Redhawk Completes One Year of Reliable Service with CCI’s Turbine Bypass Systems

 Quality and reliability go hand in hand when it comes to a CCI solution. At the Redhawk power plant, which replaced its problematic turbine bypass valves with CCI’s technology, the quality of CCI’s solution is its reliable performance – the CCI valves have been performing trouble-free for over one year.

Redhawk’s previous valves were exhibiting severe vibration that was causing such serious damage that the actuator parts were falling off. Excessive vibration in a turbine bypass valve is a critical problem because it can break pipe hangers and shake accessories off actuators, resulting in high maintenance and repair costs and unscheduled downtime.

With the help of CCI’s experienced engineering team, Redhawk was able to address the root causes of the vibration. By determining that the problem was related to the valve’s design and selection, CCI and Redhawk had already won half the battle to arrive at the right solution that would last.

To correct the situation with Redhawk’s turbine bypass valves, CCI engineered a customized DRAG ® solution that uses numerous right-angle turns to form a tortuous path in which every turn reduces the flow pressure. This technology achieves the velocity control that effectively eliminates system vibration at its source. The result has been remarkable, as the customer reports smooth operation for the past year since installation.

CCI supplied a total of four bypass valves featuring DRAG® technology – two for Redhawk’s Unit A and two for Unit B. The HP turbine bypass valves measure 6”x14” (150mm x 360mm) at design temperatures of up to 1065º F (575ºC) and design pressures of up to 2300 psia (159 bar). The HP spray valves measure 2.5”x2.5” (63mm x 63mm) at flow rates of up to 63340 lbm/hr (479 kg/min), design temperatures of up to 310ºF (154ºC), and design pressures of 3486 psia (240 bar).

Due to the exceptional performance of CCI’s turbine bypass valves installed at Redhawk, CCI recently received a follow-on order for hot reheat (or intermediate pressure) bypass valves. As with the previous order, CCI supplied two bypass systems for Unit A and two for Unit B. Because the systems have different piping, the orientation of the desuperheater water connection, handwheels, cartridge trim lifting holes, and drain for one of the units was customized to meet Redhawk’s specific capacity requirements. So that Redhawk could minimize its downtime, CCI provided an expedited delivery time of 12 weeks and installed the valves immediately.

For over a year, Redhawk has enjoyed the dependable performance of its new CCI turbine bypass systems, which offer enhanced flexibility for faster startup times, reduced downtime, and higher plant productivity. Along with Redhawk’s newer hot reheat bypass valves, this solution has also lowered fuel costs and overall plant operating costs, significantly improving the plan’s bottom line and promising to do so for years to come.

Published in SOLUTIONS Fall 20004