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A Guide to Severe
Service Control
Valve Applications
in the LNG Process
2
The LNG Process
SEVERE SERVICE CONTROL VALVES A Brief History of LNG & NGL Production
CCI Control Valves 16 Liquefied Natural Gas (LNG) production started in the 1960s when it became
DRAG® Velocity Control Technology 18 clear that there was a need for long-distance overseas shipment of clean-
Severe Service Control Valve burning gas to be applied as a fuel for motor vehicles, or for residential and
Specifications for the LNG Process 20 industrial consumption.
Surge Control System 21 Before that time, natural gas was primarily transported via long-distance gas-
Control Valve Application: transmission pipelines on the main continents. This transport is obviously
limited to cross-country pipelining.
Compressor Recycle/Anti-surge 22
LNG from Arzew was primarily shipped to European countries and the USA.
The development and experience with the cryogenic gas tankers proved to
be very successful in moving large quantities of fuel from one continent to
another.
At the same time the major oil producers in the world started to consider
energy conservation. Gas was routinely flared before the early 1960s as a
useless by-product of oil production.
At this point in time, most of the associated gas (gas produced in conjunction
with crude oil) is being gathered and used for NGL and fuel-gas production.
The NGL, or Natural Gas Liquids, are exported as ethane, propane and
butane.
New gas finds in the world are still quite abundant and can provide for a
new source of long-term supply. Firm long-term supply contracts are the
cornerstone of the LNG industry; the investments are significant and involve
not only the provider of the liquefied gas but also the customer and the
shipping companies. All have to make very large investments in equipment
that is only suitable for one type of product —LNG.
The key suppliers of liquefied natural gas are at this point in time: Sonatrach
in Algeria (North Africa); PT Arun in Sumatra, Indonesia; PT Badak Bontang
in Borneo, Indonesia; Brunei-Coldgas in Brunei; Petronas in Bintulu Serawak
East-Malaysia; Woodside, in the northwest shelf of Australia; Qatar and Ras
Laffan in the Middle East; Atlantic LNG in Trinidad; and Bonney Island in
Nigeria. Smaller suppliers of LNG are Adgas on Das-Island in Abu-Dhabi;
and Libya and Alaska. With demand for LNG increasing, more suppliers are
expected to come online. The primary consumers are Japan and South Korea,
who have their prime sources in Australia, Indonesia, and the Middle East.
France, Spain, Italy and Belgium import primarily from Algeria. Taiwan,
Italy, and the USA import small quantities from Algeria. Most of the LNG
production facilities are increasing production by adding additional trains.
Royal Dutch Shell is the key author of many design specifications for
cryogenic service that most operating companies adhere to.
On the receiving end in Japan there are Tokyo Gas and Electric, Hiroshima
Gas, Osaka Gas and Nippon Gas. In Taiwan the terminal is operated by CPC
Kaohsiung and in France the main operator of the terminals is Gaz de France.
In the USA, Colombia Gas and Boston Gas are the main operators.
5
The LNG Process
Most modern plants do not contain fired boilers for steam generation. LNG
ACID GAS REMOVAL SULFER RECOVERY
LNG STORAGE & LOADING heated water is used in various process units where heat addition is required.
NGL SHIPPING
TO CUSTOMERS
LNG SHIPPING TO CUSTOMERS
anti-surge
propane
precooling
10
hp mp lp
7
3 4 lp
mp propane
precooling
1 rich amine
letdown hp
12 11
11
mcr-2
5 6
c3-3
8 11 12
11
c3-2 mcr-1
2
11
slug catcher
propane
c3-1
mcr
tank
7
tank
VENT TO
FLARE
1
SOUR GAS TO
ACID GAS
REMOVAL
P
SEPARATOR L
3
2
COLD SEPARATOR
CONDENSATE 2
WELL GAS STRIPPER L
COOLER
WATER
TO NGL
CONDENSATE
1
Figure 2A represents an acid gas removal system feeding multiple LNG
trains, two of the three blocks would be in service with the other in standby.
Unit sparing philosophy will be such that no single unit failure will result
in shutdown of all LNG trains. This philosophy is often referred to as n + 1,
where n is the total requirement for full production.
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.
3 The amine contactor process removes primarily H2S and COS. The Benfield
contactor process removes the CO2. The H2S rich sour gas from the amine
stripper acts as feedstock for the manufacturing of elemental sulfur. Figure 2
shows a typical treating unit.
VENT TO
FLARE
SWEET GAS TO
COMPRESSION AREA
3
CO2 H2S
CONTACTORS
SOUR GAS L
2
1
CO2 H2S
REMOVAL REMOVAL
Figure 2A: Acid Gas Removal System Figure 2: Acid Gas Removal Block
8
The LNG Process
Train capacities have increased over the past 15 to 20 years as have the size of
1
2 VENT TO
FLARE
COMPRESSOR RECYCLE
2
TO DEHYDRATION
VENT COOLER
TO FLARE 600 PSI
AMBIENT TEMPERATURE KO
HP STEAM
FROM STEAM
COMPRESSOR
BOILER
SWEET GAS KO
FROM ACID WATER
GAS REMOVAL
NOTE 1
TO LP
STEAM SYSTEM
WATER
The dryer vessels contain a catalyst which absorbs water. Typically, three
moisture analyzers are contained in the catalyst beds at 25%, 50%, and 75%
of bed height. These analyzers work on conductivity and indicate when that
There are no severe service valve applications in the dehydration unit. Most
of the valves associated with a molecular sieve are traditionally rising stem
ball valves. This valve is preferred due to its ability to maintain Class VI
Shutoff for a long time period in this service. Catalyst fines are very abrasive
and damaging to valve seats and the rising stem ball valve works well in this
service.
After the dehydration unit, dry gas will typically flow through a main gas
regulator valve and then be split up and regulated into the gas lines that feed
each of the LNG trains.
SH STEAM
CYCLE
REGENERATION VALVE
THROTTLING VALVE
KO
COOLER
1
DRY GAS TO
HYDROCARBON
1 PROCESSING
TRAINS
1
Figure 4: Dehydration
10
The LNG Process
Figure 5 shows 3 propane chillers, one for each compressor stage. Treated
dry gas is fed into the 1st stage chiller and is then routed through the chillers
to the propane compressors. The liquid feeds from the propane chillers are
shown being routed to an NGL stripper where the heavier of the hydrocarbon
It should be kept in mind that most of the control valves handling liquids
in the refrigeration circuits (not shown) are flashing. Vapor pressures in the
2
application will be near inlet pressure of the control valve. The main purpose
is cooling via flashing fluids in these units. Care must be taken to avoid under
sizing of the control valves in the refrigeration circuits of an LNG facility.
VENT TO
FLARE VENT TO
FLARE VENT TO
2 FLARE
2
3 STAGE PROPANE
PROPANE
COMPRESSOR 2
CONDENSOR
HELPER MOTOR
PROP. SURGE
DRUM
1 1
KO 1
H.P. KO
ECONOM
IZER
L.P. PROPANE
ECONOM RETURN
KO
IZER FROM MCR
KO ~ 30/40°C
NATURAL GAS
TO APCI EXCHANGE
CHILLER
3rd STAGE
CHILLER
2nd STAGE
DRY GAS FROM CHILLER 3
DEHYDRATION 1st STAGE
PROPANE
TO MCR CHILLER
NGL TO STRIPPER
TO MCR CHILLER
APCI Process
Figure 6 shows a typical LNG liquefaction unit based on the APCI process.
This exchanger, which is one of the largest vessels (except for storage),
contains multiple tube bundles which operate with a number of JT valves for
the liquefaction process. The feed gas that has been chilled down to about
-40 F (–40 C) is now practically all methane and ethane. In some cases there
may be some nitrogen in the gas stream as well.
The refrigerant used in this process (MCR) is a refrigerant that will flash over
1
TO STORAGE RETURN
TANKS 2 TO PROPANE MCR FROM PROPANE CYCLE
COMPRESSOR -30°C
LNG PRODUCT COOLER
-142°C 39 BAR
MCR
2 CHILLER
2 STAGE MCR
GT 1st 2nd
COMPRESSOR
1
1
MCR VAP
FROM NATURAL -31°C
GAS PROPANE KO
CHILLERS KO
-30°C 45 BAR MCR LIQ. -31°C
MAIN LNG
MCR VAP
EXCHANGER
-31°C
Liquefaction (continued)
PRICO Process
The PRICO (Poly Refrigerant Integrated Cycle Operation) was developed for
Sonatrach at Skikda, Algeria. The PRICO process is the only LNG process
with proven installations in a wide capacity range, from small peak shaving
to large base load plants. The process is jointly owned by Pritchard and Kobe
Steel LTD. The process is modular in nature and can be designed for a broad
range of capabilities to match available gas turbine drivers. Even with the
FRAME 7 machine, the capacity of the PRICO process is limited to about 1/3
of the APCI or Phillips process units presently being constructed.
Phillips Process
The Phillips process, a more recent process developed between Phillips and
Bechtel, is now being used at Atlantic LNG in Trinidad. This process, similar
to the PRICO process, separates more of the heavier hydrocarbons than the
APCI process prior to liquefaction.
A benefit of the Phillips process is its modular design making it suitable for
large capacity trains.
FEED GAS SUPPLY
GAS RECEIVING
GAS COMPRESSION
SULFUR SHIPPING
TO CUSTOMERS
DEHYDRATION
UTILITIES
FRACTIONATION
• STEAM
• ELECTRICITY HYDROCARBON PROCESSING
• WATER
NGL TREATMENT
• NITROGEN
• FIRE & GAS
NGL STORAGE
PRICO PROCESS PHILLIPS PROCESS
— ADDITIONAL — ADDITIONAL
HYDROCARBON HYDROCARBON NGL SHIPPING
PROCESSING PROCESSING TO CUSTOMERS
LIQUEFACTION
Table 7: Applications in LNG & NGL Storage LNG & NGL Storage and Loading
and Loading
Once the gas becomes a liquid, it flows into large insulated storage tanks.
“Boil-off” gas maintains temperature and pressure in the storage system.
Periodically the LNG is pumped into tankers through insulated pipelines.
A similar unloading process occurs when the tanker reaches its port of
destination.
The load-out line is equipped with multiple pumps, and it is not uncommon
to find as many as six load-out pumps. These pumps require approximately
80% of throughput to keep from overheating. Due to this and the large
An LNG facility will contain NGL storage tanks and loading facilities which
are very similar to LNG storage and loading. Unlike the LNG, NGL is stored
at ambient temperature and similar pressures. There are no severe service
control valves in the NGL storage and loading system.
ON/OFF
VALVE
THROTTLING
2 1 VALVES
FROM
LIQUEFACATION
1.2 BAR
-160 C
LNG
STORAGE TANKS
LNG TANKER
RECIRC.
There are two other units typically found in utilities: fuel gas system and fire
1
protection. The fuel gas system will have fuel gas vent to flare applications.
Depressuring System
These valves will vary in quantity in a facility, and will be sized for various
depressuring times. These valves are primarily used in fire situations where
2
hydrocarbon inventory is depressurized to the flare prior to the relief
valves opening. As such, most end-users and contractors will accept higher
noise levels under these conditions. Most often, 105 dBA is considered an
acceptable noise level with a minimum shutoff of Class V.
These valves are typically on-off and are sized to depressurize a given area of
the facility in 15 minutes to one hour. The solenoids on these valves may be
de-energize to trip. In some cases, dual energize-to-trip valves may be used
so that if either valve energizes, air will be vented off the valve actuator.
HEADER
1
DEPRESSURIZING
VENT GAS
TO FLARE
2
P
FUEL GAS PSI
HEADER PROCESS
VENT
MAKE-UP
PROCESS
The fill condition of the steam drum makes the feedwater regulator and
recirculation valves severe service valves. The boiler feedwater pump
3
discharge will be approximately 30% higher than the HP header. Until
steam pressure is established in the headers, the pressure differential is high
resulting in severe cavitation in the regulator and recirculation valve. This
will cause trim erosion which may lead to loss of control valve operation.
4
STEAM
VENT TO
ATMOSHPERE
HP STEAM
PROCESS
GAS
P
STEAM 3
VENT TO
ATM
DRUM COMPRESSED
GAS
4 P
MP STEAM
PROCESS
GAS
WATER STEAM 3
2 VENT TO
BFW ATM
COMPRESSED
GAS
4 P
1
LP STEAM
PROCESS
For gas to flare valves, tight repeatable shutoff has ensured that product/
feedstock has not been unnecessarily flared. A minimum of Class V
Shutoff, and frequently Class VI Shutoff, has been applied successfully for
this application.
CCI Produced a 30” DRAG® Feed Gas Regulator
Valve for Atlantic LNG in their RSM g CCI was a leader in the development of multi-stage noise standards.
USA Factory
Acceptable noise levels below 80 dBA have been met through CCI’s severe
service installations globally.
CCI control valves ensure an excellent system that is reliable and efficient.
The specifications on the following pages ensure that the above requirements
are met. Based on the ISA Practical Guide to Control Valves, they provide a
consistent method for ensuring system reliabilty and efficiency from the
severe service control valves.
Until the DRAG® valve was introduced, the design of control valves for
handling high-pressure drop liquids, gases, or steam had changed little.
Even today, despite widespread attempts to copy the CCI DRAG® solution,
other makers’ modified trim valves still flow process fluids through some
version of a single path (Figure 12) or multi-path orifice. In most cases, the
Taming Velocity
Fortunately, the solution is found in basic engineering principles.
The fluid in a valve reaches its maximum velocity just slightly downstream of
the valve trim’s vena contracta or minimum flow area. This high velocity in a
Figure 11: Uncontrolled Flowing Velocity—A
Control Valve’s Worst Enemy
single path or multi-path design can produce cavitation, erosion and abrasion
— all of which can quickly destroy the valve. Even before damaging the
valve, the symptoms of excessive noise, severe vibration, poor process control
Vena
and product degradation may be observed.
Contracta
Interestingly, the high velocity is an unwanted side effect of pressure
reduction through the valve and is not treated as a design criteria in other
V2 valves. Adding harder trim, pipe lagging or downstream chokes are costly
attempts to treat the symptoms rather than the real cause of the problem.
DRAG® velocity control valves from CCI solved the problem a generation
V1 ago. DRAG® valves prevent the development of high fluid velocities at all
valve settings. At the same time, they satisfy the true purpose of a final
V2 = 2gh control element: to effectively control system pressure over the valve’s full
stroke. Here’s how the DRAG® valve accomplishes what the others can only
V2 > V1
approach:
Figure 12: Single path g The DRAG® trim divides flow into many parallel multi-path streams
(Figure 13). Each flow passage consists of a specific number of right
angle turns—a tortuous path where each turn reduces the pressure of
the flowing medium by more than one velocity head. By increasing the
V1 number of turns, damaging velocity can be controlled while an increased
V2 pressure drop across the control valve can be successfully handled.
V1 = V2
Applying this principle to the DRAG® valve’s disk stack and plug as shown
V1 in Figure 15 means that velocity is fully controlled in each passage on
every disk in the stack and that the valve can operate at a controlled,
V2 = 2gh predetermined velocity over its full service range.
V1
V2
N Turns
V2 = 2gh/N
V1 = V2
Control Device A CCC controller reads all inputs in 10–15 ms. The controllers
output is averaged for three cycles, or approximately 40 ms
before a signal is sent to the valve.
Stroking speed for the recycle valve is typically specified as <2 seconds,
more than ten times the sensing and processing speed of the transmitter
and controller. However, a two second valve stroke speed is a value most
manufacturer find difficult to achieve without unstable operation. As a
compromise, they propose a three-to-five second stroke speed. Unfortunately,
this is not an acceptable compromise. Each additional (1) sec in stroke speed
can expose the compressor to 2-3 additional surges which are detrimental to
the compressor.
21
Severe Service Control Valves
Control Valve
Protection of Major Equipment Components
Technical Specification
The compressor is one of the most expensive pieces of equipment for an
LNG plant. A compressor can go into surge if the flow drops below 80% of
the rated flow. A well specified severe service control valve is required to
respond and open within one second to protect the compressor from surge
flow. Coupled with a good control system, the valve will provide a long life
Reference:
for the compressor. This has been proven at many installations in LNG plants
around the world.
This source treatment takes the entire pressure drop through one element
and attenuates the noise to the specified level without the use of downstream
devices, or silencers.
22
Severe Service Control Valves
Table 14: Joule Thomson (JT) Valves: Allows Compressed Gas to Expand for Refrigeration
g Rangeability >100:1
g Noise level less than 85dBA at 1 meter from valve
g Trim exit velocity head less than 70 psi (450 kpa)
Throughout the world, companies rely
on CCI to solve their severe service
control valve problems. CCI has provided
custom solutions for these and other
industry applications for more than
40 years.