Control Valve Design & pp Applications

AGENDA

Introductions Control Southern/PMCC Team Local Support C Control Valve Design Pipeline Applications REXA XPAC Series 2 Electrohydraulic Actuators Pipelines Products for Isolation and Automation Needs Wrap-Up

Your Local Support Team

50 Years Experience as Fisher Controls Representative in Southeast Support S tl local l Pipeline/Terminals Pi li /T i l customers t including: i l di Atlanta Atl t Gas G Light, Li ht Colonial Pipeline, Dixie Pipeline, Plantation Pipe Line, and Transmontaigne Local Control Southern Application Engineers and Managers have years of f in-house i h knowledge k l d designing d i i flow fl control t l solutions l ti for f Plantation Pl t ti Provide On-site support during commissioning and if issues arise

REXA Representative in Southeast since 1993 Over 1,500 REXA actuator installations in SE since 1993 Full automation automation, set set-up, up and calibration capability Provide on-site support during commissioning and if issues arise

ISA Definition
A power operated t d device d i which hi h modifies difi the th fluid fl id fl flow rate t i in a process control system. It consists of a valve connected to an actuator mechanism that is capable of changing the position iti of f a flow fl controlling t lli element l ti in th the valve l i in response to a signal from the controlling system.

Selection Parameters
Pressure Ratings Temperature Considerations Capacity Shutoff Classifications Noise Considerations C Cost Considerations Pressure Drop Ratings Material Selection Flow Characteristics Cavitation and Flashing End Connections Maintenance Considerations

B16.34 vs. API 6D

ANSI B.16.34
The Fisher V260 fully meets the design criteria established by ANSI-B16.34. Specifically, ANSI now has ruled on a 3-piece ball valve and applicable wall section dimensions. Most pipeline ball valves originated in design to API - 6D criteria which only addresses stresses and test pressures with no specific wall thickness dimensional criteria. Some manufacturers appear to take a gray interpretation of ANSI B16.34 and actually publish compliance to that standard in their Sales brochures. The ANSI B16.34 B16 34 3-piece 3 piece ball valve criteria regarding minimum wall of 3-piece 3 piece ball valve now less subject to interpretation. interpretation Informational requirements are available on demand. It is our contention that certain manufacturers do not comply if audited to certify same. This issue should be of assistance in product differentiation of the new V260 ball valve. This is a complex issue to raise with a customer but many Oil & Gas Companies (Distribution and Transmission) are evolving their design standards for control valves from API-6D to ANSI B16.34. Some manual and power on-off devices are also under scrutiny. In summary ANSI B16.34 requires more metal in the valve body than API-6D. Control valves are energy absorbers by function as different from block valves. The additional metal in a control valve is generally a positive factor in systems design philosophy.

Oil Pipeline Application Capabilities

Common Oil Pipeline Control Valves

1. 2. 3. 4 4. 5. Pump Station Pressure Control Delivery Valve / Terminal Inlet Pressure Control Metering Balance Control Valves Back Pressure Control Valve Pump Recycle Valve
3 4 5 1

3 4 2

1 - Pump Station Pressure Control Valve Controls discharge pressure from pump stations
Requires wide rangeability with ability for accurate control

Most commonly y a 600/900# 16 24 V250/V260 Increased throughput requirements has increased pump p p discharge g p pressure beyond y 1500 p psig g Use of a control valve eliminates the need for variable frequency drives
Can be a 2x adder to the price of the pump

2 - Delivery Valve / Terminal Inlet Pressure Control Valve

Reduces pressure from main pipeline into terminal yard
Varying V i i inlet l t pressures with ith a 150 psig outlet pressure

Varying inlet pressures creates need for high turndown

Typically requires cavitation protection for higher dP cases Requires the use of a characterized attenuator to minimize valve size and maximize cavitation protection

Must be designed to accept electrohydraulic actuation

V260 Options

Dual seals & 2 stage domes

High Density Dome Full Attenuation thru 90 Linear Characteristic Characterized Dome Attenuation thru 65 Equal Percent Characteristic

3 - Metering Balance Flow Control Valves

Will be multiple meter runs into each terminal yard (2 to 11 parallel runs) Valves positioned to balance flow across all meter runs Turbine meters used with a maximum size of 16 16
Maximum capacity per run is 1650 m3/hr Line capacity p y limited to 40% - 80% due to turbine meter turndown

10 16 8560/8532 required
Accurate control desired to properly account for flow in and out of the facility

4 - Backpressure Control Valve

Valve controls backpressure (35 psig) on turbine meter runs to prevent cavitation in the meters Depending on head built up in tank farm, valve may experience cavitation / noise related issues V250 most commonly used, but V260 may be necessary if th there i is potential t ti l f for cavitation it ti

5 - Pump Recycle Valve

Recycles flow around the pump to protect against damaging g g cavitation Typical pressure drops up to 1500 psid 3 8 ET with Cavitrol III 2-stage trim the most common solution

Gas Pipeline p Application pp Capabilities

Gas Transmission

Three major types of gas pipelines: Gathering, Transmission, Distribution Used for transmitting Natural Gas to and from storage facilities and on to homes, power plants, etc. Most valves require noise attenuation due to high flow rates and proximity to people Particular materials are required to combat erosion/corrosion Applications include compressor anti anti-surge surge and flow/pressure control valves

Gas Transmission - Monitor Systems

In most cases, this is done with two valves in series that operate p off downstream p pressure
If one fails open, the other valve will take over control This requires proper sizing of the downstream valve to account for reduced inlet pressure

There are different types of monitors

Wide-open monitor system Worker/monitor system

Recombination of Flow Jets

Three small independent jets

Small jets recombine to form large jet: - lower p peak frequency q y - higher power - higher conversion efficiencies

Compressor Surge Overview

Compressor surge is minimum flow condition where the compressor becomes unstable Flow reversal occurs because there is not enough gas in the impeller to impart momentum Full flow reversals can damage the compressors bearings because of thrust reversals Damaged bearings can further damage the seals and impeller vanes due to internal rubs at high speed
Driver Compressor

ST FE FT

PT SC

PT

Antisurge Valve Issues

The valve must respond to trip signals in less than two seconds The valve is sized to twice its normal capacity p y The valve must handle wide flow variations The valve must provide stable and accurate control as close to the surge line as possible Excessive overshoot or undershoot may induce surge Higher surge margins mean costly recycle operation

Fisher E-body y with Whisper p t i or a V260A with trim ith an Aerodome attenuator are typical solutions

V260 Pipeline Severe Service Ball Valve with REXA Electraulic Actuation

V260 Pipeline Severe Service Ball Valve with REXA Electraulic Actuation (cont.)

X2
Xpac Series 2 Actuators ctuato s & Drives es

Xpac Series 2 Actuators

The Xpac self-contained microprocessor based electrohydraulic actuator integral control
More precise and stiffer than pneumatics More durable and higher duty cycle than electrical More compact and cleaner than conventional hydraulics

Electraulic was coined by REXA to describe this revolutionary l ti t technology h l

Simplicity of electric operation Power P of f hydraulics h d li Flexibility of user configured control

Xpac Series 2 - X2
Experience in the most demanding applications has developed extensive in-depth understanding of the product resulting in improved mechanical product reliability
One piece power module reduces the number of seals and fasteners improving reliability. Added gauges with isolation valves to standard units. Now incorporate pressure limiting valves to eliminate over pressuring the actuator and extend cylinder seal life. Motor seal installation is simplified and are now redundant for an extra level of protection. Terminal Strip connectors on Power Module.

Electraulic Electraulic Construction

Electrical Sub-Assembly Mechanical Sub-Assembly

Feedback

Motor

Power Module Cylinder

Control Enclosure Power Supply Feedback Signal Motor Power

Electrical Sub Assembly can be mounted up to 700 feet away from Mechanical SA

L Series - Linear Actuators

Cylinder bore determines thrust

Thrusts from 2000 200,000 , lbs force and strokes from .75 up to 108 Small sizes use REXA block cylinders
Up to 10,000 10 000 lbs force and 6 inch stokes

Larger bores & longer strokes use Commercial tie-rod cylinders

Double rod construction allows for constant cylinder volume Feedback is directly connected to rod free end to sense position

R Series - Rotary Actuators

Rack & pinion rotary cylinders Cylinder bore & quantity determines torque
(1 or 2 pairs of cylinder per rack)

Dual opposed cylinders allow for constant cylinder volume Feedback is connected directly to the actuator output shaft shaft.

Why are EH actuators common on Oil Pipeline Pressure Control Applications?

Thrust/Torque is too high for most pneumatics Repeatability, Frequency Response, Resolution requirements to catch/maintain pressure fluctuations exceed pneumatic actuator capabilities High cost and power requirements of compressor systems 100% modulating duty cycle requirement exceeds the capabilities gear actuators of Electric g No fail-safe options with Electric gear actuators Electro-hydraulic actuators do not have these limitations

ElectroElectro -Hydraulic Actuators

Are very fast acting. They offer very precise positioning. They are capable of continuous modulating service. They are capable of fail safe action action. They offer very high frequency response

Why Use REXA Actuators?

Low power consumption Self-contained hydraulics Standard of the industry Reliability Speed of response No scheduled maintenance Ease of Repair Repeatability of Performance 100% d duty t cycle l

Pressure Control Applications

Responsive line pressure control is essential for avoiding preventable line shutdowns due to pressure excursions Flexibility Fl ibilit i in pipeline i li operations ti requires i f frequent t changes in flow rates and delivery sites Specific S ifi valve l and d actuator t t d design i i is engineered i d to meet requirements for specific application in order to balance performance and cost

Pipeline & Engineering Firms using Fisher V260s and REXA Actuators

COLONIAL PIPELINE CO PLANTATION PIPE LINE CO KINDER MORGAN ENDBRIDGE BP FLUOR DANIEL INC. FLORIDA GAS TRANSMISSION ENERGY TRANSFER CONOCOPHILLIPS COMPANY BLACK & VEATCH INC MICHIGAN CONSOLIDATED GAS CO. PACIFIC PIPELINE SYSTEMS CONOCO INC NORTHERN BORDER PIPELINE HOWE BAKER ENGINEERS BROWN & ROOT-CONDOR S.P.A. ATHABASCA OIL SANDS PVDSA

RAMSEYER & MILLER INC COLORADO INTERSTATE GAS NORTHERN BORDER PIPELINE CHEVRON INC EXXON MOBILE WILLIAMS GAS PIPELINE SOUTHERN STAR CENTRAL GAS PETROBRAS BECHTEL CORPORATION ANR PIPELINECO ENTERPRISE FIELD SERVICES LLC ARCO ALASKA INC BEAUMONT PLANT IRVING OIL LIMITED KIEWIT INDUSTRIAL TRIGON CONSULTANTS