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For Nonstop Operation of High-Cycle Applications

Use Fisher® Control Valve Assemblies

2 | Nonstop High-Cycle Applications

Nonstop High-Cycle Applications | 3

For Nonstop Operation of High-Cycle Operations,

Use Fisher Control Valve Assemblies

High-cycle applications such as pressure swing adsorption and molecular sieve adsorption are very abusive on control

valve assemblies. Stroking frequency exceeds 60,000 cycles per year and tight shutoff to Class V or Class VI is required to maintain industrial gas purity and efficiency.

Proper selection of control valve assemblies is imperative. Fisher® control valve assemblies typically consist of the control valve, an actuator, and a digital valve controller.

Incorporating Fisher control valve assemblies from Emerson into your high-cycle applications can have significant benefits.

Improve Reliability – End users have increased turnaround schedules to five years using Fisher control valve assemblies. Their long-term reliability is demonstrated by rigorous testing to more than 1,000,000 cycles and they are licensor accepted.

Improve Uptime – When you use Fisher control valve assemblies you can expect to see improvements in uptime, as they are engineered to meet high-cycle application requirements. The durability of their mechanical moving parts and soft parts is the key to long periods of operation.

Improve Purity – Higher quantities of on-specification industrial gas can be produced using Fisher control valve assemblies that maintain tight shutoff throughout their lifetime.

In addition to providing top quality, expertly engineered control valve assemblies, Emerson offers application assistance, responsive replacement parts service, and training.

Read how Emerson’s Fisher control valve assemblies have helped customers with their high-cycle applications. These proven results flyers provide solid, quantifiable results from real customers.

Revamping Control Valves and

Adding FIELDVUE Instruments

Saved a Refinery and its PSA

Unit $2,000,000 Per Year

Control Valve Maintenance Requirements Reduced in PSA Units by Using Fisher Valves

4 | Nonstop High-Cycle Applications

Applications Discussion

Pressure Swing Adsorption (PSA)

PSA is a process that involves separating impurities from a feedgas mixture to produce a single product gas such as hydrogen, oxygen, or nitrogen.

Feedgas cycles through fixed-bed adsorbers, which are surrounded by control valves that use forward and reverse flow to rapidly switch gases between parallel vessels. Within the fixed-bed adsorber, impurities are removed from the product gas at high pressure and then rejected as the system pressure “swings” to a lower pressure. The ability to completely adsorb impurities allows the production of high purity (99.99%) end product.

PSA Unit

The PSA unit is a severe service application for control valve assemblies. High cycling action and tight shutoff is required. Annual cycle service exceeds 60,000 cycles for four-bed units like the one shown below.

The challenge of PSA is that control valve assemblies are expected to cycle as often as every thirty seconds and provide tight, bi-directional shutoff. Common failures of control valve assemblies in PSA units include:

•Stem or shaft breakage due to deficient pinning design

•Poor valve-actuator-positioner linkages leading to multiple mechanical failures in a high-cycle environment

•Loss of shutoff

Your PSA units can achieve longer lifecycles with Fisher control valve assemblies. Fisher control valve assemblies for PSA applications are tested to one million cycles to meet Emerson’s high-cycle quality standard.

The high-performance, linkage-less feedback system in FIELDVUE™ digital valve controllers has no wearing parts so cycle life is maximized. The feedback system eliminates

physical contact between the valve stem and the digital valve controller. It is completely non-contact and does not rely on linkages, eliminating the most common control valve failure mode. Scan the QR code to learn more about the linkage-less feedback system in the DVC6200 instrument.

Nonstop High-Cycle Applications | 5

Molecular Sieve Adsorption

With the competitive environment in the ethanol industry constantly increasing, now is the time to focus on improving overall plant efficiency and reliability. Regardless of plant scale, the molecular sieve adsorption application presents a significant opportunity for such improvements.

In surveying ethanol producers from around the world, some of the most commonly reported maintenance problems related to the molecular sieve adsorption unit include:

•Selection of oversized butterfly valves leading to poor control and reduced cycle life

•Accelerated bearing wear, often seen after only a few months

•Poor valve-actuator-positioner linkages leading to multiple mechanical failures in a high-cycle environment

•Poor performance from low-quality valve positioners in both the adsorption and regeneration cycles

Continued enhancement of this essential component of the ethanol process is critical to achieving plant output and

revenue targets. Fisher control valve assemblies for molecular sieve adsorption applications are tested to one million cycles to meet Emerson’s high-cycle quality standard.

Molecular Sieve Adsorption

Improper selection of control valve assemblies can lead to unscheduled downtime. During this downtime, a typical 50 million gallon-per-year ethanol facility can suffer over

$10,000 USD per hour in lost revenue.