Ehc Solutions Cb039 En

Reliable fl ow control solutions

for the energy and hydrocarbon industries

Metso’s three world-leading valve product brands are renowned for their performance. Neles represents metal-to-metal seating technology with products such as Neldisc® and Stemball® valves. Jamesbury stands for leading-edge technology in soft seating technology with products such as Double-Seal® and Wafer-Sphere® valves, as well as X-treme® seats. MAPAG is well known its highly engineered butterfl y valve solutions such as MAPABLOC for ethylene plants.

For over 50 years, the world’s major process industries have trusted Neles, Jamesbury and MAPAG valves to perform reliably and last for decades in the harshest environments. Our control, on-off and ESD valves, accessories, intelligent devices, and software products off er innovative, yet fundamentally simple construction, operation and maintenance features.

In an analysis carried out by a third party, our valves proved their reliability by having a MTBF (mean-time-between-failure) up to ten times higher than the industry average. From our wide product portfolio, you will fi nd applications from standard to very demanding, with sizes from DN15 (1/2”) up to DN2500 (100”). The temperature range extends from cryogenics at -200 °C (-320 °F) up to very high-temperature gas applications at +600 °C (+1100 °F) or even higher.

Brands trusted by the major process industries

Full scope of Life Cycle ServicesTo support your business, Metso off ers a full scope of Life Cycle Services such as:

• Specialized support• Diagnostic services• Inventory management and installed base

audit services• Spare parts and replacement products

These services are tailored based on your needs and aim to support you in the best possible way. For example, our specialized support covers:

• Training for subcontractors, contractors and end users

• Commissioning and start-up• Shutdown services• Support visits.

By using our specialists for on-site supervision during installation, commissioning or shutdowns you will ensure smooth and safe operation during the critical phases of your plant’s life cycle.

Neldisc butterfl y valves are available from size 3" to 80" and in pressure classes up to ANSI 600 with various fl ange connections.

2 – Flow control solutions for the EHC industries

To keep pace with your needs, Metso’s technology know-how has expanded from reliable, high-quality valve solutions to a broad range of intelligent software and products called Neles SmartSolutions™.

These smart products have been designed to improve the control of industrial processes. They do it by maximizing the availability of valves, minimizing the variability of control loops, in addition to increasing and maintaining plant safety. High availability and easy interpretation are the key success factors in eff ective fi eld device data analysis.

We at Metso are committed to supporting open and standardized technologies. These enable you to choose the best fi eld devices and ensure the availability and usability of diagnostics information independent of your control, safety or asset management system.

By integrating Neles smart products into all automation and safety systems Metso aims to boost your processes. Neles FieldCare™ is fi eld device asset management software with a condition monitoring capability, which supports open and standardized FDT/DTM technology.

Nelprof makes valve selection easier than ever

The correct sizing and selection of valve packages is vital for ensuring the optimal performance of your application. Nelprof® control valve selection software enables you to select the right control valve package quickly and accurately.

Metso has over 50 years of deliveries: More than130,000 smart devices connected to Neles FieldCare250,000 smart Neles control valves700,000 Neles control valves1,000,000 automated Neles on-off valves5,000,000 Jamesbury valves40,000 MAPAG valves for the gas industry

Did you know…?

The widest range of control valves Metso has the largest control valve off ering on the market, ranging from ½" to 100" valves. Our rotary control technology ensures optimum control performance with extremely low fugitive emissions to the atmosphere.

The state-of-the-art rotary plug control valve Finetrol® features a balanced plug to optimize control performance. Our segmented ball valve is perfect for low- and moderate-control applications where higher capacity is required. The triple eccentric high-performance butterfl y valves Neldisc® and Wafer-Sphere® have proven their capabilities in control applications with a low pressure diff erential or large pipe sizes. Our quiet Q-trim® valve has been leading the way in the development of rotary valve technology since the late 1970s. The wide Q-trim ball control valve range consists of fl anged and weld end connections, as well as top entry designs.

The latest addition to our control valve off ering is Neles RotaryGlobe. In it, rotary and linear control technologies are combined to achieve optimum control performance. This revolutionary valve is especially suitable for applications with low fl ow or high pressure diff erentials.

Our control valve packages are supplied with our own actuators and the unique valve controller ND9000® to ensure optimum, trouble-free control performance.

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Th i iTh i i

Neles ND9000Control valve applications

Neles ValvGuardESD (Emergency Shut Down) & ESV (Emergency Vent) valve applications

Neles SwitchGuardOn/off valve applications

Neles FieldCare Integrates all confi guration and diagnostic information. Environment to manage all intelligent fi eld devices.

Neles SmartSolutionsTM for continuous result improvement

Butterfly valves Rotary globe valves

Ball valves Rotary plug valves

Segment valves

2500

1500

900

600

300

150

Pressure class3”-100”

1”-28”

1”-10”

½”-4”

½”-36”

Flow control solutions for the EHC industries – 3

High-performance valves foroil refi ning

Metso provides oil refi neries with high-performance valves for everything from crude distillation to fi nal products. With our valve technology refi neries are able to minimize risks related to health, the environment and safety. Additionally, plants can reach their product quality targets, as well as reducing maintenance and plant shutdown costs.

Hard facings on trim (ball and seats) must resist the wear of abrasive and erosive catalyst powder, and also maintain valve tightness and prevent operating torque increasing. The hard facings need to perform above the targeted performance and capability requirements, to handle extreme temperatures of up to 700 °C. All materials and hard facings must resist temperature changes. The valve design, especially on seats, resists particle build-up in any area inside the valve fl ow ports area. The seat design prevents particle build-up in seat cavity and thus

Solutions to meet catalyst handling challenges

HydrogenGeneration

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BLE

NDIN

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REFINERY FUEL

JET FUEL

DIESEL

DIESEL

DIESEL

CRUDE OIL

H2 to hydrotreaters

FUEL-OIL

COKE

DIESEL

LUBEOILS

LPG

SULFURSulfur plant

Gas TreatmentMercaptanRemoval

IsomerisationPlant

Reforming

NaphtaHydrotreating

MercaptanRemoval

GasoilHydrotreater

Fluid CatalyticCracking

Alkylation

Lube treating

Hydrocraking

Visbreaking

DelayedCokingVa

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prevents any increases in seat loading. This also prevents increases in operating torque and the resulting wear on sealing surfaces, ultimately lengthening the valve cycle life.

To meet the many catalyst handling challenges, Metso off ers advanced Neles solutions. Our X series ball valve design has been tested and proven to meet the UOP

671 specifi cation. These valves have a full-bore design with carefully selected hard facings on balls and seats: Nibo and CrC-LF materials achieve good sliding properties for constant low torque and an extended cycle life in abrasive service, with good valve tightness. Their special J seats prevent catalyst powder accumulation behind the seat (seat cavity) and thus maintain constant and stable seat loading, which maintains the valve tightness and extends cycle life.


Neles Finetrol valves have reduced the incidence of jammed valves in the steady-state mode remarkably and have completely eliminated leaks through gaskets.

Luiz Henrique Mentzingen dos Santos Senior Instrumentation Engineer Petrobras REVAP

Case:

No more problems with heater-pass applicationsSome of the refi neries of Petrobras, a leading oil company in Brazil, had major heater-pass valve problems, which led to unscheduled shutdowns and frequent maintenance. After testing several valve options, Petrobras REVAP replaced the valves used to control the heater passes with Metso’s reliable Neles Finetrol® rotary plug-type valves.

In addition to reduced incidences of jammed valves, there has been no need for unscheduled maintenance or unscheduled shutdowns since. The more stable and accurate operation has enhanced quality and productivity. Environmental problems

previously associated with the heater have also been eliminated.

Petrobras has accepted Neles Finetrol as the preferred answer to the majority of its heater pass fl ow control problems when handling high-viscosity, high-temperature oil products. It is now recommended to sites with similar process conditions throughout Brazil and elsewhere in South America.

• Neste Oil, Finland• Shell Pernis, the

Netherlands• Shell Stanlow, UK• Shell Ceska, Czech• Shell Bukom, Singapore

• Shell Berre, France• Rabigh, Saudi Aramco,

Saudi Arabia• Petrobras, Brazil• Reliance, India

Our recent projects for refi neries:

Lloyds’ Register has certifi ed Neles D/T2-series ball valves and B1-series actuators to be capable of performing at SIL 3 with Neles ValvGuard in a single valve confi guration.

Did you know…?

For coker service valves must:• be capable of handling high application

temperatures up to + 500 °C• be capable of handling heavy bottom end feed with

solids and high viscosity liquids• prevent the potential risk of coke formation in pipes

and valves• be targeted at a long service life on isolation,

switching and control valves (tightness and accurate control performance)

Metso has just the right Neles solutions for delayed coker service: the Y4 switching valve for switching service, and drum and pump isolation valves. The valves are provided with erosion resistant CrMo materials and wear-resistant hard facings.

The risk of coking and its consequences inside the valve is eliminated with steam purges on sealing surfaces. Overhead vapor line valves are also resistant to coking and maintain their tightness. All seats are scraping type seats to prevent coke buildup on sealing surfaces. These valves provide two-way tightness at low and high diff erential pressures. The hard facings on the trim are selected for long service life in abrasive and coking conditions.

Solutions for delayed coker service


Contributing to the petrochemical industry’s success

Valves for naphtha crackers, MEG plants and everything in between – that’s the extent of Metso’s deliveries to the petrochemical industry. Our wide off ering consists not only of control valve applications but also of emergency shutdown, blowdown and other critical automated on-off applications, as well as manual services where high reliability is a must.

Petrochemical applications are always a bit diff erent from one process to an other. From us you will get the right valve solutions: rotary plug, Q-trim ball, high performance butterfl y valve or segmented ball valves.

Case:

Valves for a huge petrochemicals complexCSPC Nanhai, which a joint venture between Shell Nanhai BV and CNOOC Petrochemicals Investment Ltd., recently started up an operation at a 4.3 billion EUR petrochemical complex in Daya Bay, Huizhou, Guangdon, China.

The heart of the complex is a naphtha cracker producing 800,000 tpa of ethylene and 430,000 tpa of propylene. The total output of products is 2.3 million tpa of glycols, polyols, LDPE, HDPE, PP, and MEG. The plant has one of the biggest FOUNDATION Fieldbus installations in the world.

Metso was the main supplier for control valves, automated on/off valves and ESD & depressuring valves, covering at least 80-90% of the project valve needs. The delivery included Finetrol and RE-segment valves as principal control valves, 3,000 pcs Neles rotary control valves, 1,000 pcs

STEA

M CR

ACKE

RNaphta

Ethane

LPG

PROPYLENE

C4 STREAM

METHANOL

Polypropylene

Polyethylenes LDPE, HDPE, LLDPE

Ethylbenzene

Ethylene oxide

Ethyl alcohol

ETHYLENE (Mono)ethylene glycol

Jamesbury automated and manual valves, 3,500 pcs Neles ND9000 intelligent FOUNDATION Fieldbus valve controllers, and 150 pcs Neles ValvGuard TUV approved partial stroke testing systems. The plant especially appreciated the valves’ diagnostic capabilities, their ability to integrate into diff erent DCS systems, as well as their enhanced fugitive emission control.

Metso’s strengths in handling this major project included a total project approach from quote to start-up and further, a reliable partnership, and a good network of offi ces covering EPC project partners.

Our valve packages for petrochemical applications are supplied with their own actuators, piston or diaphragm, and the state-of-the-art valve controller ND9000®, partial stroking Neles ValvGuard or switching Neles SwitchGuard, in order to ensure reliability and the optimum trouble-free process performance.


Rotary control valves have proven to be suitable for more than 90% of applications used in the petrochemical industry. Eccentric plug and V-shape segmented ball valves can be selected as the primary control valves for a complete petrochemical complex.

Did you know…?

Case:

All metal-seated valves in a product discharge systemRecently, Reliance Industries Ltd., India’s biggest petrochemical producer, expanded polypropylene (PP) production at its Jamnagar refi nery in Gujarat State.

Even though neither the original Unipol specifi cation nor the PP line expansion were favorable to Metso, Reliance overruled these issues due to previous good experiences and the many challenges presented by the application. For example, polymer build-up can cause jamming in the valves and/or blocking in the valve seats. It is therefore important to allow adequate safety margins when sizing both the valves and the actuators. PP discharge is also an abrasive application. The valves normally execute a high number of cycles per annum (160,000 and over) under conditions of high diff erential pressure.

Metso supplied stainless steel, trunnion-mounted, metal-seated Neles X and M series valves for the product discharge area and mostly Jamesbury 9000 series soft seated ball valves, ranging in size from ½" to 10", for the remainder of the PP line expansion. The Neles valve seats are stainless steel with a tungsten carbide coating; they are in eff ect polymer-proof and off er long-term tightness and a long cycle life.

This was the fi rst time Metso supplied a PP train with all metal-seated valves for the product discharge system (PDS), and Jamnagar’s train is probably the fi rst Unipol PP train in the world to have all metal-seated valves in the PDS.

Case:

On/off valves for Russia’s fi rst polycarbonate plant AOA ”Kazanorgsintez”, located in Kazan in the Tatarstan region, is one of the largest chemical companies in Russia. It chose Metso from among several suppliers to deliver valves for its new polycarbonate production plant, which is the fi rst of its kind in the Russian Federation. The scope covers both metal-seated and soft-seated on/off valves: 448 ball valves, two thirds of which are Jamesbury 9000 series ball valves.

The signifi cant advantage of the Jamesbury Xtreme Seat – much higher quality than PTFE – was the main reason why the plant decided to choose Jamesbury valves. Neles valves, mostly D and X series valves up to 18", complemented the off ering.

Successful work on high density polyethylene (HDPE) plant modernization, the competence of the specialists and their high level of technical capacity determined our choice of all on/off valves in favor of Metso.

Arthur Sarbazyan Chief Instrument EngineerKazanorgsintez Polycarbonates Plant

Our recent valve projects for the petrochemical industry:• Nanhai, Shell/CSPC, China • Shell Moerdijk, the Netherlands• Sannest, Shell Pernis, the Netherlands• Sasol. South Africa• Equate, Kuwait• Rabigh, Saudi Aramco, Saudi Arabia• Formosa Petrochemical, Taiwan• Copesul, Brazil


The fact that more than 60% of the world’s LNG fl ows through Neles valves is living proof of our customers’ trust in us. Our ball, butterfl y and control valves perform reliably in cryogenic, low-temperature and ambient applications. They are used for purifi cation, dehydration, fractionation, liquefaction, LNG tanks and loading applications. No conditions are too severe for them, thanks to their excellent, long-lasting seat tightness.

The LNG valves are tested in Metso’s cryogenic testing facility, which is one of the largest and most advanced of its kind in the world.

LNG valves for extremely cold conditions

Metso has delivered numerous Neles and MAPAG valves to LNG installations around the world:• Indonesia LNG • Malaysia LNG• Brunei LNG• Australia NWS • Abu Dhabi• QatarGas

• RasGas• Oman LNG• Algeria LNG• Nigeria LNG• Sakhalin LNG• Yemen LNG

Did you know…?

Case:

Valve technology improves LNG plant safetyEmergency shutdown systems on the upgraded trains of the PT Badak LNG plant in Bontang, East Kalimantan, Indonesia, rely on Metso’s proven LNG technology for plant safety.

Since part of the LNG process uses extremely low temperatures, Metso performed stringent cryogenic testing procedures in its world-class cryogenics lab. Valves were pressurized and leak-tested with helium, because traces of moisture found in other media would freeze under such extreme conditions.

All PT Badak valves passed rigorous cryogenic testing with leakage rates at a fraction of the specifi ed limits. This is a very good start and the plant expects years of trouble-free valve performance, both for optimized productivity and safety.

As our specifi cation required very strict tightness and testing requirements for low temperature ESD valve service, Metso was one of only a few vendors who could provide facilities to test for full compliance with the specifi cation requirement.

Yhenda PermanaInstrument/Electrical Group HeadPT Badak LNG

Safety valve testingThe automatic partial stroke testing (PST) makes sure the safety valves meet required SIL targets. Automatic and real time reporting of test results ensures that information regarding safety demand availability is reported immediately to maintenance personel. Neles ValvGuard was the fi rst TÜV-certifi ed PST safety device.

MAPAG 36” butterfl y valve is ready to be delivered to Qatar LNG plant. The valve was tested in MAPAG facilities in -200C for operation and tight-ness. Mapag valves cover pressure ranges from ASME 150 to ASME 2500 with a size range of 3"–100".

MAPAG big size 36” butterfl y to Qatar LNG plant


GTL requires a lot from valves

Valves encounter many demands in a gas-to-liquid (GTL) process, such as high temperatures, high pressure diff erentials and impurities. Slurry and/or waxy services may require valve designs, which are not prone to clogging. Valve materials for oxygen valves, as well as for erosive applications, should be chosen carefully.

Featuring metal-seated rotary technology, Neles rotary valves provide long-lasting performance for the demanding GTL industry. They are less vulnerable to impurities and minimize fugitive VOC emissions through the gland packing. Neles Q-trim® valves off er high capacity, anti-cavitation and noise reduction in a way no sliding stem valve can match.

GTL process background Carbon dioxide emissions from traffi c and the transportation sector can be improved by dieselization. One of the key ways to reduce diesel-related emissions is to use GTL (gas-to-liquid) fuel.

In the GTL process, natural gas is converted to clean, high-quality fuels via the Fischer-Tropsch synthesis. GTL fuel can be blended or used as a pure fuel product. The process begins with the creation of synthetic gas (syngas) from feedstock, such as natural gas, coal or biomass.

Syngas is converted to hydrocarbon liquid by the Fischer-Tropsch synthesis in the presence of a catalyst. A hydrocarbon liquid product upgrading process is used to improve the quality of fi nal GTL products, such as diesel, naphtha and LPG.

Nat gas

Biomass

Coal

SYNGASGENERATION

F-T SYNTHESIS

PRODUCTUPGRADING

Liquid fuels

Utilities

• Qatar Petroleum and Shell, Qatar• Shell Bintulu, Malaysia• Oryx, Ras Laff an LNG, Qatar

Our recent valve projects for GTL processes:

Neles rotary valves • Non-clogging design• Simpler construction• Smaller body sizes• Fugitive emission control• Excellent controllability

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Meeting the needs ofbiofuels producers

Replacing fossil fuels with biofuels is an important step in curbing greenhouse gas concentration. Legislation and new initiatives to set binding minimum targets for the proportion of biofuels in overall petrol and diesel consumption are springing up around the globe.

The production processes for biodiesel and bioethanol vary considerably, but valves are required at many stages in the main and intermediate processes. Metso has supplied substantial quantities of valves, actuators and intelligent controllers to bioethanol and biodiesel plants across the world.

Deliveries to over 60 US bioethanol plants

Jamesbury and Neles products are ideally suited to US bioethanol production, which has led to their use in over 60 such plants, most of which are in the 35-50 mmgy or 100 mmgy size range.

Typically, Metso supplies most of the on/off and control valves with Jamesbury soft-seated ball valves and Wafer-Sphere butterfl y valves for on/off and Neldisc butterfl y, and Finetrol rotary plug and segmented ball valves for control.

Case:

Valves for a major new biodiesel plant Metso will supply a large number of valves to a major new biodiesel plant in Finland. The Neles products will include Finetrol rotary plug, segmented ball, and T5 rotary ball control valves, all with spring return B1J actuators and Neles ND9000 intelligent valve controllers for use in the main process.

Over 50 Finetrol rotary plug and segmented ball control valves with EJ actuators and Neles ND9000 intelligent valve controllers will be employed in pre-treatment and transportation, as well as at the tank farm.

Neles RotaryGlobeThe new control valve Neles RotaryGlobe strengthens Metso’s control valve off ering, especially in small sizes, in all pressure classes. It combines the best features of linear and rotary valve technologies. The body shape of the valve is that of a linear globe valve, while the rotating stem guarantees a low fugitive emission level.

Neles RotaryGlobe can be used in general duties, but also in severe service control applications up to the ASME 1500# pressure class. It is possible to fi nd the correct capacity value or fl ow characteristics for a particular application. For low fl ow applications, there are also several diff erent Cv trims, starting from the Cv value 0.1. For applications with a higher pressure diff erence, the valve off ers a specially designed balanced trim which eff ectively eliminates the noise problems, and the cavitation phenomenon and resulting damage.

Back in 1912, Rudolf Diesel, the inventor of the diesel engine said:

“The use of vegetable oils for engine fuels may seem insignifi cant today. But such oils may become in course of time as important as petroleum and the coal tar products of the present time.”

Did you know…?

Delivover bioet


The right choice for complex fertilizer applications

We already deployed this valve technology from Metso in our very fi rst plant in Qatar, which has been in operation since 1997 and set new standards at that time for production volume. Our long years of experience with Neles valves has shown that they are the right choice for complex applications as their quality goes well beyond that of standard components.

Dietmar Müller Lead Buyer InstrumentationUhde GmbH

Case:

One of the world’s largest fertilizer plants runs with Neles valvesIn the fertilizer industry, Uhde GmbH of Dortmund, Germany, is known as the world’s leading supplier of large-scale plants. In 2004, Uhde fi nished building the “QAFCO-4” complex, which is one of the largest single production sites for fertilizers in the world. The site, located in Qatar, has an annual capacity of 2 million tonnes of ammonia and 2.8 million tonnes of urea.

“Maximizing a plant’s uptime is the fi rst priority,” explains Dietmar Müller in Dortmund. “If this kind of plant has to shut down operations for any length of time, the damage can quickly add up to hundreds of thousands of euros; that’s why all components have to be as reliable as possible. This applies in particular to components used in complex applications or diffi cult media.”

“We’ve been working with Metso for over 20 years and have never had a major problem with their butterfl y or ball valves.”

Uhde uses Neles metal-seated butterfl y valves from the Neldisc® series up to a nominal diameter of DN 1000, soft-seated valves from the Wafer-Sphere® series up to a nominal diameter of DN 600, and metal and soft-seated ball valves. In addition, a special version of the Neldisc series L4/L5/L10 is deployed, which Metso originally developed expressly for special applications such as the one required by Uhde. The metal-seated butterfl y valves are available with nominal diameters ranging from DN 100 to 900 for nominal pressures of PN 100 to 320 (ANSI Class 600 to 2500).


www.metso.com/automation

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Improving performance and reducing costs are always challenges for the process industry.

Neles control valves utilize unique and sophisticated technologies to improve process control performance

and reliability. Simple to use and easy to maintain, our valves are designed to provide trouble-free

operation throughout the whole life cycle.

Our intelligent on-line diagnostics ensure that your control valves always stay in control.

The new Neles RotaryGlobe control valve meets these challenges. Its innovative design that combines

globe style body and trim selection ensures all rotary valve benefi ts including low emissions.

Get Smart and stay in control

Ehc Solutions Cb039 En

Documents

pp line expansion

long service life

recent valve projects

high pressure differentials

flow control solutions

segmented ball valves

seated ball valves

seated butterfly valves