LNG

A Guide to Severe
Service Control
Valve Applications
in the LNG Process
2
The LNG Process

THE LNG PROCESS Introduction: What is LNG?

INTRODUCTION 2 When natural gas is cooled to a temperature of approximately –256 F

A Brief History of LNG
PROCESS UNITS OF AN LNG PLANT
SEVERE SERVICE APPLICATIONS
THROUGHOUT AN LNG PLANT
3 (–160 C) at atmospheric pressure it condenses to a liquid called liquefied
natural gas (LNG). One volume of this liquid takes up about 1/600th the
5
volume of natural gas at a stove burner tip. LNG weighs less than one-half of
water, actually about 45% as much. It is odorless, colorless, non-corrosive,
and non-toxic. When vaporized, it burns only in concentrations of 5% to

A Guide to Severe Service Control Valve Applications in the LNG Process

Gas Receiving 6
15% when mixed with air. Neither LNG nor its vapor can explode in an
• Vent to Flare
unconfined environment. LNG is a safe and efficient way to transport gas
• Separator Level Control
across long distances and bodies of water.
• Gas Intake/Regulator
Acid Gas Removal 7 Composition
• Rich Amine Letdown Natural gas is composed primarily of methane (typically, at least 90%),
• Lean Amine Recirculation but may also contain ethane, propane and heavier hydrocarbons. Small
• Vent to Flare quantities of nitrogen, oxygen, carbon dioxide, sulfur compounds, and water
Gas Compression 8 may also be found in “pipeline” natural gas. The LNG process removes the
• Compressor Recycle oxygen, carbon dioxide, sulfur compounds, and water. The process can also
• Vent to Flare be designed to purify the LNG to almost 100% methane.
Dehydration 9
• Gas Regulator Have There Been Any Serious LNG Accidents?
Hydrocarbon Separation First, one must remember that LNG is a form of energy and must be respected
Propane Cycle 10 as such. Today LNG is transported and stored as safely as any other liquid
• Compressor Recycle fuel. Before the storage of cryogenic liquids was fully understood, however,
• Vent to Flare there was a serious incident involving LNG in Cleveland, Ohio in 1944. This
Liquefaction 11 incident virtually stopped all development of the LNG industry for 20 years.
• Compressor Recycle The race to the Moon led to a much better understanding of cryogenics and
• Joule Thomson cryogenic storage with the expanded use of liquid hydrogen (–423 F /
LNG & NGL Storage and Landing 13
–253 C) and liquid oxygen (–296 F / –182 C ). LNG technology grew from
• Compressor Recycle
NASA’s advancement.
• Joule Thomson
Utilities and Depressurizing System 14 In addition to Cleveland, there have been two other U.S. incidents sometimes
• Fuel Gas Vent System attributed to LNG. A construction accident on Staten Island in 1973 has been
• Emergency Depressurizer cited by some parties as an “LNG accident” because the construction crew
Steam Boiler 15 was working inside an (empty, warm) LNG tank. In another case, the failure
• BFW Recirculation of an electrical seal on an LNG pump in 1979 permitted gas (not LNG)
• BFW Regulator to enter an enclosed building. A spark of indeterminate origin caused the
• Steam Head Pressure Control building to explode. As a result of this incident, the electrical code has been
• Steam Vent revised for the design of electrical seals used with all flammable fluids under
pressure.

SEVERE SERVICE CONTROL VALVES
CCI Control Valves
DRAG® Velocity Control Technology
Severe Service Control Valve
Specifications for the LNG Process
Surge Control System
Control Valve Application:
Compressor Recycle/Anti-surge
Vent to Flare
Steam Vent
Amine Handling
Joule Thomson
Depressurizing
Steam Header Pressure Control
Separator Level Control
Gas Intake/Regulator
3
The LNG Process
A Brief History of LNG & NGL Production
16 Liquefied Natural Gas (LNG) production started in the 1960s when it became
18 clear that there was a need for long-distance overseas shipment of clean-
burning gas to be applied as a fuel for motor vehicles, or for residential and
20 industrial consumption.
21 Before that time, natural gas was primarily transported via long-distance gas-
transmission pipelines on the main continents. This transport is obviously
limited to cross-country pipelining.
22
A Guide to Severe Service Control Valve Applications in the LNG Process
Natural gas was introduced in the USA on a large scale just after W.W.II.
23
Europe started a few years later when large quantities of natural gas were
23
found in Western Europe, the North Sea and many other locations on that
24 continent. Major gas finds in Siberia led to long distance gas-transmission
24 systems all over Western Europe. Algerian gas was pipelined across the
Mediterranean Sea to Italy. Many developing countries like Japan, however,
25
could not benefit from those pipeline systems, as there was no local gas
25 source of significance in the area available to them.
26
The need for clean-burning energy became a high priority for Japan, so a
27 program was developed to ship natural gas in liquefied form from overseas
sources. Sonatrach in Algeria was the first operator to install a natural gas
liquefaction project in Arzew, which was called the Camel project. This
project was recently rejuvenated (early 1990s) and is now called GL4Z.
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.
Ethane is primarily a feed-stock for the petrochemical industry, while
propane and butane are mainly used as LPG (liquefied petroleum gas) for
motor fuel and residential fuel in rural areas. Another important application
for LPG is its use as “peak-shaving” gas in natural gas distribution systems
during periods of high consumption.
4
The LNG Process

The fuel-gas often supports a petrochemical industry in the country of

production. It is very suited for the production of chemicals like methanol
and a large number of chemicals based on that product. It is a key source
for ammonia production and nitric acid, which leads to the production of
artificial fertilizers and many related chemicals. As a last resort, the lean-gas
can be re-injected into the oil producing formation to maintain a sufficiently
high pressure in the oil field and support the future oil-production efficiently.

A Guide to Severe Service Control Valve Applications in the LNG Process

Surpluses of this gas, however, could theoretically be liquefied for export use.

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.

The major contractors involved in LNG projects are KBR, Bechtel

International, Technip, Snamprogetti, Nippon-Kokan, Chiyoda and JGC.
New to this field are the local contractors in Malaysia and Indonesia like
PT Int. Karya Persada Tehnik (IKPT) that has been deeply involved in
expansions in Badak as the prime contractor. The major participants in LNG
projects are Royal Dutch Shell, Exxon Mobil, Phillips-Petroleum, British
Petroleum, Total, Mitsui Gas and Atlantic LNG.

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

FEED GAS SUPPLY

Process Units of an LNG Plant
GAS RECEIVING

Most modern plants do not contain fired boilers for steam generation. LNG
ACID GAS REMOVAL SULFER RECOVERY

facilities such as Bontang in Indonesia utilize fired boilers to generate steam

GAS COMPRESSION
SULFER SHIPPING
TO CUSTOMERS for driving the compressors.
DEHYDRATION
UTILITIES
FRACTIONATION
• STEAM
• ELECTRICITY
• WATER
HYDROCARBON PROCESSING The more modern plants contain waste heat recovery units associated with
NGL TREATMENT
• NITROGEN
• FIRE & GAS LIQUIFICATION the tailpipe exhaust system of the gas turbine. This low-pressure steam and
NGL STORAGE

LNG STORAGE & LOADING heated water is used in various process units where heat addition is required.
NGL SHIPPING
TO CUSTOMERS
LNG SHIPPING TO CUSTOMERS

A Guide to Severe Service Control Valve Applications in the LNG Process

1. choke
2. compressor anti-surge
3. gas-to-flare blowdown 13
4. line depressurizing
5. flow pressure regulator
6. import pressure - flow regulator 9 13
9
7. level control
8. depressurizing gas-to-flare 8 8 14
9. lean amine pump recycle
min. flow control
10. export pressure - flow regulator
11. compressor anti-surge
12. hot gas bypass
13. joule-thomson letdown
stripper
stripper

14. boil-off-gas compressor

CO2
H2S

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

production processing liquifaction transport

Applications in LNG Processing

6
The LNG Process

Table 1: Applications in Gas Receiving Gas Receiving

The gas receiving facility, often referred to as a slug catcher, receives the
product from the gathering station and consists of multiple sloped pipe
sections. The sour gas is taken from the top end of the sloped pipe to the
first separator. Condensed water and hydrocarbon is drained to the second
and third separators where the water is separated from the condensed
hydrocarbon.
1
It is not uncommon to find a small refrigeration unit to allow for additional
condensation of the water from the hydrocarbon condensate.

A Guide to Severe Service Control Valve Applications in the LNG Process

The separators, usually three or four in series, provide separation of the water
and hydrocarbon condensate. Sour gas is also pressure controlled from the
separators to gas treating.
2
The hydrocarbon condensate is usually routed to a condensate stripper where
the light components are stripped from the heavier products. The heavy ends
of the stripper (NGL) are routed to storage and sold as a separate product.
This product may enter a pipeline to an additional processing unit but is most
often loaded onto condensate or NGL tankers. The lighter hydrocarbon is
routed to the gas treating plant.

When starting a unit or train it is required to establish a reliable gas flow,

3
which is accomplished using a vent valve to flare. After sufficient flow is
established the flow is diverted from the flare to the treating area.

VENT TO
FLARE

1
SOUR GAS TO
ACID GAS
REMOVAL

P
SEPARATOR L
3
2

FROM GAS GATHERING

COLD SEPARATOR

CONDENSATE 2
WELL GAS STRIPPER L
COOLER

WATER
TO NGL

CONDENSATE

Figure 1: Typical Gas Receiving System PRODUCED WATER

TO DISPOSAL
 7
The LNG Process

Table 2: Applications in Acid Gas Removal Acid Gas Removal

In some LNG facilities, an acid gas removal unit will be contained in each
liquefaction unit (LNG train). In other LNG facilities, a large acid gas
removal unit will feed multiple LNG trains.

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.

A Guide to Severe Service Control Valve Applications in the LNG Process

2

The acid gas removal processes are typically Licensor packages.

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.

Figure 2 is a simplified sketch of a treating block in Figure 2A. This sketch

shows one contactor and flash drum, but there will be several sets of this
equipment. Figure 2A illustrates a possible configuration that may be
required based on feed gas composition.

Each of the blocks in Figure 2A is a grouping of equipment similar to that in

Figure 2. Multiple sets of this equipment may be required based on the flow
through the facility and the amount of the unwanted component in the feed
gas composition.

VENT TO
FLARE
SWEET GAS TO
COMPRESSION AREA

3
CO2 H2S
CONTACTORS

REMOVAL REMOVAL SOUR GAS

TO SULFUR PLANT
STRIPPER

SOUR GAS L

FROM GAS TO GAS FROM GAS FLASH DRUM

CO2 H2S
RECEIVING COMPRESSION RECEIVING
REMOVAL REMOVAL
(RAW FEED GAS)

2
1

CO2 H2S
REMOVAL REMOVAL

Figure 2A: Acid Gas Removal System Figure 2: Acid Gas Removal Block
8
The LNG Process

Table 3: Applications in Gas Compression Gas Compression

Earlier LNG facilities (1960s and 1970s) are equipped with steam boilers and
use steam drivers for the compressors. These facilities typically use sea water
cooling for the process. In 1984/85 studies were performed by Shell and gas
turbines and air coolers were found to be more cost effective. The gas turbine
by this time period was very reliable and the cost of boilers and alloy piping
to route the steam to the compressor was more expensive than the use of gas
turbines.

Train capacities have increased over the past 15 to 20 years as have the size of

A Guide to Severe Service Control Valve Applications in the LNG Process

1 the gas turbines. The mid-1980s typically used frame 5 (~30 MW) machines.
It is not uncommon to find frame 6 (~50 MW) and even frame 7 (~70 MW)
machines used in today’s LNG facilities. The typical compressor discharge is
approximately 600 psi (41 barg).

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

Figure 3: Gas Compression

Note 1: Steam turbine driven compressor shown. Newer plant will generally be equipped with a gas turbine
 9
The LNG Process

Table 4: Applications in Dehydration Dehydration

Figure 4 shows three dehydration vessels which are most often contained in
the typical LNG train. These vessels are often referred to as molecular sieves.
The figure shows two dryers in the normal gas drying mode and one dryer in
the regeneration mode.

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

A Guide to Severe Service Control Valve Applications in the LNG Process

portion of the bed is saturated with water.

Moisture concentrations at the outlet of the dehydration unit must be less

than 1 ppm to prevent hydrate in the chilling/liquefaction unit.

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

WET GAS FROM

COMPRESSOR COOLING HEATING
KO
REGENERATION
DRYER IN

CYCLE

COOLING DRYERS IN DEHYDRATION CYCLE

REGENERATION VALVE

THROTTLING VALVE
KO

COOLER

1
DRY GAS TO
HYDROCARBON
1 PROCESSING
TRAINS
1

Figure 4: Dehydration
10
The LNG Process

Table 5: Applications in Hydrocarbon Hydrocarbon Separation Propane Cycle

Separation Propane Cycle
The propane compression section is intended to remove all or most of the
NGL (natural gas liquid) in the gas stream. Figure 5 shows a gas turbine
driving a 3-stage compressor. Most multiple train facilities use a single
compression circuit using a large GT and compressor.

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

A Guide to Severe Service Control Valve Applications in the LNG Process

1
can be separated and sold as a number of individual products or sold as a
combined NGL product. When gas reaches a temperature of approximately
-22 /-40 F(–30 /-40 C), it is routed from the 3rd stage chiller to the APCI
exchanger for liquefaction.

The feed to the Mixed Component Refrigerant (MCR) compressor, which is

typically a two-stage compressor, operates in much the same manner as both
the propane compressor using the associated chillers and knock out vessels.

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

3rd 2nd 1st GT

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

Figure 5: Hydrocarbon Separation Propane Cycle (1 Train)

Note: Vent locations may differ
 11
The LNG Process

Table 6: Applications in Liquefaction Liquefaction

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

A Guide to Severe Service Control Valve Applications in the LNG Process

a wide vapor range. This property makes the fluid extremely suitable for a
staged chilling-process using a number of JT valves to liquefy larger amounts
of LNG. At the exchanger outlet, the LNG flashes into the storage tank
system. The flash gas that becomes available in this letdown process is fed via
a compressor into the fuel gas system (not shown). This gas often contains a
high percentage of inert gas and it is not economical to try to recycle this gas
back in the system in order to extract more LNG.
The MCR refrigeration compressor package functions more or less the same
as the propane system. The compressed MCR is liquefied partially in an aerial
2 condenser. It flows from there as a mixed phase to a MCR chiller that uses
low-pressure propane to chill the MCR to about -40 F (–40 C). From the
MCR chiller an MCR-vapor and liquid stream pass through the main LNG
exchanger tubing.
The vapor tubing is chilled with JT liquid in the top of the tower. The
MCR liquid is flashing in the lower part of the unit, resulting in a product
temperature at the discharge of the exchanger of around -220 F (–140 C). The
MCR vapor returns to the MCR compressor for recompression.

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

Figure 6: Liquefaction MCR Cycle (1 Train)

12
The LNG Process

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.

A Guide to Severe Service Control Valve Applications in the LNG Process

The process uses only one refrigerant compressor feeding eight exchanger
cold boxes. Partially cooled feed gas -87 F (-66 C) is withdrawn from the
refrigerant exchanger at an intermediate point and is forwarded to the
fractionation process where the heavier components are separated. The
remaining gas returns from the fractionation process, reenters and then exits
the exchanger cores as a liquid at -227 F (-144 C). The liquid -227 F (-144 C)
is flashed in both a high and low pressure flash drum. The flash gas in these
drums is recovered, recompressed and is sent to the fuel gas system with the
liquid being sent to storage.

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

ACID GAS REMOVAL SULFUR RECOVERY

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

LNG STORAGE & LOADING

LNG SHIPPING TO CUSTOMERS

Figure B: PRICO and Phillips LNG Process

 13
The LNG Process

Table 7: Applications in LNG & NGL Storage
and Loading
LNG & NGL Storage 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

A Guide to Severe Service Control Valve Applications in the LNG Process

capacity for load-out, flow control consists primarily of starting and stopping
the loading pumps. There are no severe service valves in storage and loading,
other than boil-off compressor recycle valves.

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.

Figure 7: LNG & NGL Storage & Loading

14
The LNG Process

Table 8: Applications in Utilities and Utilities

Depressuring System
Grassroot LNG facilities contain various units for plant operation. These
units will include electric power generation, instrument and utility air,
nitrogen, and potable water production as a minimum. Most of these units
are packages supplied by Original Equipment Manufacturers (OEMs), except
for electric power generation.

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

A Guide to Severe Service Control Valve Applications in the LNG Process

The depressuring system in a plant is typically not a plant unit or a utility, but
nevertheless is worth mentioning.

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.

FLARE 15-20 PSI

HEADER
1
DEPRESSURIZING
VENT GAS
TO FLARE
2
P
FUEL GAS PSI
HEADER PROCESS

VENT
MAKE-UP

PROCESS

Figure 8: Fuel Gas and Depressuring System

Various gas vents in a plant will relieve to the fuel gas system rather than to flare. As a result, there will be a fuel gas vent to flare,
which will be a high-noise valve requiring tight shutoff.
 15
The LNG Process

Table 9: Applications in Steam Boiler Steam Boiler

Several boilers supplied by a packaged vendor may be used to supply steam to
an LNG train. In some facilities multiple boilers are connected to a common
header feeding one or more LNG trains.
1
Figure 9 shows a typical fired boiler operation. The figure shows three
steam headers with steam drivers being fed from the high pressure (HP)
and medium pressure (MP) headers. In the event a driver or compressor is
tripped, the steam consumption normally required for that service will be
let down to the next lower pressure header through a steam header pressure

A Guide to Severe Service Control Valve Applications in the LNG Process

2 control valve. Normally, the atmospheric steam will vent on the low-pressure
header, however it may vent on all three steam headers.

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

Figure 9: Typical Fired Boiler with Steam Drivers

16
CCI Produced a 30” DRAG® Feed Gas Regulator
Valve for Atlantic LNG in their RSM
USA Factory
Severe Service Control Valves
CCI Control Valves
CCI valve technology has advanced along with the LNG industry:
g Fast-stroking requirements for compressor recycle have reached one
second or less using low cost, highly reliable pneumatic actuation — a
major trademark advantage of CCI control valves. Hydraulic actuation
which was used in the past is no longer favored due to high maintenance,
high cost and problems with reliability. LNG plants have begun to
retrofit their problematic hydraulic actuator systems with the reliable CCI
pneumatic actuator system.
A Guide to Severe Service Control Valve Applications in the LNG Process
g Repeatable, tight shutoff is achieved using CCI’s balance seal design
unique in the industry. The design clamps the seal in the bonnet,
providing superior performance when compared to other balance seal
designs that place a groove on the plug. The resulting benefit is that the
CCI balance seal remains effective at cryogenic temperatures as the seal
shrinks to form a better plug seal, while other seal designs shrink and
move away from the cage and reduce sealing.
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.
g CCI was a leader in the development of multi-stage noise standards.
Acceptable noise levels below 80 dBA have been met through CCI’s severe
service installations globally.
g CCI can assist in the selection of severe service valve applications to
ensure low ownership costs. CCI control valves can lower total installed
cost due to smaller pipe sizes, fewer parallel valve installations and high
valve rangeability. For example, in compressor recycle, a startup ball valve
may be in parallel to the recycle valve. However, CCI can combine these
application requirements into one compressor recycle application, saving
the client installation costs.
 17
Severe Service Control Valves

Ensure High System Reliability and Efficiency

There are many aspects related to system reliability and efficiency:

g Maintaining plant efficiency

g Maintaining high plant throughput
g Ensuring high valve and equipment reliability
g Increasing plant availability.

All of these factors are consistent with each other.

CCI control valves ensure an excellent system that is reliable and efficient.

A Guide to Severe Service Control Valve Applications in the LNG Process

Compromising with an unreliable technical solution having a lower initial
cost will end up costing more money in the long run than CCI control valves.

Specify Severe Service Control Valve Applications

How can you meet the above purposes? By specifying the critical control
valves important to the project at an early stage. Severe service control valves
heavily impact the aspects of the LNG plant the owners are measuring.

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.

What Control Valve Applications are Severe Service?

g Compressor Recycle
g Vent to Flare
g Joule Thomson
g Separator Level Control
g Rich Amine Letdown
Figure 10: 100D Valve g Gas Intake/Regulator
g Depressurizing
g High P Applications
g Steam Vent
g Turbine Bypass
g Steam Header Pressure Control
g Lean Amine Recirculation
g Fuel Gas Vent
g Emergency Depressurizing
18
Severe Service Control Valves

DRAG® — Velocity Control Technology

How to Solve Severe Service Valve Problems

Uncontrolled flowing velocity—a control valve’s worst enemy.

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

A Guide to Severe Service Control Valve Applications in the LNG Process

results are the same — problems.

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

Figure 13: Multi-path

 19
Severe Service Control Valves

V2 g The number of turns, N, needed to dissipate the maximum expected

differential pressure across the trim is determined by limiting the velocity
to an acceptable level, then changing the equation in Figure 12 to a new
equation: V DRAG® element = √2gh/N and solving for N.

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.

A Guide to Severe Service Control Valve Applications in the LNG Process

V1 = V2 g In the DRAG® trim, the resistance, number and area of the individual flow
passages is custom matched to the specific application and exit velocities
are kept low to eliminate cavitation of liquids and erosion, vibration and
Figure 15: Pressure-drop from right-angle
turns noise in gas service.

V1

V2
N Turns

V2 = 2gh/N
V1 = V2

Figure 16: Number of turns depends on the

differential pressure

Figure 17: DRAG® disk

20
Severe Service Control Valves

Surge Control Systems

A valve that does not stroke fast enough will cause a machine to surge. This
surge may be sufficient to shut down the compressor. A compressor may trip
due to surge protection in the compressor controller or axial shaft movement
in the machinery protection package (typically 25 µm to 75 µm [or 0.001 to
0.003] axial displacement). A compressor trip will cause loss of production
for several hours. Of equal consequence, each trip increases the required main-
tenance and shortens the life of the compressor.
Resolution/Closing Speed

A Guide to Severe Service Control Valve Applications in the LNG Process

In the past CCI has stated that closing speeds of 1.5 times the opening speed is
acceptable. The point should be made that although acceptable, it is not pre-
ferred. Most vendors will provide even slower closing speeds as this helps the
valve attain set point with fewer oscillations about the set point value. Oscilla-
tions around the set point should be avoided.
Surge Protection

In order to protect the compressor, a surge protection system consisting of

a measurement device, a control device and a recycle valve is provided. The
key function of the surge protection system is to respond quickly to a process
upset and avoid sending the compressor into surge by recycling the process
fluid.

Measurement Most transmitters used in surge control have a 300 ms rise

time from 0 – 100%. It is fair to say that at least 1/3 of this
time is required for the measuring device to change values
detected by the controller.

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.

Valve Approximately 150 ms after a process upset that can result

in surge (100 ms for sensor + 40 ms for controller to process
signals), the recycle valve will receive the signal to open.

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 Technical Specification

Specification - Surge Control System

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.

A Guide to Severe Service Control Valve Applications in the LNG Process

“Control Valves – Practical Guides for Measurement
and Control” edited by Guy Borden, Jr. and Paul G.
Friedmann, 1998 edition published by ISA.

Increase Compressor Efficiency

The compressor will have the highest efficiency when the compressor recycle
valves are specified with repeatable tight shutoff. It is well known that a
major part of the cost of the compressor is the energy cost to run it over
Control Valve Specifications Based on ISA.
a period of time. When a valve is leaking, the compressor requires more
energy to meet the throughput. This leaking inefficiency can far outweigh the
costs of the valve over time, in some cases, even the cost of the compressor.

Minimize Loss of Product/Feedstock

A well specified severe service control valve should not leak. If a gas vent-to-
flare valve is leaking, valuable product is going to flare where it will be wasted.
Repeatable, tight shutoff is absolutely necessary to ensure that product/
feedstock will go where it belongs, which is to the customer, and not flared.

Eliminate Unwanted Noise and Vibration

High fluid velocities through the pressure letdown process will create
aerodynamic noise. A well specified control valve will control the fluid
velocities through the letdown path to an acceptable level and will ensure
that noise and vibration is not created in the first place. Noise is not hidden—
instead it is not created. Vibration is limited.

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

Control Valve Application: Compressor Recycle /Anti-surge

Table 10: Compressor Recycle/Anti-surge Valves

Ensures compressor will not surge by recycling gas from discharge to suction side of compressor when flow drops below 80% of
compressor capacity.

A Guide to Severe Service Control Valve Applications in the LNG Process

Recommended Specification for Compressor Recycle/Anti-surge Valve
g Stroke speed less than 1 second in both open and close directions
g A maximum of one overshoot, not to exceed 1% of travel
g Leakage Class VI (minimum Class V)
g Noise level less than 85 dBA at 1 meter from valve
g Resolution less than 1%
g Trim exit velocity head less than 70 psi
 23
Severe Service Control Valves

Control Valve Application: Vent to Flare

Table 11: Vent Valve to Flare: Vents Gas to Flare During Startup, Shutdown, or Load Rejection

A Guide to Severe Service Control Valve Applications in the LNG Process

Recommended Specification for Vent to Flare Valve
g Trim exit velocity head less than 70 psi (450 kpa) g Leakage Class VI (minimum Class V)
g Noise level less than 85 dBA at 1 meter from valve

Control Valve Application: Steam Vent

Table 12: Steam Vent Valve: Steam to atmosphere during startup, shutdown, and steam turbine load rejection

Recommended Specification for Steam Vent Valve

g Trim exit velocity head less than 70 psi (450 kpa)
g Leakage Class VI (minimum Class V)
g Noise level less than 85 dBA
24
Severe Service Control Valves

Control Valve Application: Amine Handling

Table 13: Amine Letdown Valves: Rich Amine Letdown or Lean Amine Pump Recirculation

A Guide to Severe Service Control Valve Applications in the LNG Process

Recommended Specification for Vent Valve to Flare
g Noise level less than 85 dBA at 1 meter from valve
g Trim exit velocity less than 75 ft/sec (23 m/sec)

Control Valve Application: Joule Thomson

Table 14: Joule Thomson (JT) Valves: Allows Compressed Gas to Expand for Refrigeration

Recommended Specification for Joule Thomson Valve

g Trim exit velocity less than 75 ft/sec (23 m/sec)
 25
Severe Service Control Valves

Control Valve Application: Depressurizing

Table 15: Depressurizing Valves: Emergency Application Dumping Hydrocarbon Inventory to Flare.

A Guide to Severe Service Control Valve Applications in the LNG Process

Recommended Specification for Depressurizing Valves
g Noise level less than 105 dBA at 1 meter from valve
g Trim exit velocity head less than 300 psi (2060 kpa)
g Leakage Class VI (minimum Class V)
g Type approval for cryogenics

Control Valve Application: Steam Header Pressure Control

Table 16: Steam Header Pressure Control Valves: Controls Pressure in the Steam Header

Recommended Specification for the Turbine Bypass Valve

g Noise level below 85 dBA at 1 meter from valve

g Trim exit velocity head below 70 psi (450 kpa)
g Shutoff Class V
26
Severe Service Control Valves

Control Valve Application: Separator Level Control

Table 17: Separator Level Control Valves: Maintains Fluid Level in a Separator

A Guide to Severe Service Control Valve Applications in the LNG Process

Recommended Specification for the Separator Level Control Valve

g Trim exit velocity less than 75 ft/sec (23 m/s)

g Large passages sizes greater than 0.18-in. (5-mm) in width
g Noise level less than 85dBA at 1 meter from valve
g Erosion resistant hard trim material
 27
Severe Service Control Valves

Control Valve Application: Gas Intake/Regulator

Table 18: Gas Regulator Valves: Controls Feed Gas Flow Rate

A Guide to Severe Service Control Valve Applications in the LNG Process

Recommended Specification for the Gas Regulator Valve

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.

A Guide to Severe Service Control Valve Applications in the LNG Process

Sales and service locations worldwide.
CCI World Headquarters— CCI Japan
California Telephone: 81 726 41 7197
Telephone: (949) 858-1877 Fax: 81 726 41 7198
Fax: (949) 858-1878 194-2, Shukunosho
22591 Avenida Empresa Ibaraki-City, Osaka 567-0051
Rancho Santa Margarita, Japan
California 92688
USA CCI Sweden (BTG Valves)
Telephone: 46 533 689 600
CCI Switzerland Fax: 46 533 689 601
formerly Sulzer Thermtec Box 603
Telephone: 41 52 262 11 66 SE-661 29 Säffle
Fax: 41 52 262 01 65 Sweden
Hegifeldstrasse 10, P.O. Box 65
CH-8408 Winterthur CCI Austria
Switzerland formerly Spectris Components GmbH
Telephone: 43 1 869 27 40
CCI Korea Fax: 43 1 865 36 03 Contact us at:
Telephone: 82 31 985 9430 Carlbergergasse 38/Pf.19 info@ccivalve.com
Fax: 82 31 985 0552 1233 Vienna
26-17, Pungmu-Dong Austria Visit us online at:
Kimpo City, Kyunggi-Do 415-070 www.ccivalve.com
South Korea CCI Italy
Telephone: 39 035 29289
DRAG is a registered trademark of CCI.
Fax: 39 035 2928246 ©2002 CCI 429 5/02 10K
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Italy