petroleum handbook

Oil & Gas Hand Book

Refinery & LNG

HYDROCRACKING PROCESS FLOW DIAGRAM

PETROLEUM REFINERY

Application: Hydrogen makeup compressor recycle valve – Hydrocracker Unit

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Process

The Hydrocracker unit is fed with hydrocarbon liquid and hydrogen and the compressor is for feeding hydrogen to the reactor. The hydrogen / hydrocarbon feed blend is typically heated in a fired heater and sent to the reactors where the cracking reaction occurs. After heat exchange, the hydrocarbon products are separated from hydrogen and light gases in a series of separators and flash drums. Hydrocarbon products are further processed in a fractionation section. The reactions taking place in the Hydrocracker process include cracking, whereby long chain hydrocarbons are broken into smaller chains, and hydrogenation, where any free radicals or double bonds are saturated. The end result is a hydrocarbon product whose average molecular weight is much smaller than the molecular weight of the feed.

Typical Valve Installation Schematic

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ts Common Valve Problems

Reliability

High pressure drop, noise & vibration

Leakage across the valve

Wear of the valve trim

Clogging / sticking of the valve

Inadequate response times

Instability in valve operation

Key Requirements

Tight shutoff – typically ANSI Class V or VI

Fast stroking – typically less than 2 sec opening, often in modulation mode

Pneumatic actuation

Stability – min overshoot with no oscillation

Multi-stage trim for velocity control

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CCI Value Proposition

Trim velocity Control

Bi-linear Trim

Quick Response Trim.

Stable actuator control.

Repeatable shutoff

CCI Application Benefits

Low noise & vibration

Better process control

Reliability

High performance

Low maintenance

High compressor efficiency

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Fisher: Trim Up to 3-stage trim, limited noise reduction, uses diffuser, muffler or silencer.

Mokveld: (RZD-RCX/RQX 1 or 2-stage cage) (RZD-RMX multi-stages), 1 or 2 stage cage, uses diffuser,

Valtek – Tigertooth, Limited stages, short stroke, Poor resolution, Linear stack

Masonelian – 72000 Series Valve with V-Log Trim

CC

I Ref

eren

ce References

ExxonMobil –Malaysia

Petronas – Malaysia

Pertamina, P.T. Badak NGL Co.

Shell International Petroleum, Brunei

Sarawak Shell BHD., Bintulu, Malaysia, MLNG Tiga, Mlng-Dua gas inlet facility

PETROLEUM REFINERY

Application: Cold High Pressure Separator Letdown in Hydrocracker Unit

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Process

The hydrocracking process converts (or cracks) heavy feedstocks into lighter components by selective reactions with hydrogen in multiple heated catalyst beds. The process is most commonly used to create gasoline or diesel product streams.

The incoming gas oil feed is heated in a furnace to reaction temperature. It is combined with a recycle hydrogen stream before flowing through the reactor with multiple catalyst beds. Additional recycle hydrogen is added between each bed to control the cracking conversion. The reactor effluent is sent to high-pressure, then low-pressure separators. The vapor from the separators is recycled through a compressor back to the feed. Makeup hydrogen is added to this stream as necessary. The liquid from the low pressure separator is sent to a fractionator where the reactor effluent is separated into component product streams.


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Common Valve Problems:

High pressure drop, flashing service causes vibration & trim wear

Solids (corrosion product) in the service cause erosion & clogging problems

High temperature sour service limits material selection

Variable flow rates due to startup, shutdown & variable feedstock

“Condensate” is a mixture of oil & water with gas at a high vapor bubble point

Typical CCI Valve Design

Body: Typically material which can survive severe erosion & corrosion – e.g. F 347

Plug: Tungsten Carbide or equivalent high erosion material.

Trim: Inconel 718 providing high erosion & corrosion.

Actuation: Double Acting Piston Actuator.

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DRAG® trim to Reduce trim velocities, erosion & vibration

Trim to Handle different pressures & fluids during startup

Large flow passages to pass residual solids

Disk stack made from Inconel 718, 316SS/HP plug are suitable for NACE

High force cylinder operator for optimum stiffness & control


DRAG Velocity control – controlled valve velocities limit damage due to velocity erosion.

Plug made of solid tungsten carbide minimizing effect of erosion due to coke particles.

Specialized Disk design to prevent clogging.

High force piston cylinder for optimum control & stiffness.

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Fisher : DST Trim in the appropriate valve body

Masoneilan : Axial flow Lincoln Log Anti cavitation Trim

PETROLEUM REFINERY

Application: Hot High Pressure Separator Letdown in Hydro Cracker Unit

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Process

The hydrocracking process converts (or cracks) heavy feedstocks into lighter components by selective reactions with hydrogen in multiple heated catalyst beds. The process is most commonly used to create gasoline or diesel product streams.

The incoming gas oil feed is heated in a furnace to reaction temperature. It is combined with a recycle hydrogen stream before flowing through the reactor with multiple catalyst beds. Additional recycle hydrogen is added between each bed to control the cracking conversion. The reactor effluent is sent to high-pressure, then low-pressure separators. The vapor from the separators is recycled through a compressor back to the feed. Makeup hydrogen is added to this stream as necessary. The liquid from the low pressure separator is sent to a fractionator where the reactor effluent is separated into component product streams.


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Primary Function: Level Control

The selected valve sees high pressure drop as the separator is under high pressure & the fractionator is under vacuum.

The feedstock is multi constituent with high vapor pressure resulting in severe flashing.

There is a carryover of at least of 1% catalyst & traces of H2S & NH3 making it highly corrosive.

The media has a high concentration of coke particles making is erosive.

Start up & Shut down modes.





Actuation: Double Acting Piston Actuator

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Lower ownership cost of the valve.

Fewer plant downtimes due to valve failure.

Efficient control of the process.






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Masonelian 77000 – Cage Guided Technology

Fisher Dirty Service Trim – Axial flow Cage Guided 3 Stage plug

Fisher 461 Sweep Flo – 1 Stage plug

SchuF GmBH 74CS - 3 stage plug.

Ref

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Pertamina – Bolongan, Indonesia

Pertamina – Cilacap, Indonesia

CATALYTIC REFORMER PROCESS FLOW DIAGRAM

PETROLEUM REFINERY

Application: Hydrogen Compressor Recycle Valve in Catalytic Reforming

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Process

Catalytic reforming is a process used in petroleum refining to increase the octane rating of naphtha so it can be used for gasoline blend stocks. In this type of process, there are three reactors stacked on top of each other so that the catalyst pellets can be moved from reactor 1 to 2 and from 2 to 3. From reactor 3 the catalyst is regenerated by burning off (1000°F) coke formed in the reactors. The catalyst is then returned, or adjusted, then sent to the No.1 reactor. The catalyst (pellets) normally takes one day to be regenerated and adjusted before returning. Hydrogen is circulated through the reactors with the naphtha feed to minimize the formation of coke on the catalyst. This Hydrogen Recycle Compressor service can be suitable for CCI Anti surge valve application.


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Common Valve Problems

Reliability







Key Requirements



Pneumatic actuation



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Bi-linear Trim



Repeatable shutoff




Reliability

High performance

Low maintenance

Avoids lost in production


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Fisher : Trim Up to 3-stage trim, Limited noise reduction, uses diffuser, muffler or silencer.

Mokveld: (RZD-RCX/RQX 1 or 2-stage cage) (RZD-RMX multi-stages), 1 or 2 stage cage, uses diffuser, limited noise reduction

Valtek – Tiger tooth

Masoneilan-72000 Series valve, with V-Log Trim

Ref

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ExxonMobil –Malaysia





H2S & CO2 STRIPPER PROCESS FLOW DIAGRAM

PETROLEUM REFINERY

Application: H2S/CO2 Stripper Loop Sour Water Letdown Valve

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Process

An additional output of the CHPS is sour water, which is sent to the sour water flash drum to remove residual hydrogen-sulphide and ammonia. In this instance the pressure must be reduced from approximately 100bar to atmosphere, flashing occurs and the entrained catalysts and H2S and NH3 can cause severe erosion.


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Problems

Fluid normally flashing or out gassing with entrained catalyst

There is a carryover of catalyst & traces of H2S & NH3 making it highly corrosive.


Vibration due to high pressure drop across the valve


Body: Typically material which can survive severe erosion & corrosion.




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Fisher: NotchFlo DST with HP valve model

SchuF: Model 74BS X-Flash

Masoneilan 78200 and 18200 Series valve with Lincoln Log Trim

Ref

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Pemex – Mexico

Chevron – El Segundo

PETROLEUM REFINERY

Application: H2S/CO2 Stripper Loop Lean Amine Pump Recirculation Valve

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Process

After absorption of H2S and CO2 in Amine Contactor, rich amine is sent to Amine regenerator. In the regenerator, the acidic components are stripped by heat and reboiling action and, and the is recycled. Regenerated amine called as LEAN AMINE, is then fed back to the contactor tower and the cycle continues.


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Primary Function: Lean Amine Pump Protection

Lean amine recirculation valve maintains the minimum NPSH for the pump. Typical parameters (P1= 50 - 205 bar g, T1= 115 – 125 Deg C, P2=6 bar g)

Due to high pressure drop and temperature and fluid being water with corrosive amine, cavitation is of high probability leading to high vibration, noise and high erosion.

Maintain high leak tightness in order to avoid wastage of pump energy.


Body: Body material which can survive severe erosion and corrosion. Eg. A182 316, CF8M, A479-316.

Plug: High erosion resistant A 276-XM19, UNS31803.

Trim: High erosion and corrosion resistant, Inconel 718, UNS31803.

Actuation: Double acting piston cylinder for accurate positioning, with higher stem diameter to reduce vibration.

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HIGH MTBF & Low MTTR




Specialized Disk design with sufficient stages to reduce effect of cavitation.


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Taoyuns Refinery - China

Ulsan 1000 - Korea

Reliance Refinery - India

PETROLEUM REFINERY

Application: H2S/CO2 Stripper Loop Rich Amine Letdown Valve

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Process

Amine, often called MEA or DEA, is a chemical liquid used to remove contaminants such as hydrogen sulfide (H2S) and carbon dioxide (CO2) from raw gas. The amine liquid is pumped into the top of a column. The raw gas enters through the bottom of the column and, as it rises, the raw gas passes through the amine liquid. In this process, the H2S and CO2 are absorbed in to the amine liquid and are removed from the gas. This process is similar to carbon dioxide being absorbed into a carbonated beverage. The gas leaving from the column is referred to as “clean” and is sent for distribution or use in the refinery. The amine at the bottom of the column is referred to as rich amine. This level control valve is referred to as the rich amine letdown valve.


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Rich amine let down valve controls the level in the absorption column (T-35 to 50 Deg C, Pr. 5 to 205 bar) to the flash tank (115 to 126 deg C, Pr. 1.4 to 1.7 bar)

Due to high pressure drop, outgassing occurs in the valve making the media two phase flow which causes high vibration, noise, high erosion, due to increased velocities.

Amine itself is corrosive in nature and along with absorbed H2S and CO2 & increased velocities, cause accelerated corrosion.






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Specialized Disk design to accommodate two phase flow.


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Ref

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ASMI Dal

La Maqyina

Pertamina, PT. BADAK NGL Co. Trains A to H

Shell Brunei & Sarawak shell BHD, Malaysia.

HYROTREATING PROCESS FLOW DIAGRAM

PETROLEUM REFINERY

Application: Feedstock Pump Recycle Valve in Hydrotreating Unit

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Process

Hydro processing is used for removal of unwanted constituents from feedstock using a catalyst bed. The High pressure reactor removes unwanted components like Sulphur & Nitrogen are removed by a catalytic process & hydrogen rich gas is flashed & sent for further processing. The reactor is operated under high pressures with temperatures upwards of 400 Deg C.

The feedstock pump which feeds to the feedstock requires minimum flow to avoid the pump from getting overheated and to avoid cavitation and Feedstock Pump recycle valve is used to maintain the minimum required flow for the pump.


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ts Control valve Problems:

High pressure drop causes vibration & trim wear

Solids (catalyst, coke, corrosion product) in the service can cause problems with lo-DB cage guided trim

Leakage across the valve causes energy loss & can limit production rates


Body: Typically material which can survive severe erosion & corrosion




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DRAG® trim to Reduce trim velocities & eliminate cavitation, & erosion

Reduced vibration improve seal life

Large flow passages to pass residual catalyst, coke, & other solids

High force cylinder operator for optimum stiffness & tight shutoff





High force piston cylinder for optimum control & stiffness

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Masoneilan: 78200 series valve with Lincoln log trim.

PETROLEUM REFINERY

Application: Hydrogen Compressor Recycle Valve in Hydrotreating Unit

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Process

Hydrogen is used in the refining industry primarily as feed for reactors to avoid coke deposition on the catalyst and to provide enough hydrogen to avoid the production of olefins. Most of the hydrogen is recycled through the process. There are several refining processes such as hydrodesulphurization, Hydrotreating /hydro cracking processes that require hydrogen recycle compressors in their process.


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Reliability







Key Requirements



Pneumatic actuation



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Bi-linear Trim



Repeatable shutoff




Reliability

High performance

Low maintenance



Extended life

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Masoneilan -72000 Series valves with V-Log Trim

Ref

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ce ExxonMobil –Malaysia





PETROLEUM REFINERY

Application: Hot High Pressure Separator Letdown in Hydrotreating Unit

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Process

Hydro processing is used for removal of unwanted constituents from feedstock using a catalyst bed. The High pressure reactor removes unwanted components like Sulphur & Nitrogen are removed by a catalytic process & hydrogen rich gas is flashed & sent for further processing. The reactor is operated under high pressures with temperatures upwards of 400 Deg C.

The feedstock is recovered and sent to flash drum or fractionators for further processing.

Typical feedstock media coming out of separator is 3-phase. The media has entrained H2S & NH3.


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The selected valve sees high pressure drop as the separator is under high pressure & the fractionator is under vacuum.

The feedstock is multi constituent with high vapor pressure resulting in severe flashing.

There is a carryover of at least of 1% catalyst & traces of H2S & NH3 making it highly corrosive.


Start up & Shut down modes.






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SchuF GmBH 74CS - 3 stage plug.

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s Pertamina – Bolongan, Indonesia

Pertamina – Cilacap, Indonesia

PETROLEUM REFINERY

Application: Cold High Pressure Separator Letdown in Hydrotreating Unit

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Process

In a typical refinery, the cold high pressure separator (CHPS) separates the rich hydrogen gas, which is sent to the recycle compressor, from the liquid effluent. The liquid phase is separated into recoverable products and sour water. The recoverable products are sent to the fractionation tower or low pressure separator through the CHPS letdown valve. The letdown valve controls the level in the separator as flow moves to the fractionation column. Many separators also include a sour water separation section. In some processes, these valves may dump the liquid effluent from the HHPS and the CHPS to a low pressure separator (HLPS or CLPS) before flowing to the tower. Utilizing a low pressure separator allows additional removal of hydrogen and light hydrocarbons.


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High pressure drop, flashing service causes vibration & trim wear

Solids (corrosion product) in the service cause erosion & clogging problems

High temperature sour service limits material selection

Variable flow rates due to startup, shutdown & variable feedstock

“Condensate” is a mixture of oil & water with gas at a high vapor bubble point






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DRAG® trim to Reduce trim velocities, erosion & vibration

Trim to Handle different pressures & fluids during startup

Large flow passages to pass residual solids

Disk stack made from Inconel 718, 316SS/HP plug are suitable for NACE

High force cylinder operator for optimum stiffness & control






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Fisher : DST Trim in the appropriate valve body

Masoneilan: 78200 and 18200 Series Lincoln Log Valves.

Schuf: Model 74TS- Multistage Pressure control valve

LNG Process

ACID GAS REMOVAL PROCESS FLOW DIAGRAM

LNG

Application: H2S/CO2 Stripper Loop Lean Amine Pump Recirculation Valve

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Process

After absorption of H2S and CO2 in Amine Contactor, rich amine is sent to Amine regenerator. In the regenerator, the acidic components are stripped by heat and reboiling action and, and the is recycled. Regenerated amine called as LEAN AMINE, is then fed back to the contactor tower and the cycle continues.


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Primary Function: Lean Amine Pump Protection

Lean amine recirculation valve maintains the minimum NPSH for the pump. Typical parameters (P1= 50 - 205 bar g, T1= 115 – 125 Deg C, P2=6 bar g)

Due to high pressure drop and temperature and fluid being water with corrosive amine, cavitation is of high probability leading to high vibration, noise and high erosion.

Maintain high leak tightness in order to avoid wastage of pump energy.






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Specialized Disk design with sufficient stages to reduce effect of cavitation.


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Ref

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Taoyuns Refinery - China

Ulsan 1000 - Korea

Reliance Refinery - India

LNG

Application: H2S/CO2 Stripper Loop Rich Amine Letdown Valve

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Process

Amine, often called MEA or DEA, is a chemical liquid used to remove contaminants such as hydrogen sulfide (H2S) and carbon dioxide (CO2) from raw gas. The amine liquid is pumped into the top of a column. The raw gas enters through the bottom of the column and, as it rises, the raw gas passes through the amine liquid. In this process, the H2S and CO2 are absorbed in to the amine liquid and are removed from the gas. This process is similar to carbon dioxide being absorbed into a carbonated beverage. The gas leaving from the column is referred to as “clean” and is sent for distribution or use in the refinery. The amine at the bottom of the column is referred to as rich amine. This level control valve is referred to as the rich amine letdown valve.


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Rich amine let down valve controls the level in the absorption column (T-35 to 50 Deg C, Pr. 5 to 205 bar) to the flash tank (115 to 126 deg C, Pr. 1.4 to 1.7 bar)

Due to high pressure drop, outgassing occurs in the valve making the media two phase flow which causes high vibration, noise, high erosion, due to increased velocities.

Amine itself is corrosive in nature and along with absorbed H2S and CO2 & increased velocities, cause accelerated corrosion.






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Specialized Disk design to accommodate two phase flow.


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Ref

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ASMI Dal

La Maqyina

Pertamina, PT. BADAK NGL Co. Trains A to H

Shell Brunei & Sarawak shell BHD, Malaysia.

LNG

Application: Acid Gas Removal – Vent to Flare

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Process

The acid gas removal system removes the sour gas components – hydrogen sulfide (H2S), carbon dioxide (CO2) and carbonyl sulfide (COS) – from the raw feed gas. This operation prepares the feed gas for further processing.


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Primary Function

Limits noise and vibration caused by high pressure drop ratio with high mass flow

Ensure minimum leakage to flare

Used during plant startup to establish a reliable gas flow

Relieve excess pressure during upset conditions and depressurize the system during shutdown

Quick stroke requirement to prevent plant trip during load rejection

Key Requirements

Reduced noise and vibration to reduce the failure of valve trim and piping

Allow lesser Leakage

Very Fast Stroking Time

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Leakage Class VI or Class V

Quicker Stroke Time



Reliability

Low maintenance

Extended life

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Mokveld: (RZD-RCX/RQX 1 or 2-stage cage) (RZD-RMX multi-stages), 1 or 2 stage cage, uses diffuser,

Valtek – Tigertooth,

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MLNG – Malaysia

Saudi Aramco - UAE

Qatar Fertilizer - Qatar

MCR UNIT PROCESS FLOW DIAGRAM

LNG

Application: Antisurge valves in MCR (Mixed Component Refrigeration) cycle.

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Process

The adjacent figure shows a typical MCR cycle. Natural Gas cooled upto -40 deg C is brought into main LNG exchanger. This compression requires an intercooler and chiller, shown pictorially, to reject the heat from the liquefaction cycle to the environment. The high pressure MR is partially condensed in the chiller before flowing into the spiral-wound main cryogenic heat exchanger (MCHE) (not shown). In this exchanger this stream is continuously cooled and condensed tube-side against the cold, LP mixed refrigerant stream. Once condensed the cool high pressure MR is expanded. The cold expanded MR returns to the MCHE as the cold stream and continuously cools the warm refrigerant stream and cools, condenses, and subcools the incoming high pressure, dry natural gas. The warmed, vaporized, LP MR then leaves the MCHE and returns to the first stage of the refrigerant compressor to complete the cycle.


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Low temperatures







Key Requirements



Pneumatic actuation



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CCI Value Proposition Trim velocity Control

Bi-linear Trim

Quick Response Trim. Stable actuator control.

Repeatable shutoff




Reliability

High performance

Low maintenance



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Ref

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HYDROCARBON PROPANE RECYCLE PROCESS FLOW DIAGRAM

LNG

Application: Antisurge valves in Propane cycle

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Process

The treated & dry natural gas obtained from the dehydration unit is fed in to the propane compression section to remove most of the natural gas liquids. There could be 1, 2 or 3 stage propane compressors in the cycle, or a single, huge, gas turbine driven compressor, for precooling of the natural gas and condensation of heavier NGL. The gas is cooled down to a temperature of around -30 to -40 deg C. This pre-cooled gas is then sent for liquefaction and sub cooling in further stages using MCR as the refrigerant.


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Low temperatures







Key Requirements



Pneumatic actuation



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Bi-linear Trim



Repeatable shutoff




Reliability

High performance

Low maintenance



Extended life

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DEHYDRATION PROCESS FLOW DIAGRAM

LNG

Application: Turboexpander Bypass – JT Valve

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Process - Demethanizer

Turbo expanders are high efficiency devices which are used in LNG to for separation of Natural Gas Liquids ( Eg. propane, butane & ethane) from natural gas. High pressure gases undergo isentropic expansion in turbo expanders. During this process the gases get cooled as they pass through and work is produced as a by product. Gases get cooled sufficiently enough, that the temperature falls below the dew point of many of the heavier constituents resulting in condensation.

J-T valve is used as bypass to turbo expander. Gases undergo similar cooling process, but in an isenthalpic pressure reduction. Here no work is done. This valve is used for more efficient startup and shut down of turbo expanders. Also if the expander reached full capacity, additional requirement can be taken care of, by the J-T Valve.

P1 – 48 to 103 bar

P2 – 13.8 to 48.3 bar

Temperature - down to (-160 Deg C)

Typical Installation Schematic:

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Primary Function: Bypass Full Capacity OR Make UP GAS

Ensure smooth Startup and Shutdown and used if capacity

of turbo expander is reached.

High Pressure drop causes high noise and vibration.

Valve should posses same characteristic and capacity as

that of the turbo expander.

Body and trim material selection is important due to low

temperatures

Possibility of hydrate formation

Typical CCI Valve Design:

Body: Typically material which can survive low temperatures. Eg : A 351 CF8M, LCC

Plug: SS 316 Stellited

Packing : Special extended bonnet with special packing


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CCI Value Proposition:




CCI Application Benefits:



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Fisher Whisper I, Whisper III or Whisper Flow trim in Cryogenic E body.

Masoneilan 72000 series with V-LOG Energy management or Lo-DB Trim

Valtek – Tiger tooth Design

Ref

eren

ce Qatar, Ras Laffan, Adgas

Petronas

PT ARUN

PT Badak Bontang

Brunei Cold Gas

petroleum handbook

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