GE Severe Service Valves masoneilan 77000 series Brochure

GE Oil & Gas
Masoneilan*
77000 Series
High Pressure Labyrinth Trim Control Valves
Integrated Smart Engineered
Best Fit Solutions
• Engineering Expertise
• Leading Technology
• Longer Service Life
77000 Series: High-Pressure
Labyrinth Trim Control Valve
GE’s Masoneilan 77000 Series axial flow, labyrinth trim control
valve combines decades of engineering expertise with leading
technology and in-depth customer application knowledge.
With a multi-stage, expanding area flow passage, the 77000
Series valve is designed to effectively handle difficult pressure
reduction applications while managing noise and vibration
levels that can otherwise severely damage equipment. The
result is smoother process flow and longer service life, which
not only saves time and money, but also mitigates risks in
demanding and crucial applications.
Used across a wide range of process applications, the 77000
Series controls high-pressure compressible fluids without
the erosion, vibration and high noise levels associated with
conventionally designed control valves. The 77000 Series is
also particularly well-suited for service applications involving
two-phase flow for either gas with entrained liquids/solids
or liquids with entrained solids. From upstream oil and gas
production to downstream refining and petrochemical
processing to some of the most severe steam applications in
power generation, the 77000 Series valve stands up to intense
temperatures and high pressures.
Customer Benefits
•Cost savings
•Improved process control
•Increased uptime
•Longer service life
•Maintenance simplicity
•Risk mitigation
Industries and Applications
UPSTREAM OIL AND GAS
High pressure, erosive-choke applications
Steam injection for tar sand oil extraction
DOWNSTREAM OIL AND GAS:
Refining and Petrochemical
High-pressure process control applications
Hot , high pressure separation
Delayed coker letdown
PTA crystallizer blow down
POWER GENERATION
Superheater bypass
Boiler blowdown
2 | GE Oil & Gas
Proven Control
Through Advanced Design
Multi-Stage, Expanding Area
Pressure Reduction
Using proven principles of energy management technology,
the 77000 Series gradually reduces fluid pressure, yielding
dramatically reduced noise and vibration. The product features
a multi-stage trim design that creates flow path friction to
simulate the gradual pressure loss that occurs over long
pipelines. This effect is produced by passing the fluid through a
tortuous flow pattern with multiple restrictions, referred to as
pressure reduction stages. Consequently, energy is dissipated
through high head loss without undesirable shock waves.
high-pressure-drop environments. The 77000 Series’ advanced
design results in minimized fluid velocity, which reduces erosion
damage to the trim and downstream process equipment,
particularly in applications—such as wellhead chokes in the oil
and gas industry—that include particulate in the flow stream.
Additionally, the 77000 Series’ low velocity outlet area minimizes
phase transformation process effects. That is an advantage for
many applications that experience flashing or hydrate service
conditions, such as startup valves in supercritical power plants,
hot high-pressure separator letdown valves in refineries, and
gas injection valves in gas extraction plants.
By reducing fluid velocity throughout the throttling process, the
77000 Series’ advanced design eliminates the damaging erosive
effects caused by high kinetic energy spikes and vibration.
The unique flow area of the 77000 Series trim gradually
increases at successive trim stages and offers an enlarged
outlet connection. The expanded flow areas are designed
to compensate for the change in gas density resulting from
pressure reduction, thus making the 77000 Series well-suited
for high-pressure-drop off-gassing applications. With more
than 30 years of installed experience, the Masoneilan 77000
Series has performed successfully in some of the most extreme
77000 Series - Axial Flow Labyrinth Trim Control Valves | 3
Engineered Features
Axial Flow, Unison Throttling
The 77000 Series design separates itself from more conventional
pressure-reducing valves by nature of its multi-stage axial flow
path design. Unlike radial flow path designs, the 77000 Series
throttles the fluid across successively larger stages along the axis
of the valve plug. With up to nine separate stages, the control
valve positions each stage so that they all operate in unison as
the plug strokes, ensuring that the fluid energy is managed in a
controlled manner to avoid cavitation. This design concept avoids
the stair-step performance that can characterize many radial
flow path designs. No single stage or radial flow path trim can
match the performance of the 77000 Series.
Travel vs Cv
Tight Shutoff, Upstream Seat,
Durable Trim Design
Seat protection in a high-pressure valve
design is critical to prevent premature seat
wear leading to unwanted and undetected
leakage. A damaged valve seat can lead to wire
drawing and eventually to rapid trim damage
from cavitation or flashing when the valve is in
the closed position. Seat damage effects are
minimized in the 77000 Series by locating the
seat on the upstream section of the trim. This
design feature ensures that the seat is isolated
from the most severe and potentially damaging
pressure-reduction
stages, which
are located in the
downstream section
of the trim.
4 | GE Oil & Gas
Unbalanced,
Flow-to-Open
Design
The 77000 Series employs
a simple unbalanced plug
design that eliminates any
secondary leak paths that
could compromise shutoff integrity. The resulting high-actuator
loads are managed by using an offset actuator where loading
forces are multiplied by the actuator lever arm. The flow-toopen trim orientation can be useful for applications where
service conditions warrant a reliable failure mode.
Trash-Tolerant, Robust Design
The 77000 Series provides large flow paths that allow for
the passage of flow-entrained particulate, which can clog
conventional drilled-hole or stacked-disk trim. The smooth axial
flow path allows particulate to move through the valve without
navigating complex trim geometry. This prevents plugging
and galling of the trim, which can lead to loss of capacity or
premature valve failure. The 77000 Series has a proven track
record in many high-pressure, dirty-service applications where
a robust valve design delivers essential reliability.
Flexible Platform, Ease-of-Maintenance
The 77000 Series design comes in two styles for easy trim access
in the field. A bottom-loaded, flanged-end connection is ideal
for process plants, while a top-loaded, butt-weld end design
works well in high- pressure power applications. Both styles offer
flex- ibility and simple field maintenance for reduced service
complexity and cost.
Oil & Gas
UPSTREAM
A staple in the oil and gas Industry for high-pressure-letdown
process control, the 77000 Series has solved a variety of severeservice challenges throughout the industry. The 77000 Series’
compact design is ideal for high-pressure, erosive-choke applications in wellheads. It has solved many challenges associated with
controlling high-pressure letdown involving dirty fluids.
High-Pressure Choke Valves
The 77000 Series choke valve has
hundreds of world-wide installations with
more than 30 years of successful service
life in active wells—some with pressures
exceeding 300 Bar and startup conditions
in excess of 400 Bar. Designed with a
progressively expanding trim, the 77000
Series stages pressure reduction with the
smallest pressure drop at the final stage,
which is the point where the pressure approaches or drops
below the fluid vapor pressure. This minimizes the damaging
effects of flashing, cavitation, and gas icing (hydrates). These
benefits also make the 77000 Series an ideal solution for injection and extraction at underground gas storage facilities.
The 77000 Series choke valve is available with three interchangeable trim designs for each valve size (Trims A, B and C). Each
incremental trim designation features less flow restriction and
thus higher capacity. These flexible options adapt to pressure
decreases over the course of a well’s life. During initial implementation, the 77000 Series offers higher resistance and staging
to minimize the effects of high-pressure reduction in new wells.
Later, as the pressure gradually drops, the valve can be easily
retrofitted with a trim configuration that provides less restriction.
In addition to trim flexibility, the 77000 Series is also available
with hardened materials such as boronized stainless steel
trim and stellite-clad bodies to provide superior resistance to
entrained solids within the flow stream. The result is minimal
field maintenance. In addition, the trim’s area expansion further
reduces the fluid velocity, thus limiting the erosive effects where
the particulate in the fluid stream interacts with the valve trim.
Another advantage of the 77000 Series in high- pressure choke
applications is its compact mount- ing. A lever arm design
amplifies the force of the off-set actuator and minimizes the
installation size for space-saving, lightweight implementation
on offshore platforms. Additionally, the off-set actuator can be
inverted, which reduces the overall height of the assembly so
that the valve can be installed and accessed in the tight spaces
between platform decks.
For sour service applications, the 77000 Series design can be
configured with several designs for tight fugi- tive emissions
regulations, including packing designs qualified to ISO 15848
specifications.
Steam Generation for SAGD
Many of today’s oil fields are in regions that have a more dense
oil product called bitumen—commonly referred to as tar sands.
This heavier product is more difficult to extract and process
through traditional methods. Recovery techniques often
require the injection of steam into the bitumen to reduce the oil
viscosity and allow the oil to flow more freely—a process that
requires extremely rugged valves.
Available in durable, high-temperature materials, the 77000
Series serves as a reliable steam injection valve that offers high
performance and long service life. As the pressure in the well
varies, the 77000 Series can provide the necessary range of
differential pressure drop via the staged trim design. Further,
the valve is designed to handle two-phase flow in cases where
steam and condensate are mixed. Under these conditions, the
77000 Series can prevent trim damage caused by condensate
flashing as it changes phase.
With its rugged design, the 77000 Series serves as a reliable
control valve that offers high performance and lower cost of
ownership. Whether the application is for a steam generator
startup system or for the steam injection system, the 77000
Series is well-suited to handle the erosive effects of wet steam
under high- pressure-drop conditions.
Depressurizing Valves
The 77000 Series design is well-suited for depressurizing
valve applications in gas production facilities. The pressure
reduction from the high- pressure gas line to the low-pressure
flare header poses some application challenges such as noise
with associated vibration, leakage, and hydrate formation.
For this service, the
77000 Series features a
trash-tolerant trim design
with multi-stage pressure
reduction for noise and
hydrate control, and an
unbalanced plug for Class
V or MSS SP-61 shutoff.
77000 Series - Axial Flow Labyrinth Trim Control Valves | 5
Oil & Gas
DOWNSTREAM
Refining
Continued global demand for improved production yields,
reduced pollutants, and increased plant effi- ciencies has led to
the use of the latest technology in refining and petrochemical
processes. The 77000 Series valve, with its unique features and
rugged design, is a leading technology platform that helps users
meet these demanding requirements.
Some of the most advanced refinery units in the industry are
those associated with hydroprocessing. The processes of
hydrocracking, hydrotreating, resid- hydrocracking, and catalytic
dewaxing can improve production yields from lower grade
feedstocks while also removing the damaging pollutants that
would prevent compliance with ever-increasing environmental
standards for fuels. These processes include critical applications
where control valves require a combination of high-pressure
letdown with cavitation prevention, passing of entrained solids,
and handling of multi-phase flow.
Available in stainless steels and advanced alloys, the 77000
Series valve offers long-term resistance to corrosive fluids. In
addition, the 77000 Series’ enlarged flow passages prevent
clogging caused by catalyst carryover, while preventing choking due to expansion of entrained gases. For a more robust
design and long-term wear protection, material options include
valve trim that is hardened by advanced material treatments
and hard-facing techniques.
PTA Crystallizer Blow Down Valves
Crystallizer blow down processes are highly demanding
petrochemical plant applications. As high-pressure steam is
let down to atmospheric conditions, the intense pressure drop
can lead to high noise and vibration. Unlike other steam vent
applications, this process typically includes particle carryover
that can clog the small holes employed to reduce noise in
traditional control valves.
The 77000 Series’ multi-stage energy management trim and
expanding area design deliver advanced noise and vibration
reduction without the need for small holes. Additionally, the
large flow path technology keeps the fluid moving smoothly
through the valve without clogging.
Well-proven in these environments for more than 30 years, the
77000 Series offers industry-leading technology to handle the
most difficult of applications in a reliable and safe package. The
unique combination of attributes of the 77000 Series has led to
its endorsement by many worldwide process technology owners
and licensors. It is common to see the 77000 Series design
specified by name in technical specifications for industry-leading
processes.
Hot High-Pressure Separator Valves
The combination of high-pressure reduction and high temperatures, along with entrained gases and corrosive agents, makes
this application one of the most demanding processes in the
refinery. Operators require a control valve that can withstand
both erosion and corrosion, as well as a severe-service valve
that can manage high-pressure drops without the adverse
effects of noise, cavitation, and vibration.
An advantage of the 77000 Series’ expanding area trim
and wider outlet design is the proper handling of flashing/
off-gassing as the pressure is reduced and the fluid rapidly
expands in the valve outlet. The staged gas expansion, coupled
with the continuous plug guiding, minimizes vibration levels
while providing smooth control.
6 | GE Oil & Gas
GE is committed to minimizing the impact
of our operations and products on the
environment through resource conservation,
pollution prevention, environmental
protection, and product innovation.
Power
The 77000 Series can be used in many severe power- industry
applications with demanding temperature and pressure
conditions. The 77000 Series valve’s advanced engineering
and proven long service life make it a solid choice in tough
environments.
Startup Bypass Valves
The startup procedures of a supercritical power plant can be
extremely severe as the process fluid transitions from a liquid
water phase to a supercritical steam phase. Operating conditions
fluctuate dramatically throughout the process, from cavitation
and flashing occurring at startup, to higher-pressure liquid and
steam as the load builds, and finally to superheated steam that
can produce high noise levels and vibration. The 77000 Series
valve is designed to handle the many levels of severe-service
criteria created by the superheater bypass process.
Boiler Blow Down Valves
The 77000 Series offers exceptional service in both continuous
and intermittent boiler blowdown applications—crucial processes
that cannot be jeopardized to prevent loss of flow to the
downstream system. The 77000 Series is capable of managing
the high-pressure drop and low-noise requirements of blowdown
applications while preventing blockage caused by scale in the
pipeline. As a result, the 77000 Series valve can be a valuable
part of continuous plant operation, particularly in critical boiler
blowdown applications that require system cleanliness and
optimal plant operation.
With its unique combination of angled-body, multi- stage energy
management technology and expanding area trim, the 77000
Series delivers the right combination of features to serve as the
startup valves, also commonly referred to as the BW-202, BW207 and BE valves in licensed boiler specifications. The expanding
area trim allows flashing fluids to safely expand without causing
trim damage by managing the fluid pressure drop when outlet
conditions are below the vapor pressure. The multi-stage
trim also enables the valve to safely eliminate cavitation of
high-pressure hot water at startup and attenuate the noise of
high- pressure superheated steam at low boiler loads.
To maximize plant efficiency, the 77000 Series assures shutoff
integrity through the use of a true unbalanced plug design. For
additional reliability, the seating areas are safely located away
from the final pressure drop stage. Shutoff integrity permits
maximum utilization of the steam through the turbine instead of
steam leakage to a downstream tank where the steam energy is
lost.
77000 Series Top Entry
77000 Series - Axial Flow Labyrinth Trim Control Valves | 7
Specifications
•Body
Type:
Sizes: Ratings: End Connections:
•Bonnet
Type:
Cast or Forged Angle Style
1” to 8” (expanding outlets available)
(DN 25 to 200)
ANSI Class 600 to 4500
API Class 2000 to 15000
RF Flange, RTJ Flange
BWE and SWE
HUB Connections
Bottom Entry, Bolted Outlet Spool
Top Entry, Bolted Bonnet
•Body and Bonnet
Materials:
Carbon Steel
Stainless Steel/Duplex
Chrome-Moly
•Trim
Plug Type:
Seat Type:
Guide:
Cv Ratio:
Flow Characteristic:
Multi-Stage Axial Flow
(Trim A, B, C Options)
Metal Seat
Top and Bottom Guiding
See Table (page 15)
Linear
•Actuator
Mounting:
Toggle Arm Mount
Direct Mount
Type:Spring-Diaphragm
Spring-Return Cylinder
Double-Acting Cylinder
Hydraulic & Electric
Optional designs are also available, such as larger sizes, higher pressure ratings, special materials, modified
staging, and other configurations as required. Consult the factory for design details and specifications.
8 | GE Oil & Gas
Numbering System
1st
2nd
Actuator Type
Spring Diaphragm
37Spring-Diaphragm
Direct, Air to Open
(fail close action)
1st
2nd
7
7
Body Series
3rd
Trim Type
77Multi-stage,
axial flow
labyrinth trim control valve
4th
5th
Trim
Characteristic
0Undefined
Design
0Undefined
0Undefined
1 Trim A
Unbalanced
1 Bottom Entry, Outlet Spool Design
1Linear
2 Trim B
Unbalanced
38Spring-Diaphragm
Reverse, Air to Close
(fail open action)
Options
FForged
Body
2 Top Entry,
Bolted
Bonnet
Design
3 Trim C
Unbalanced
87Spring-Diaphragm
Direct, Air to Open
(fail close action)
6th
88Spring-Diaphragm
Reverse, Air to Close
(fail open action)
Piston Cylinder
84
85
Cylinder: spring return,
Direct, Air to Open,
single or double acting
(fail close action)
Cylinder: spring return,
Reverse Air to Close,
single or double acting
(fail open action)
86Cylinder:
double acting, without
spring, Air to Open or
Air to Close action
Flow Coefficient (Cv) & Expansion Ratios
Trim Size
Valve Size
(inch)
1
2
3
4
6
8
Outlet Options
(Inch)
A
Expansion
Ratio
B
Cv
Expansion
Ratio
C
Cv
Expansion
Ratio
Cv
1
4:1
2
2:1
4
1.5:1
6
2
4:1
2
2:1
4
1.5:1
6
3
4:1
2
2:1
4
1.5:1
6
2
4:1
12
2:1
22
1.5:1
35
3
4:1
12
2:1
22
1.5:1
35
4
4:1
12
2:1
22
1.5:1
35
3
4:1
31
2:1
45
1.5:1
72
4
4:1
31
2:1
45
1.5:1
72
6
4:1
31
2:1
45
1.5:1
72
4
4:1
54
2:1
72
1.5:1
110
6
4:1
54
2:1
72
1.5:1
110
8
4:1
54
2:1
72
1.5:1
110
6
4:1
72
2:1
120
1.5:1
170
8
4:1
72
2:1
120
1.5:1
170
10
4:1
72
2:1
120
1.5:1
170
8
4:1
120
2:1
180
1.5:1
260
10
4:1
120
2:1
180
1.5:1
260
12
4:1
120
2:1
180
1.5:1
260
* Note: Special designs with oversized and reduced Cv trim are available. Please consult the factory.
77000 Series - Axial Flow Labyrinth Trim Control Valves | 9
Features & Benefits
4
2
9
7
3
5
6
1
8
4
77000 Series Bottom Entry
77000 Series Top Entry
12
10
11
High
Performance
Actuation
SVI® II AP
Digital Positioner
10 | GE Oil & Gas
FEATURE
ADVANTAGE
END USER BENEFIT
Longer Installed Trim Life
2
Robust One-Piece Plug
Stem Design
Trim Durability
Longer Installed Trim Life
3
Various Trim Resistance
Designs
Flexible Design for Multiple Trim
Capacities
Reduced Capital Spending
4
Flexible Trim Access
Designs
Ease of Installation and Maintenance
Reduced Downtime
5
Expanding Area Trim
Velocity Control and Noise Reduction
Decrease Trim Erosion Caused by
Particles in Flow Stream
6
Axial Flow Technology
Trim Stability and Protection
Eliminates Direct Impingement
and Reduces Trim Wear
7
High Resistance Tortuous
Flow Path
Effective Fluid Energy Management
Minimizes Damage Induced by
System Noise and Vibration
8
Large Flow Passages
Trash Tolerance
Improves Uptime for Dirty Fluid
Applications
9
Seat Location Upstream of
Flow Restriction
Long-Term, Reliable Tight Shutoff
Prevent Loss of Product and Trim
Damage
10
SVI II AP or FVP Positioner
Optimized Control Performance
Precise Control of Process
11
ValVue On-line Valve
Diagnostics
Remote Real Time Monitoring of
Operating Performance
Eliminate Unscheduled Outages
12
High Performance Actuation
Trim Stability and Control Reliability
Repeatable Control of Process
Revenue
Enhancement
Cavitation Elimination and Noise
Reduction
Risk Management
Multi-stage Trim
Cost Reduction
1
Customer for Life
To provide comprehensive local support, GE maintains a global
network of fully authorized repair and service centers, MARC®s.
GE and our Masoneilan Authorized Repair Centers are driven by
a “Customer for Life” philosophy that manifests itself through a
comprehensive suite of aftermarket services including OEM rapid
parts, onsite diagnostics, service, and repair. The service offerings
from GE span all phases of the equipment life cycle, from
engineering to startup and through operation and maintenance:
•Technical support from custom design to applications engineering
•Support of installation, setup and commissioning
•Products with best-in-class control performance
Severe-Service Innovation
Severe-service valve design innovation at GE is evidenced by
the extensive portfolio of field-proven engineered products
we provide for the most severe process control applications.
Indeed, GE’s Masoneilan control valve portfolio has long served
as the benchmark for severe service innovation in industries
such as power generation, oil and gas production and LNG.
These industries are home to many of the toughest control
valve applications, particularly those involving large-mass flow
rate and high- differential pressure such as compressor antisurge, high-pressure vents, and turbine bypass.
•Diagnostic tools that can support process control
optimization objectives
•Tools providing the intelligence necessary for
preventive maintenance
77000 Series - Axial Flow Labyrinth Trim Control Valves | 11
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Fax:+65-6861-7172
* Masoneilan is a registered trademarks of the General Electric Company.
Other company names and product names used in this document are the registered trademarks
or trademarks of their respective owners.
© 2014 General Electric Company. All rights reserved.
GEA19882A03/2014