Emerson OLHO

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Fisher Amine Pump Recirculation Solutions


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Technology an d Innovation in Process Control

Application Discussion

In many refineries and gas processing facilities acid gas removal systems are present to remove corrosivegases. The removal, sometimes referred to as sweetening, occurs in a tower called an absorber or contactor.The absorption process removes the acid gases from the hydrocarbon stream yielding a cleaner product while

also protecting critical downstream equipment from damage.

An amine derivative normally is used to remove the acid gases from the hydrocarbon stream. After the acidgases have been removed, the amine is regenerated and pumped back to the top of the absorber to repeat theprocess.

The amine pumps are a critical asset to a gas processing unit. Each amine pump must be protected from lowflow operation and loss of net positive suction head (NPSH), which are conditions that always occur at plantstartup and shutdown. At low flow the pump can overheat, and the amine flowing through the pump canseparate causing vortices that can cavitate and damage the pump. Protection against overheating andcavitation is gained by recirculating a minimum amount of flow to the pump inlet.

A control valve is used to recirculate a portion of the total pump flow back to a collection reservoir. Because of the high pump outlet pressures and low collection vessel pressures, this valve can be exposed to severalchallenges.

n Improper valve selection can cause cavitationdamage to the pump

n Cavitation damage due to high differentialpressures across the valve

n Leakage leading to decreased absorber efficiency

n Inadequate seat load to maintain tight shutoff

n Potential plugging during plant startup

The recirculation valve must reduce pressure ashigh as 1000 psig while avoiding cavitationformation. Cavitation formation is eliminated byunique pressure control of flow through the valve.

Also, the recirculation valve is shut during normaloperation, at which time tight shutoff (ANSI Class V or greater) is critical. Any leakage results in reducedabsorber efficiency along with damage to the valve.

Emerson offers a variety of Fisher control valve solutions that offer protection against cavitation, erosion,plugging, and leakage. Also, to ensure proper operation after installation, a Fisher FIELDVUE Digital ValveController can be used to monitor valve performance. The FIELDVUE DVC provides diagnostic reviews that canbe conducted without interrupting the process in order to identify potential performance issues. This helps toensure proper operation and tight shutoff over the normal service life of the valve.


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Technology and Innovation in Process Control

Severe Service Control Hierarchy

FISHER CUSTOMIZATION

BASIC TECHNOLOGY

FISHER OPTIMIZATION

A large gas plant in Kazakhs tan required 16 val ves with charac terized Dir ty Service Trim(DST) to meet capacit y needs and to eliminate potential erosion caused by cavitationand entrained par ticulate. See D351296X012 at w ww.Fishersevereser vice.com foradditional details.

Amine Pump Recirculation Control Valve Solutions

Patented, multi-s tage, anti-cavitation control trim Combines axial and radial flow pat ter ns that can pass par ticulate without plugging Features protec ted seat design that helps avoid clearance flow erosion for long-term

shutof f integrity

DST Trim

On-of f, automated block v alve or standard trim control valve with restric tion orif ice Restriction orifice downstream to spli t the total pressure drop; optimum operation is

res tricted to one ser vice condition. Hardened trim materials to e xtend ser vice life

Utilizes multi-stage, axial flow process to control pressure drop, prevent cavitation andpass entrained par ticles

Features protec ted seat design that helps avoid clearance flow er osion for long-termshutof f integr ity

Of fered in a wide range of materials to accommodate specific applications needs

NotchFlo Trim

Employs special-shaped orifices and drilled-hole technology in keeping the flowingmedia above its vapor pressure

Used in combination with Fisher high-pressure and high-capacit y valve bodies toprevent cavitation, achieve tight shutof f and reduce v ibration levels

Cavitrol Trim


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NORTH AMERICA

Emerson Process ManagementMarshalltown, Iowa 50158 USAT 1 (641) 754-3011F 1 (641) 754-2830www.EmersonProcess.com/Fisher

ASIA PACIFIC

Emerson Process ManagemeSingapore 128461 SingaporeT +(65) 6777 8211F +(65) 6777 0947www.EmersonProcess.com/Fishe

LATIN AMERICA

Emerson Process ManagementSorocaba, Sao Paulo 18087 BrazilT +(55)(15)238-3788F +(55)(15)228-3300www.EmersonProcess.com/Fisher

EUROPE

Emerson Process ManagementCernay 68700 FranceT +(33) (0)3 89 37 64 00F +(33) (0)3 89 37 65 18www.EmersonProcess.com/Fisher

MIDDLE EAST & AFRICA

Emerson FZEDubai, United Arab EmiratesT +971 4 883 5235F +971 4 883 5312www.EmersonProcess.com/Fisher

D351235X012 CD140 Printed in U.S.A. / April 2006

Fisher Controls International LLC 2006 All Rights Reserved.

Fisher, FIELDVUE, Cavitrol and NotchFlo are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co.The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy they are notto be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All salesare governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Fisher does not assume responsibility for the selection, use or maintenance of any product. Responsibility forproper selection, use and maintenance of any Fisher product remains solely with the purchaser.

Emerson. Your partner in instrument and valve reliability.The way you manage your key production assets directly affects yourplants performance and profitability. Emersons Asset Optimizationcapabilities deliver world-class services and innovative technologies toincrease the availability and performance of mechanical equipment,electrical systems, process equipment, instruments and valves forimproved bottom-line results. Asset Optimization helps you improveprocess availability and attain peak performance, which meanswherever you are in your plants life cyclestartup, maximizingoperations or life extensionby relying on Emersons AssetOptimization capabilities, youll be on the path to realizing the truepotential of your plants instruments and valves.

The Next StepContact your local Emerson Process Management sales office or salesrepresentative location for more information or to make a purchase.

For severe service solutions, see us at www.FisherSevereService.com


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Fisher Boiler Feedwater Regulator Solutions


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Used with constant speed, motor-operated feedpumps, the feedwater regulator valve controls flow to theboiler during normal plant operation when the boiler is under pressure. In this mode the pressure dropsare small, and cavitation is not a concern. The main consideration is stable, reliable throttling operation.

In smaller plants, the feedwater startup and regulator applications often are combined into one control valve.

The combined startup / regulator valve eliminates cumbersome cross-over points and eases operation. During

startup the valve must reduce pressure as high as 6000 psig and prevent cavitation. Upon reaching normal

operating conditions, it then must provide stable control to maintain load and turndown. Turndowns of at

least 75:1 are common. Also, this valve must handle such other conditions as:

n Filling of the boiler prior to firing

n Potential cavitation damage due to high differential pressures

at startup

n Maintaining drum level or plant load during all operating

conditions

n Adequate seat load to prevent leakage while the feedpump is in

recirculation mode

n Control issues that can cause excessive drum level or plant load

swings, potentially tripping the plant during star tup

Emerson has specific Fisher-engineered solutions for variations in plant design. These solutions offer

protection from cavitation, erosion, plugging, and leakage while providing high rangeability. Also, to ensure

proper operation after installation, the Fisher FIELDVUE Digital Valve Controller can be used to monitor valve

performance. The FIELDVUE DVC provides diagnostic reviews without interrupting the process in order to

identify potential performance issues. This helps to ensure proper operation and tight shutoff over the normal

service life of the valve.


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BASIC TECHNOLOGY

FISHER OPTIMIZATION

An existing feedwater regulator valve e xperienced excessive noise and vibr ation due toinadequate trim design. A new valve was ins talled with Cavitrol III trim speciallycharac terized to match the motor drive pump cur ve. Also utilized was a highper formance ac tuation s ystem that allows monitoring the new valve in real time. SeeD351190X012 at w ww.Fishersevereser vice.com for additional details.

Boiler Feedwater Regulator Control Valve Solutions

Employs special-shaped orifices and drilled-hole technology in keeping the f lowingmedia above its vapor pressur e

Used in combination w ith Fisher high-pressure and high-capacity valve bodies toprevent cavitation, achieve tight shutoff and reduce vibration levels

Cavitrol Trim

Standard trim control valve Hardened trim materials to ex tend ser vice life


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Fisher Controls International LLC 2006 All Rights Reserved

Fisher and FIELDVUE are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. The Emerson logois a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.


NORTH AMERICAEmerson Process ManagementMarshalltown, Iowa 50158 USAT 1 (641) 754-3011F 1 (641) 754-2830www.EmersonProcess.com/Fisher

ASIA PACIFIC Emerson Process ManagemeSingapore 128461 SingaporeT +(65) 6777 8211F +(65) 6777 0947www.EmersonProcess.com/Fishe

LATIN AMERICAEmerson Process ManagementSorocaba, Sao Paulo 18087 BrazilT +(55)(15)238-3788F +(55)(15)228-3300www.EmersonProcess.com/Fisher

EUROPE Emerson Process ManagementCernay 68700 FranceT +(33) (0)3 89 37 64 00F +(33) (0)3 89 37 65 18www.EmersonProcess.com/Fisher

MIDDLE EAST & AFRICAEmerson FZEDubai, United Arab EmiratesT +971 4 883 5235F +971 4 883 5312www.EmersonProcess.com/Fisher





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Fisher Compressor Anti-Surge Solutions


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NORTH AMERICA

Emerson Process ManagementMarshalltown, Iowa 50158 USAT 1 (641) 754-3011F 1 (641) 754-2830FisherSevereService.com

ASIA PACIFIC

Emerson Process ManagementSingapore 128461 SingaporeT +(65) 6777 8211F +(65) 6777 0947FisherSevereService.com

LATIN AMERICA

Emerson Process ManagementSorocaba, Sao Paulo 18087 BrazilT +(55)(15)238-3788F +(55)(15)228-3300FisherSevereService.com

EUROPE

Emerson Process ManagementCernay 68700 FranceT +(33) (0)3 89 37 64 00F +(33) (0)3 89 37 65 18FisherSevereService.com


Emerson FZEDubai, United Arab EmiratesT +971 4 883 5235F +971 4 883 5312FisherSevereService.com

Fisher Controls International LLC 2006 All Rights Reserved.Fisher, FIELDVUE, PlantWeb, WhisperFlo and ValveLink are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.






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Fisher Condensate Recirculation Solutions


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The condensate pumps are a critical asset to any power plant. Each condensate pump must be protectedfrom low flow operation and loss of net positive suction head (NPSH), which are conditions that alwaysoccur at plant startup and shutdown. At low flow the pump can overheat, and the water flowing through thepump can separate causing vortices that can cavitate and damage the pump. Protection against overheating

and cavitation is gained by recirculating a minimum amount of flow to the pump inlet.

A control valve is used to recirculate a portion of the total pump flow back to a collection reservoir such as the

condenser hot well. Because of the high pump outlet pressures and low collection vessel pressures, this valve

is exposed to challenging operating conditions. The main challenges with this application are:

n Improper valve selection can cause cavitation damage to the pump

n Cavitation damage due to high differential pressures across the valve

n Leakage leading to valve damage

n Inadequate seat load to maintain tight shutoff

n Potential plugging during plant star tup

The recirculation valve must reduce pressure as high as 600 psig

down to vacuum while avoiding cavitation. Also, a recirculation

valve is shut during normal operation, at which time tight shutoff

(ANSI Class V or greater) is critical. Any leakage results in damage

to the valve as well as added power being consumed by the

condensate pump instead of power sold to the plant's customers.

Emerson offers the broadest line of condensate pump control

valves, which utilize a variety of solutions to protect against

cavitation, erosion, plugging and leakage. The Fisher valve

solution eliminates the cavitation potential by unique pressure control of flow through the valve, and the valve

provides tight shutoff. Also, to ensure proper operation after installation, a Fisher FIELDVUE digital valve

controller can be used to monitor valve performance. Diagnostic reviews can be conducted without

interrupting the process in order to identify potential performance issues. This helps to ensure proper

operation and tight shutoff over the normal service life of the valve.


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Fisher, FIELDVUE, Cavitrol and NotchFlo are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co.The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.











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Fisher Deaerator Level Control Solutions


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Adeaerator removes non-condensable gases that can corrode boiler internals. It does so by heatingincoming condensate to the saturation point in order to reduce the solubility of any entrained gases.These are mainly oxygen, carbon dioxide and ammonia that become very corrosive at elevated temperatures.

The deaerator level control valve is used to control level in the deaerator to maximize elimination of entrained

gases. Because of condensate pump rangeability, the deaerator level control valve has to control a wide range

of process conditions. This valve provides startup and regulating functions in one valve eliminating

cumbersome cross over points and easing operation. During initial operation, this valve must address the

potential for cavitation formation and provide adequate rangeability to address the entire condensate

requirements. Turndowns of at least 75:1 are common.

The deaerator level control valve has to provide high rangeability and stable throttling control. However, this

valve must be designed to handle other conditions such as:

n Filling of the deaerator prior to plant startupn Cavitation potential due to high differential pressures

at startupn Maintaining deaerator level during all operating

conditionsn Adequate seat load to prevent leakage while the

condensate pump is in recirculation moden Providing availability for high plant turndown

Since the deaerator valve is shut during plant startup,tight shutoff (ANSI Class V or greater) is critical. Any

leakage can cause the deaerator level to rise, risking a

plant trip during startup along with damaging to the

valve.

At startup the valve must reduce pressure as high as 600

psig while avoiding cavitation. The cavitation potential

in the deaerator level control valve subsides with the decay in condensate pump pressure. As this occurs and

as system capacity demands increase, the valve must affect a smooth transition from anti-cavitation

protection to that of providing higher flow rates. It also must provide stable control to maintain load and theturndown required (at times, greater than 75:1) during normal plant operation.

Emerson offers specific Fisher-engineered solutions for the variations encountered in plant design. These

solutions provide protection against cavitation, erosion, plugging and leakage while providing the necessary

rangeability. Also, to ensure proper operation after valve installation, a Fisher FIELDVUE Digital Valve

Controller can be used to monitor valve performance. The FIELDVUE DVC provides diagnostic reviews that can

be conduced without interrupting the process in order to identify potential performance issues. This helps to

ensure proper operation and tight shutoff over the normal service life of the valve.


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BASIC TECHNOLOGY

FISHER OPTIMIZATION

Lack of control and recurring cavitation damage were constant problems with acombination rotar y valve/attenuator, t ypically requiring cos tly trim replacement ever yyear. The Fisher solution was a high capacit y globe valve with characterized Cavi trol III,two-stage trim along with the unmatched stem sealing capabilities of ENVIRO-SE ALpacking. See w ww.Fishersevereser vice.com for additional details.

Deaerator Level Control Valve Solutions

Employs special-shaped orifices and drilled-hole technology in keeping the flowing

media above its vapor pressure Used in combination with Fisher high-pressure and high-capacity valve bodies to

prevent cavitation, achieve tight shutoff and reduce vibration levels

Cavitrol Trim

Standard trim control valve Hardened trim materials to ex tend ser vice life


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Fisher, FIELDVUE, Cavitrol and Micro-Flat are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co.The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.


NORTH AMERICAEmerson Process ManagementMarshalltown, Iowa 50158 USA

T 1 (641) 754-3011F 1 (641) 754-2830www.EmersonProcess.com/Fisher

ASIA PACIFIC Emerson Process ManagemeSingapore 128461 Singapore

T +(65) 6777 8211F +(65) 6777 0947www.EmersonProcess.com/Fishe

LATIN AMERICAEmerson Process ManagementSorocaba, Sao Paulo 18087 Brazil

T +(55)(15)238-3788F +(55)(15)228-3300www.EmersonProcess.com/Fisher

EUROPE Emerson Process ManagementCernay 68700 France

T +(33) (0)3 89 37 64 00F +(33) (0)3 89 37 65 18www.EmersonProcess.com/Fisher

MIDDLE EAST & AFRICAEmerson FZEDubai, United Arab Emirates

T +971 4 883 5235F +971 4 883 5312www.EmersonProcess.com/Fisher





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Fisher Expander Bypass Valve Solutions


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Turboexpanders typically are used in natural gas processes that have high feed pressures (greater than 400 psig),varying feed products and where a large amount (greater than 30%) of ethane recovery is desired. Consisting of alternate sets of nozzles and rotating blades through which vapor or gas flows in a steady-state expansion process, the

turboexpander is utilized also to convert the energy of an expanding gas stream into mechanical work.

The use of a turboexpander, however, does not eliminate the need for the Joule Thompson expansion valve that is used in

a conventional refrigeration system. In a turboexpander system the valve typically is referred to as the expander bypass

valve (Figure 1). It enables a more efficient startup and shutdown of the turboexpander. The valve also allows continuing

the process should the turboexpander go offline or if flow increases beyond the full speed capability of the

turboexpander.

There are many factors to consider when selecting the proper valve for expander bypass service:

n Proper valve trim must be chosen to offset the damaging noise and vibration that can occur as process inlet pressures

can vary between 700 and 1500 psig and outlet pressures between 200 and 700 psig.

n At the low temperatures encountered, proper body and trim material selection is important and use of an extension

style bonnet should be considered. Cryogenic temperatures can exist

n To protect the turboexpander in the event of a system upset, the valve

must open quickly.

n Ideally, the valve possesses the same capacity and

flow characteristic as the turboexpander to provide

a seamless transition between the devices.

n The turboexpander is a much more efficientdevice than the valve, making tight shutoff

important to avoid the loss of energy.

n The possibility of hydrate formation in the

line must be considered. Hydrates are solid

compounds formed by the chemical combination

of gas and water under pressure that can cause

deposits to form on the pipe and valve trim. Most

facilities utilize dehydration units to prevent

hydrate formation, and the turboexpanders

are usually installed at the end of the

process. However, this should be explored when selecting the expander bypass valve. If hydrates are present, trims

with small passages can plug and render the valve useless.

Emerson has developed Fisher valve solutions that address the potential for excessive noise at high pressure drops as well

as the need for materials suited to cryogenic service. Additional Fisher control valve solutions offer protection against

erosion, plugging and leakage. Also, to ensure proper operation after installation, a Fisher FIELDVUE Digital Valve

Controller can be used to monitor performance. The FIELDVUE DVC provides diagnostic reviews that can be conducted

without interrupting the process in order to identify potential performance issues. This helps to ensure proper operation

over the normal service life of the valve.

Figure 1. Natural Gas Process Including Turboexpander

and Expander Bypass Valve


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Fisher Controls International LLC 2006 All Rights Reserved.Fisher, FIELDVUE, PlantWeb, WhisperFlo and ValveLink are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.


NORTH AMERICA


ASIA PACIFIC


LATIN AMERICA


EUROPE

Emerson Process ManagementCernay 68700 FranceT +(33) (0)3 89 37 64 00F +(33) (0)3 89 37 65 18www.EmersonProcess.com/Fisher







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Apower plants operating pressure and efficiency are highly dependent upon the performance of itsfeedwater pumps. Each feedwater pump must be protected from low flow operation and loss of netpositive suction head (NPSH), which are conditions that always occur at plant startup and shutdown. At low

flow the pump can overheat, and the water flowing through the pump can separate, causing vortices that

cavitate and damage the pump. Protection against overheating and cavitation is gained by recirculating a

minimum amount of flow to the pump inlet.

Maintaining this minimum flow is the task of the boiler feedpump recirculation valve. It recirculates a portion

of the total pump flow back to a collection reservoir, such as a deaerator or condenser hot well. Because of the

differential between the high pump outlet pressure and the low pressure at the collection vessel, the

recirculation valve is exposed to some of the most difficult operating conditions in the plant. The main

challenges with this application are:

n Improper valve selection that can result in cavitation damage to the pump

n Cavitation damage at the valve and immediate downstream piping due to high

differential pressures across the valve

n Valve leakage due to inadequate seat load, with the leakage causing increased

heat rate and decreased plant efficiency

n Potential valve plugging during plant startup

The feedpump recirculation valve must reduce pressure as high as 6000 psig

down to 50 psig while avoiding cavitation. The Fisher valve solution eliminates

the cavitation potential by unique pressure control of flow through the valve.

Also, the recirculation valve is shut during normal operation, at which time tight

shutoff (ANSI Class V or greater) is critical. Any leakage results in damage to the

valve as well as added power being consumed by the feedwater pump instead of

being sold to the plants customers.

Emerson offers the broadest line of boiler feedpump recirculation control valves, which utilize a variety of

solutions to protect against cavitation, erosion, plugging and leakage. Also, to ensure proper operation after

installation, a Fisher FIELDVUE digital valve controller can be used to monitor valve performance. The

FIELDVUE DVC provides diagnostic reviews that can be conducted without interrupting the process in order to

identify potential performance issues. This helps to ensure proper operation and tight shutoff over the normal

service life of the valve.


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Fisher, FIELDVUE, and Cavitrol are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. TheEmerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.











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Fisher Feedwater Startup Solutions


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The boiler feedwater startup valve is used in many power plants to provide higher rangeability of thefeedwater system, which favorably impacts plant flexibility. However, this valve is used for numerous otherfunctions as well, including:

n Filling of the boiler prior to firing

n Maintaining drum level during startup conditions

n Properly transferring drum level control to a variable speed pump or feedwater regulator valve

n Providing availability for high plant turndown

During filling and plant startup, there is the potential for high pressure differentials across the startup valve.

This condition continues until downstream pressure rises, at which time drum level control transfers to the

variable speed pump or feedwater regulator. Common issues seen with the feedwater regulator valve are:

n Cavitation damage due to high differential pressures across the valve

n Inadequate seat load to maintain tight shutoff, with leakage leading to valve damage

n Potential plugging during plant star tup

n Poor controllability can cause excessive drum level swings, potentially tripping the plant during startup

The feedwater startup valve must reduce pressure as

high as 6000 psig while eliminating the cavitationpotential and providing stable control to maintain

drum level. Since this valve is shut during normal

plant operation, tight shutoff (ANSI Class V or greater)

is critical. Any leakage can make drum level control

difficult and can damage valve trim.

The function of the startup valve can be combined

with the feedwater regulator into one valve.

Combining these valves minimizes piping costs and

eases installation and configuration.

Emerson offers the broad line of Fisher solutions to address the tough feedwater conditions of cavitation,

erosion, plugging and leakage while providing high rangeability. To ensure proper operation after valve

installation, the Fisher FIELDVUE Digital Valve Controller can be used to monitor valve performance. The

FIELDVUE DVC provides diagnostic reviews without interrupting the process in order to identify potential

performance issues. This helps to ensure proper operation and tight shutoff over the normal operating life of

the valve.


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Fisher, FIELDVUE and Cavitrol are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. TheEmerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.











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Fisher Oil Sands SolutionsSteam Separator Letdown


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Emerson has specific Fisher valve and valve trim solutions for steam

separator letdown systems that offer protection from erosion due to

flashing, plugging and leakage while providing excellent control.

Flashing damage is eliminated by utilizing the correct passage shape and

hardened materials. Also, since the letdown valve controls condensate

levels in the steam separator, tight shutoff (ANSI Class V or greater) is

critical. Any leakage results in a decrease of steam injection, which in

turn affects production and can potentially cause valve trim damage.


Extracting oil from the oil sands that are too deep to mine, that are beneath impermeable rock or are unrecoverable due toenvironmental issues, presents challenges to the oil and gas industry. Under severe conditions such as these, conventional oilextraction methods are often ineffective. In-situ thermal recovery, Steam Assisted Gravity Drainage (SAGD) in particular, is extremely

successful for recovery of heavy and extra-heavy oil (bitumen).

A typical SAGD process consists of two horizontal wells placed near the base of an oil sands deposit. A steam injection well is placed a

short vertical distance above a producing well. Steam is injected into the upper well and rises in the formation, creating a steam

chamber. The bitumen surrounding the steam chamber is heated and becomes mobile. Gravity causes the mobilized bitumen and

condensed steam to drain to the producing well and is subsequently brought to the surface via natural steam lift, gas lift or down hole

pump.

Most SAGD facilities generate steam using once-through steam generators, or OTSGs. OTSGs generate steam at a quality of

approximately eighty percent. In order to increase the steam quality for the best thermal efficiency, the low quality steam passes

through a steam separator, which separates the water droplets from the steam and increases the quality to approximately 97 percent

or higher. The level of the condensate that collects in the bottom of the steam separator is controlled by a letdown valve. The letdown

valve may be located directly at the bottom of the steam separator, or it may be placed downstream after multiple heat exchangers.

This valve is exposed to a number of challenges depending on the location:

STEAM SEPARATER

LEVEL LETDOWN

STEAMCONDENSATE

SEPARATOR

STEAM DISTRIBUTIONTO WELLS

SAGD STEAM

WELLHEAD

STEAMWELL

To ensure proper operation after installation, a Fisher FIELDVUE digital valve controller can be used to monitor valve performance. The

FIELDVUE instrument provides diagnostic reviews without interrupting the process in order to identify potential performance issues.

This helps to ensure proper operation and tight shutoff over the normal service life of the valve.

Erosion damage caused by cavitation and/or flashing

Vibration due to high pressure drops

Inadequate seat load to maintain tight shutoff

Reduced capacity

Plugging due to entrained particulate

Flooding of the steam separator

Packing leakage and stem corrosion

STEAM SEPARATOR

LEVEL LETDOWN


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D351711X012 / MU19-CD200 / 10-2008

The Next StepContact your local Emerson Process Management sales office orsales representative location for more information. Their highlyskilled and experienced applications personnel are ready to helpyou take advantage of the many benefits of SAGD solutions.

For severe service solutions, see us at

www.FisherSevereServ ice.com

Fisher Controls International LLC 2008 All Rights ReservedFisher, FIELDVUE, NotchFlo, and Cavitrol are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co.Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy they are notto be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All salesare governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility forthe selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any product remains solely with thepurchaser and end user.

NORTH AMERICA


ASIA PACIFIC


LATIN AMERICA


EUROPE

Emerson Process ManagementChatham, Kent ME4 4QZ EnglandT +44 (0)1634895800F +44 (0)1634895842www.EmersonProcess.com/Fisher




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Fisher Oil Sands SolutionsSteam Distribution and Injection


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D351713X012 / MU47-CD200 / 10-2008


For more severe service solutions, see us atwww.FisherSevereServ ice.com

Fisher Controls International LLC 2008 All Rights ReservedFisher, FIELDVUE, Whisper Trim, and WhisperFlo are marks owned by one of the companies in the Emerson Process Management business division of EmersonElectric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are theproperty of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy they are notto be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All salesare governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility forthe selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any product remains solely with thepurchaser and end user.

NORTH AMERICA


ASIA PACIFIC

Emerson Process ManagemenSingapore 128461 SingaporeT +(65) 6777 8211F +(65) 6777 0947www.EmersonProcess.com/Fisher

LATIN AMERICA


EUROPE





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Fisher Oil Sands SolutionsSteam Generator Blowdown


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Emerson has specific Fisher valve and valve trim solutions for steamer

blowdown systems that offer protection from cavitation, erosion,

plugging and leakage while providing reliable performance. Cavitation

formation is eliminated by unique pressure control of flow through the

valve. Also, since this valve controls condensate level in the steam

separator, tight shutoff (ANSI Class V or greater) is critical. Any leakage

results in a decrease of the steam injection, which in turn affects

production and can potentially cause valve trimdamage.


Extracting oil from the oil sands that are too deep to mine, that are beneath impermeable rock or are unrecoverable due toenvironmental issues, presents challenges to the oil and gas industry. Under severe conditions such as these, conventional oilextraction methods are often ineffective. In-situ thermal recovery, Steam Assisted Gravity Drainage (SAGD) in particular, is extremely

successful for recovery of heavy and extra-heavy oil (bitumen).

A typical SAGD process consists of two horizontal wells placed near the base of an oil sands. A steam injection well is placed a short

vertical distance above a producing well. Steam is injected into the upper well and rises in the formation, creating a steam chamber.

The bitumen surrounding the steam chamber is heated and becomes mobile. Gravity causes the mobilized bitumen and condensed

steam to drain to the producing well and is subsequently brought to the surface via natural steam lift, gas lift or down hole pump.

Most SAGD facilities generate steam using once-through steam generators or OTSGs. Boiler blowdown systems are installed onto these

OTSGs to control start-up and shut-down of the boiler as well as manage blowdown maintenance requirements.

These blowdown valves are exposed to a number of challenges:

Erosion damage caused by low quality steam and particulate

Cavitation damage at start-up

Inadequate seat load to maintain tight shutoff

Plugging due to entrained particulate

Special sizing due to flashing

Packing leakage and stem corrosion

STEAMERBLOWDOWN

ASS

STEAMER

To ensure proper operation after installation, a Fisher FIELDVUE digital valve controller can be used to monitor valve performance. The

FIELDVUE instrument provides diagnostic reviews without interrupting the process in order to identify potential performance issues.

This helps to ensure proper operation and tight shutoff over the normal service life of the valve.


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D351712X012 / MU46-CD200 / 10-2008

Fisher Controls International LLC2008 All Rights ReservedFisher, FIELDVUE, NotchFlo,and Cavitrolaremarksownedbyoneof thecompaniesin theEmerson Process Management businessdivision ofEmerson Electric Co.Emerson Process Management,Emerson,andthe Emersonlogoaretrademarksandservice marksof Emerson ElectricCo.Allothermarksare theproperty oftheirrespective owners.

The contents of thispublication are presented for informational purposes only, and whileevery effort hasbeen made to ensure their accuracy theyare notto be construed aswarrantiesor guarantees, expressed or implied,regarding theproductsor servicesdescribedherein or their useor applicability. All salesare governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility forthe selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any product remains solely with thepurchaser and end user.

NORTH AMERICA


ASIA PACIFIC

Emerson Process ManagemenSingapore 128461 SingaporeT +(65) 6777 8211F +(65) 6777 0947www.EmersonProcess.com/Fisher

LATIN AMERICA


EUROPE



Emerson FZEDubai, United Arab EmiratesT +9714 883 5235F +9714 883 5312www.EmersonProcess.com/Fisher


For severe service solutions, see us at

www.FisherSevereService.com


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Fisher Rich Amine Letdown Solutions


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Amines and other chemicals are used selectively to remove acid gases (H 2S, CO2) from raw natural gasstreams. This makes the gas composition acceptable for sale or for use in other parts of a given process.The gas stream is fed into the bottom of an absorption tower while the absorption liquid is fed into the top of

the tower to create a counter flow contact system. The level valve, also known as the rich amine letdown

valve, controls the liquid level in the tower. Clean gas flows from the top of the absorber.

At the bottom of the absorption tower, the rich amine leaves through the level control valve. The rich amine

then goes to a flash tank where large portions of the absorbed gases are off-gassed. From there, the rich

amine goes through various processes to be regenerated. The control challenge with this application is

created by the entrained gas in the rich-amine solution. As the fluid passes through the letdown valve it takes

a pressure drop due to the pressure differential between the tower and the flash tank. As this pressure drop

takes place, some of the entrained gas comes out of solution; this is called outgassing.

As a result of this outgassing, two-phase flow will develop in the valve. One phase is the liquid amine, the

other involves the CO 2 or H2S that come out of solution. This two-phase flow can produce excessive vibration

and erosion problems. Outgassing requires special consideration in the selection of valve type, trim style and

materials. Generally speaking, the overall approach is dependent on the severity of the pressure drop and the

amount of gas released. Other effects that need to be considered are:

n Vibration due to outgassing of entrained gases in the

process streams

n Erosion due to outgassing, cavitation and flashing

n Valve internal corrosion due to entrained corrosive gases

Emerson has developed specific Fisher valve and trim

selections based on the pressure drop and outgassing for

each installation. These solutions offer protection against

cavitation, erosion, plugging and leakage. Cavitation formation and outgassing effects are eliminated byunique pressure control of flow through the valve. The valves can be exposed to high pressure when closed so

tight shutoff (ANSI Class V or greater) is critical as any leakage results in extensive damage to the valve.

Also, to ensure proper operation after installation, a Fisher FIELDVUE Digital Valve Controller can be used to

monitor valve performance. The FIELDVUE DVC provides diagnostic reviews can be conducted without

interrupting the process in order to identify potential performance issues. This helps to ensure proper

operation and tight shutoff over the normal service life of the valve.


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BASIC TECHNOLOGY

FISHER OPTIMIZATION

The liquid amine solution within a large gas plant in Kazakstan contained a subs tantialvolume of entrained gas. Special-design, high-capaci ty Fisher valves were utilized toaddress the need for expansion of the gases as well as the erosive ef fects associated withoutgassing. See D351296X012 at w ww.Fishersevereser vice.com for additional details.

Rich Amine Letdown Control Valve Solutions

Patented, mul ti-stage, anti-cavitation control trim Combines axial and radial flow pat terns that can pass par ticulate without plugging Features protected seat design that helps avoid clearance flow erosion for long-term

shutof f integrit y

DST Trim

Standard trim control val ve Hardened trim materials to e xtend ser vice life Flow direction to accommodate rapid gas expansion Downstream pipe designed to accommodate rapid fluid expansion

Utilizes multi-stage, axial flow process to control pressure drop, prevent cavitation andpass entrained par ticles

Features protec ted seat design that helps avoid clearance flow erosion for long-termshutof f integrity

NotchFlo Trim

Utilizes multiple orifices of special shape, size and spacing to achieve noise reductionsto 30 dBA

Process flow-up technique keeps energy sources away from critical trim par ts Trim parts furnished in hardened mater ials to extend ser vice life

Whisper Trim


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Fisher Controls International LLC 2006 All Rights Reserved.

Fisher, FIELDVUE, Whisper Trim and ENVIRO-SEAL are marks owned by one of the companies in the Emerson Process Management business division of EmersonElectric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.



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Fisher Separator Letdown(HHPS & CHPS) Solutions


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The hydrotreating process removes undesirable materials (sour gases) from a feedstock and converts heavyfeedstocks into lighter components by selective reactions with hydrogen in a heated catalyst bed. Thisprocess typically is most used in the production of gasoline and diesel fuel to remove sulfur, nitrogen and

certain metal contaminants.The hydrotreating reactor operates at high temperature to convert 40 to 50 percent (volume) of the reactoreffluent to a material that boils below 400 degrees. The effluent goes through heat exchangers to the hot highpressure separator (HHPS) where thehydrogen-rich gases flash off. Thehydrogen rich gases undergoadditional separation in the cold highpressure separator (CHPS).

Remaining hydrogen rich gases aresent to the first stage of the processfor mixing with additional hydrogenand the fresh feed. The liquid effluentfrom both the HHPS and CHPS is sentto a fractionation column where thelighter gases are taken off overhead.Light and heavy naphtha, jet fuel anddiesel fuel are removed as liquid sidestreams.

The HHPS and CHPS each have twoletdown valves that maintainseparator level to ensure properseparation of liquid and gas products.Because of the multiple constituentsinvolved along with the entrained gases and catalyst, these valvesare exposed to a number of challenges:

n Special sizing due to flashing and outgassing

n Vibration due to outgassing of entrained gases

n Erosion due to outgassing, cavitation, flashing and entrainedcatalyst

n High temperatures requiring thermally-compensated trim

n Internal corrosion due to entrained corrosive gases

The valves also can be exposed to high pressure when closed, sotight shutoff (ANSI Class V or greater) is critical. Any leakage canresult in extensive damage to the valve.

Emerson has specific Fisher sizing and engineered solutions for all separator letdown applications. Thesesolutions are designed to address outgassing effects that can occur in most HHPS letdown valves and someCHPS letdown valves. They offer protection against cavitation, erosion, plugging and leakage.

Also, to ensure proper operation after installation, a Fisher FIELDVUE Digital Valve Controller can be used tomonitor valve performance. The FIELDVUE DVC provides diagnostic reviews without interrupting the processin order to identify potential performance issues. This helps to ensure proper operation and tight shutoff overthe normal service life of the valve.

Generic Hydrocracking Process Flow Diagram

Cold High Pressure Separator and Sour Water Flash Drum


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Fisher Sky Vent Solutions


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Valves within the sky vent system of a combined cycle plant serve one of the more important controlfunctions. During initial operation of the HRSG, these valves bypass steam (HP/HRH/LP) around thesteam turbine to ensure that the unit doesn't come up to temperature too quickly. This is done as the processlines are warmed prior to admitting steam through the turbine bypass valves that dump to the condenser.

The large pressure differential across the sky vent valve can cause high noise levels that need to be attenuated.

To reduce the noise potential, the pressure drop is split between the valve and a downstream diffuser or

silencer. The pressure split also serves to optimize the size of each component. Other key challenges to this

application are:

n

High temperatures (1065F) require the use of high-alloy materials and thermally compensated trim designs

n Valve leakage due to inadequate seat load, with the leakage causing reduced plant load and efficiency as

well as valve damage

n Fast opening in case of a plant upset condition

n Properly addressing noise for two separate noise sources (valve and diffuser or silencer)

Emerson offers specific Fisher-engineered solutions for various sky vent designs. The sky vent system is

optimized for each application to maximize performance from the valve and diffuser or silencer, while

minimizing size and weight. Noise attenuation is accomplished by utilizing unique pressure control of flow

through the valve and diffuser or silencer. Also, since the valve is closed after startup, tight shutoff (ANSI Class

V or greater) is critical. Any leakage can reduce unit capacity and increase heat rate, along with causing

damage to the valve.

To ensure proper operation after installation, a Fisher FIELDVUE Digital Valve Controller can be utilized on the

sky vent valve to monitor valve performance. The FIELDVUE DVC provides diagnostic reviews that can be

conducted without interrupting the process in order to identify potential performance issues. This helps to

ensure proper operation and tight shutoff over the normal service life of the valve.


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Fisher, FIELDVUE, WhisperFlo and Whisper Trim are marks owned by one of the companies in the Emerson Process Management business division of EmersonElectric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.











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Fisher Sootblower Solutions


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Fouling of the boiler tubes becomes a concern when firing fuels such as coal, oil, biomass or other wasteproducts. Deposits from the combustion process can collect on the heat exchanging tubes, reducingthermal efficiency and causing operational difficulties. To keep the unit operating an online cleaning methodmust be used. This is usually accomplished by using what are called sootblowers. There are several types of

sootblowing media with steam being the most common.

Steam sootblowing systems present a control challenge due to the combination of high pressure (2400 - 3600

psig) and temperature (650F - 950F). Others challenges include:

n Noise and vibration due to high pressure differential and small pipe size

n Thermal cycling caused by on/off operation

n Tight shutoff to protect trim and to minimize steam loss

Emerson offers specific Fisher-engineered solutions for various sootblower designs. Fisher sootblower trim

offers protection from noise, vibration, erosion, thermal cycling and leakage while providing high rangeability.

Noise generation is limited via frequency shifting using drilled-hole trim. A heavy-duty, plug to stem

connection protects against thermal cycling and fatigue. Since this valve is closed after startup, tight shutoff

(ANSI Class V or greater) is critical as any leakage can reduce unit capacity, increase heat rate and cause

damage the valve trim.

To ensure proper operation after installation, a Fisher FIELDVUE Digital Valve Controller can be used to

monitor valve performance. The FIELDVUE DVC provides diagnostic reviews that can be conducted without

interrupting the process in order to identify potential performance issues. This helps ensure proper operation

and tight shutoff over the normal service life of the valve.


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BASIC TECHNOLOGY

FISHER OPTIMIZATION

Most sootblower applications e xperience vibration due to high pressur e drop, high f lowrates and small piping. Fisher sootblower trim consis ting of Whisper Trim III andspecially construc ted valve internals eliminates damage due to these effects. At one U.S.plant this solution has yet to experience leakage or failur e af ter 25,000 c ycles. SeeD351072X012 at w ww.Fishersevereservice.com for additional details.

Sootblower Control Valve Solutions

On-of f or throt tling standard control valve Tight shutoff cons truc tion Reinforced par ts to resist vibr ation damage Hardened trim materials to e xtend service life

Utilizes multiple orifices of special shape, size and spacing to achieve noise reduc tionsto 30 dBA

Process f low-up technique keeps energy sources away from critical trim par ts Trim parts furnished in hardened materials to extend ser vice life

Whisper Trim


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Fisher and FIELDVUE are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. The Emerson logois a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.











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Fisher Superheater and ReheaterAttemperator Solutions


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As with any superheated steam cycle, the temperature of the superheat needs to be controlled to ensurethat it does not exceed the material limits of the steam turbine and boiler. Temperature control isaccomplished by use of an attemperator or desuperheater that injects a controlled amount of cooling water

into the superheated steam flow.

There are two types of attemperation systems in power plants: superheat attemperation and reheat

attemperation. Superheat attemperation occurs in the superheater section prior to steam introduction into

the high-pressure steam turbine. Reheat is applied to steam that is exhausted from the high-pressure turbine.

The steam is sent through the boiler again to gain more heat before being admitted into the IP/LP turbine.

Attemperator spray water flow is regulated by an external control valve. For proper temperature control, the

spray water valve must react quickly to downstream temperature variations, and at low flows, provide the

rangeability needed to handle multiple operating loads. Critical performance criteria are:

n Accurate control at low flow and wide rangeability to maintain superheater outlet temperature

n Adequate seat load to prevent leakage during plant startup

n Fast-acting response to steam temperature changes

The reheat attemperator uses water from the main boiler

feedwater line to control reheat steam temperature. Because

the spray water is taken from the main feedwater line and the

cold reheat is at a much lower pressure than high pressure

steam, cavitation concerns arise, in addition to those above.

Emerson offers specific Fisher-engineered solutions for

variations in plant design for both superheat and reheat

attemperators. These solutions offer protection from

cavitation, erosion, plugging and leakage while providing high rangeability. The reheat attemperator spray

valve in particular can be exposed to the potential for cavitation. Cavitation formation is eliminated by unique

pressure control of flow through the valve. Also, since these valves can be exposed to full pump pressure

during plant startup, tight shutoff (ANSI Class V or greater) is critical. Any leakage can have an effect on steamtemperature, which in turn affects heat rate and efficiency along with potentially causing valve trim damage.


monitor valve performance. The FIELDVUE DVC provides diagnostic reviews without interrupting the process

in order to identify potential performance issues. This helps to ensure proper operation and tight shutoff over

the normal service life of the valve.


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BASIC TECHNOLOGY

FISHER OPTIMIZATION

Original valves in a supercritical power plant experienced repeated pack ing failures andtrim erosion. Replacements using Fisher cus tomized v alve plugs and drilled-hole cagesprovide the required high tur ndown and also prevent the valves from continuallyoperating near the seat, thereby eliminating tr im erosion. Pack ing failure was solved byusing Fisher High-Seal live-loaded packing. See D351191X012 atwww.Fishersevereser vice.com for additional details.

Superheater & Reheater Attemperator Spray Control Valve Solutions

Eliminates cavitation at higher flow rates Prevents cav itation damage to the val ve seat at low flow conditions Maintains Class V shutof f capability Standard hardened trim materials provide e xcellent wear resis tance

Reheater Attemperator S pray

Cavitrol III,Micro-Flat Trim

Standard trim control valve Trims designed for low-flow control Hardened trim materials to ex tend ser vice life Angle valves to ex tend body life

Tight shutof f construc tion


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Fisher Turbine Bypass Solutions


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The turbine bypass valves isolate the steam turbine from the boiler during startup, shutdown and loaddisturbances. This protects the turbine from water carry-over and protects additional plant equipmentfrom large thermal transients. Also, by isolating the boiler and steam turbine it is possible to reduce fuel

consumption during startup and shutdown. In the event of a load rejection, reloading times through the

turbine bypass system are improved by allowing the boiler to remain online.

The turbine bypass system is designed to provide the quickest startup time by controlling both boiler pressure

and temperature. This requires accurate throttling performance to control steam pressure and accurate

temperature control to protect downstream equipment by matching conditions normally experienced exiting

the turbine. Other critical concerns are:

n High pressure differential can lead to noise generation and piping vibrationn Steam temperature control to prevent damage to downstream equipment

n High temperature gradient across the valve

n High temperatures (1065F) require the use of high-

alloy materials and thermally compensated trim

designs

n Inadequate seat load can reduce plant load and

efficiency while causing valve damage

n Fast opening in case of a plant upset condition

Emerson offers specific Fisher engineered solutions for

various turbine bypass designs. Each incorporates

accurate throttling and noise control within the valve

trim and accurate temperature control within the steam

conditioning section. Noise attenuation is accomplished

by utilizing unique pressure control of flow through the valve. The specially designed spray nozzles in the

steam conditioning section provide accurate temperature control with wide rangeability. Since this valve is

closed after startup, tight shutoff (ANSI Class V or greater) is critical as any leakage can reduce unit capacity,increase heat rate and damage the valve trim.


monitor valve performance. The FIELDVUE DVC provides diagnostic reviews that can be conducted without

interrupting the process in order to identify potential performance issues. This helps ensure proper operation

and tight shutoff over the service life of the valve.


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BASIC TECHNOLOGY

FISHER OPTIMIZATION

A combined cycle power plant installed Fisher TBX valves to address turbine bypassneeds. The valve trim and ac tuation system were specially matched to the star tupprofile of the facilit y to minimize s tar tup times and address such critical issues asvibration and shutof f. See D351138X012 at w ww.Fishersevereser vice.com for additionaldetails.

Turbine Bypass Con

Documents

Emerson OLHO