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

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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:info@ccivalve.com

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