CCI DRAG Compressor Recycle Anti-surge Valve

Fast response with precise control.

Severe Service Anti-surge and Compressor Recycle Solution The optimum solution for safety and reliability, CCIs compressor recycle and anti-surge valve combines premium DRAG flow control technology with reliable fast stroking actuation. The result is a complete severe service valve solution designed to maximize the reliability, efficiency, and control of your compressor recycle system. Within this solution, the DRAG disk stack controls flow velocity to provide low noise and exceptional reliability. Flow energy and velocity is controlled to minimize wear and ensure reliable performance and longevity. Control is provided by CCIs fast acting
Figure 1: DRAG disk stack with multi-stage tortuous path gas flows shown in the lower portion and slotted cage in the upper portion.

pneumatic actuator which provides one second stroking times, fast and accurate control, and simple and reliable operation. Benefits of this proven design include: Fast actuation and continual control Reliable performance with proven technology Exceptional shutoff with minimized leakage Proven attenuation of noise and vibration

Customized DRAG Trim to Maximize Performance CCI custom-designed DRAG trim is ideally suited to minimize noise while providing the capacity and control that is necessary in anti-surge and compressor recycle applications. For these applications, the multi-stage DRAG disk stack is in the lower portion of the trim to provide control and maximize noise attenuation. Slotted or drilled-hole-cage trim can be provided in the upper portion of the stack to provide additional capacity for when compressor bypass is required in addition to anti-surge. Accurate Control and Reliable Operation CCIs long history of developing advanced technology valves and actuation
Figure 2: Forged body anti-surge valve with fast acting pneumatic actuator.

CCI DRAG Compressor Recycle / Anti-surge Valve

systems has led to the development of the most reliable pneumatic actuation system available for a severe service control valve. CCI has supplied this design worldwide for the past 30 years as a reliable, accurate, and fast acting control solution. For anti-surge and recycle applications, CCIs pneumatic actuation system can deliver stroke speeds of less than one second while maintaining precise resolution and control. Control systems on gas compression trains place great demands on the control valves within the process. Requirements for continual control, with the ability to provide full capacity within seconds, add to the strains on the valves in the system. CCIs compressor recycle and anti-surge solutions combine established trim and actuation designs to provide optimal performance and continued valve longevity.

Figure 3: Typical anti-surge system: A compressor anti-surge valve is controlled by inlet flow and differential pressure across the compressor.

Exceptional reliability.

Improve Plant Efficiency Eliminate Energy Waste During normal operation, any leakage past an anti-surge valve creates wasted energy and increased cost. A leaking anti-surge valve causes fluid to return to the suction side of the compressor, which causes the driver to work harder for the same output. Subsequently, the money spent compressing the additional gas is lost. CCI anti-surge DRAG valves are designed with either a soft or hard seat to ensure either an ANSI/FCI 70-2 Class VI or ANSI/FCI 70-2 Class V shutoff. This design provides dependable and repeatable shutoff for long periods of time over very high pressure differentials. The CCI anti-surge valve minimizes lost energy through leakage and lost production which results in significant cost savings.
Figure 4: Fast acting pneumatic actuator with accessories.

Capacity and Control for Anti-surge Applications For turbocompressors, the consequences of surge are severe. Surge is a powerful disturbance that can disrupt or trip a process. It can damage equipment, and in catastrophic incidents, may result in the complete destruction of the compressor rotor. To avoid compressor surge, selection of the correct control valve is mandatory. Because the consequences of surge are too costly to ignore, surge protection

100

Percent of Full Stroke Change

75

Stroke

is necessary for all turbocompressors. Properly sized and engineered antisurge recycle valves and their reliable operation are critical to protect the compressor. The valve capacity must be large enough to prevent surge under all possible operating conditions, including start-up and shut down, without being oversized. An excessively large valve will provide poor control precision and will drive the compressor into choked flow when fully open. The CCI anti-surge valve design maximizes control while providing reliable and safe protection from compressor surge.

CCI DRAG Compressor Recycle / Anti-surge Valve

Position Signal
50

25

Time (Seconds)

Figure 5: Valve Position vs Time Opening

Large Volume Booster

Pneumatic Actuator Double Acting

Quick Exhaust Valve

Small Volume Booster

Large Volume Booster

Large Volume Booster

Power Signal Exhaust

Input Signal

Valve Positioner

Figure 6: Optimized High Speed Actuator Control Schematic

Low noise and low vibration.

Long Stroke Exceptional resolution and fine control.

Bonnet Extension (Optional) Excellent for cryogenic applications.

Balanced Construction Minimizes thrust requirements and speeds actuation.

Multi-stage DRAG Technology Ensures low noise/vibration levels.

Expanded Outlet Lower fluid velocity.

CCI DRAG Compressor Recycle / Anti-surge Valve

Quick Change Trim Minimizes maintenance costs.

Soft or Hard Seat Repeatable tight shutoff.

Valve Performance Characteristics (% Cv vs. % Stroke)

Flow curves are custom characterized to accommodate a wide range of variables.

Linear Trim

High Capacity Bilinear Trim

Use this checklist to evaluate the benefits of CCIs compressor recycle/anti-surge valve.

Benefits

CCI DRAG

Competitors

One second stroke time to optimize performance and safety.

Precise control throughout the operating range of the valve.

Repeatable Class V or VI shutoff to minimize leakage.

CCI DRAG trim to control fluid velocity and minimize noise and vibration.

Control and capacity necessary to protect equipment during surge and bypass conditions.

CCI DRAG Compressor Recycle / Anti-surge Valve

Bilinear flow characterization available to eliminate the need for additional bypass valves.

Extended trim life through the reduction of flow velocity through DRAG trim.

Quick change trim to minimize maintenance costs.

Reliable design with proven CCI technology.

Technical specifications and materials.

Table 1: CCI Pneumatic Actuator Performance

Stroke Speed, Modulating

Fast, 1-2 Seconds

Emergency Trip

Less Than 1 second

BALANCE SEAL ORIENTATION

Resolution

Less than 1%
3

Thrust

3 to 5 Times Industry Standard Table 2: Materials Component Item No.

Reliability

Very Reliable and Robust

Materials of Construction Standard Optional

CCI DRAG Compressor Recycle / Anti-surge Valve

Body Maintenance Easy, with Medium Skills Bonnet Disk Stack (Cage) Plug Components Low Pressure, Reliable Accessories Stem Seat Ring Balance Seal

1 2 3 4 5 6 7

A105/WCB A105 316 SS 316 SS 17-4 PH 316 SS Teflon

A182-F316 A182-F316 316 SS 316 SS 17-4 PH 316 SS/Stellite Teflon

Table 3: Performance Data Standard Valve Characteristics (% Cv vs % Opening) Shutoff Class Actuator Type Stroking Speed Fail Mode Resolution Linear ANSI/FCI Class VI Double Acting Pneumatic Piston Less Than 1 Second Open <1% Optional Bilinear ANSI/FCI Class V Double Acting Pneumatic Piston Less Than 1 Second Open <1%

Application Details

Table 4: Typical DRAG Valve Applications In Compressor Recycle Service

Application
Gas Production
Separation

Differential Pressure

Temperature

Inlet/Outlet

300-3000 psi 2.1-21 MPa

100-200F 37-93C

4-12/6-16 100-300 mm/ 150-400 mm 4-8/6-8 100-200 mm/ 150-200 mm

Reinjection

3000 psi 21 MPa

100-150F 37-65C

Figure 7: Tortuous path punched disks within the DRAG disk stack control noise and vibration.

Gas
Hydrogen 70-300 psi 0.48-2.1 MPa 100-130F 37-54C 6-12/8-14 150-300 mm/ 200-355 mm 8-24/10-30 200-600mm/ 255-760 mm 4-8/6-12 100-200 mm/ 150-300 mm 4-16/6-24 100-400 mm/ 150-600 mm

Natural Gas

100-150 psi 0.69-1 MPa

100-120F 37-49C

Ammonia

50-100 psi 0.34-0.69 MPa

100-200F 37-93C

CCI DRAG Compressor Recycle / Anti-surge Valve

Air

50-700 psi 0.34-4.8 MPa

100-200F 37-93C

LNG
Propane 80-400 psi .55-2.7 MPa -94-248F -70-120C 8-24/10-24 200-600 mm/ 25-600 mm 12-24/18-32 300-600 mm/ 450-800 mm

Material Refrigerant

150-700 psi 1-4.8 MPa

-49-212F -45-100C

Olefins
Figure 8: Globe body anti-surge valve with fast stroking pneumatic piston actuator. Syngas 300-500 psi 2.1-3.4 MPa 100-120F 37-49C 4-8/6-10 100-200 mm/ 150-250 mm 6-16/8-16 150-400 mm/ 200-400 mm 4-6/6-10 100-150 mm/ 150-250 mm 6-8/8-12 150-200 mm/ 200-300 mm

Propane

50-150 psi 0.34-1 MPa

50-150F 10-65C

Ethylene

100-500 psi 0.69-3.4 MPa

20-50F -6-10C

Multicomponent

50-300 psi 0.34-2.1 MPa

100-150F 37-65C

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.

Sales and service locations worldwide.

CCI World Headquarters California Telephone: (949) 858-1877 Fax: (949) 858-1878 22591 Avenida Empresa Rancho Santa Margarita, California 92688 USA CCI Switzerland (Sulzer Valves) Telephone: 41 52 262 11 66 Fax: 41 52 262 01 65 Hegifeldstrasse 10 CH-8404 Winterthur Switzerland CCI China Telephone: 86 10 6501 0350 Fax: 86 10 6501 0286 Room 567/569 Office Tower, Poly Plaza 14 Dongzhimen South Avenue Beijing 100027 China CCI Korea Telephone: 82 31 980 9800 Fax: 82 31 985 0552 26-17, Pungmu-Dong Gimpo City, Kyunggi-Do 415-070 Republic of Korea CCI Japan Telephone: 81 726 41 7197 Fax: 81 726 41 7198 194-2, Shukunosho Ibaraki-City, Osaka 567-0051 Japan CCI Sweden (BTG Valves) Telephone: 46 533 689 600 Fax: 46 533 689 601 Box 603 SE-661 29 Sffle Sweden CCI Austria (Spectris Components GmbH) Telephone: 43 1 869 27 40 Fax: 43 1 865 36 03 Carlbergergasse 38/Pf.19 AT-1233 Vienna Austria CCI Italy (STI) Telephone: 39 035 29289 Fax: 39 035 2928246 Via G. Pascoli 10 A-B 24020 Gorle, Bergamo

Contact us at: info@ccivalve.com Visit us online at: www.ccivalve.com

DRAG is a registered trademark of CCI. 2003 CCI 274 01/03 7K