Severe Service Overview & Capabilities Short Verison.ppt
- 1. Severe Service Control Valve Severe Service Control Valve Solutions Solutions • Update on Severe Service Technology • Optimized Anti-Surge Solution
- 2. Defining “Success” Defining “Success” Project-Level Considerations – Lowest Hardware Cost? – Best Delivery? – Quickest Commissioning and Startup? – Minimum Engineering Hours? Operations Considerations – Longest Trim Life? – Best Process Control? – Lowest Life cycle cost? – Best Local Support? True Success is a Combination of the Above
- 3. Road Map to Success Road Map to Success The Fisher Process – LBP Role – Factory Role – End user Role – Contractor Role Equipment Selection and Performance – Technology – Products – Application experience Service and Support TEAM Effort
- 4. Defining “Severe Service” Defining “Severe Service” Severe service control valves are designed to perform very specific tasks. Examples include: – Controlling high pressure drops – Reduce noise – Combat fluid or particulate erosion – Handle fluid phase changes • Cavitation • Flashing • Outgassing
- 6. Investing in the Business Investing in the Business 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 *2000 Valtek Neles M/N Fisher 0 50 100 150 200 250 300 350 *2000 year to date - January Cumulative U.S. & International Patents
- 7. Flow lab Flow lab Fisher Controls Marshalltown 1/2” through 24” test capability 14,000,000 scfh of air or 17,500 gpm of water flow capability Largest valve test lab in the world
- 8. Additional test labs – Asia Pacific Additional test labs – Asia Pacific
- 9. Sakura Factory – Floor area of 70,000 sq ft – Employees 57 – Main Facilities • Machining Center • NC Turret Lathe • NC Cage Drilling Machine • EDP System • Heat Treatment Furnace • Clean Room • Cryogenic Test Equipment – Products Manufactured • Control Valves • Special Control Valves • Leveltrols Valves Division Manufacturing Plant - Sakura
- 10. Fisher Controls opens a “World Class Control Valve Manufacturing Facility” in Malaysia in 1999 Valves Division Manufacturing Plant - Nilai Nilai Plant – Floor area of 75,000 sq ft – Employees 140 – Plant Location • 15 minutes from the new KL Int’l Airport • Within 45 minutes of Port Kelang • Only 3.5 hours from Singapore – Products Manufactured • Control Valves • Special Control Valves • Leveltrols
- 11. Emerson Process Management (Tianjin) Valves Co. Ltd – Floor area of 2,700 sq. m – Operational Mar 2004 – Products Manufactured • Local manufacture 1” - 8” E- Series Control Valves for China market • GX and B-Lite Control Valves • A41 Series Butterfly Valves (2005) – Service & Repair Valves Division Manufacturing Plant – Wuqing
- 12. Bao’an Plant – Floor area of 10,000 sq ft – 70 Employees – Products Manufactured • Valve Insrtuments – 3582 – 582i – 646 – 546 – 3622 – 3610 – 3660 – 3661 Valves Division Manufacturing Plant – Bao’an
- 13. Solution Selection Solution Selection Establish requirements – Accurate service conditions – Application experience – Operation, maintenance, other life-cycle issues Proper Sizing – Accurate prediction of noise – Proper accounting for fluid properties – Proper sizing method Wide Variety of Equipment to Choose From – Rotary and Sliding Stem body styles – Application-Specific Trim Geometry – Integrated Actuation and Instrumentation – Custom Engineered Solution
- 14. Sliding Stem Severe Service Valves Sliding Stem Severe Service Valves NotchFlo DST DSTG Cavitrol III WhisperFlo Whisper I Whisper III EH/HP Cavitrol IV 461 EU FB
- 15. WhisperFlo WhisperFlo Flow In Flow Out Contours of Mach Number Fluent Inc. Mon Dec 01 1997 Fluent/UNS 4.2 (3d, ke) 1.49e+00 1.36e+00 1.22e+00 1.09e+00 9.52e-01 8.16e-01 6.80e-01 5.45e-01 4.09e-01 2.73e-01 1.38e-01 1.89e-03 Z Y X WhisperFlo Trim
- 16. Fisher NotchFlo DST Fisher NotchFlo DST •Pressure staging reduces vibration •Available in 4 stages and capable of up to 2600 psi of pressure drop •Ability to pass particles up to 1/2” in diameter •Protected seat maintains shutoff integrity •Hardened materials resist erosion damage •Can be used for globe or angle valve configurations
- 17. A11 Rotary Severe Service Valves Rotary Severe Service Valves V260 V250 V150S V500 V150,V200,V300 Rotary Attenuator CV500 Ceramic Micro-notch
- 18. Engineered Products Solutions for special, one-of-a-kind applications
- 19. Natural gas compressor Natural gas compressor
- 20. Fisher Optimized Fisher Optimized Anti-Surge Anti-Surge Digital Valves Digital Valves
- 21. Typical Antisurge Control System Typical Antisurge Control System Provides faster response than adjusting turbine speed to control the onset of surge Antisurge controller is looking at multiple variables to prevent onset of surge System requires fast, accurate response to prevent surge conditions
- 22. Objectives of Anti-Surge Control Objectives of Anti-Surge Control Increase reliability of machinery and process • Prevent surge and surge damage • Prevent unnecessary process trips and downtime • Minimize process disturbances • Simplify and automate startup and shutdown Increase efficiency of machinery and process • Operate at lowest possible energy levels • Minimize antisurge recycle or blow-off • Minimize set-point deviation • Maximize throughput using all available horsepower
- 23. Compressor Controls Compressor Controls Technology State of Art Technology State of Art Surge control line initiate PI closed loop control Older Technology provided only trip actions or step responses – Little need for closed loop precise control Communication between multiple controllers requires valves with 1-2% off-the-seat response and ability for small step changes 1 PIC 2 UIC 1 UIC VSDS Section 1 Section 2 Serial network Serial network
- 24. There is More to Antisurge Control There is More to Antisurge Control Valves than Stroking Speed Valves than Stroking Speed Figures Courtesy of CCC’s Integrated Turbomachinery Control System at Petrokemya Olefins #1
- 25. Compressor Antisurge Valves Compressor Antisurge Valves Antisurge Valve Installation Reality Antisurge Valve Installation Reality – Ensure that the valve is installed as close to the compressor and check valve as possible • Minimizes dead time and lag time in the antisurge system • Minimizes energy loss due to operating the compressor further from surge point – Located close to turbine, which is much louder than valve • Noise attenuation necessary to address potential vibration during normal operation • Concern is to address potential pipe fatigue issues caused by excessive vibration – May throttle intermittently from 0 - 100% opening • Requires valve to have fast, accurate control for incremental step sizes, not just close to open - often overlooked in specifications • Closed-loop control is used when the compressor crosses the surge control line (SCL), used to provide loop decoupling between multiple antisurge controllers and between the antisurge controller and performance controller, and used to limit discharge and suction pressures. • Delay can allow surge to occur • Cumbersome accessory packages require constant tuning of positioner and accessories
- 26. Antisurge Control Valve Antisurge Control Valve Older Technology Older Technology Open-loop control only: lacked the accuracy to precisely position the antisurge valve. Performance requirements for good closed-loop control are rarely specified for control valves Cumbersome accessory packages require constant tuning of positioner and accessories Fisher * / 585CLS (12) / DVC6000 / 2625-12 / Rexroth Large Open-Loop Step Study. 14-7/8" Stroke, 2 Vol. Boosters on Bottom, 1 Vol. Booster on Top. 90 psig Supply Pressure, K = 8.5 / 5.4 / 50, Rexroth Bypass Open 1/2 Turn; Top Vol. Booster Bypass Open 1/4 Turn Time (sec) 0 50 100 150 200 250 300 350 400 450 500 550 Input & Travel (%) 0 10 20 30 40 50 60 70 80 90 100 110 Stem Travel Command File: (2001)10301148
- 27. Antisurge Control Valve Antisurge Control Valve Technology – State of Technology – State of Art Art Closed-loop control is used when the compressor crosses the surge control line (SCL), used to provide loop decoupling between multiple antisurge controllers. Requires valve to have fast, accurate control for incremental step sizes, not just close to open - often overlooked in specifications – Delay can allow surge to occur Requires only pneumatic supply and 2-wire 4-20 mA Servo loop tuning has been simplified. Tuning simplified, set one booster each side once. Commissioning and maintenance through ValveLink Software Fisher 12" x 18" FB / 585CLS(12) / DVC6020 Antisurge Large step study, K = 14.5 / 8.1 / 38 14-7/8-in. stroke, 80 psig supply Time (sec) 0 50 100 150 200 250 300 350 400 450 500 550 Ref Tvl (%) 0 10 20 30 40 50 60 70 80 90 100 Data Set: (2004)05141704
- 28. Fisher Optimized Digital Valve with a Fisher Optimized Digital Valve with a Lead-Lag Input Filter Lead-Lag Input Filter K Volume Boosters / QEVs I / P Actuator & Valve Relay Kml Kxs 4-20 mA Reference Forward Path Gain Minor Loop Feedback Gain Velocity Feedback Gain Relay Position Valve Travel _ _ _ 1s+1 2s+1 Lead-Lag Input + + DVC
- 29. Enhanced Stabilize / Optimize User Enhanced Stabilize / Optimize User Interface Interface
- 30. Lead-Lag Input Filter Lead-Lag Input Filter - Lead-lag filter can help improve performance for small amplitude steps by bumping the accessories for a short amount of time. - Lead-lag on servo set point does not introduce dynamics in the closed-loop controller. - Fast acting actuators need fast lead- lag dynamics. Process controllers generally do not have the update rates required. The best place to implement lead-lag dynamics is in the servo controller since the microprocessor updates very quickly. - Integrated, real-time graphics allow adjustments to be done remotely. -Preview graph of expected response -Actual live graph showing valve response -Apply tuning changes while the valve is in service - Asymmetric lead-lag available.
- 31. New Lead-Lag Boost Algorithm New Lead-Lag Boost Algorithm
- 32. On-Line Travel Stop Diagnostics and On-Line Travel Stop Diagnostics and Partial Stroke Tests Partial Stroke Tests -2 -1 0 1 2 3 4 5 -30 -20 -10 0 10 20 30 40 50 60 Travel (in) Differential Pressure (psi) X: -2.77 Y: 13.13 Open
- 33. Fisher Optimized Anti-Surge System Fisher Optimized Anti-Surge System Designed to maximize reliability of compression systems by: – Simplified accessories - Reduced by over 50% with one knob adjustments – Remote tuning capabilities - Online and from the control room rather than at the valve. Can also readjust tuning with the valve in service. – Onseat diagnostics - Provides diagnostics while the valve is on the seat, unlike any other solution – Partial stroke testing - Verifies valve performance and will address SIL 1 requirements Improved performance via: – Enhanced tuning capability not available with standard instrumentation - This means higher gains and better performance. – Minor-loop feedback based on relay motion is used to dampen the response before motion is detected in travel. – Lead-lag filter - Allows for user adjustable asymmetric or symmetric dynamics. – Lead-lag boost - Ensures valve comes off the seat quickly (<1 sec.) for small step changes Valve Internals Designed for Antisurge Applications – Whisper III/WhisperFlo trim specially designed to meet the turndown requirements of the application. – Fully Balanced/Spoked Plugs to eliminate potential for flow induced instability. Performance Specifications – Designed to meet Fisher FGS 4L11 performance specification and FAT criteria - Each valve is designed to meet stringent performance criteria and is tested prior to shipment. This is the criteria CCC has bought in to. – System is approved to meet Nuovo Pignone performance criteria.
- 34. Singapore France First to use dynamic open-loop and closed- loop testing. Initiated testing over 12 years ago. Dynamic testing is standard for product development. Only valve supplier to utilize closed-loop variability testing. All five test facilities in the world are owned by Fisher. Long-time leader in valve monitoring and diagnostics. FlowScanner™ introduced over 13 years ago. FIELDVUE® DVC introduced over 10 years ago. Valve Performance Doesn’t Just Happen Marshalltown
- 35. Order & Manufacturing - Manufacturing - Test & Inspection - Factory Signature testing data for DVC - Complete & update FisherFirst data Fisher Defined valve requirement with specifications Technical Clarification and discussion End Uer Engineering & Selectioin Sizing & selection with use of FisherFirst Purchase Order All Valves from any Fisher factories all over the world has the Signature Series Factory Testing Control Valve Performance Management Control Valve Performance Management
Editor's Notes
- #1: Slide Intro: Severe service control valve applications are somewhat complex by definition. It may be tempting to superimpose simple, single-parameter “rules of thumb” when confronted with these applications, but such an approach may significantly compromise the product selection process. This talk will demonstrate why over-simplification of the problem may result in less effective valve performance and more costly control valve solutions.
- #2: Slide Intro: Severe Service control valves are often asked to perform a wide variety of specific tasks. To accomplish this, each valve manufacturer must specifically design the valve and valve trim for the task at hand, whether it be Aerodynamic Noise, Liquid Cavitation, Particulate Erosion, or some other fluid phenomena. During this process, lab testing, computer modeling, field results, and many other considerations are accounted for and result in the establishment of appropriate product ratings and selection parameters. These selection parameters established by the manufacturer during the trim development process enjoy the highest level of accuracy and dependability.
- #4: Slide Intro: Severe Service control valves are often asked to perform a wide variety of specific tasks. To accomplish this, each valve manufacturer must specifically design the valve and valve trim for the task at hand, whether it be Aerodynamic Noise, Liquid Cavitation, Particulate Erosion, or some other fluid phenomena. During this process, lab testing, computer modeling, field results, and many other considerations are accounted for and result in the establishment of appropriate product ratings and selection parameters. These selection parameters established by the manufacturer during the trim development process enjoy the highest level of accuracy and dependability.
- #6: Clearly illustrates the technology leadership of Fisher over its competitors, with Fisher being granted more patents than the combined totals of the three competitors listed.
- #7: It is important to touch upon the fact that we test all of our own equipment in this lab, but also competitors’ equipment. Address the sound proof box that is used to measure the actual noise produced by a piece of equipment. This allows us to determine where the limitations of our products occur. Also discuss that we do mean time failure analysis over in the corner dealing with stresses such as heat, cold, multiple cycling to determine what product is best. We also have the capabilities with a scanner electron microscope to determine causes for material failures and to ensure that we are using the best grade of material available. Not only our Fisher valves tested in M’town. Rosemount transmitters, Micromotion flow meters, etc. are tested in the loop to the right.
- #13: Slide Intro: Severe Service control valves are often asked to perform a wide variety of specific tasks. To accomplish this, each valve manufacturer must specifically design the valve and valve trim for the task at hand, whether it be Aerodynamic Noise, Liquid Cavitation, Particulate Erosion, or some other fluid phenomena. During this process, lab testing, computer modeling, field results, and many other considerations are accounted for and result in the establishment of appropriate product ratings and selection parameters. These selection parameters established by the manufacturer during the trim development process enjoy the highest level of accuracy and dependability.
- #15: Talk about the capabilities of the CFD analysis to show that in this trim, the fluid is allowed to fully recover prior to entering the next stage. This allows for a large reduction in trim noise due to the fact that we are not taking a large pressure drop across the last stage of the trim.
- #16: Again depending on the amount of vapor in the outlet this is a different selection. If the amount of vapor is relatively small then cavitation of the liquid component must be addressed. Just like with Aspiration where excess air induced into the flow stream cushions the collapse of vapor cavities, and thus reduces the intensity of cavitation, the gas that comes out of solution cushions the cavitation. So if the vapor fraction is small in the outgassing situation, and the liquid fraction is cavitating then a multi-stage trim is called for. The NotchFlo accomplishes staging with multiple “notches” in series. This is a flow up design with a “protected seat”. The seat is protected in that the pressure drop is taken across the series of notches. With no flowing pressure drop across the seat then the velocity is kept low and erosion potential is reduced.
- #29: Note the guys sitting on the valves the ‘old’ way with walkie-talkies. Now can tune on-line, the control system has the control, user can preview the changes before hitting apply,. Only one booster each side needs to be adjusted. Valve does not need to be taken off-line to tune. CCI’s does.
- #31: New lead-lag boost algorithm has been added to rev. 7. This algorithm improves the speed of response off the seat to small amplitude signal changes. The DCV goes into this mode after 30 sec at cutoff or stauration.The lead-lag boost lasts 100-200 msec. Why is this important? Antisurge controllers stay on the seat most of the time. However, when the compressor looses load (for whatever reason), the antisurge controller will try to compensate by slowly moving the valve off the seat. If that doesn’t work, the antisurge controller will bump the valve to prevent surge. To prevent upsetting the rest of operations, it is desirable to minimize the bumps in the system. Getting the antisurge valve off the seat faster to small amplitude signals will significantly help the controller’s response. People involved: Jim Snowbarger – programmed this feature in 32 bytes ( “This is thirty-two bytes in text”) Ryan Jwanouskos – wrote code and documentation to automate testing of this feature (60 tests in all).
- #32: Whiteboard a graph showing 2 mins of 5% change. State if control system has a change the test is aborted. If valve is stuck by the DVC looking at actuator pressures, the test is aborted