fcc reactor overhead line vapor isolation valve · what is a reactor overhead line vapor isolation...
TRANSCRIPT
FCC Reactor Overhead
Line Vapor Isolation Valve
Freddie Gines
Application Manager – North America
IMI Z&J – Houston, TX
‣ Outline
‣ What is a Reactor Overhead Line Vapor Isolation Valve
‣ Where is it located on a typical FCC unit
‣ Why install this valve on your unit
‣ Overview of key features
‣ Details of Internals
‣ How does it work
‣ Purge
‣ Design considerations, methods and characteristics
‣ Reference List
‣ Questions
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FCC Reactor Overhead Line Vapor Isolation Valve
What is a Reactor OverheadLine Vapor Isolation Valve
‣ Double Disc Through Conduit Gate Valve
‣ Valve has two separate, independent shut-off discs with an internal split-wedge-ball arrangement providing reliable operation and true double block & purge
‣ Full or reduced bore port
‣ Able to function in severe coking services
‣ Corrosion and wear resistant weld overlay on all seats
‣ The seat surfaces are completely protected from the process flow when in the open or closed position
‣ Active and controlled mechanical sealing force due to split-wedge-ball arrangement
‣ The internal wedge-ball arrangement gives discs clearance to move and minimizes the seat-to-seat friction and wear
‣ Open throughway has movable seat rings to allow for better sealing in the open position (bellows) minimizing effect of seat deflections due to line loads
‣ Any type of actuator can be used:
‣ Closed position: torque seated (torque switch); open position: position seated (limit switch)
‣ Patented design
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What is a Reactor OverheadLine Vapor Isolation Valve
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OpenOpenOpenOpen ClosedClosedClosedClosed
What is a Reactor OverheadLine Vapor Isolation Valve
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1B
1A8
Air
6
7
CatalystWithdrawal
1C
2
Wet Gas / LPG
Naphtha / Gasoline
LCO / Middle Distillate
HCO / Fuel Oil
PumpAround
BottomResidual
BottomDischarge
Pumps
Pumps
5
5
5
5
5
5
5
5
5
2
3 - Butterfly Valve
3A - Diverter Valve4 - Goggle Valve / Automatic Blind - Isolation
5 - High Performance Gate Valve (Double Disc) - Isolation6 - Catalyst Withdrawal Plug Valve - Control
7 - Catalyst Withdrawal Ball Valve - Isolation8 - Special Check Valve - Air Blower
3
1D
4
3
4
3
Reactor
Regenerator
Separator
Expander
OrificeChamber
Stack
ElectrostaticPrecipitator
CO Boiler orWaste Heat Boiler
Flue Gas Cooler
3
4
4
4
4
3A
43
3 4
4
1A - Regenerated Catalyst Slide Valve (Single Disc)1B - Spent Catalyst Slide Valve (Single Disc)
1C - Recirculated / Cooled Catalyst Slide Valve (Single Disc)1D - Flue Gas Slide Valve (Double Disc)2 - Double Disc Through Conduit (Double Disc) - Isolation
3A
Fractionator
Where is it Located on
a Typical FCC Unit
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Why Install it on YOUR Unit
‣ Safety
‣ Takes personnel out of the line of fire
‣ Allows for much safer conditions during fractionator blinding operations
‣ Quick Isolation of the Reactor from the Fractionator
‣ Valve can be stroked in minutes vs. hours or shifts
‣ Shortens Critical Path of Turnaround during Shutdown and Startup
‣ No need to cool down to isolate during shutdown
‣ Continue startup without delay after refractory curing
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ThroughwayThroughwayThroughwayThroughwayBodyBodyBodyBody
DiscSpringDiscSpringDiscSpringDiscSpring
Guide PlatesGuide PlatesGuide PlatesGuide Plates
StemStemStemStem
ActuatorActuatorActuatorActuator
Wedge Wedge Wedge Wedge MechanismMechanismMechanismMechanism
DiscDiscDiscDisc
Locking Locking Locking Locking PinPinPinPin
Overview of Key Features
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ThroughwayThroughwayThroughwayThroughway
StemStemStemStem
CarrierCarrierCarrierCarrier
Wedge Wedge Wedge Wedge MechanismMechanismMechanismMechanism
DiscDiscDiscDisc
Cup Cup Cup Cup SpringsSpringsSpringsSprings
Types of Internals
• Stationary
• Actuated
GuidesGuidesGuidesGuides
Overview of Key Features
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ThroughwayThroughwayThroughwayThroughway
StemStemStemStemCarrierCarrierCarrierCarrier
Wedge Wedge Wedge Wedge MechanismMechanismMechanismMechanism
DiscDiscDiscDisc
Cup Cup Cup Cup SpringsSpringsSpringsSprings
Actuated Valve Internals
Overview of Key Features
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Discs and Wedges
WedgesWedgesWedgesWedges---- 2 piece2 piece2 piece2 piece---- FloatingFloatingFloatingFloating
DiscsDiscsDiscsDiscs---- Overlay Overlay Overlay Overlay ----Stellite Stellite Stellite Stellite 6666---- FloatingFloatingFloatingFloating
StemStemStemStem---- “Tee” “Tee” “Tee” “Tee” HeadHeadHeadHead---- FloatingFloatingFloatingFloating
BallBallBallBall---- CenteringCenteringCenteringCentering---- FloatingFloatingFloatingFloating
Carrier Carrier Carrier Carrier Disc SpringsDisc SpringsDisc SpringsDisc Springs
Thrust WasherThrust WasherThrust WasherThrust Washer
Overview of Key Features
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Seal WeldSeal WeldSeal WeldSeal Weld---- Located on Located on Located on Located on upstream sideupstream sideupstream sideupstream side----Valve is unidirectional flowValve is unidirectional flowValve is unidirectional flowValve is unidirectional flow
Inner Sleeve PipeInner Sleeve PipeInner Sleeve PipeInner Sleeve Pipe----Maintains Maintains Maintains Maintains SSSSmmmmooooooootttthhhh FFFFlllloooowwww PPPPaaaatttthhhh----Bellows ProtectionBellows ProtectionBellows ProtectionBellows Protection
Seat RingsSeat RingsSeat RingsSeat Rings---- FloatingFloatingFloatingFloating- OverlayOverlayOverlayOverlay
---- Stellite #6Stellite #6Stellite #6Stellite #6
Expansion BellowsExpansion BellowsExpansion BellowsExpansion Bellows----Single orSingle orSingle orSingle or
Multi ConvolutionMulti ConvolutionMulti ConvolutionMulti Convolution
Throughway
Bellows Spring PacksBellows Spring PacksBellows Spring PacksBellows Spring Packs
FLOW
Overview of Key Features
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Stuffing Box Details
Lip SealsLip SealsLip SealsLip Seals
Live Load SpringsLive Load SpringsLive Load SpringsLive Load Springs
StemStemStemStem
Lantern RingLantern RingLantern RingLantern Ring
Packing GlandPacking GlandPacking GlandPacking Gland
BushingBushingBushingBushing
EmergencyEmergencyEmergencyEmergencyInjection PortInjection PortInjection PortInjection Port
PackingPackingPackingPacking
Packing Gland FlangePacking Gland FlangePacking Gland FlangePacking Gland Flange
Overview of Key Features
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Locking Pin DetailsLocking PinLocking PinLocking PinLocking Pin
Locking PinLocking PinLocking PinLocking Pin
Hole in CarrierHole in CarrierHole in CarrierHole in Carrier
Overview of Key Features
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Position Indicators
Position IndicatorPosition IndicatorPosition IndicatorPosition Indicator
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Details of Internals
CarrierCarrierCarrierCarrier
DiscDiscDiscDisc
WedgeWedgeWedgeWedge
BallBallBallBall
TTTT----HeadHeadHeadHeadStemStemStemStem
Details of Internals
DiscDiscDiscDisc
CarrierCarrierCarrierCarrier
TTTT----HeadHeadHeadHead
StemStemStemStem
WedgesWedgesWedgesWedges
Thrust WasherThrust WasherThrust WasherThrust Washer
Jam NutJam NutJam NutJam Nut
Stem NutStem NutStem NutStem Nut
Disc SpringsDisc SpringsDisc SpringsDisc Springs
Details of Internals
StemStemStemStemCarrierCarrierCarrierCarrier
Wedge MechanismWedge MechanismWedge MechanismWedge Mechanism
DiscDiscDiscDisc
DiscSpringsDiscSpringsDiscSpringsDiscSprings
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Details of Internals
StemStemStemStem
Wedge MechanismWedge MechanismWedge MechanismWedge Mechanism
DiscDiscDiscDisc
CarrierCarrierCarrierCarrier
Cup Cup Cup Cup SpringSpringSpringSpring
Details of Internals
Discs and Wedges
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Details of Internals
Throughway
Throughway Downstream ForgingThroughway Downstream ForgingThroughway Downstream ForgingThroughway Downstream Forging
Throughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingSeat OverlaySeat OverlaySeat OverlaySeat Overlay
ThroughwayBellowsThroughwayBellowsThroughwayBellowsThroughwayBellows
Details of Internals
Throughway
Throughway Downstream ForgingThroughway Downstream ForgingThroughway Downstream ForgingThroughway Downstream Forging
Throughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingSeat OverlaySeat OverlaySeat OverlaySeat Overlay
ThroughwayLinerThroughwayLinerThroughwayLinerThroughwayLiner
Spring Pack Spring Pack Spring Pack Spring Pack Mounting HoleMounting HoleMounting HoleMounting Hole
Details of Internals
Throughway Spring Pack
Set ScrewSet ScrewSet ScrewSet Screw
Mounting StudMounting StudMounting StudMounting Stud
Disc SpringsDisc SpringsDisc SpringsDisc Springs
Lock RingLock RingLock RingLock Ring
AdjusterAdjusterAdjusterAdjuster
Lower BoltLower BoltLower BoltLower Bolt
Upper BoltUpper BoltUpper BoltUpper Bolt
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Details of Internals
Throughway
Throughway Downstream ForgingThroughway Downstream ForgingThroughway Downstream ForgingThroughway Downstream Forging
Throughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingSeat OverlaySeat OverlaySeat OverlaySeat Overlay
ThroughwayLinerThroughwayLinerThroughwayLinerThroughwayLiner
Spring PacksSpring PacksSpring PacksSpring Packs
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Details of Internals
Throughway
ThroughwayThroughwayThroughwayThroughwayDownstream ForgingDownstream ForgingDownstream ForgingDownstream Forging
Throughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingThroughway UpstreamForgingSeat OverlaySeat OverlaySeat OverlaySeat Overlay
ThroughwayLinerThroughwayLinerThroughwayLinerThroughwayLiner
Spring PacksSpring PacksSpring PacksSpring Packs
Details of Internals
Bellows Sleeve
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Details of Internals
Throughway Live Loading Bellville Washer Spring Assemblies
F F
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Details of Internals
ThroughwayThroughwayThroughwayThroughway
StemStemStemStem
CarrierCarrierCarrierCarrier
Wedge MechanismWedge MechanismWedge MechanismWedge Mechanism
DiscDiscDiscDisc
Disc SpringsDisc SpringsDisc SpringsDisc Springs
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Details of Internals
Carrierfor Discs and
Throughway
Assemblies
29
Stationary Valve Internals
Details of Internals
Guide PlatesGuide PlatesGuide PlatesGuide Plates
Guide Plates Guide Plates Guide Plates Guide Plates ----Free FloatingFree FloatingFree FloatingFree Floating
on Body Bosses on Body Bosses on Body Bosses on Body Bosses
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Details of Internals
StemStemStemStem
DiscDiscDiscDisc
CarrierCarrierCarrierCarrier
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Details of Internals
Internals Installed in the Body
32
Details of Internals
33
‣ Permanent & continuous purge flow through the valve body must be maintained under all process conditions
‣ Open
‣ Closed
‣ Stroking
‣ The purge pressure shall be throttled and maintained at approximately 7 psi above the operating process pressure for the following reasons:
‣ Avoids particle entry into the valve body and prevents build-up on internal parts in the open position
‣ Provides additional sealing against leakage in the closed position (double block and purge)
‣ Maintains the valve body cavity free of debris so that the valve can stroke freely
‣ Purge media is typically superheated steam or N2
‣ Purge steam pressure shall never exceed the design pressure of the body.
Purge
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Purge – Automatic
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• Mitigation against coking of the internal working components
• Protecting seats from Erosion & Coking while the valve is in the open position
• Valve body must be designed to resist line loads
• Double Block & Purge Isolation to allow for the quick / safe installation of a blind
• Typical mounting orientation – Valve: Vertical Stem, Line: Horizontal
• Valves can range in size from 6” to 100”
• Pipe installation connections: Welded or Flanged
• Materials of construction are based on customer specifications and design
conditions
• Cast refractory and/or erosion resistant lining can be used to further protect the
valve body and throughway
• Valve sealing performance.
Design Considerations, Methods and Characteristics
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Design Considerations, Methods and Characteristics
Typical Materials
Label Description
A SA-516 Gr 70; shell; 1 inch; no corrosion
B SA-516 Gr 70; shell; 1 inch; 1/16 inch corrosion
C SA-516 Gr 70: 1/16” CA removed on ID surfaces solid
D SA-387 Gr 11 CL2; shell; 2 inch; no corrosion
E SA-387 Gr 11 CL2; shell; 2 inch; 1/16 inch corrosion
F SA-105; 1/16” CA removed on ID surfaces solid
G SA-182 F11 CL2; 1/16” CA removed on ID surfaces solid
H SA-36; see Figure 3; no corrosion
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Design Considerations, Methods and Characteristics
Structural MeshThermal Mesh
38
Finite Element Results
Stress Profile Thermal Profile
Design Considerations, Methods and Characteristics
39
Design Philosophy - Distortion Analysis
Design Considerations, Methods and Characteristics
40
Design Considerations, Methods and Characteristics
41
Design Considerations, Methods and Characteristics
Contact Assessment FEA – Inlet Seats
Design Pressure + Line Loads Design Pressure42
Design Considerations, Methods and Characteristics
Contact Assessment FEA – Inlet Discs
Design Pressure + Line Loads Design Pressure43
FCC Reactor OverheadLine Vapor Isolation Valve
100” FCC Reactor Overhead Line Valve
Design and Final Assembly 44
100” FCC Reactor Overhead Line Valve Installation
FCC Reactor OverheadLine Vapor Isolation Valve
45
88” FCC Reactor Overhead Line Valve
Design and Final Assembly
FCC Reactor OverheadLine Vapor Isolation Valve
46
88” FCC Reactor Overhead Line Valve Installation
FCC Reactor OverheadLine Vapor Isolation Valve
47
FCC Reactor Overhead
Line Vapor Isolation Valve
World Wide
Reference List
Size Operation
in psi bar °F °C Electric / Manual
1 North America 1994 36 50 3.45 1030 555 Manual
2 Europe 1995 16 40 2.76 890 477 Electric
3 Europe 1995 28 40 2.76 1022 550 Manual
4 North America 1997 48 31 2.14 1050 566 Manual
5 Asia 1998 78 59 4.07 1050 566 Manual
6 North America 1999 30 35 2.41 1050 566 Manual Bevel Gear
7 North America 2000 52 40 2.76 1150 622 Manual Bevel Gear
8 North America 2001 36 50 3.45 1050 566 Manual Bevel Gear
9 North America 2001 48 50 3.45 1020 549 Manual Bevel Gear
10 North America 2002 44 46 3.17 1050 566 Manual Bevel Gear
11 Europe 2003 48 60 4.14 1076 580 Electric
12 North America 2004 36 45 3.10 1200 649 Electric
13 North America 2005 30 50 3.45 1050 566 Manual Bevel Gear
14 North America 2005 48 45 3.10 1050 566 Manual Bevel Gear
15 North America 2005 24 45 3.10 1050 566 Manual Bevel Gear
16 North America 2005 66 45 3.10 1050 566 Manual Bevel Gear
17 Asia 2007 60 40 2.76 932 500 Electric
18 Asia 2007 78 60 4.14 1050 566 Manual Bevel Gear
19 North America 2008 48 45 3.10 1050 566 Manual Bevel Gear
20 North America 2008 48 45 3.10 1050 566 Manual Bevel Gear
21 North America 2008 60 45 3.10 1050 566 Manual Bevel Gear
22 Africa 2009 36 50 3.45 750 399 Manual Bevel Gear
23 Europe 2010 36 50 3.45 1050 566 Manual Bevel Gear
24 Asia 2010 72 50 3.45 1050 566 Electric
25 North America 2011 24 45 3.10 1025 552 Electric
26 North America 2012 26 50 3.45 1025 552 Electric
27 Europe 2012 26 50 3.45 1025 552 Electric
28 Asia 2012 66 56 3.86 1067 575 Electric
29 Europe 2012 30 50 3.45 1050 566 Electric
30 North America 2012 (x2) 50 50 3.45 1050 566 Electric
31 North America 2013 44 40 2.76 1025 552 Electric
32 North America 2013 42 50 3.45 1025 552 Electric
33 Asia 2013 100 50 3.45 1125 608 Electric
34 Asia 2014 88 70 4.83 1050 566 Electric
35 Europe 2014 60 66.7 4.60 1049 565 Electric
36 Asia 2015 75 79.8 5.50 1049 565 Electric
37 Asia 2015 42 79.8 5.50 1049 565 Electric
38 North America 2015 76 50 3.45 1050 566 Electric
39 North America 2016 52 45 3.10 1050 566 Manual Bevel Gear
40 North America 2016 36 75 5.17 1050 566 Electric
41 North America 2017 28 40 2.76 1025 552 Electric
42 South America 2017 30 48.3 3.33 1000 538 Electric
43 North America 2017 30 75 5.17 1050 566 Electric
Design P Design TYear
ManufacturedContinent
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