Compressor Recycle Service Centrifugal compressors are used extensively in industries where large volumes of compressible gases, including

natural gas, many organic and inorganic gases, and refrigerants must be handled. They come in a wide range of sizes to handle medium and large gas volumes, and pressure differentials to 3000 psi (21 MPa) and higher with temperatures ranging from cryogenic levels to 600F (315C). Typical DRAG Valve Applications In Centrifugal Recycle Service
Application Feed Gas Hydrogen Differential Pressure Temperature Inlet/Outlet

70-300 psi 0.48-2.1 MPa 100-150 psi 0.69 - 1MPa 50-100 psi 0.34-0.69 MPa 50-700 psi 0.34-4.8 MPa 300-500 psi 2.1-3.4MPa 50-100 psi 0.34-1 MPa 50-300 psi 0.34-2.1 MPa 100-500 psi 0.69 - 3.4MPa 50-300 psi 0.34-2.19 MPa

100-130F 37-54C 100-120F 37-49C 100-200F 37-93C 100-200F 37-93C 100-120F 37-49C 50-150F 10-65C 50-100F 10-37C 20-50F -6-10C 100-150F 37-65C

6-12"/8-14" 150-300mm/200-355mm 8-24"/10-30" 200-600mm/255-760mm 4-8"/6-12" 100-200mm/150-300mm 4-16"/6-24 100-400mm/150-600mm 4-8"/6-10" 100-200mm/150-250mm 6-16"/6-16" 150-400mm/200-400mm 4-12"/6-16" 100-300mm/150-400mm 4-6"/6-10" 100-150mm/150-250mm 6-8"/8-12" 150-200mm/200-300mm

Natural Gas

Ammonia

Air Olefins Syngas

Propane

Propylene

Ethylene

Multicomponent

Gas production Separation 300-3000 psi 2.1-21MPa Reinjection 3000 psi 21 MPa

100-200F 37-93C 100-150F 37-65C

4-12"/6-16" 100-300mm/150-400mm 4-8"/6-8" 100-200mm/150-200mm

to the required pressure-energy level in the discharge line. When discharge pressure exceeds impeller discharge pressure, backflow occurs until the discharge pressure is less than impeller outlet pressure. At this point, flow reversal again occurs, and compressor operation becomes unstable, resulting in excessive vibration and probable damage to the compressor. This phenomenon is called stall and produces a surge in the system. As a function of its design. every centrifugal compressor has a stall-flow surge point at any given operating speed. The gas flow corresponding to this surge point is fixed for a constantspeed compressor, but changes at each operating speed for a variable-speed compressor. In either case, good industry practice dictates that compressor gas flow should never drop below a margin of 105 percent of the surge point. It is for this purpose that compressor recycle valves are used to appropriately recycle gas flow from compressor discharge to suction to prevent operation below this critical flow.

These compressors are powered by constant-speed or variable-speed drivers in the range of 5000 hp (3700KW), hilt power requirements above 40,000 hp (29,800KW) are not uncommon. Essentially, their function is to convert the kinetic energy of the gas into potential energy at the compressor discharge. Compressors are designed for single stage (single impeller) or multistage (multiple impellers in series) operation in a single casing. Often multiple centrifugal compressors are used in parallel and/or in series (with intercooling) to increase overall efficiency. Regardless of design or application, centrifugal compressors have one common characteristic. At low capacities, orderly gas flow through the compressor is impossible since gas velocities are too low to be converted

Compressor Recycle Valves Compressor Recycle Valves are sometimes called kickback, spill back, or return valves perform this function. Actually, they perform two functions: 1) to react quickly to emergency situations and during start-up operations which would otherwise force a compressor flow less than the surge point; and 2) to modulate recycle flow during normal operation to avoid compressor operation near or below this critical point. The main problems associated with compressor recycle valve service include the potential for high noise levels, vibration, long stroke time, i.e. the time required to fully open a closed recycle valve on system upset, control instability (hunting) due to inadequate actuator selection, and inadequate capacity for all service conditions. An unacceptable noise level of as much as 120 dB at three feet (1m) is not uncommon with conventional recycle valves. Because of the high mass flow at large pressure drops, severe vibration is created. This severe mechanical vibration usually leads to valve and trim fatigue and associated piping failure. Also, this valve vibration can be transmitted through piping or interconnected structural elements to the compressor, exciting compressor-blade natural frequencies, and resulting in damage to the compressor itself. Stroking time is also critical. Full-open time from shutoff is normally four seconds or less with one-second requirements not uncommon fully closed to fully open, or some predetermined percentage of fully open for compressor protection in emergency situations. In a given centrifugal compressor application, a variety of service conditions are frequently encountered. For example, these compressors are often started at reduced speeds, and sometimes gas composition changes during upset conditions. This latter practice in some processes can have a profound effect on recycle valve adequacy because of molecular weight changes. Increasing molecular weight increases the surge volume with a corresponding decrease

in the stable operating range. In a constant-speed centrifugal compressor, an increase in molecular weight increases discharge pressure and a decrease in molecular weight decreases discharge pressure. As the molecular weight is increased, the volume into each impeller in a multi-stage compressor is reduced even more because of the higher discharge pressure of the preceding stage. This forces the last stage to surge sooner. Formerly two valves in parallel performed two distinct functions. A quick-opening ball valve protected the compressor against emergency low-flow conditions, and a throttling modulation valve performed the latter function. But for many years CCI DRAG valves have performed both functions because of their unique design, thus eliminating the need for the parallel ball valves used previously. DRAG Valve Design For Compressor Recycle Service Control Components DRAG valve design is uniquely suited for compressor recycle service because it specifically addresses and solves the potential problem areas in this tough service application.

Noise and Vibration Control DRAG valves incorporate a tortuous-path flow design. That is, pressure energy is dissipated at a constant, controlled velocity head through the use of multiple, rightangle turns in a stack of individual disks. These disks are either etched in lower gas-flow applications (gas flow turns are horizontal) or punched in high gas flow applications (gas flow turns are vertical).

Compressor Recycle Valve Configuration Normally gas flow through a DRAG recycle valve is under the plug, i.e. gas flow passes through the plug/seat ring area under full compressor discharge pressure before entering the energy-dissipating stack. This configuration takes into account the expanding gas volume as it passes from the inside diameter of the disks to the larger outside diameters. For this same reason, compressor recycle valves are usually provided with larger outlet than inlet nozzles. These inlet and outlet nozzles are sized to hold velocity heads below 30 psi (0.21 MPa). Compressor Recycle Valve Actuation In an upset situation, recycle valves must rapidly stroke from full closed to full open to adequately protect the compressor from severe damage. In many cases this means a valve stroke travel of up to 24 in. (600mm) in less than four seconds. Pneumatic Actuation For GAS Compressor Systems Control systems used on natural gas compressing trains place great demands on the control valves used in the process. These valves must be capable of opening to full capacity in just a few seconds while maintaining a high degree of control about any intermediate set point. CCIs long experience in recycle valves for gas compression trains and their control system has led to the

Etched DRAG valve tortuous-path disk stack with horizontal gas flow shown

Punched DRAG valve tortuouspath disk stack with vertical and horizontal gas flows shown

The disk stack surrounds the plug throughout its travel from closed to wide open. Thus the velocity head throughout the valve is controlled regardless of plug position. Velocity head ( p V2/2) through this disk stack is limited to 70 psi (0.48 MPa) to minimize noise and vibration. In addition, the disk stack incorporates a pressure equalizing ring (PER) on the inside diameter of each disk. This assures equal pressures acting radially on the valve plug at all times to eliminate vibration that could occur due to rapid plug radial movement. This design can hold noise levels to 80 dB or below at three feet (1m) to comply with the latest noise abatement regulations. DRAG valves for compressor recycle service are designed with an ANSI Class V plug/ring seat design and materials to assure tight valve closure at shutoff.

development of an optimized control schematic. Using a valve stroke speed of 12 in./sec (305mm/sec), valves with a stroke length of up to 24 in. (610mm) can stroke to full open in less than two seconds. With a properly tuned series booster, the quick exhaust opens to atmosphere under sudden positioner signal changes, yet closes early enough in the stroke to eliminate any instability at the end of the stroke.

The figure below shows field-test results in terms of percent valve stroke versus time. It demonstrates that this valve with a 24-in. (500mm) stroke opened to 95 percent in only 1.7 seconds.

Compressor Recycle Valve Operation Upon compressor startup, the recycle valve is fully open to prevent the compressor gas flow from exceeding its maximum design. This is necessary when down stream pressure is low or when the process system is bypassed and the gas is flowing to a flare. As outlet pressure and gas throughput are established, the recycle valve is gradually closed and goes into its modulating mode to cover normal plant load swings. In the event of an upset condition, it rapidly goes fully open or to that predetermined percent of full stroke required to protect the compressor against flows below its surge point plus margin. CCI DRAG Valve Services To Industry CCI's service to the many users of centrifugal compressors starts at the very beginning of our relationship with a compressor user. All engineers in our sales organization are trained to select the correct valve for even the most demanding recycle application. CCI always recommends that its Field Service organization physically assures proper installation and training to make sure of trouble-free startup. For these reasons, CCI customers are assured of buying the correct valve for their compressor recycle application and that they will experience the long-term performance they expect. CCIs Customer Service and Field Service organizations are fully integrated to provide the ultimate service to all DRAG valve customers. Complete files are kept on each and every DRAG valve in service. These include records on any valve that has been upgraded in the field or has been serviced in the past. Customers are routinely contacted to review current DRAG valve performance. The CCI Customer Service organization can respond immediately to many questions that come up, but some problems must be referred to the CCI Field Service organization. Field Service then, through customer consultation, may recommend that a Field Service technician visit the site for a hands-on analysis. Because of their field-proven expertise in recycle valve application, CCI has retrofitted other manufacturers recycle valves with CCIs DRAG design. The end result is improved operation, reduced noise and vibration, and improved recycle valve performance overall.

While pneumatic actuators are usually used, electrohydraulic actuators may be used to assure an even faster stroke time. In any event, compressor recycle actuators and their controllers must be specifically designed and integrated with the DRAG valve designed for this service. While full closed to full operation is suited to most compressor application, there are special cases where this rapid valve function is required over only a portion of total valve travel perhaps only 30 percent. Then, after the emergency condition has been dealt with, the actuator and controller must assume a modulating mode. Corrosion problems have historically been a concern at natural gas liquification facilities as a result of the gases released by the process itself, high humidity, and salt-air environments. To effectively combat these corrosive conditions, CCI uses components throughout its pneumatic actuators in which all exposed surfaces are either stainless steel or are thoroughly coated and protected as needed for the users application.