Business bulletin - MPOWER Group · Supply of high-pressure valves for ... Bodies of the check valves K05 are made ... Butterfly valves for the electric power plant Prunéřov II:

MPOWER Engineering, a.s. | Pod Vinicí 2028/20 | 143 01 Praha 4 - Modřany, CZ | T: +420 225 371 300 | E: [email protected] | W: www.mpowergroup.eu 1

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Supply of high-pressure valves for the "Project RK3 - Recovery Boiler 3", Mondi SCP, a.s. Rožumberok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Butterfly valves for the electric power plant Prunéřov II: Control system description . . . . . . . . . . . . . . . . . .7

New product in the MPOWER product range: Ball valve K30/K31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Calendar of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Control and expansion audit of the quality management system . . . . . . . . . . . . . . . . . . . . . .10

How our customers see us: Customer Satisfaction Survey 2013 . . . . . . . . . . . . . . . . . . . . . . .11

CONTENT

Miloš SuránSales directorT: +420 225 371 300 M: +420 725 076 101E: [email protected]

Martin ČervenkaSales managerT: +420 225 371 300M: +420 725 014 090E: [email protected]

Alexandr GašparSales managerT: +420 225 371 300M: +420 725 076 072E: [email protected]

Ladislav NykodýmSales manager seniorT: +420 225 371 318M: +420 725 014 129E: [email protected]

Miroslav ZemanskýSales managerT: +420 225 371 300M: +420 777 483 124E: [email protected]

Michal BezákSales manager T: +421 373 141 120M: +421 911 174 274E: [email protected]

CONTACT THE SALES DEPARTMENT:

On April 25, 2013 at the companyMondi SCP, a.s. Ružomberok(Slovakia) the foundation stone of128-million project for theconstruction of a new recovery boiler3 (RK3) was laid. Boiler RK3 will serveas a replacement of the previousboiler 1 and will meet the latestemission and pollution standards. Inthe Project RK3 consisting of severalpartial sections, the companyMPOWER will participate in thesupply of high-pressure valves for thepart of the boiler RK3supplied byAndritz and the part of the turbineTG9 supplied by Siemens. In thefollowing article you can see the

closer range and specifics of thesupply for the boiler RK3 which willbe realized in December 2013 and forpart of the turbine TG9 with acompletion date in April 2014.

The bulk of supplies for both contractscreatesthe supplies of the high-pressureforged gate valves K02 and shut-off valveswith the control plug K91. Part of thesupply of our product range is also twohigh-pressure check valves K05.

Gate valve K02 characteristicsGate valves with the type number K02 aremade of free or die forgings, yoke of thesevalves is cast or welded. Seats in the body


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Supply of high-pressure valves for the "Project RK3 - Recovery Boiler 3", Mondi SCP, a.s. RožumberokMichal Bezák, sales manager, MPOWER SLOVAKIA, a.s.

The foundation stone of the "Project RK3 -Recovery Boiler 3", Mondi SCP, a.s. Rožumberok

Membrane rupture insurance device


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are pressed and then seal welded. Thesealing surfaces of the seats and wedge arehard-alloyed (Stellite). To seal the glandpacking and pressure seal bonnet, ringsand sealing made of the expanded graphiteare used. The design of those gate valvesincludes the layout of the maincomponents according to the pressure andtemperature system and operatingparameters specified by the customer.

In some pipe systems may occur a situationwhere after the shutdown of the systemand after subsequent cooling, a certainamount of water remains in the central partof the closed gate valve, ie in the spaceabove the wedge. If after a time such valvein a closed state is heated through thebypass, the pressure of the mediumincreases between the plates of the wedgein the space above them (in the chamber)

due to temperature. If there is possibilitythe above situation may occur during theoperation of valve, it is necessary to requestto supply the gate valves with theprotection of the inner part of the body.

For the project RK3, the gate valves will besupplied with the relief valve protecting theinside of the body. It is a universal solutionapplicable to all gate valves and alloperating parameters. Gate valve with theprotection using the safety device isbidirectional. The safety device is fitted tothe condenser loop lead out of the gatevalve body outside its thermal insulation.Due to the replacement of the rupture diskduring operation, the part of the safetydevice is the pressure measurement shut-offvalve with locking device to preventunallowed manipulation. By selecting anappropriate condensing loop will be used

the relief device with horizontal or verticalconnection.

Another specific feature of the supply willbe the gate valve K02 DN 350 with installedblowdown wedges. These are standardwedges drilled in the middle. The sealingsurfaces of the seats in the closed positionof the gate valve are thus protected duringthe blowdown and will not be damaged.After blowdown, these temporary wedgeswill be dismantled by our service team andreplaced with the wedges designed for fulloperation.

Gate valves with actuators are controlled bythe actuators from AUMA equipped with theAUMATIC and AUMAMATIC control units.

Valve K91 description Valves K91 are designed for rough controlwith linear characteristics. K91 valve body isdie forging with the independent body andcast yoke. The seat in the body is hard-facedwith alloy. The plug with stem are made ofone piece with the sealing surface of hardweld alloy. Control valves can be alsooperated in an intermediate position. 177valves from 179 units will be equipped withthe hand wheel and two AUMA actuatorswith the AUMATIC control unit.

Check valve K02Bodies of the check valves K05 are madefrom one piece of free forging (withoutwelding). Body seats are, as well as valvesK02, pressed and seal welded. The sealingsurfaces of the seats and the disk arehard-faced with alloy. Sealing rings of thepressure seal bonnets are made of theexpanded graphite.

Forged gate valve, type K02 Control valve, type K91


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Gate valves with manual control

Series DN Pressure range Material of the body Quantity

K02-AK1-01 80/75 250/320 10CrMo9-10 4

K02-AK1-04 80/75 250 P250GH 6

K02-AK1-10 80/75 160 16Mo3 1

K02-AK1-01 100/75 250/320 10CrMo9-10 2

K02-AK1-04 100/75 250 P250GH 1

K02-AK1-01 200/150 250/320 10CrMo9-10 1

K02-AK1-10 200/150 250 16Mo3 2

Valves controlled by the electric actuator


K02-AK3-04 80/75 250 P250GH 3

K02-AK3-10 80/75 250 16Mo3 1

K02-AK3-04 100/75 250 P250GH 2

K02-AK3-01 200/150 250/320 10CrMo9-10 1

K02-AK3-10 200/150 320 16Mo3 1

K02-AK3-01 350/275 250/320 10CrMo9-10 1

Shut-off valves with the control plug and manual control


K91-AK1-04 15 250 P250GH 12

K91-AK1-03 20 160 13CrMo4-5 8

K91-AK1-04 20 160 P250GH 8

K91-AK1-10 20 160 16Mo3 16

K91-AK1-10 20 160 16Mo3 4

K91-AK1-33 20 320 X6CrNiTi18-10 2

K91-AK1-03 25 250 13CrMo4-5 10

K91-AK1-04 25 320 P250GH 20

K91-AK1-04 25 250 P250GH 57

K91-AK1-04 25 160 P250GH 12

K91-AK1-10 25 160 16Mo3 2

K91-AK1-03 40 160 13CrMo4-5 4

K91-AK1-04 40 250 P250GH 2

K91-AK1-10 40 160 16Mo3 4

K91-AK1-04 50 160 P250GH 12

K91-AK1-04 65/50 320 P250GH 4

MPOWER supply for the boiler RK3


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Check valves


K05-AK7-10 80/75 250 16Mo3 1

K05-AK7-10 200/150 250 16Mo3 1

Shut-off valves with the control plug, controlled by the electric actuator


K91-AK3-01 25 250 10CrMo9-10 1

K91-AK3-04 25 63 P250GH 1

MPOWER supply for the boiler RK3

Gate valves with manual control


K02-AK1-08 125/110 160 X10CrMoVNb9-1 1

K02-AK1-08 150/110 160/250 X10CrMoVNb9-1 1

K02-AK1-08 250/200 160/250 X10CrMoVNb9-1 1

K02-AK1-01 350/275 160 10CrMo9-10 1

Valves controlled by the electric actuator


K02-AK3-08 125/110 160 X10CrMoVNb9-1 1

K02-AK3-08 150/110 160/250 X10CrMoVNb9-1 1

K02-AK3-08 250/200 160/250 X10CrMoVNb9-1 1

K02-AK3-01 350/275 160 10CrMo9-10 1

MPOWER supply for the turbine TG9

For the project entitled "Full recoveryof the power plant Prunéřov II, PS16,cooling water pumping station", inJune 2013, the company MPOWERshipped three pieces of specialbutterfly valves C05 with nominaldiameter DN 1800 and nominalpressure PN 16. The article describesthe technical specifics of the butterflyvalves with a particular focus on thecontrol system.

The valve C05 is mounted on the pipingbehind the cooling water pump and worksprimarily as the check valve (protection of thepump) and at the same time as the shut-offvalve. The valve is made of carbon steelP265GH (1.0425). It is plain, low-carbonunalloyed steel, suitable for highertemperatures. The body is welded from thecurved metal sheet reinforced with horizontal

and transverse ribs. The flanges are alsowelded to the body. The disk reinforced withribs is stored in the body with doubleeccentricity. The valve is characterized as

"soft-seated". As the sealing element is usedelastomer EPDM (Ethylene Propylene DieneMonomer). This one is fixed to the disk by thestop collar. The seat is made of the material


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Butterfly valves for the electric power plant Prunéřov II: Control system descriptionMartin Červenka, sales manager, MPOWER Engineering, a.s.


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1.4404 and is welded to the body. Totalweight of one complete valve is 7.5 tons.

ControlActive control of the valve consists ofa hydraulic piston coupled to the unit withthe pump. To develop passive control force,weight is applied on the lever. The wholevalve is designed for the pressure of 6 bar(PN 6), the piston is able to open the valveat the pressure drop 2.5 bar. The logic of theactuator is set to two different controloptions. The valve can be controlledremotely from a control room, or (if theremote control room permits) the valve canbe operated on site from the control panel.This is part of the unit with the pump. Themain advantages of the control includetwo-phase locking (higher rate in the firstphase, slow setting in the seat), adjustableduration of two phases and alreadymentioned possibility of controlling at thepressure drop of 2.5 bar. Function of thecheck valve including two-phase completeclosing is retained even when the powersupply fails.

The so-called local logic of the controlwhich can be represented as the "brain" orcontrol unit of the valve is of course linkedto the control system of the entire powerplant. Signals necessary for the operationof the valves are controlled (eg Ready andthe position of the valve disc), the valvereceives commands from the system (open,close, etc.).

Surface protectionWithin the project, the customer definedthe colored performance of the valves. Thevalve itself is pea-green (RAL6019), theframe is pastel gray (RAL7035), the weightsand moving parts have signalling orangecolor and the equipment for oil is darkocher (RAL8001).

The MPOWER supply also includedcompensators DN 1800 of rubber with steelflanges. With regard to the operationalparameters, engineering test instituteStrojírenský zkušební ústav, s.p., Brnoperformed assessment of the conformity ofthe essential requirements of Government

Regulation No. 26/2003 Coll. (Module Gused by PED - "EC unit verification"). ECcertificate of conformity is issued on thebasis of the submitted technicaldocumentation, personnel qualificationand the final assessment, which includesa successful pressure test.

Moscow exhibition Valve IndustryForum & Expo, which we attended on5 - 7th of November 2013, meant forus mainly the opportunity tointroduce at the market a newproduct of our production range: Ballvalve of type K30/K31.

UsageBall valves are primarily designed to fullyopen or close the flow. The main advantageof the ball valves compared to other valvesis negligible hydraulic loss at fully open anda wide range of temperatures and pressuresand types of the medium:

Temperature of a medium: from -20°C to +425°CMaximum working pressure: 16 MPa

Technical descriptionThe preliminary plan is to manufacture theball valves with DN 15, 20 and 25 withfloating ball. In this case the ball in the closedstate has the possibility of a shift in the axis of flow and is pressed into the seat by thepressure of the working medium. For thelarger diameters (DN 40, 50, 80, 100) the ballis attached to the pins (trunnion mountedball + floating seats). Here is a ball rotatablysupported by two integral studs, seats canmove. The main sealing knot ball/seat ismetal-metal. Seats and the control shaftare sealed using special graphite sealing.Ball and seats are coated with solid carbideand lapped together to achieve maximumtightness and good sliding properties. Thebody and the lid are made of low-alloyheat-resistant steel. Pressure range for bothversions: PN 64, 100, 150, 250.

To control ball valves can be used allstandard controls from the lever over tomanual gearbox and electric or pneumaticactuator.

As the sample pieces were selected ballvalves DN 20 / PN 250 and DN 50 / 250.Externally cooperating designer developedtechnical documents and drawings, which

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New product in the MPOWER product range: Ball valve K30/K31Jan Kadrliak, design engineer, Technology Center, s.r.o.

Typ K30 (Floating Ball) Typ K31 (Trunnion Mounted Ball + Floating Seats)

MPOWER Engineering, a.s. | Pod Vinicí 2028/20 | 143 01 Praha 4 - Modřany, CZ | T: +420 225 371 300 | E: [email protected] | W: www.mpowergroup.eu


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were forwarded for processing to thecompany Technology Center , s.r.o. Threeprototype pieces of each DN were put intoproduction. Since these were the firstvalves of this type, the production wasgiven special attention. Production ofindividual components in the TechnologyCenter was carried out without any majorproblems. In October this year, one ballvalve DN 50 / PN 250 was installed. Authorof the drawings was present at theworkshop and as an experiencedpractitioner supervised the proper conductof the assembly and trained installers forwhich the ball valve assembly was a newexperience. The finished piece was coatedwith, anchored to the frame and sent to thetrade fair Valve Industry Forum & Expo inMoscow, where it was presented in theexposition of the MPOWER Russian branch.Other pieces, after the assembly at the

Technology Center, will be subject to theprototype tests, which results shouldhighlight any shortcomings. The experiencegained in the form of any adjustments isthen reflected in the forward-looking serial

production. If the ball valves become astable part of the production program, itwill be another step to increase thecompany's competitiveness to attract newcustomers.

The ball valve control

MPOWER team at the international fair PCVExpo 2013, October 29 – November 1, 2013, Moscow. We look forward to meeting you at other events with the participation of MPOWER!

Conference All for Power 2013

December 9 – 10, 2013

Prague, Clarion Congress Hotel

www.afpconference.com

Calendar of Events

conference2013

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At the end of each year our task is to proveto the certification company auditors thatthe used Quality Management System(QMS) is a fully functional and effective.After last year's re-certification audit thecertificate was extended for anotherthree years; this year the first review auditand also, according to our decision, theexpansion audit was carried out, theresults of which tend to confirm thevalidity of the certificate and theexpansion of the certified area witha special welding process.

This year in the QMS we devotedconsiderable effort to the special processes,ie, welding and heat treatment. The goal setfor this year is to complete the preparationprocess of the both production sites,Technology Center, s.r.o. and ArmaturkaVranová Lhota, a.s., to meet therequirements of the standard ČSN EN ISO3834. This international standard consistingof six parts , describes the qualityrequirements for welding and the methodof to prove their fulfillment. Quality isunderstood here as the set of allrequirements in the process, which isachieved by meeting the required quality atthe output of the process, i.e. a qualityproduct with the expected properties.According to the field of application of itsproducts, the manufacturer, in compliancewith the standard, has the possibility tochoose the level of difficulty, basic,standard or higher. With regard to thesupply of our valves to the nuclear powerengineering and pressure equipment to theEU it was logical that we chose the higherquality requirements and, therefore,verification and certification of welding

processes according to ČSN EN ISO 3834-2.The welding process affects virtually allparts of the QMS from trade (specificationrequirements for the product) throughimplementation (carrying requirements),technology (acceptance and incorporationof the requirements) , purchase(requirements application) , production(requirements performance) to the quality (verification of the requirements complianceand its documentation). For this reason, itwas necessary to complete somedocuments describing the activities in theQMS and to create new ones. The actualprocess of welding is the core activity of thequalification of the welding procedure, ieverification of the proposed procedure bychecking and testing of the samplesleading to the confirmation of the desiredproperties of the weld, all under thesupervision of an independent accreditedbody. Qualified welding procedures areavailable for standard product portfolio andfurther for supplementation according tothe actual. In the personnel area wemanaged to ensure the vacancy of weldingsupervision by fully qualified staff andgradually ensure the necessary

qualifications of welders. Equipment andworkplace equipment is at a very high level.Upon completion of training, we reviewedthe status by verifying the effectiveness ofthe fulfilled corrective measures.

Surveillance audit was conducted in lateOctober by two auditors of the certificationcompany TÜV NORD Czech, at theheadquarters in Prague and at the bothproduction sites belonging to the QMS, ie inOstrava and Vranová Lhota. Audit result ispositive; there were no critical deviations orsignificant findings, only suggestions forimprovement, which we will respond by usingthe standard system tools.

In the new issued certificate ISO 9001 willtherefore be stated that the companyMPOWER Engineering performs in theproduction of valves higher qualityrequirements for welding in accordance withthe standard ČSN EN ISO 3834-2. By meetingthis goal, we have again confirmed the trendof continuous improvement and rightfulnessof the inclusion of our company among theleading manufacturers and suppliers ofindustrial valves.

Control and expansion audit of the quality management systemJan Vaněk, representative for QMS, MPOWER Engineering, a.s.

MPOWER Engineering, a.s. | Pod Vinicí 2028/20 | 143 01 Praha 4 - Modřany, CZ | T: +420 225 371 300 | E: [email protected] | W: www.mpowergroup.eu


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During this year, together with ourcustomers and business partners wehave investigated satisfaction withour products and services provided.The aim of the survey was to find outwhat we mean for our customers asfor the quality of our products,prices, speed and timeliness ofdelivery, pricing policy and level oftransferred documentation, as wellas complaint proceedings andprofessionalism of our salesrepresentatives.

Reasons for survey Since 2009 when the MPOWER brandentered the market, we have delivered tensof thousands of valves to the customers inthe Czech Republic and abroad. This hasencouraged us to perform full and detailedanalysis of the perception of our companyand its activities by our customers andbusiness partners, get comprehensivefeedback and subsequently better adaptbusiness processes to their needs. Inaddition to obtaining information on theoverall customer satisfaction with ourproducts and services, the main purpose ofthe survey was to identify our strengths andweaknesses from the perspective of ourcustomers and, last but not least, to get acredible basis for the annual inspection andexpansion audits of the qualitymanagement system.

How we came off this year?Customers rated each question accordingto a school scale from 1 to 5, where eachgrade means:

1 – very satisfied / very high level of assessment2 – satisfied / high level of assessment3 – neutral4 – dissatisfied / low level assessment

5 – very dissatisfied / very low level ofassessment

0 – the customer is unable to express

How our customers see us: Customer Satisfaction Survey 2013Alena Marová, marketing manager, MPOWER, a.s.

Area / issue Average markA. Business and Technical Affairs 1,78The scope of the production and commercial product range 1,80Quality of products 1,62Offered delivery time 1,80Speed of response to demand 1,53Speed of processing of orders 1,43Operational solutions of customer needs 1,60Advice and consultation 1,47Price level 2,43Payment terms 2,38B. Implementation of the order 1,69Compliance with agreed delivery deadlines 2,00Compliance with agreed quality conditions 1,62Method of delivery and packaging of products 1,62Method of communication 1,50C. Accompanying documents 1,60Range of offer 1,57Professional level of documentation 1,57Comprehensibility and clarity of documentation 1,50Completeness of documentation 1,43Timeliness of delivery 1,92D. Solving the shortcomings 1,72Method of communication 1,36Quality and flexibility of solving claims 2,08E. Service 1,90Quality and level of service 2,00Speed of service 1,70Course of service 2,00Completeness of service 1,90F. Staff 1,52Professional standards of the MPOWER staff 1,53Behaviour and practice of the MPOWER staff 1,47Method of communication 1,40Overall impression from cooperation 1,67G. Web www.mpowergroup.eu 2,00Clarity and structure of web pages 2,07Information value of web presentation 2,00Overall level of web presentation 1,93Average mark 1,7

Outputs for this year's assessment we haveobtained from 15 customers in the CzechRepublic and abroad.

Based on the results, we are verypleased that as a company do not standbad with our customers (overall averagemark 1.7)! Top rated areas are the qualityof our staff (average mark 1.52), itsprofessional level and overallrepresentation of the company. Thiscorresponds with the overall strategy ofour personnel policy: we pay the utmostattention to the staff selection and striveto provide the staff with the mostmotivating background for thesuccessful execution of the work.Satisfied, motivated and trainedemployees are among our top priorities.One of the proofs of our care about thestaff is currently implemented businessskills training for all individuals of salesand purchases department or recentlyimplemented training workshops forbusiness and technical departmentfocused on planning of the engine roomof classic power plants and the use ofvalves in these systems.

The worst-rated area was our website(mark 2), customers characterized it asbadly organized and structured. It

motivates us to continue working on andimproved the content. At this point, it istherefore prepared the redesign of thecorporate website with a clear structure,customer zone and more detailedinformation about our production. Wefirmly believe that the new concept ofour website will get higher assessmentfrom our customers! From the answers tospecific questions the worst, but basicallyexpected, was the evaluation of ourproduct price levels and payment terms.

We thank to all our business partners whoparticipated the satisfaction survey thisyear and provided us with valuableanalytical information.

Your feedback is greatly appreciated!You can express you views on the cooperation the whole year through a form on our website:

http://www.mpowergroup.eu/en/satisfaction-survey.html Thank you for your willingness!

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© MPOWER Engineering, a.s., IČ 27819647Pod Vinicí 2028/20, 143 01 Praha 4 - Modřany, Czech RepublicT: +420 225 371 300, E: [email protected], W: www.mpowergroup.euEditorial Board: Alena Marová, Miloš Surán, Jan Vaněk, Martin Červenka, Michal Bezák, Jan Kadrliak

together we are strongwww.mpowergroup.eu

We believe that our corporate newsletter of the MPOWER company became for you an interesting source of information from theworld of valves. In case you have no interest in sending the newsletter or other commercial messages of our company, please informus via e-mail [email protected].

Documents

Business bulletin - MPOWER Group · Supply of high-pressure valves for ... Bodies of the check valves K05 are made ... Butterfly valves for the electric power plant Prunéřov II: