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CCI DRAG® Compressor RecycleAnti-surge Valve
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Severe Service Anti-surge and Compressor Recycle Solution
The optimum solution for safety and reliability, CCI’s compressor recycle
and anti-surge valve combines premium DRAG® flow control technology
with reliable fast stroking actuation. The result is a complete severe service
valve solution designed to maximize the reliability, efficiency, and control
of your compressor recycle system. Within this solution, the DRAG® disk
stack controls flow velocity to provide low noise and exceptional reliability.
Flow energy and velocity is controlled to minimize wear and ensure reliable
performance and longevity. Control is provided by CCI’s fast acting
pneumatic actuator which provides one second stroking times, fast and
accurate control, and simple and reliable operation. Benefits of this proven
design include:
Fast actuation and continual control
Reliable performance with proven technology
Exceptional shutoff with minimized leakage
Proven attenuation of noise and vibration
Customized DRAG® Trim to Maximize Performance
CCI custom-designed DRAG® trim is ideally suited to minimize noise
while providing the capacity and control that is necessary in anti-surge and
compressor recycle applications. For these applications, the multi-stage
DRAG® disk stack is in the lower portion of the trim to provide control
and maximize noise attenuation. Slotted or drilled-hole-cage trim can be
provided in the upper portion of the stack to provide additional capacity for
when compressor bypass is required in addition to anti-surge.
Accurate Control and Reliable Operation
CCI’s long history of developing advanced technology valves and actuation
systems has led to the development of the most reliable pneumatic actuation
system available for a severe service control valve. CCI has supplied this
design worldwide for the past 30 years as a reliable, accurate, and fast acting
control solution. For anti-surge and recycle applications, CCI’s pneumatic
actuation system can deliver stroke speeds of less than one second while
maintaining precise resolution and control.
Control systems on gas compression trains place great demands on the
control valves within the process. Requirements for continual control, with
the ability to provide full capacity within seconds, add to the strains on
the valves in the system. CCI’s compressor recycle and anti-surge solutions
combine established trim and actuation designs to provide optimal
performance and continued valve longevity.
Figure 1: DRAG® disk stack with multi-stage tortuous path gas flows shown in the lower portion and slotted cage in the upper portion.
Fast response with precise control.
Figure 3: Typical anti-surge system: A compressor anti-surge valve is controlled by inlet flow and differential pressure across the compressor.
Figure 2: Forged body anti-surge valve with fast acting pneumatic actuator.
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Figure 6: Optimized High Speed Actuator Control Schematic
ValvePositioner
Input
Signal
Power
Signal
Exhaust
Large Volume Booster
PneumaticActuatorDoubleActing
Large Volume Booster
Quick ExhaustValve
Small Volume Booster
Large Volume Booster
Figure 4: Fast acting pneumatic actuator with accessories.
Figure 5: Valve Position vs Time Opening
0 1 2 3
25
50
75
100
0
Perc
ent
of
Full
Str
oke
Ch
ang
e
Time (Seconds)
Position Signal
StrokeStroke
Exceptional reliability.
Improve Plant Efficiency – Eliminate Energy Waste
During normal operation, any leakage past an anti-surge valve creates wasted
energy and increased cost. A leaking anti-surge valve causes fluid to return to
the suction side of the compressor, which causes the driver to work harder for
the same output. Subsequently, the money spent compressing the additional
gas is lost.
CCI anti-surge DRAG® valves are designed with either a soft or hard seat to
ensure either an ANSI/FCI 70-2 Class VI or ANSI/FCI 70-2 Class V shutoff.
This design provides dependable and repeatable shutoff for long periods
of time over very high pressure differentials. The CCI anti-surge valve
minimizes lost energy through leakage and lost production which results in
significant cost savings.
Capacity and Control for Anti-surge Applications
For turbocompressors, the consequences of surge are severe. Surge is a
powerful disturbance that can disrupt or trip a process. It can damage
equipment, and in catastrophic incidents, may result in the complete
destruction of the compressor rotor. To avoid compressor surge, selection of
the correct control valve is mandatory.
Because the consequences of surge are too costly to ignore, surge protection
is necessary for all turbocompressors. Properly sized and engineered anti-
surge recycle valves and their reliable operation are critical to protect the
compressor. The valve capacity must be large enough to prevent surge under
all possible operating conditions, including start-up and shut down, without
being oversized. An excessively large valve will provide poor control precision
and will drive the compressor into choked flow when fully open. The CCI
anti-surge valve design maximizes control while providing reliable and safe
protection from compressor surge.
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Valve Performance Characteristics (% Cv vs. % Stroke)Flow curves are custom characterized to accommodate a wide range of variables.
Balanced Construction
Minimizes thrust requirements and speeds actuation.
Linear Trim
Bonnet Extension (Optional)
Excellent for cryogenic applications.
High Capacity Bilinear Trim
Expanded Outlet
Lower fluid velocity.
Long Stroke
Exceptional resolution and fine control.
Multi-stage DRAG® Technology
Ensures low noise/vibration levels.
Soft or Hard Seat
Repeatable tight shutoff.
Quick Change Trim
Minimizes maintenance costs.
Low noise and low vibration.
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Benefits CCI DRAG® Competitors
1 One second stroke time to optimize performance and safety.
2 Precise control throughout the operating range of the valve.
3 Repeatable Class V or VI shutoff to minimize leakage.
4 CCI DRAG® trim to control fluid velocity and minimize noise and vibration.
5 Control and capacity necessary to protect equipment during surge and bypass conditions.
6 Bilinear flow characterization available to eliminate the need for additional bypass valves.
7 Extended trim life through the reduction of flow velocity through DRAG® trim.
8 Quick change trim to minimize maintenance costs.
9 Reliable design with proven CCI technology.
Use this checklist to evaluate the benefits of CCI’s compressor recycle/anti-surge valve.
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Component Item No.
Materials of Construction
Standard Optional
Body 1 A105/WCB A182-F316
Bonnet 2 A105 A182-F316
Disk Stack (Cage) 3 316 SS 316 SS
Plug 4 316 SS 316 SS
Stem 5 17-4 PH 17-4 PH
Seat Ring 6 316 SS 316 SS/Stellite
Balance Seal 7 Teflon Teflon
Table 2: Materials
2
7
3
4
5
6
6
1BALANCE SEAL
ORIENTATION
Stroke Speed, Modulating
Fast, 1-2 Seconds
Emergency Trip Less Than 1 second
Resolution Less than 1%
Thrust 3 to 5 Times Industry Standard
Reliability Very Reliable and Robust
Maintenance Easy, with Medium Skills
Components Low Pressure, Reliable Accessories
Table 1: CCI Pneumatic Actuator Performance
Standard Optional
Valve Characteristics(% Cv vs % Opening)
Linear Bilinear
Shutoff Class ANSI/FCI Class VI ANSI/FCI Class V
Actuator Type Double Acting Pneumatic Piston Double Acting Pneumatic Piston
Stroking Speed Less Than 1 Second Less Than 1 Second
Fail Mode Open Open
Resolution <1% <1%
Table 3: Performance Data
Technical specifications and materials.
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7 Application Details
Table 4: Typical DRAG® Valve Applications In Compressor Recycle Service
Application DifferentialPressure
Temperature Inlet/Outlet
Gas Production
Separation 300-3000 psi2.1-21 MPa
100-200°F37-93°C
4-12”/6-16”100-300 mm/150-400 mm
Reinjection 3000 psi21 MPa
100-150°F37-65°C
4-8”/6-8”100-200 mm/150-200 mm
Gas
Hydrogen 70-300 psi0.48-2.1 MPa
100-130ºF37-54°C
6-12”/8-14”150-300 mm/200-355 mm
Natural Gas 100-150 psi0.69-1 MPa
100-120°F37-49°C
8-24”/10-30”200-600mm/255-760 mm
Ammonia 50-100 psi0.34-0.69 MPa
100-200°F37-93°C
4-8”/6-12”100-200 mm/150-300 mm
Air 50-700 psi0.34-4.8 MPa
100-200°F37-93°C
4-16”/6-24”100-400 mm/150-600 mm
LNG
Propane 80-400 psi.55-2.7 MPa
-94-248°F-70-120°C
8-24”/10-24”200-600 mm/25-600 mm
Material Refrigerant
150-700 psi1-4.8 MPa
-49-212°F-45-100°C
12-24”/18-32”300-600 mm/450-800 mm
Olefins
Syngas 300-500 psi2.1-3.4 MPa
100-120ºF37-49°C
4-8”/6-10”100-200 mm/150-250 mm
Propane 50-150 psi0.34-1 MPa
50-150°F10-65°C
6-16”/8-16”150-400 mm/200-400 mm
Ethylene 100-500 psi0.69-3.4 MPa
20-50°F-6-10°C
4-6”/6-10”100-150 mm/150-250 mm
Multicomponent 50-300 psi0.34-2.1 MPa
100-150°F37-65°C
6-8”/8-12”150-200 mm/200-300 mm
Figure 8: Globe body anti-surge valve with fast stroking pneumatic piston actuator.
Figure 7: Tortuous path punched disks within the DRAG® disk stack control noise and vibration.
CCI World Headquarters—CaliforniaTelephone: (949) 858-1877Fax: (949) 858-187822591 Avenida EmpresaRancho Santa Margarita,California 92688 USA
CCI Switzerland (Sulzer Valves)Telephone: 41 52 262 11 66Fax: 41 52 262 01 65Hegifeldstrasse 10CH-8404 WinterthurSwitzerland
CCI ChinaTelephone: 86 10 6501 0350 Fax: 86 10 6501 0286Room 567/569 Office Tower, Poly Plaza14 Dongzhimen South AvenueBeijing 100027China
DRAG is a registered trademark of CCI.©2003 CCI 274 01/03 7K
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.
Contact us at:[email protected]
Visit us online at:www.ccivalve.com
CCI KoreaTelephone: 82 31 980 9800Fax: 82 31 985 055226-17, Pungmu-DongGimpo City, Kyunggi-Do 415-070Republic of Korea
CCI JapanTelephone: 81 726 41 7197Fax: 81 726 41 7198194-2, ShukunoshoIbaraki-City, Osaka 567-0051Japan
CCI Sweden (BTG Valves)Telephone: 46 533 689 600Fax: 46 533 689 601Box 603SE-661 29 SäffleSweden
Sales and service locations worldwide.
CCI Austria(Spectris Components GmbH)Telephone: 43 1 869 27 40 Fax: 43 1 865 36 03Carlbergergasse 38/Pf.19AT-1233 ViennaAustria
CCI Italy(STI)Telephone: 39 035 29289 Fax: 39 035 2928246Via G. Pascoli 10 A-B24020 Gorle, Bergamo