SUMMER 2002

SPOTLIGHT ON OIL & GAS

PAGE 2-4
BAD VIBES
REPLACED WITH
SEVERE SERVICE
DESIGN

PAGE 4
CONTROLS A GAS
WITH CCI

PAGE 5
THE PRESSURES
OFF AT SECUNDA

PAGE 6
NOISE TAKES ON
GULLFAKS C TURNS
FOR THE BETTER
WITH DRAG

PAGE 7
CCI HELPS WILPRO
GO FULL THROTTLE

PAGE 7
TECHNOLOGY IS A
DRAG AT DAKOTA

PAGE 8
DRAG HELPS KEEP
THUNDER HORSE
UNDER CONTROL

Bad Vibes Felt at Offshore

Platform Replaced with
DRAG Design

VER SINCE INITIAL OPERATION IN MID-1998, the 8-in.

HOW DRAG

(200-mm) recycle valves in the main oil line (MOL) export

system Eastern Trough Area Project offshore platform had been

experiencing extreme vibration problems. This North Sea platform is

operated by BP AMOCO on behalf of its partners.

E L I M I N AT E S

Flow-induced vibration was extreme in the valves themselves, causing

excessive vibration as well as of the associated piping and structures.
The valves were suffering from continual failures in the gland-packing

H I G H V I B R AT I O N L E V E L S

assemblies, instrument and air supply tubing, and the mechanical and
electronic components of the position feedback control assemblies.
These MOL export pump recirculation valves were designed for a
maximum flow of 900,000 lb/hr (404,000 kg/hr) at inlet pressures
as high as 3200 psia (220 BarA) and Ps of 2900 psi (200 Bar) at
150 F (63 C).
After an evaluation of the problem in July of 1999 by JMDynamics,
it was recommended that the valves be replaced. However, for
operational reasons, this could not be immediately done. A reviseddesign trim replacement in these three-stage cage/diffuser valves was
accomplished, but this failed to mitigate the severity of the vibration
problem.
On May of 2001, JMDynamics was called in to again evaluate this
continuing vibration problem. The company used Southwest Research
Institutes (SRI) vibrationlevel criteria as a guide
only for the evaluation
of results from piping
vibration testing. These
provide vibration criteria
acceptance as a function
of frequency and use two
predominant levels of
acceptance.

Figure 1: The replacement A MOL recycle valve

Figure 2 A multi-stage pressure reduction

disk stack with individual disks showing the
right-angle, tortuous flow paths.

This is accomplished through multi-stage pressure reduction

(over 20 stages) within a stack of tortuous-path, electrodischarge-machined (EDM) disks containing a series of
sequential, right-angle turns, Figure 2. In addition, each disk
incorporates a pressure-equalizing ring (PER) on its inside

When these MOL

pumps startup
or shutdown,
the control
valves are 100percent open. From
a vibration point of view, this is
their most critical operating condition,

diameter to ensure that equal pressure acts radially around the

circumference of the plug at any position in its stroke. This
design keeps the plug centered at all loads, thus preventing plug
vibration that could cause galling and impede free stroking
motion.
Also, the actuator control is provided with a snap-action relay
which is set to reduce operating time of the valve at very low

and a maximum vibration level of 25 mm/sec RMS

(Continued on page 4)

was recorded in the horizontal direction on the control-assembly

mounting plate; the dominant frequency was 29 Hz.
At this point, JMDynamics original recommendation that
these valves be replaced with new CCI severe service valves was
instigated. These valves are specifically designed to minimize
vibration through limiting trim flow velocity for this severe, very
high P service.
Replacement Valve Design
To eliminate the destructive effects and potential dangers of
high vibration levels in the severe-service application, the new
replacement valves (Figure 1) are designed to limit trim fluid
velocities to less than 100 ft/sec.

Figure 3: A schematic of the two, parallel MOL pump recycle

systems showing the points of valve vibration measurement.

Table 1: A 1999 vs. 2001 comparison of the RMS vibration measurements on valve actuators and bodies taken in XYZ directions.

July 1999 Results*

Description

Location

Valve
Actuator

Valve A
Body

Valve B
Actuator

11

Valve B
Body

14

October 2001 Results*

Valve A

Valve A

Test 1

Test 2

100% Open

30% Open

A-100%, B-60%

B-100%, A-10%

24.7

4.5

2.1

17.4

8.4

3.1

4.0

1.2

1.6

8.6

1.4

0.7

0.6

10.3

1.4

1.4

1.4

18.6

1.3

12.5

2.9

2.6

16.1

4.4

3.8

1.2

6.8

0.9

0.8

8.0

0.9

0.8

0.7

* Pump and valve A operating only, no flow through pump or valve B

(Continued from page 3)

flows when the plug would be close to the seat. Under the
close seat/plug conditions, high, resultant fluid velocities
could result over time in seating surface erosion.

relatively comparable conditions. This vibration level reduction is

even more significant since the replacement valves operate at a higher
flow and pressure drop than the original valve. In addition, there is
now virtually no transmission of vibration energy to the piping and
support structure.

Results of Valve Replacements

Vibration levels were recorded not only at many points
throughout the MOL recycle valve associated piping and
support structures, but of course also on the two valve bodies
and actuators involved as indicated in Figure 3. Table 1
shows comparatively the root-mean-square (RMS), vibration
reduction by a factor of 10 at these valve locations between
the original valves tested in 1999 and the multi-stage
pressure reduction valves tested in October of 2001. Figure
4 shows a typical peak actuator vibration comparison under

Figure 4: A typical plot of before and after actuator peak vibration

spectra over a wide frequency range.

Controls a Gas with CCI

ONTROL VALVES IN THE GAS

DRAG valve. This creates a substantial overall reduction in maintenance costs and

TRANSMISSION INDUSTRY have

eliminates the need for low-end bypass control for most gas transmission applications.

traditionally sacrificed capacity and noise

At a minimum, Rotary DRAG technology will impact future design considerations for

for low-end control. For many systems,

gas interconnect, distribution and blending stations, as well as the basic design and

flow-impinging valves may seem the best

solution, but they dont offer both high

The valve industry realizes that designs

capacity and low-end control in optimal

utilizing expanding right-angle

ranges. This results in gas transmission

flow paths effectively reduce

organizations having to accept the

fluid velocities and provide

need for expensive bypass systems and

effective valve control.

The cost of this

the willingness to live with noise and

control has always

cavitation.

been capacity;

To address these needs, CCI has introduced

however, with the

the Rotary DRAG valve which marries

introduction of

the high capacity of a rotary valve and the

the CCI Rotary

proven multi-stage technology of DRAG .

DRAG valve, gas

With the potential for more than 28

transmission

stages of pressure reduction, the result is

groups will no

an axial flow control valve with very high

longer need

capacity, and low-end control that rivals

to make the

all other valves on the market. Now the

decision between

applications that traditionally utilized two

valve capacity and

valves in parallel will only need one Rotary

performance.

control philosophies used within the transmission industry.

The Pressures Off at Secunda

ASOL RECENTLY FACED A CHALLENGE WHEN ONE OF

The DRAG disk

THE VALVES INSTALLED AT ITS SECUNDA PLANT BEGAN

stack incorporates a

EXPERIENCING PROBLEMS. The plug on one of the existing valves

kept separating; this caused rotating and damaging of the plug, the

pressure equalizing
ring on its inside
diameter to ensure

seal ring, and jamming of the valve. The pin holding the stem also

equal pressure

came loose, requiring an efficient replacement at Secunda.

acting radially on

Understanding why a selected valve is not performing satisfactorily

the valve plug at all

times. This eliminates

is not always known and in many cases is accepted as the norm.

the vibration that could

Many attempts throughout the industry aim to resolve the

occur because of rapid plug

problems by addressing the effects of the damage. For example, the

radial movement.

use of harder materials when erosion and cavitation damage occur.

These solutions only marginally prolong the time at which failure

with design temperatures of 570 F (300 C). Incorporating

will take place. Problems like erratic control, noise, mechanical

DRAG technology, the disk stacks have pressure equalizing

vibration, cavitation, erosion, and short life are best solved by

ring (PER) grooves built into them and each disk is made with

controlling the cause of damage.

a land on the inside diameter so that localized pressure from

To overcome Secundas challenges, CCI provided a resolution that

would address the root cause of the problem with a customized
specification for the sites steam pressure application. Sasol
received two, 16-in. x 16-in. (400-mm x 400-mm) control valves

each disks outlet is equalized around the plug. This eliminates

radial forces on the plug which might otherwise cause binding
in under-the-plug applications and/or radial vibration and
buffeting in over-the-plug applications.

Rich-Amine Letdown in Refineries and Gas

Processing Plants

HE CHALLENGE OF THE RICH-AMINE APPLICATION IS

If a valves design is based on a

A COMPLEX ONE; the process begins when amine liquid is

presumed lower vapor pressure,

pumped into the top of a column and raw gas enters along the

catastrophic consequences can

bottom, passing through the amine liquid as it rises. This process

result, such as high mechanical

removes H2S and CO2 from the gas and absorbs it into the amine

vibration that shuts down

liquid, allowing the gas to leave the column clean and ready
for distribution or use in a refinery. The remaining amine at the
bottom of the column is now referred to as rich amine.

the train. DRAG technology

provides the number of pressurereducing stages required to limit
the kinetic energy produced,

The column is maintained under pressure to improve the

providing the needed reliability

efficiency of the absorption process. At this pressure and

to keep production running and

saturation point, the rich amine is a multi-constituent fluid with

producing profit.

a vapor pressure close to that in the column. As the fluid passes

through the rich amine letdown valve, the pressure drops across it,
causing the gases to be released from the amine.

Noise on Gullfaks C Takes a Turn

for the Better with DRAG

HEN STATOILS GULLFAKS C PLATFORM RECENTLY

observed. After this

UPRATED ITS COMPRESSORS, they revamped their

modification was

piping and replaced their compressor-recycle valves. During

initial testing on Train A in early October 2001, they observed

excessive noise levels as high as 126 dBA within the
revamped piping surrounding a new recycle valve and the valve
itself, Figure 1.

upon restarts of the

Train A compressor,
a significant noise
reduction was
observed (in excess

The piping revamp included five new elbows and two flange

of 10 dBA) such that

joints within 15-ft (4.5-m) of the valve inlet. It also included

the dominant noise

an 18.5-in. (455-mm) spool piece to reduce the pressure class

now seemed to be coming from the upstream side of the valve. The

just downstream of the valve. This was accommodated by a

dominant frequency remained at about 2000 Hz.

spool piece that included one 1500 ANSI flange joint, one 600
ANSI flange joint and a slight expansion in the spool itself to
accommodate the decrease in pipe wall thickness, Figure 2. The
flanged joints were all the ring-type joint (RTJ) design.

Figure 2

Based on this experience, it was concluded that the source of the

noise was probably not the valve, but rather the piping, and it
was further decided to install soft fill-in gaskets in the RTJ flanges
upstream of the recycle valve as well. This was carried out a few days

Because the high frequency noise was judged to be in excess

later during a scheduled compressor stop. New noise measurements

of 85 dBA, and the noise seemed to have a trigger point

were again taken that showed the previous high-frequency noise

associated with a specific valve lift, CCI was contacted by Statoil

in the piping system adjacent to the anti-surge valve had been

and Aker Engineering to assist in determining the source of

eliminated.

the noise. An audit confirmed that the valve should not be

producing the noise, and that there was no noticeable vibration
of the valve stem or actuator, something frequently related to
noise.

The final conclusion was that the noise arose solely from significantly
increased gas velocity in the piping following the uprated capacity
of the export compressor. When the gas velocity in the piping, as
determined by the valve opening position, became sufficient, it

Statoil and Aker Engineering contracted a consulting firm to

triggered a resonant frequency in the flange gaps (similar to blowing

learn about the specifics of the observed noise. They carried

across the top of an empty bottle).

out detailed and accurate noise measurements under varying

compressor and valve operating conditions. The dominant
noise frequency was 2000 Hz and the peak noise level was
126 dBA. This peak noise level occurred at the ANSI 1500/600
transitional spool piece. The noise level in the upstream piping
ranged from 112 to 115 dBA. Farther downstream, where the
piping was insulated, the noise level dropped off from 123 dBA
to 113 dBA.

completed, and

Checking conventional design rules for gas service pipe sizing also
showed that the
compressor uprating
had produced
a significantly
increased gas
velocity over normal
recommendations

It was decided that a spare valve made at the same time as the

for the pipe sizes

one at Train A would be disassembled and inspected while the

involved. It was

installed valve continued to be used for compressor testing. It

further concluded

was also decided that at the next shutdown, a flexible perfluoro-

that the anti-surge

elastomer filler material would be installed into the RTJ flange

recycle valves did

gaps at the inlet and outlet end of the spool piece to assess

not represent any

its impact on reducing the noise at that location. At that time,

significant noise

the installed valve could also be visually inspected through

problem in Satoils

the valve outlet to see if any constructional anomaly could be

current operations.

Figure 1

CCI Helps Wilpro Go Full Throttle

T WILPROS EL FURRIAL SITE

experiencing high noise levels during

IN VENEZUELA, gas to flare

venting, which in gas to flare can

valves were creating problems in

indicate a high-pressure drop that

production. These existing valves

results in shortened life and high

were suffering from gas leakage when

maintenance costs.

closed, and high noise levels during

For these reasons, El Furrial is

venting conditions that Wilpro found

replacing its valves with two, 14-in.

unacceptable.

(355-mm) 100D DRAG valves. With

design pressures up to 1350 psig (93

Leakage in the gas to flare application

bar) at temperatures that range up to

creates serious issues for a plant,

120 F (50 C), these replacements will

particularly since the products that

eliminate the possibility of excessive

need to be flared tend to be high cost

noise by using unique multi-passage

items. A constantly leaking valve also

trim designed to control high pressure

causes energy from the system to be

drop. In addition to this, the DRAG

lost, which increases plant costs. Even

valves are specifically designed for

a minute leak can grow quickly into

long-term shutoff, to avoid any

a large one, eventually affecting the

valves internal parts performance.
Additionally, El Furrial was also

unnecessary seat leakage.

A DRAG block angle valve similar in design to the
one supplied to El Furrial.

Technology is a DRAG at Dakota

T THE DAKOTA GASIFICATION

To address this issue, Dakota Gasification

COMPANY, AN EXISTING VALVE was

is replacing the valve with a 1-in. (25-mm)

experiencing erosion of the trim. This resulted

globe valve, specifically designed to handle

in high maintenance for the company, and

Dakotas application requirements. By

required a solution to handle the process

utilizing DRAG technology, the risk of

conditions of the Dakota Gasification

uncontrolled fluid velocity is eliminated

Company.

through the unique tortuous path trim

design. This controls fluid velocity by

Typical problems caused by incorrect

forcing the pressure drop to occur in

technology in severe service valves include

several stages, reducing it as it passes

premature trim and body erosion due to lack

through each channel and stage. The

of velocity control along the flow path. Trim

replacement valve will have design

damage reduces the trims ability to control

pressures of up to 1500 psig (103 bar) with

spraywater flow, which is why its important

temperatures up to 300 F (150 C).

to avoid high velocity areas. Avoiding this

occurrence allows for the life of the trim to
increase considerably.

CCIs unique DRAG design produces a highly

reliable and precise level of flow control to
eliminate the possibility of erosion problems.

DRAG Helps Keep

Thunder Horse Under
Control

P AMOCO DISCOVERED FOUR OIL FIELDS IN

THE GULF OF MEXICO, known as Atlantis, Mad Dog,
Holstein and Thunder Horse. Of these Thunder Horse

is the largest, located 6,000 ft (1830 m) in the Boarshead Basin.

With estimated recoverable oil of at least one billion barrels of

oil equivalent (boe), it is the biggest discovery ever made in the
Gulf deepwater.
To ensure that all equipment used in this project will have the
utmost reliability, BP Amoco chose DRAG valves for their water
injection pump recycle application. These four, 4-in. (100-mm)
100D angle valves have been designed for inlet pressures of up to
8600 psig (593 bar), with temperatures up to 200 F (93 C).
Challenging the project is the need for absolute reliability:
because most deepwater projects are justified by their huge

DRAG technology will be supplied to Thunder Horse, one of the

largest oil discoveries made to date by any company.

energy reserves, any loss of revenue as a result of unexpected

shutdown can easily exceed the high remediation cost.

Experience shows that fluid velocity control along the flow path,

poor process control that can result from excessive fluid velocities.

as in DRAG technology, is necessary for long-term reliable

This is why it is essential that the valve design features match the

performance. By combining CCIs unique capability to easily

specific application requirements. If this is not so, then there is

vary the number of disks in each stack, a DRAG valve eliminates

little hope that corrective actions after installation will be able to

problems such as trim and body erosion, noise vibration and

overcome the initial errors.

CCI World Headquarters

Telephone: (949) 858-1877
Fax: (949) 858-1878
22591 Avenida Empresa
Rancho Santa Margarita,
California 92688
USA

CCI Austria
(Formerly Spectres Components GmbH)
Telephone: 43 1 869 27 40
Fax: 43 1 865 36 03
Carlbergergasse 38/Pf. 19
AT-1233 Vienna
Austria

CCI Switzerland
Telephone: 41 52 262 11 66
Fax: 41 52 262 01 65
Hegifeldstrasse 10
CH-8404 Winterthur
Switzerland

CCI Italy
Telephone: 39 035 29289
Fax: 39 035 2928246
Via G. Pascoli 10A-B
24020 Gorle, Bergamo
Italy

CCI Sweden (BTG Valves)

Telephone: 46 533 689 600
Fax: 46 533 689 601
Box 603
SE-661 29 Sffle
Sweden

CCI Japan
Telephone: 81 726 41 7197
Fax: 81 726 41 7198
194-2, Shukunosho
Ibaraki-City, Osaka 567-0051
Japan

CCI China
Telephone: 6501 0350 0650
Fax: 6501 0286
Room 567/569 Office Tower
Poly Plaza
14 Dongzhimen South Avenue
Beijing 100027
China
CCI Korea
Telephone: 82 341 980 9800
Fax: 82 341 985 0552
26-17, Pungmu-Dong
Gimpo City
Kyunggi-Do 415-070
Republic of Korea

Visit us online at:

www.ccivalve.com
Contact us at:
info@ccivalve.com
All rights reserved. Solutions, DRAG and CCI
DRAG are trademarks of CCI. CCI valves are
manufactured under various United States and
international patents.

2002 CCI

518

8/02 10K