitudebetweenthereservoirandthetreatmentplantisover120metres.
Thetwowatertreatmentplantshaveatotaldailytreatmentcapacityof900,000litresofwater.
Tobeabletocontrolthewaterpressureandtheflowrateovertheentiredistanceandtocompensatefortheslope,VAGPlungerValveswithaninternaldiameterof1.60mwereinstalled.
Picture 2: Pump station
Picture 3: A VAG Plunger Valve is being put into operation
Picture 1: VAG Plunger Valve DN 1400
PlaceApplicationDate
Products
Project description
IntheBoxbergpowerplant,aVAGRIKO®PlungerValvewasinstalledinabypasspipelineatthecondensatepurifier.
Hereitcontrolsthevolumeflowratewhilethecartridgefiltersarebeingreplaced.
Incaseofadisturbancethecondensatemayheatupto120°C.Forthisreason,thevalvehadtobecustomisedanddesignedfortemperaturesofupto120°C.
TheTÜVhasissuedvariousdirectivesandprescribesanumberoftestsforthisdesign.Compliancewiththesedirec-tiveswasverified,thetestswereperformedandthevalvesacceptedbytheTÜVinVAG’sfactorybeforethevalvewasinstalled.Theyincludeforexample:
• ValvebodyandvalveshafttoEN102043.2(formerdesignation3.1C)
• Testaccordingtothematerialstestsheet0-27-01672.4
• PressuretesttoEN102043.1fortightnessandresistance
Boxberg(Saxony)/GermanyPowerplant2009to2010
VAGRIKO®PlungerValveDN500-PN16formediaofupto120°C
The Boxberg Power Plant
Pictures at the bottom:VAG RIKO® Plunger Valve for media temperatures of up to
120°C in open (left) and closed position (right)
PlaceApplicationDate
Products
Project description
TheSchwelgerncokingplantisoneofthelargest,mostmodernandcleanestcokingplantsintheworld.Everyyear,2.5milliontonnesofcokeforthesteelproductionofThyssenKruppSteelAGareproducedhere.
Forthenewlydeveloped,low-emissionwetcoolingprocessofthecoke,VAGRIKO®PlungerValvesareused.
Afterarefiningtimeof25hours,thecokingcoalisquenchedwithin70secondswithover100m³of60°Chotwaterthroughtheplungervalves.Thisprocessisrepeatedevery10minutes,135timesperday,365daysperyear.
Thegatesvalvesusedbeforewerenotabletomanageabrasion,cavitationorthecontroltasksrequired.Additi-onally,theirclosingtimesweretoolongsothatmalfunctionsoccurred.
ThecustomisedVAGRIKO®PlungerValveswereequippedwithinternalpartsmadeofstainlesssteel.Combinedwithashapeadjustedtotheprocess,whichshiftsabrasiontotheoutside,thesemodifi-cationsensureextremelylittlewearandteareveninconti-nuousoperation.
Uptothepresentdaythismeans450,000trouble-freecycleswithoutanytechnicalmaintenanceofthevalves.
Duisburg/GermanySteelmill2004to2005
4xVAGRIKO®PlungerValvesDN300-PN104xVAGRIKO®PlungerValvesDN500-PN10
KBS Coking Plant Operating Company Schwelgern
Pictures on the left: VAG RIKO® Plunger Valves after 450,000 cycles
PlaceApplicationDate
Products
Project description
ThecityofJaipuristhecapitaloftheIndianstateofRajasthaninthenorth-westofIndia.
Viaa106kmlongsupplypipeline,theBisalpur-JaipurwatersupplyprojectdeliverswaterfromtheBisalpurdamtoJaipur.Thetargetoftheprojectistosupply5.3millionpeoplewithdrinkingwaterwithouthavingtodrawonthearea’sgroundwaterresources.
TheplanningconceptconsistsofseveralphasestomeetJaipur’srisingdemandforwaterandtoreducetheextractionofgroundwatertoasustainablelevel.
Gradually,thedailytotaloutputcapacityistobeincreasedfromcurrently400,000m³toover1,000,000m³ofdrinkingwater.
Besidesalargenumberofbutterflyvalvesandairvalves,atotalof58VAGplungervalveswereinstalledintheover100kmlongpipelinetocontrolthewaterflowrate.
Rajasthan/IndiaWatersupply2007to2008
22xVAGRIKO®PlungerValvesDN100to400-PN1036xVAGRIKO®PlungerValvesDN80to500-PN16114xVAGEKN®ButterflyValvesDN250to2200-PN10and16189xVAGDUOJET®AirValvesDN50to200-PN10
Bisalpur-Jaipur Water Supply Pipeline
Picture on the right: Water supply pipeline DN 400
PlaceApplicationDate
Products
Project description
The„DaHuoFang“reservoirnearthecityofFuShunsuppliesdrinkingwaterforsixcitiesintheChineseprovinceofLiaoning.Thewaterofthelakeistransportedviagravitylinesoveradistanceof238kmtothevariouscities.
Toensureuninterruptedwatersupply,thecustomerrequiredcontrolvalvesabletoadaptautomaticallytothevariablewaterlevelsofthelakewhilethewatersupplyprojectwasinitsplanningstage.
Whenthelevelinthereservoirislow,thewaterpressureinthepipelinedrops.Inthiscasetheplungervalvemustopenwidertocompensatethelowerwaterpressureandtokeeptheflowrateataconstantlevel.Arisingwaterlevelwithincreasingpressureinthepipelinemustbecompensatedbythetargetedclosingofthevalve.
Thevalvesareopenedandclosedviaanautomaticcontrolunitwhichcapturesthewaterpressureandopensorclosesthecontrolvalvesondemand.
DaHuoFang/ChinaWatersupply2007to2010
9xVAGPlungerValvesDN1600-PN105xVAGPlungerValvesDN1400-PN102xVAGPlungerValvesDN1200-PN102xVAGPlungerValvesDN1000-PN101xVAGPlungerValveDN800-PN10
Liaoning Da Huo Fang Water Reservoir
PlaceApplicationDate
Products
Project description
ThemasonrydamoftheLeibis-LichteDamwasbuiltasaconcretegravitydamintheyear2002.Withaheightof102.5mitisGermany’ssecondhighestdam.
Asbottomoutletvalves,5VAGRIKO®PlungerValveswereinstalled.
ThethreelargeplungervalveswithanominaldiameterofDN1000areusedtocontrolthebottomoutlet.
Thetwosmallerplungervalveswithadiameterof150and300mmareusedtodischargesmalleramountsofwaterintotherunningwaters.
Eachofthelargeplungervalveshasamaximumflowrateof14m³persecond.Incaseofanemergencythisensuresthat14,000litresofwaterpersecondcanbedischargedfromthereservoir.
Unterweißbach(Thuringia)/GermanyDam2002to2005
3xVAGPlungerValvesDN1000-PN163xVAGRIKO®PlungerValvesDN150toDN600-PN163xVAGEKN®ButterflyValveswithhydr.brake-and-liftcylinderDN1200-PN2518xVAGEKN®ButterflyValvesDN150toDN1000-PN166xVAGDUOJET®AirValvesDN200-PN16/25
The Leibis-Lichte Dam
Picture in the centre left: VAG RIKO® Plunger Valves DN 1000 (at the back) and DN 150 (at the front)
Picture on the left: Bottom outlet with 2 open VAG RIKO® Plunger
Valves and stilling basin
PlaceApplicationDate
Products
Water Supply Pipeline in the North of Spain
Santander/SpainWatersupply2007
1xVAGRIKO®PlungerValvewithhydr.brake-and-liftcylinderDN600-PN1001xVAGRIKO®PlungerValvewithhydr.brake-and-liftcylinderDN800-PN1001xVAGRIKO®PlungerValvewithelectricactuatorDN600-PN1001xVAGRIKO®PlungerValvewithelectricactuatorDN800-PN1005xVAGRIKO®PlungerValveswithelectricactuatorDN450to800-PN10/16/25
Project description
ThecitiesofSantanderandTorrelavega,locatedinthenorthofSpain,aresuppliedwithwaterviaa40kmlongwatermain.
OnitsroutefromtheEbroreservoirtothecities,thepipelinehastoovercomeelevationsofupto735m.
Atfivepointsinthepipeline,pumpstationswereinstalledtokeepthewaterflowing.
Alreadyatanearlystageinthisproject,VAG’sprojectengineerswereconsultedtoprovideadviceontheselectionofvalves,thedeliveryandinstallationofthevalves.
Duetothegreatdifferencesinaltitudeandthepressuresgeneratedinthepipelinesduetothisfact,VAGRIKO®PlungerValvesofanominalpressureofPN100wereinstalled.
Theextremelytightprojectschedulebecameanothergreatchallenge.Ameresixmonthsafterthecustomerhadplacedhisorder,thevalvesweredelivered.
PlaceApplicationDate
Products
Project description
ThedrinkingwatersupplyofthecityofMumbaiwithitspopulationof20millionisasomewhatdifficulttask:
• Theimmediatevicinityoftheseamakesthegroundwaterbrackishandsalty.
• Onlyfewhouseholdsareconnectedtothesewagesystem.
• Floodscomingduringthe4month-longmonsoonperiodcausesomesectionsofthesewagesystemtobreakdownandthendrinkingwatermixeswithwastewater.
Toensurethepopulation’sdrinkingwatersupply,damswerebuiltwhosereservoirssupply35millionlitresofwaterperdaytothecity’ssupplynetworkviafourlong-distancepipelineswithadiameterof3m.
OneofthemainsourcesofwatersupplyistheRiverBhatsa.Thepressureofthewatertakenfromtheriverisincreasedby24verticalturbinepumpshousedinapumpstation.Thewateristhentransportedtowaterworksfortreatment.
Theremaining700millionlitresofservicewaterarefedintoagravitymainofthewatersupplynetworkatAgraRoad.
Mumbai/IndiaWatersupply1978
7xVAGPlungerValvesDN1200-PN167xVAGButterflyValvesDN1200-PN167xVAGGatevalvesDN1200-PN16
AGRA ROAD, Mumbai
Tocompensatethepressureinthegravitymain,7VAGplun-gervalvesareused.Thevalvesareoperatedatleastonceperday.TheVAGplungervalveshavebeenperformingthistasktrouble-freeforover30yearsnow.
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