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Sebastian Puls
Product Manager Valves Uhde High Pressure Technologies GmbH
Germany
Optimization of Life Cycle Costs for a High Pressure
Valve through intelligent Design Concepts for Criti-
cal Operating Conditions
Sebastian Puls
UHDE High Pressure Technologies,
Hagen, Germany
Uhde High Pressure Technologies designs and manufactures valves and piping for the Urea industry
since 1960. Over the years Uhde HPT has co-operated with all major licensors and contractors in the
industry, like Stamicarbon, Snamprogetti, Toyo, Urea Casale, Kawasaki Heavy Industries, Mitsubishi
Heavy Industries, Chiyoda and Uhde GmbH. In these years Uhde HPT has gained vast experience on
the various requirements stipulated by licensors and contractors as well as on the actual plant per-
formance.
Introduction
According to the interaction of pressure, temperature and aggressive media the high
pressure part of the Urea process is the most critical section.
This leads to the fact that beside the reactors, the design and dimensioning of the
control valves of the high-pressure-synthesis has a particular importance.
In the past 10 years the plant capacities have almost been doubled and according to
the leading licensors this trend will continue in the future.
Industry is already considering capacities of 5000 mt/d and more.
This demand for higher capacities of the plants and tightened technical requirements
lead to larger and more complex valves.
The valve manufacture has to identify the critical parameter and design the most
suitable and cost optimized valve for the customer from the point of view of the life
cycle costs for a valve.
This includes:
• Design parameters and their influence on the lifetime of a valve.
• Corrosion
• Knowledge of the critical parameter “Cavitation”
• Implementation of counter measurements to extend the lifetime
• Repairing and overhauling of valves
• Stocking of spare parts
The intention of this paper is to allow plant operators and contractors to look at the
life cycle costs for a valve from the design till the decommissioning of the valves and
to get a feeling for the criteria to be taken into account having the most suitable valve
for the least possible life cycle costs.
- The capital cost (C) of a project includes the initial capital expense for equip-
ment, the system design, engineering, and installation. This cost is always
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considered as a single payment occurring in the initial year of the project, re-
gardless of how the project is financed.
- Maintenance (M) is the sum of all yearly scheduled operation and mainte-
nance (O&M) costs. Fuel or equipment replacement costs are not included.
O&M costs include such items as an operator's salary, inspections, insurance,
property tax, and all scheduled maintenance.
- The energy cost (E) of a system is the sum of the yearly fuel cost. Energy cost
is calculated separately from operation and maintenance costs, so that differ-
ential fuel inflation rates may be used.
- Replacement cost (R) is the sum of all repair and equipment replacement cost
anticipated over the life of the system.
- The salvage value (S) of a system is its net worth in the final year of the life-
cycle period. It is common practice to assign a salvage value of 20 percent of
original cost for mechanical equipment that can be moved. This rate can be
modified depending on other factors such as obsolescence and condition of
equipment.
For the Life Cycle Cost of a valve especially the Maintenance expenses (M) and the
extension of the lifetime for a valve have to be taken into consideration. The optimiza-
tion of the Life Cycle Costs already starts during the design of the valve.
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Of certain importance to increase the lifetime of the valve and therefore to reduce the
life cycle costs is the chosen material.
While defining the material for the valve body and for other internal parts that are in
direct contact with the media, the operator should be aware of the different limits of
corrosion rates. The obvious differences between the different types of materials are
highlighted below.
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The table shows that the corrosion rate varies up to 350% depending on the used
material and requested specification. A better corrosion resistance leads to a longer
lifetime and therefore could reduce the life cycle costs.
Beside the above mentioned materials the material SAFUREX or other premium al-
loys also have a positive effect on the reduction of the life time costs through their
good corrosion resistance.
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Cavitation occurs when the vapour pressure of the medium running through the valve
is between the inlet pressure P1 in the upstream and the outlet pressure P2 in the
downstream as shown in the picture 4 above.
The cavitation causes damages on the surface especially on the stem head and re-
duces the lifetime of the valve significantly in case no counter measurements are
taken into consideration. This life time reduction has again an influence on the life
cycle costs.
The technical solutions that are necessary to master the higher requirements will be
introduced in the next chapter. The above picture visualizes the case of occurring
cavitation.
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down time enormous. For the key valves it is therefore essential to have the main
spare parts on stock. Special spare part recommendations by the valve manufacturer
can help the plant operator to define the right parts and quantity.
The most common spare parts to be replaced during the lifetime of a valve are:
o the packing
o the base/ground ring
o the valve stem
o the valve seat (if available)
o the stuffing box body
o actuator parts.
Especially the packing system is one of the critical points of the valve that should be
replaced frequently during the use of the valve and when starting the process after a
maintenance period.
Besides the stocking of spare parts, it might be recommended to stock a complete
spare valve in order to secure the lowest shut-of time of the plant. This is mainly for
the critical control valves the case.
This on one hand increases the initial capital costs (C) but enables the plant operator
to act immediately and to reduce the shut-of time and in the same context increases
the plant efficiency.
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The shown angle valve has a diameter of 8inch, a pressure of 200 bars, a pneumatic
actuator and is designed for a temperature of 200°C.
UHDE`s angle valve portfolio contains the types on/off and regulating whereas the
regulating valves are available with an exchangeable seat. The dimensions reach
from 4–500 millimetres.
Beside angle type valves also a butterfly control valve is available shown in the pic-
ture below.
The shown butterfly valve has a diameter of 8inch, a pressure rating of 180 bars, a
pneumatic actuator and a design temperature of 210°C. UHDE´s range of butterfly
valves reaches up to a diameter of 12 inches.
The picture below shows an example for a check valve from UHDE`s product portfo-
lio.
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Sebastian Puls
The shown check valve has a diameter of 8inch, a pressure rating of 200 bars and
the valve is designed for a temperature of 205°C.
Different types of cones are available and the dimensions reach from 4–500, too.
Beside this standard portfolio a lot of special designed valves are available on cus-
tomer request.
Conclusion
During the past thirty years the design criteria and multitude of varieties increased
enormously so that the development of valves has become more complex. Due to the
possible valve varieties the valve manufacturer has to pay special attention to all de-
tails in order to meet the customer requirements enabling the operator to optimize the
life cycle costs of the valve. It should be taken into consideration that the initial costs
for a valve do not always offer the best solution. The plant operator should be aware
of the Life Cycle Costs and that he may be able to minimize the total costs of owner-
ship through intelligent design solutions, spare parts and smart maintenance strat-
egy.
Mastering the process of choosing the appropriate valve for each application for the
most optimized Life Cycle Costs is a joint effort that can ideally be guided by the ex-
perienced valve manufacturer.
As explained other criteria like maintenance costs, spare parts or the chosen material
may also have an influence on the overall life cycle costs are eventually the more
expensive solution.