Emerson Fisher Easy E Ed Brochure

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Fisher® LNG Liquefaction Solutions

Proven control valve technology for your LNG facility

2 | Fisher® LNG Liquefaction Solutions

Let Emerson Help Solve Your Toughest Challenge

Your plant must produce LNG at an efficient and constant rate. If you don’t meet your production obligations,

you not only lose revenue, you may be subject to contractual penalties. This means the control valves in

your facility must operate reliably, the way you need them to in your most critical applications 24/7—with no

surprises—to help your facility operate at its nameplate capacity.

Please use this brochure as a guide to discovering the breadth of Fisher® control valve solutions for the most

critical applications in your LNG facility.

1

1

A History of Proven Results

From the first LNG facilities built in Alaska, Brunei, and Algeria in the 1960s and 1970s, to the most

advanced facilities currently under development, Fisher valves can be found in the majority of

liquefaction facilities in the world. In fact, more than 70 percent of existing LNG production flows

through Fisher valves.

More than 40 years of experience in LNG has allowed Emerson to develop reliable, field-proven

Fisher solutions for your most critical applications. By partnering with Emerson, you’ll be able to

leverage our wealth of LNG experience and utilize proven Fisher technologies to help you ensure

the reliability of your plant. From the feed gas pipeline to the export jetty, the Fisher brand is the

name to trust in LNG.

Number of LNG Trains Utilizing Fisher Control Valves

Fisher® LNG Liquefaction Solutions | 3

1

4

4

13 2

2

12

2

2

35

3

2

5

87

2

The majority of existing LNG plants utilize a variation of the propane pre-cooled, mixed refrigerant liquefaction process. This process utilizes

propane refrigerant to chill the feed gas and a mixed refrigerant to achieve liquefaction and sub-cooling. Most recent variations of the process

produce 4.0 — 5.0 megatons per annum (mtpa) of output per train. Greeneld plants will commonly consist of one to three trains with room

for additional trains depending on long term feed gas supply. Larger-scale variations of the process utilize a third refrigerant loop of nitrogen

to achieve sub-cooling, and have been used to achieve nearly 8.0 mtpa of output per train. This “mega train” conguration is featured in the

process diagram below.

Typical Mixed Refrigerant Liquefaction Process

4 | Fisher® LNG Liquefaction Solutions

Fisher® LNG Liquefaction Solutions | 5

A cascade liquefaction process typically utilizes three pure-component refrigerant loops: propane, ethylene, and methane. Feed gas is

pre-cooled as it passes through the propane chiller before undergoing liquefaction and sub-cooling through ethylene and methane cold

boxes. Most recent variations of the process produce 4.5 — 5.2 mtpa per train. Greeneld plants will commonly consist of one to three trains

with room for additional trains depending on long term feed gas supply.

Typical Cascade Liquefaction Process

6 | Fisher® LNG Liquefaction Solutions

Fisher® LNG Liquefaction Solutions | 7

Inlet Feed Gas Control Valve

The inlet receiving facilities serve a number of functions that

are critical to the smooth operation of the entire facility. The

receiving facilities knock out any liquids present in the feed

gas, reduce the pressure from the gas pipeline, and throttle

the ow of gas into the downstream processing units. Stable

and reliable operation of the receiving facilities lays the

foundation for the protable operation of the entire facility.

The location of the inlet feed gas valves will depend on the

extent of gas treatment located onsite. If the facility includes a

gas treatment unit and receives raw feed gas from production,

the inlet valve is located upstream of the acid gas removal

unit. If the liquefaction plant receives sales-quality gas from

the local grid, which requires minimal treatment, the valve will

be located upstream of the liquefaction trains.

At some facilities, a single large valve is used in this

application. At others, a number of smaller valves in parallel

will be used to control the ow of the feed gas. Reliability is the

foremost requirement for the inlet feed valves. Unexpected

maintenance or surprise failures have the potential to bring

down LNG production, which can incur signicant contractual

penalties. In addition, these valves must also be able to

provide precise, stable control through a wide range of gas

ow rates from startup and commissioning through full rated

output of the plant. These valves must operate with minimal

variability to ensure stable and predictable performance of

all process units downstream. Depending on the operating

pressure of the pipeline, these valves can also experience a

signicant pressure drop. This can cause the potential for

damaging noise and vibration if not addressed properly.

The operator of a multi-train

liquefaction facility in Australia

needed absolute assurance that

their critical feed gas inlet valves

would provide the proper rate of

flow into the facility. Too much

flow could overwhelm the plant’s

pressure relief capacity, requiring

expensive modifications. Too little flow could restrict the overall

capacity of the entire multi-billion dollar facility.

Emerson engineers developed custom Fisher Whisper Trim

designs for these NPS 12 ANSI 1500 valves tailored specifically to

the noise and capacity requirements of this critical application.

To provide the ultimate assurance that these custom valves

would meet the exacting application requirements, the

valves were flow tested at the Emerson Innovation Center to

demonstrate the maximum capacity.

Flow testing confirmed the actual capacity of the valves to be

within 3% of the design values, well within the plant operator’s

specification.

A Case-In-Point

8 | Fisher® LNG Liquefaction Solutions

Fisher NPS 30 ET Control Valve with FIELDVUE DVC6200 Digital Valve Controller

Fisher® LNG Liquefaction Solutions | 9

Rich Amine Letdown Control Valve

In facilities that receive raw gas from production, the

acid gas removal unit plays a critical role in the process

by stripping CO2 and/or H2S contaminants from the feed

gas. The presence of these acid gases in excess of specied

limits can cause signicant issues in downstream units. The

presence of H2S can cause serious corrosion issues and CO2

can cause freeze-up in the liquefaction train. As a result,

specications for feed gas are very stringent and typically

require max acid gas content of 50 parts per million (ppm)

CO2 and 2 ppm H2S.

As feed gas enters the contactor at the bottom and ows

upward, lean amine solution owing countercurrent

gradually strips the gas of impurities. The rich amine

letdown valve serves two purposes. First, it regulates the

level of rich amine solution that accumulates in the bottom

of the contactor vessel. Second, it facilitates a pressure

drop into the downstream ash tank, which liberates a

portion of the acid gases entrained in the solution. If not

addressed properly through detailed valve sizing and

selection, this outgassing of the entrained gases can cause

signicant vibration and damage to the valve.

Fisher control valve engineers have decades of experience

with the most severe outgassing applications and have

learned that no two amine letdown applications are

exactly the same. Proprietary outgassing modeling

ensures that the valve type selected is tailored specically

to each application and sized appropriately to mitigate the

gas coming out of the solution.

In some facilities, solids or pipe scale will accumulate in the

bottom of the amine contactor. Emerson offers Fisher dirty

service solutions to prevent plugging while also addressing

the outgassing phenomenon.

10 | Fisher® LNG Liquefaction Solutions

Fisher NPS 16 ET Control Valve with FIELDVUE DVC6200 Digital Valve Controller

Fisher® LNG Liquefaction Solutions | 11

Amine Pump Recycle Control Valve

Maintaining the proper ow of lean amine within the

acid gas removal unit is necessary to ensure sufcient

removal of CO2 and H2S from the feed gas stream. The lean

amine pump ensures the stable ow of lean amine to the

contactor.

The amine pump recycle valve is most commonly used

to facilitate startup and commissioning as the acid gas

removal unit is brought up to capacity. This valve controls

the pump discharge ow that is routed back around to the

suction side of the pump. When needed, the recycle ow

boosts the suction pressure to keep it above the vapor

pressure of the amine. As a result, the amine pump recycle

valve must be very responsive in order to protect the pump

from cavitation damage.

Due to the high pressure differential from discharge back

to suction, the valve trim must be capable of mitigating

the potentially damaging effects of cavitation as it recycles

ow. Any unplanned maintenance on these valves due to

cavitation damage can bring the amine pumps down and

reduce plant throughput.

To learn more about how Fisher anti-

cavitation technologies can help prevent

damage to your valves, view an animation

video at www.FisherSevereService.com

Scan this code to discover the broad

range of Fisher anti-cavitation technology

solutions for both clean and dirty service

applications.

12 | Fisher® LNG Liquefaction Solutions

Fisher NPS 8 ET Control Valve with FIELDVUE DVC6200 Digital Valve Controller

Fisher® LNG Liquefaction Solutions | 13

Gas-to-Flare Control Valve

All gas processing facilities have a are system to safeguard against

overpressure of critical assets within the plant and dispose of

any waste gas. Failure of the are system to successfully relieve

pressure from the process can lead to unexpected downtime or

damage to costly pressure-retaining equipment.

Gas-to-are valves are installed at numerous locations throughout

the gas treatment and liquefaction units to control the ow of

feed gas or refrigerant to the are stack for disposal. They are

primarily used during plant startup, shutdown, or short-duration

upset conditions. During these periods, are valves will experience

signicant pressure differentials and high ow rates. If not

addressed properly, these conditions can lead to excessive noise

levels and even damaging vibration.

Emerson utilizes the industry standard for aerodynamic noise

modeling and prediction in control valves, IEC 60534-8-3. This

standard models two independent sources of noise -- the valve

trim and the valve body outlet. In applications with moderate

pressure drop, noise attenuating trim is commonly sufcient to

maintain overall noise levels at acceptable levels. However, in

high pressure drop applications such as gas-to-are, the valve

body outlet noise will commonly overcome the trim noise as the

dominant source. To account for this, Emerson’s engineers use the

latest IEC noise prediction model to account for both independent

sources of noise when developing custom valve solutions for your

high pressure drop applications. This comprehensive approach

incorporates noise-attenuating technology to reduce trim noise

and a properly-sized valve body outlet to maintain acceptable

noise levels at the outlet.

During the normal operation of the plant, gas-to-are valves will

remain closed. Because of this, it is important that these valves

maintain tight, long-term shutoff in order to prevent loss of

valuable product to the are stack.

A gas processing plant in Saudi Arabia

experienced cracking of a NPS 54 acid

flare header made of Inconel. Two

Emerson engineers studied the process

conditions and concluded that the

existing valves were contributing to

excessive vibration and noise. Despite the

use of noise-attenuating trim, the valves

had not been properly sized to account for valve body outlet noise,

which resulted in valve outlet velocities close to sonic – 0.7 mach.

After several visits to this remote site, Emerson recommended a larger

replacement valve with Fisher WhisperFlo™ trim that would meet all of

the process conditions.

Existing valves were replaced by two NPS 16 Fisher ET control valves

with WhisperFlo Level Z trim. The valves lowered the velocity of the

outlet to 0.3 mach, which significantly reduced the noise at the valve

and the vibration affecting the downstream piping.

A Case-In-Point

Scan this code or visit

www.FisherSevereService.com

to learn about the science of noise

attenuation in control valves and

our history of solving noise issues in

facilities just like yours.

14 | Fisher® LNG Liquefaction Solutions

Fisher NPS 20 FBT Control Valve with FIELDVUE DVC6200 Digital Valve Controller

Fisher® LNG Liquefaction Solutions | 15

Compressor Antisurge Control Valve

The efciency and availability of a plant’s compressors

both have a direct impact on the protability of the facility.

Unexpected downtime of any of the plant’s refrigerant

loops will lead to reduced LNG production and the

potential for hefty contractual penalties. Compressors also

represent some of the most valuable pieces of equipment

within an LNG facility. Not only will damage to these assets

cause unexpected production downtime, it can also lead

to very costly repairs.

Antisurge valves provide recycle ow to each stage of

the multi-stage compression trains that are common to

liquefaction processes. During startup and commissioning,

the valve provides throttling control to recycle a portion

of the discharge ow as the compressor is brought up to

capacity. During the normal operation of the plant, the

antisurge valve will remain closed or slightly open to allow

for a small portion of the discharge to be recycled. When

closed, it is important that the valve provides tight shutoff

to prevent unwanted recycle ow.

The primary purpose of the antisurge valves is to protect

the most critical and expensive pieces of equipment in the

plant, the compressors. During a surge event, the valve

must open in one to two seconds to recycle the discharge

ow back around to the suction side of the compressor.

Failure of the valve to react quickly to the antisurge

controller can result in severe damage to the impellers of

the compressor from the reversed ow of a surge event.

An LNG facility in Brunei needed

to replace all of its existing

propane and mixed refrigerant

compressor antisurge valves.

After seeing a demonstration of

the Fisher optimized antisurge

valve, the plant turned to

Emerson who has proven its

ability to understand and meet stringent valve performance

criteria.

The 25 existing valves were replaced by NPS 12 through NPS

30 Fisher optimized antisurge valves.

•The valves open in less than two seconds, as well as meet

stringent closed-loop control criteria.

•The measured linearity is less than 0.75%, and the valves

have minimal overshoot in the open and closed directions.

• It often requires about 12 hours to tune a non-Fisher

antisurge valve. With its fewer accessories and diagnostic

capabilities, tuning time for a Fisher optimized antisurge

valve takes only minutes.

All this added up to an antisurge valve solution that helped

to protect compressors and increase process efficiency.

Scan this code to learn more about

the Fisher optimized antisurge

solution designed specifically for

antisurge applications.

A Case-In-Point

16 | Fisher® LNG Liquefaction Solutions

Fisher NPS 42 FBT Control Valve with Optimized Digital Valve Actuation

Fisher® LNG Liquefaction Solutions | 17

Joule-Thomson/Expander Bypass Control Valve

The Joule-Thomson effect is leveraged throughout all of

the primary liquefaction processes to achieve cooling

of the feed gas or the refrigerant streams. It is used to

achieve cooling of liquids, gases, or multi-phase uids.

Traditionally, this effect has been facilitated by a control

valve that reduces the pressure of the uid signicantly

and induces the desired cooling. Because of the elevated

pressure drop, the valve can experience excessive noise

levels if not addressed properly. It also experiences very

low process temperatures and must be capable of precise

throttling down to full cryogenic temperatures.

In some facilities, expanders are utilized to facilitate

Joule-Thomson cooling while also recovering energy from

the uid to improve overall process efciency. Expanders

are used in both gas and liquid applications (commonly

referred to as hydraulic turbines in liquid applications).

Regardless of the uid, expander bypass valves are

installed in parallel with expanders to ensure process

availability. In instances when the expander is required to

go ofine, the bypass valve is opened to facilitate Joule-

Thomson cooling of the process stream and allow the unit

to continue operating in the absence of the expander. The

bypass valve must be highly responsive and reliable to

ensure process availability. It is also commonly subjected

to a large pressure differential, which creates the potential

for signicant noise levels in gas applications and ashing

in liquid applications.

18 | Fisher® LNG Liquefaction Solutions

Fisher NPS 16 ET Control Valve with FIELDVUE DVC6200 Digital Valve Controller

Fisher® LNG Liquefaction Solutions | 19

The way you manage key production assets like control valves directly affects your plant’s efficiency, reliability, and profitability. Emerson

Process Management’s Fisher Services provides trusted expertise for control valve maintenance and repair.

Whether you’re starting or commissioning a process, scheduling diagnostics and repair, or planning a turnaround with upgrades to optimize

and extend your plant’s lifecycle, our network of owned and authorized service centers around the world provide effective maintenance

through a network of experienced, highly skilled technicians when and where you need them.

To help you maintain your plant’s efficiency and reliability, Fisher Services uses only certified OEM parts and assemblies sourced through local

inventories, regional parts distribution centers, and Quick Ship facilities to deliver unmatched response to customer needs.

You’re Never Alone

Contact your local sales office to

get in touch with the Service Center

nearest you. To learn more, scan the

QR code or visit www.Fisher.com.

20 | Fisher® LNG Liquefaction Solutions

Our extensive network of Service Center

locations spans every continent. We’re

there for you day or night, when and

where you need us, 24/7/365. To learn

more, scan the QR code or visit www.

Fisher.com/LifecycleServices

Plant Lifecycle Events and Demands

Fisher® LNG Liquefaction Solutions | 21

THE CONTROL VALVE YOU CHOOSE MATTERS

WHEN YOU HAVE TO ACHIEVE EFFICIENT,

PRODUCTIVE, AND RELIABLE PLANT OPERATION.

When you buy Fisher control valves, you get the application expertise that comes from more than forty years of

experience in the LNG industry. Plus you benefit from millions of dollars of research invested in reliability-centric

testing of Fisher control valve technologies.

Fisher product specifications are, in many cases, more stringent than the industry accepted standards set

by regulatory agencies. Our attention to and evaluation of product quality is necessary to bring you Fisher

technologies of the highest reliability and performance.

Using Fisher technology can help you achieve efficient, productive, and reliable plant operation. Want to see for

yourself? Visit the Emerson Innovation Center for Fisher Technology in Marshalltown, Iowa, USA. To schedule a

visit, please contact your local Emerson sales office.

Fisher technology development capabilities extend worldwide with engineers and labs in North America, Europe,

and Asia.

Whether driven by process

temperatures or climate extremes,

control valves need to operate as

specified. Fisher control valves in

LNG applications are commonly

tested at cryogenic temperatures of

-196°C (-321°F) in numerous Fisher

sites around the world.

While control valves are on-line

and in service, Fisher digital

valve controllers can detect,

capture, and trend more than

200 fault conditions and provide

recommended actions to prevent

unexpected downtime.

Many of Emerson’s standard Fisher

products are used in extremely

high-cycle applications, and must

be tested to more than one million

cycles. Those same standard

products are used in your LNG

plant to enhance reliability.

Fisher control valves are designed

and tested for robustness in

vibration applications. They are

subjected to additional testing

for millions of cycles at their

resonant (worst case) frequency

to enhance performance in your

facility.

Fisher control valve assemblies

are subjected to on-line, dynamic

performance testing to evaluate

their ability to reduce your

process variability. These tests

replicate how control valves are

used in your plant.

Supported with a 4,738 m2

(51,000 ft2) facility and a unique

2, 415 m2 (26,000 ft2) sound

chamber, Emerson can quantify

noise from valves, piping, and

vents. This capability provides

insight to ensure highly accurate

noise prediction and helps

you comply with regulatory

requirements.

THRIVING IN EXTREME

TEMPERATURES

TROUBLESHOOTING

CONTROL VALVES

HIGH CYCLE TESTING

WITHSTANDING VIBRATION REDUCING PROCESS

VARIABILITY

QUIETING NOISE

Fisher® LNG Liquefaction Solutions | 23

D352208X012 / (H) MY208 / Jul13

© 2013 Fisher Controls International LLC. All rights reserved.

Fisher, FIELDVUE, WhisperFlo, and Whisper Trim are marks owned by one of the companies in the Emerson Process

Management business unit 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, nothing herein is to be construed as a warranty

or guarantee, express or implied, regarding the products or services described herein or their

use, performance, merchantability or fitness for a particular purpose. Individual results may vary.

All sales are governed by our terms and conditions, which are available upon request. We reserve the right

to modify or improve the designs or specications of our products at any time without notice. Responsibility

for proper selection, use and maintenance of any product or service remains solely with the purchaser and

end user.

Emerson Process Management

Marshalltown, Iowa 50158 USA

Sorocaba, 18087 Brazil

Chatham, Kent ME4 4QZ UK

Dubai, United Arab Emirates

Singapore 128461 Singapore

www.Fisher.com

http://www.YouTube.com/user/FisherControlValve

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Fisher Optimized Antisurge Control Valves

High reliability to meet world-class production demands

®

“Fisher® Optimized Antisurge Control

Valves Brochure”

Document Number: D351146X012

www.EmersonProcess.com/Fisher/Documentation

“Fisher Cavitation-Control Technologies Brochure”

Document Number: D351912X012

www.EmersonProcess.com/Fisher/Documentation

The Silent Treatment

Fisher® Solutions to Noise Problems

“The Silent Treatment Brochure”

Document Number: D351989X012

www.EmersonProcess.com/Fisher/Documentation

FIELDVUE™ DVC6200 Series Digital Valve Controllers

Higher Process Reliability and Performance

“FIELDVUE™ DVC6200 Series Digital Valve

Controllers Brochure”

Document Number: D351908X012

www.EmersonProcess.com/Fisher/Documentation

Fisher easy-e Sliding-Stem Control Valves

™

®

For easy application and unmatched performance

“Fisher® easy-e™ Sliding-Stem Control

Valves Brochure”

Document Number: D350365X012

www.EmersonProcess.com/Fisher/Documentation

“Emerson Innovation Center Brochure”

Document Number: D351843X012

www.EmersonProcess.com/Fisher/Documentation

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