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Also in this issue

4 Keep the noise down
7 Device Management Solutions
8 Problem solved with butterfly valve
10 The 90
anniversary of Mapag valves
11 Marine-certified Neles intelligent valve
controller for severe offshore conditions
11 Order of over 4,000 intelligent
valves controllers in China
12 SIL certifications for Neles flow
control products
12 Long-lasting seawater control in Chile
13 Automated solution for batch cooking
with Neles capping valves in Sweden
14 Superior tightness in difficult applications
15 Valves for geothermal power plant
installation in Kenya
15 Spare part service contract in Qatar
16 New service center in the Netherlands
results valves
Metso customer newsletter for Neles, Jamesburyand Mapagproducts.
and efficient
under demanding
Sources of regulation
The very first broadly defined air pollution laws were enacted in the United Kingdom in
the 19th century, due to concerns stemming from that countrys rapid industrialization.
The same happened in the United States and Germany during the1960s. As industrialization
has progressed further, limitations have become more specific, a trend which has brought
a narrower focus on fugitive emission sources, e.g. industrial valves.
Numerous studies show that valves are a major source of fugitive emissions from an
industrial plant. Today there are several different valve-related fugitive emission standards
issued by a variety of sources:
Normative standards (e.g. API624, FCI-91-1)
International standards (e.g. ISO 15848)
End user specifi cations (e.g. Shell SPE 77/312)
National legislative and regulatory agency standards (e.g. EPA 40 Parts 60/63, TA-Luft)
Over the past two decades, oil and gas processing facilities
have been challenged with increasingly stringent regulatory
and legislative requirements impacting environmental health
and safety. This is particularly true of the rules governing
allowable Fugitive Emissions (FE) from process valves.
TEXT: Tarmo Laitinen
Enhanced safety
with Fugitive Emissions certication
2 1/2014 results | valves
results | valves
the difference in permeability of these gases
and the precautions that must be taken
when using methane, leak test results are
not strictly comparable.
There are two methods for detecting
emissions. A local method (e.g. sniffing)
measures concentration which is typically
associated with methane based tests (e.g.
100ppm). Sniffing can only be used as an
estimate of the actual leakage. A correlation
is applied to the leakage measured by
sniffing to estimate actual leakage from the
valves stem. Global methods (e.g. under
vacuum) capture and accurately measure
the actual leakage (e.g. mbar*l/s) into the
atmosphere surrounding the valve. Because
the local and global methods are so different,
their results are not directly comparable.
These are not the only procedural differ-
ences among the standards. Others include
different testing temperatures, temperature
cycles, and number of operational cycles
before test data is collected. Moreover, there
is flexibility in some standards to interpret
test results more or less strictly. Finally, the
FE limits set out by the different standards
are also different.
So, how do we arrive at meaningful
comparisons that will allow us to make the
best choice? First, we need to take a more
detailed look into the different standards
to better understand the intent of their FE
limitation requirements for the valve and the
actual benefit of using a particular standard
to evaluate fugitive emission performance.
All of these standards have the same
general purpose: to encourage and enforce
compliance to the applicable local fugitive
emission laws, and reduce fugitive emissions
from the valves to prevent damage to health
and the environment.
Understanding FE standards
It requires considerable expertise to
understand the different fugitive emission
standards and to use that understanding
to develop valve packages that are
appropriate to the processes for which
they are intended, while conforming to
the applicable regulatory standards.
Among the most commonly used
global fugitive emission standards are:
EPA 40 Parts 60/63
(Limiting emissions to 100/500 ppmv)
ISO15848-1, which has been a favored
standard during the recent years
Shell Oil Companys end user
Direct comparison of different fugitive emis-
sion standards is not straightforward due to
the fact that they each rely on their own test
procedures. The most important variables
within these procedures are the test fluid,
detection methods for leakage and limits.
The test fluid may be either helium of
methane. Helium is a very permeable gas
and safe to use, whereas methane does not
have similar permeability or safety. Due to
Which FE standard is the most useful?
EPA 40 Parts 60/63 sets only 100/500ppm
leakage level criteria which must be met
during the actual usage conditions and
throughout the usage life of the valves.
The leakage detection flow medium is a
hydrocarbon from the pipeline, and the
detection method is sniffing. The approach
is very simple and clever because of the use
of a process plant as the origin for fugitive
emissions. Another advantage is that FE
level is measured throughout the valves life
cycle. However, hydrocarbons have different
leakage behavior depending on the nature
of the flow medium (gas/liquid). So it makes
difficult to compare fugitive emission
performance of different valves in cases of
different flow mediums. Also these leakage
limits are not very strict, so they are easier
to fulfill.
TA-Luft is a standard that requires a
valve manufacturers designs to comply
with certain requirements. TA-Luft sets
the leakage criteria to be at bellows seal
leakage level or the equivalent. The leakage
detection flow medium is helium, which is
a very permeable gas. Only global leakage
detection methods are allowed. There are
two different FE leakage level limits based
on the applications temperature level.
The leakage limit for under 250C can be
regarded strict, where above 250C limit
can be regarded as less demanding.
The TA-Luft standard does not define
the exact number of operating cycles, so
Figure 1:
Leakage value comparison of diferent
valve fugitive emission standards.
The leakage values (mbar*l/s) could
be characterized better in real life
leakage values indicating the leakage
in liters per year for 25mm stem.
ISO Class A = 0.014 L per year
(volume of d = 3cm ball,
35% of a golf ball)
TA-Luft <250 C = 0.3 L per year
(a soda can)
ISO Class B = 1.4 L per year
(~ two wine bottles)
TA-Luft =>250 C = 30 L per year
ISO Class C = 140 L per year
(~ barrel)

Shell MESC
SPE 77/312
CFR 60
CFR 60
ISO Class A ISO Class B ISO Class C TA-Luft
<250 C
=>250 C
*=snier value
**=converted value (Leybold L200)
Shell MESC
SPE 77/312
Figure 1. Leakage value comparison of dierent valve fugitive emission standards.
3 results | valves 1/2014
results | valves
it leaves room for different interpretations.
For example, should the operational life
of a control valve be established at 500 or
60,000 operational cycles? In addition to
that, TA-Luft does not contain a defined
temperature cycle procedure, which is a
slight disadvantage when evaluating a
valves FE performance under actual usage
ISO15848-1 does not regulate the valves
design but rather the type of approval tests
with which valve manufacturers design
must comply. The leakage detection flow
medium is typically helium. Methane can
be used, but such testing is uncommon due
to safety concerns. ISO15848-1 has three
different leakage limits which range from an
extremely stringent (Class A) to a non-strict
(Class C) measured with the global leakage
detection methods.
ISO Class A is the most demanding
leakage level that exists at the moment. It
is meant for valves equipped with bellows
type seal packings. Quarter turn valves can
reach ISO Class A leakage level in a short
term, lower temperature tests with current
graphite packings at the moment. This
means that emission performance of current
graphite packing rings greatly exceed PTFE
based chevron packing rings that have been
used as a fugitive emission solver in the past.
Additional benefits of current graphite pack-
ings compared to PTFE chevron packings are
their fire safe properties and greatly elevated
temperature range.
ISO Class B leakage level can be regarded
as a quarter turn valves performance level
which can be reached with current graphite
packing rings in long duration tests at a high
temperature (400C).
ISO 15848 also establishes separate FE
limits for a valves body joints (like bonnets
or covers) measured by the sniffing method.
There are three endurance classes for both,
on-off and control valve types. Testing
temperature classes ranging from -196C up
to 400C may be used to define the testing
temperature and compulsory temperature
cycle procedure.
Figure 1 summarizes allowed leakage values
of different FE standards relating allowable
annual leakage to the volume of everyday
objects. From it we can see that ISO 15848
offers the most comprehensive leakage
level classification. It does so with testing
procedures that can be varied to simulate
actual operating conditions. This allows
the easy, quantifiable comparison of valves
fugitive emission performance in order to
select the most appropriate product for
specific applications.
Accelerating the pace of
ISO 15848 certifcation
During the past five years, many process
industry end users have clearly begun
favoring ISO 15848 emission standard as the
most unified tool for measuring and realizing
their FE performance objectives. This has
provided a strong incentive for valve suppliers
like Metso to actively pursue a wide range
of theoretical and technical knowledge as
well as laboratory facilities, along with the
testing and reporting capabilities needed to
fulfill current ISO 15848 standards Class A/B
leakage requirements.
The requirements of the ISO 15848 FE
standard are very demanding for the valves.
Here are some of the measures Metso has
adopted to support them:
Simulating actual thermal cycling
conditions: A mandatory heat cycling
program simulates potential processs heat
cycling which sets high demands for the
valves design. For example, a weak valve
design may lose its FE performance after a
heat cycle. The severe heat cycling program
combined with extremely low (Class A) and
low leakage (Class B) limit criteria measured
with accurate methods is a strong indication
of low FE leakage at the harshest conditions
that a valve may see during its life cycle.
Third Party Certifications: Highly regarded
3rd party certifications are frequently
obtained to verify testing conditions and
actual FE performance of valves. In this way,
end users can be sure that they receive high
fugitive emission performance valves.
Expanding the number of valve models
tested: In 2012, a corporate initiative to
increase the number of valves certified to
the most stringent environmental standards
was expanded to certify numerous soft-
and metal-seated valves to the ISO 15848-1
standard and to translate the test results
into evidence of compliance with other
strict regional standards.
Metsos corporate initiative to expand
and intensify FE certification coverage will
continue in the future as it is the only way to
provide proven, added value for the end users.
Many benefts of FE reduction
Valves with low fugitive emission levels
benefit end users in many ways. First, valves
which have very low fugitive emissions help
end users to fulfill current environmental
rules and regulations which must be
adhered to if the plant is to continue its
operations and avoid heavy fines (which can
be far more costly than FE-certified valves.)
Secondly, minimization of fugitive
emissions can also avoid other costs that
occur when product is lost via leaking valves.
The lost flow medium results in both lost
raw material and smaller endproduct yields.
The more complex and processed the flow
media is, the higher price it has per mass
unit. The loss of flow medium is also lost
energy, as the pumps or compressors must
do extra work to compensate for the leak-
age. A considerable amount of money can
be saved by minimizing fugitive emissions.
FE-certified valves improve safety. A
leaking packing can represent an enormous
safety issue in a process plant. For example,
a hydrogen leak can autoignite and cause
hardly detectable flames. Such a flame
will burn surroundings and compromise
personnel and plant safety.
Of course, health issues will also be
minimized by reducing fugitive emissions.
A healthier environment protects people
and it also makes them more productive. For
example, reducing H2S content in air allows
workers to work a longer time period in high
H2S content areas.
By asking their valve suppliers to require
FE testing to the most comprehensive
standard available (currently ISO15848-1)
end users can introduce significant health,
safety and environmental benefits at their
process plant, even as they improve their
operating cost factors.
For further information, please contact:
Reprinted with the permission of Valve World magazine. This
article was published in Valve World magazine, June 2013.
Health issues will also be minimized by reducing fugitive
emissions. A healthier environment protects people and it
also makes them more productive.
4 1/2014 results | valves
our products and solutions
Essential utilities
Steam is widely used in industries such as power production where
high pressure drops and vibration is a concern. It is needed for various
purposes in chemical and hydrocarbon processing: It can be used as
a source of power, taking part in a reaction, like in steam reforming to
produce hydrogen; or it can be used as stripping steam in columns
and reactors, purging piping and equipment to keep them clean from
fouling such as in delayed coking coke drum operations and steam
cracking furnaces in ethylene production. Wherever steam is used,
there is a likely need to control noise and large pressure drops. Special
attention is required in the sizing and selection of valves to ensure that
they are also clean, safe and reliable.
Compressors and surge
Compressor surge protection is a severe application requiring noise
control. Capacity instability is accompanied by a characteristic noise
known as pumping or surge. The resulting violent gas pressure oscil-
lation can cause damage to the compressor in just a few seconds.
The anti surge valve must be able to pass approx. 100% capacity of
a compressor, react quickly, handle high pressure drops and reduce
noise while keeping a tight shutoff to avoid energy losses.
Answering noise demands
How does a valve manufacturer answer these extreme demands
when noise needs to be controlled under various flow conditions
and ever tightening noise level requirements? One will start by
looking at the history and milestones of flow control noise abate-
ment technology developments that are leading the way to modern
Rotary control valves have been used for decades in numerous
processing industries. In the late 1970s, rotary control ball valves
were already in wide use. The same design of the first low noise
anticavitation, patented Neles Q-Ball introduced in 1979 still works
on the same field proven principle of a multi stage trim of variable
resistance depending on the valve opening. The difference between
the noise level of a Q-trim ball and conventional ball can be up to 20
dBA. The Q-trim ball also has wider rangeability, and it is not sensitive
to fluid impurities. The Q-trim ball became a common solution for
many applications in steam, gas or liquid service. The next step
towards higher pressure drops was taken in the mid 1980s when
diffusers were introduced and sized so that their performance was
optimised in conjunction with the control valve. The segmented ball
control valve introduced in the 1980s added more possibilities in the
way of extremely wide rangeability to flow control. Using Q-trim in
segmented ball valves gives a control valve with low recovery.
The late 1980s saw an extension in the applicability limits of the
control butterfly valve when the silencer disc (Neles S-Disc
) was
launched. The solution was again very simple. The non-symmetrical
pressure distribution pattern on both sides of the disc has been
made symmetrical with a partial flow obstacle (S-Disc) inside the
Noise can be a problem in even low and medium pressure steam applications, resulting in issues like
heavy vibrations or health, safety and environmental hazards. In processing facilities like oil reneries we
can hear the loud noise generated by the ow of uids. Avoiding excessive noise is a common requirement
in many oil and gas plants, especially those related to gas processing, LNG, GTL or industrial gas production.
The usual limit for noise is 85 dBA, but the limit for the whole project may be as low as 80 dBA.
TEXT: Sari Aronen and Ville Khknen
our products and solutions
Rotary valve noise abatement in gas and steam fow control applications
Keep the noise down
volume is at the maximum. The acoustic noise can be controlled in
two ways: flow division into multiple streams and the modification
of the acoustic field. Location control involves designing a valve trim
in such a way that the location and the shape of the jet streams in,
and especially leaving the trim, are such that the minimum amount
of noise is produced. Dividing the pressure drop between a control
valve and a downstream diffuser provides an effective way of further
reducing the noise in cases where there is a constant, high pressure
drop across the control valve and the flow is relatively constant. An
attenuator plate can be used for noise attenuation in cases where the
pressure drop is close to constant across the valve.
Short theory behind source treatment
Velocity control: Controlling the maximum fluid velocity inside a con-
trol valve trim is a very effective way of controlling noise at subsonic
flow velocities in the trim, as the acoustic intensity of a jet has been
shown to be proportional to the sixth power of the flow velocity in a
system with solid boundaries like a valve trim or a pipe. The relation
between sound pressure level (SPL) and acoustic intensity is given in
equation (1).
Control valve aerodynamic noise is mainly caused by dipole
sources when the flow velocity is subsonic. The acoustic intensity is
given by the following proportionality equation (2).
Equation (1):
Equation (2):
5 results | valves 1/2014
our products and solutions
valve body. This design helps to eliminate the dynamic torque,
and because of the more turbulent flow pattern, it lowers the high
recovery behaviour.
Decades of experience and development form an essential basis
to take further development steps in control valve noise abatement.
Controlling noise and understanding the fluid behavior in valves is
based heavily on experimentation and supported by computational
fluid dynamics.
The new Q2-trim is the second generation of Q-trim technology
and is designed to reduce high aerodynamic noise to a tolerable
level. The design itself follows the same principle as Q-trim and
also utilises the same techniques of pressure staging, flow division,
acoustic control and velocity control.
The idea behind the new development was to create high noise
attenuation trim, which takes into account the 30 years history
of the Q-trim and brings the noise attenuation to a new level of
performance. The theory behind the design is based on the same
physical phenomena that can be found with the Q-trim.
The science behind the development
What creates noise in the first place? The answer to this question
is not straightforward. Although there are still unknown factors
behind noise, theories have been built for them. The noise created
by throttling gas or steam flow is called aerodynamic noise. There
are various sources where the noise originates, for example, from
the downstream turbulence of the valve, which can cause pressure
fluctuations and pressure waves, high flow velocity and vibrations
from shock waves. Once high noise has been generated inside a
pipeline, it can propagate in several ways: inside the pipeline, along
the pipe wall, along the pipe supports and into the surroundings.
Noise abatement can be done in several ways. The basic division
of these is between source treatment, like valve and trim modification
where excessive noise is prevented, and path treatment with dampen-
ing the noise generated by using silencers, insulation and heavier pipe
schedule. Source treatment is the preferred choice, whenever feasible,
because it also ensures reliable process operation by preventing the
high mechanical vibration levels always associated with noise.
Source treatment of noise can be performed by at least four
different methods: velocity control, acoustic control, location control
and by using diffusers. The velocity inside a control valve trim can be
controlled most effectively by using a multistage pressure drop and
by increasing the valve trim outlet area such that the flow velocity
and pressure at the valve outlet are at the minimum and the gas
our products and solutions
A very important implication in equation (2) is that the noise
intensity is proportional to the velocity to the sixth power.
I = acoustic intensity
= density of jet
v = velocity of jet
= diameter of jet
r = distance from source
I = acoustic intensity
= 10 12W/m
= jet velocity


SPL (dB) = 10



SPL (dB) = 10

6 1/2014 results | valves
our products and solutions
Acoustic control affects the noise level by means of acoustics. Two
methods used in control valves are described here: flow division into
multiple streams and the modification of the acoustic field.
In theory, flow division into multiple streams is effective because
the intensity of the noise generated by a single orifice decreases
rapidly when the hole diameter is decreased. Thus, a number of small
holes attenuates noise more effectively than one big hole. A rule of
thumb is that each doubling of the number of holes reduces noise by
3 dB, as illustrated in Figure 1.
Location control involves designing a valve trim in such a way that
the location and the shape of the jet streams in the valve trim, and
especially leaving the valve trim, are such that the minimum noise is
produced. The formation of turbulence in the mixing region between
where the jet exits from an orifice and the gas flow at the outlet
region as well as the attachment and interaction of shock waves
(generated during throttling if the flow reaches sonic velocity in the
valve) are major sources of noise that can be controlled to a certain
extent by intelligent valve trim design.
One way to do this is to smooth the velocity profile of the jet by
introducing a lower velocity gas stream alongside the jet, as shown
in Figure 2.
As mentioned earlier, the further development of enhanced
noise reduction trim is based on applying the known technologies
in experimental research. This method has proved to be successful in
providing enhanced noise attenuation for gas and steam applications.
It provides very low pressure difference over the last stage, effective
flow division to reduce noise level in low and high pressure differen-
tials, avoiding resonances and extra turbulence as well as taking into
account the insertion loss related to separate static resistors.
Sizing valves and predicting noise
Computerized control valve sizing and noise prediction arrived during
the 1980s with sizing programs, which acted as tools for evaluating
the true performance of the control valve. Today, control valve sizing
programs are the key to appropriate valve noise prediction for overall
noise control. Aerodynamic noise equations for control valve sizing
have been defined by using international standards like IEC 60534-8-3.
The capability to avoid excessive noise is a common requirement
in many oil and gas plants. Valves play a critical role in noise control.
Wherever there are gaseous hydrocarbons processed or utilities
such as steam, hydrogen, nitrogen and oxygen used in hydrocarbon
processing, there is a likely need to control noise at large pressure
drops. Special attention should be paid in extreme applications, like
compressor anti surge, to handle the extreme service demands.
There are various sources for aerodynamic noise generation.
Several noise theories have been built to understand the complexity
of noise generation and the factors behind it. The unknown factors
make it more challenging to predict the noise behavior in real condi-
tions. Experience forms an essential basis for further development
steps in control valve noise abatement. The new noise attenuation
designs are based on a balance between the theory and practice.
For further information, please contact: or
1. Neles-Jamesbury, Valve Book, 1990.
2. Metso Automation, Flow Control Manual, 2005.
3. Khknen, Ville., Aerodynamic noise attenuation in rotary control valves,
Valve World Magazine, December 2012.
Reprinted with the permission of Hydrocarbon Engineering magazine.
This article was published in Hydrocarbon Engineering magazine, October 2013. The principle of anticavitation and noise reduction (Neles Q-trim).

Figure 1.
Eect of increasing
the number of holes
on noise level.
Figure 2:
Jet velocity prole
Figure 1. Figure 2.
v > 100 m/s
v > 100 m/s
v < 100 m/s
v < 100 m/s
jet streams
lowest trim
7 results | valves 1/2014
Signicant savings in China
Excellent results of Metsos service concept led customer
to sign the ve-year contract again for another ve years.
Metsos solution has been designed to
improve the availability of critical spare
parts for maintenance activities while
reducing overall costs associated with
stocking spare parts. As part of the con-
tract, Metso will also provide its On-site
Supervising Service at the Gdask refinery
so as to ensure that daily maintenance
and turnaround activities always meet the
high standards set by Grupa Lotos. The
contract value has not been disclosed.
Technical Director of Grupa Lotos
Grzegorz Bdowski said: We chose
Metso to improve our capabilities in
managing valve repairs and spare
parts inventory. To support operational
processes and to keep high refinery
availability, we need reliable equipment
and good partners like Metso.
Through in-depth understanding of
the criticality of individual devices and
an intelligent stocking strategy, Metso
is able to simultaneously reduce the
number of spare parts and components
held in stock while increasing the
number of devices covered by spare
parts in the refinery. Through this
approach at other sites, Metso has been
able to substantially cut spare parts
inventory, reduce yearly spare parts
capital and operational expenditure,
while significantly increasing the number
of devices covered by spare parts.
Metsos On-site Supervising Service
ensures that maintenance and repair
work done by the end user and third
parties has been done correctly and
meets stringent quality thresholds.
As part of the service, Metso assists
in maintenance planning, checks the
completed maintenance and repair work
done on Metso items, carries out testing
on repaired equipment to ensure that it
has been performed correctly and assists
Lotos with all other daily and long-term
activities related to Metso valves.
Mikko Keto, President of Metso
Automation Services commenting on
the deal said: Metsos presence in the
oil & gas sector continues to grow with
this significant new service contract with
leading Polish refinery Grupa Lotos.
For further information, please
Optimized valve spare parts
stocking and supply in Gdansk
Grupa Lotos S.A. has chosen Metsos Device Management
Solution to optimize its valve spare parts stocking and supply.
Metsos Device Management Business
Solution (previously known as Valve
Management Solution) has reduced
storage expenses, valve spare parts
purchases and networking capital tied
up in valves at a major Chinese paper
mill. In the contract Metso is responsible
for managing spare parts inventory. In
this way Metso has satisfied customers
priority requirement of reducing its
inventory and also ensured that contract
inventory is sufficient to cover all valves
in critical parts of the process while
saving inventory costs at the same time.
The five year service contract started
in 2008 and is continued for another
5 year period. The contract covers areas
such as inventory stock management,
spare parts agreement and pricing,
delivery timescales, field services,
rapid response services and technical
guidance services.
The satisfied customer said about
Metsos services, With Metsos service
team we do not have any worries. We
do not have to contend with inventory
issues any longer, and neither do we
have to consider matters such as on-site
valve maintenance. During this period,
Metsos customer has not encountered
any incidence of equipment failure due
to valve issues.
Automations President Perttu
Louhiluoto said in an interview with
Valve World: I believe strongly in Chinas
rapid development because I have seen
for myself how it has developed in 5 to 7
years in a way that would take 30 years
elsewhere. Under such circumstances,
I believe that in the coming 5 years,
the element of service will become
a factor considered by suppliers, and
they will receive attention and be
trusted as long as they perform well in
terms of the supply of spare parts and
value the quality of their products. This
is why we are taking the initiative to
develop our services with regard to our
solutions end-users. Metso is committed
to promote our Device Management
model so that our customers in China
and elsewhere can enjoy high-quality
management services for valve and
other device inventory, more stable
workflow management, more timely
supplies as well as higher efficiency.
For further information, please
our customers
Device Management Solutions
8 1/2014 results | valves
Since starting production in 1972, the Dow
plant on the river Elbe in Stade has grown
to be one of the largest and most important
industrial enterprises in northern Germany.
Around 4 billion euros have been invested
there over the years to optimise existing
plants and to build new ones. Key issues
have been maintaining the companys
market position and competitiveness, reduc-
ing energy consumption and protecting the
environment. Although energy consump-
tion in the plants is equivalent to that of a
large city such as Hamburg, Dow products
are used for high-performance rotor blades
in wind power plants, special media for solar
power plants and insulation material. This
can save many times the amount of energy
needed for production.
Compared to such complex processes,
the installation of a shut-off valve seems
small and insignificant. Yet experience shows
that every single component matters. The
search for the ideal valve solution at the
DME reactor turned out to be a long and
costly task. Gate valves, ball valves and plug
valves were installed, tested and rejected
over the years. Finally, Ludger Michalczak
had the idea of installing a butterfly valve,
a solution that hadnt been considered in
the past due to the requirements of the
reactor. Michalczak has been working for
Dow in Stade for about 41 years and as SPP
coordinator he is responsible for making
changes to instrumentation and pipework
at three of the plants. One of these plants
is the chloromethane plant for processing
dimethyl ether (DME). The fixed bed reactor
needed for this purpose must be separated
from the nearby process and sealed with a
valve when maintenance personnel enter
the DME reactor, for example to make
repairs or to change the catalyst. Also, the
reactor must be isolated in an emergency to
prevent emissions.
Metsos solid-proof Mapag buttery valve signicantly reduces
operational costs in extreme process conditions at Dow in Stade.
Buttery valve installed
problem solved
TEXT: Ursula Gehl
Metso has identied
our problem and
has delivered a
functioning solution.
Ludger Michalczak
SPP coordinator, Dow in Stade
our customers
9 results | valves 1/2014
Challenges: coke fnes and heat
This valve must close on demand with
100% safety and reliability, says Michalczak.
The problem is that we have an exothermic
catalyst, which is a chemical reaction with
heat, which produces coke, among other
things. Both the coke fines and the heat
kept damaging the first valves and causing
them to fail. Gate valves didnt stay closed,
because the coke built up in the casings.
The ball valves and plug valves that we
installed next suffered due to heat. As the
material expanded, deposits built up in the
dead spaces, so that over time these valve
types became leaky due to blocking and
were no longer adjustable.
Ludger Michalczak sums up the
problem: We have extreme processes
here, so we need extreme solutions. A
solution that seems reasonable doesnt
make sense if it doesnt keep working. The
valve types that we installed at first had
to be changed after a short time and this
led to increased investment and operating
costs at the DME reactor. A butterfly valve
hadnt been the first choice because its
sealing surface is small compared to ball
valves or plug valves, but as an innovative
engineer Michalczak decided to try
one. The principle of the butterfly valve
soon proved successful, but still needed
improvement to fulfil the bidirectional
tightness function specified by Dow.
After positive experiences with a Metso
valve in another area, Dow eventually started
talks with Metso to discuss a new solution.
It was essential for us that we finally put a
stop to our longstanding problem with the
valve in the DME reactor. We wanted to have
a valve that was durable, reliable and safe,
Ludger Michalczak stresses.
Higher efciency through
innovative details
Dow decided to order a special solution
from Metso Automation that would be
appropriate for the extreme application.
Metso engineers started with a standard
Mapag Solid-Proof valve as the base and
developed it into a customer-specific
solution to meet Dows requirements. The
highlights of this valve are Monel as the
basic material and the borated seat and
sealing surfaces. The coated material offers
significantly higher abrasion resistance than
chrome, nickel or stellite thanks to a hard-
ness of 6,000 HV, which also gives it a 100%
guarantee for tightness. Also, the rotation
mechanism is protected as a prestressed
bearing seal prevents coke from entering
the shaft and bearing, which guarantees its
longevity and efficiency in the reactor.
The Mapag valve has a fail open
function, that is, it must open if a failure
occurs in the reactor to prevent overpres-
sure. When the reactor is shut down for
repair work, the valve must have bubble-
tight shut-off to prevent the inflow of any
The Dow Chemical Company produces basic chemicals such as chlorine, ethylene
oxide and methylcellulose for international markets as well as a variety of plastics and
specialty chemicals. The worlds second largest chemical company in terms of turnover,
Dow has been operating in the north German town of Stade for over 40 years. Around
1,500 people are employed at the 16 production plants. Nearly three million tons of
basic and specialty chemicals are manufactured per year in this ultramodern integrated
plant complex.
Due to the high volume of chemicals produced, the plants and their components must
always be available and a high level of safety maintained. To make sure this happens, Dow
has installed a Solid-Proof Monel valve, developed by Metso Automation specifically
for the customer, to reliably shut off the DME reactor in Stade. The valve meets
the demands of the environment and reduces operating costs due to its reliability.
Dow Chemical Company
in Stade, Germany
our customers
medium from the connecting column.
This means that the valve performs a
safety function, Ludger Michalczak stresses.
The valve has been functioning well since
its installation in 2009 and is still practicable.
That wouldnt be the case with any of
our previous solutions after four years of
exposure to heat and coke fines, Ludger
Michalczak concludes and adds, Were
happy to work with Metso as a supplier, as
they have solved our problem with a valve
that functions even under the extreme
conditions at our plant, so that we can
finally have stable conditions.
Install & forget
Under the motto install & forget, the valve
has been functioning smoothly since its
installation in 2009. As a qualified process
measuring and control engineer, Michalczak
is in a position to recognise the value of the
Mapag valve: Metso has understood our
requirements for the fittings at the DME
reactor. This valve, which was developed
uniquely for us, is therefore what I call a real
solution, which has paid for itself in reduced
operating costs. We call this long term
cost of ownership and this cost has tallied
because the valve just does its job.
For further information, please contact:
Reprinted with the permission of Valve World magazine. This
article was published in Valve World magazine, December 2013.

10 1/2014 results | valves
The range of Mapag valves increases productivity, minimizes
security risk and optimizes the cost of advanced processes.
Celebrating the 90

anniversary of our
renowned Mapag valves
to solve our
in wide range
of applications

On October 1, Metso celebrated 90 years of success for its
Mapag product brand of valves at the Metso Valve Technol-
ogy Center in Horgau, Germany. This range of butterfly valves
has been especially valued internationally in all types of
challenging industrial applications thanks to its exceptional
reliability and low life cycle costs.
One of our strong family of valve product brands, Mapag,
has developed over the years into a product brand well
known for its high performance and specialty
valves for safety areas in industrial plants.
These valves improve process efficiency in
applications in the oil & gas, industrial
gas, chemical and petrochemical
industries, offshore, and in power
Demand for these valves has
been continuing to grow as raw
materials and energy
sources are becoming
scarcer and costs
continue to rise. The
range of Mapag
valves increases
productivity, minimizes security risk and optimizes the cost
of advanced processes.
The current range of butterfly valves covers operating
temperatures from -270 C (-454 F) up to +1,450 C (+2,642 F)
and works reliably in high pressures from a vacuum up to
400 bar (5,800 psi).
The Metso Valve Technology Center in Germany is well
equipped especially with refrigeration technology. Valves
are tested to ensure they comply with both cryogenic
and thermal shock tests that meet the latest international
Three core values that the Metso Mapag product brand
will continue to offer customers are customization through
continuous innovation for a wide range of applications,
reliability with advanced performance, and strong partner-
ship through operational savings. By further focusing on
these values, customers can be assured that their needs
will continue to be met as they face ever more challenging
operating environments and strive to lower their costs of

For further information, please contact:
with advanced
10 1/2014 results | valves
11 results | valves 1/2014
Tang Yezhu, Area Sales Manager, Metso Auto-
mation says: The ND product series models
come with online diagnostic functionality and
a wide capacity range. It is also possible to use
the same type of positioner with single- and
double-acting actuators, linear actuators, and
rotary actuators. These are the three technical
advantages that put us ahead of the pack.
Online diagnostics enables predictive
maintenance, so our customers save money
by making the right maintenance decisions.
Thanks to high pneumatic capacity, less extra
instrumentation is needed, which both saves
on investment costs and improves reliability
during the run time of the plant. By being
able to use the same device with single- and
double-acting as well as linear and rotary
actuators, customers can keep the spare
device inventory low, Yezhu continues.
To ensure smooth operation of the
positioners at the site of installation, we will
provide our client with a comprehensive
suite of technical services, including on-site
technical training. Service engineers will
be available to oversee the controller
installation, and we will also work with
the DCS supplier to handle installation and
to debug the valve management software.
In the early stages of operation, Metso
Automation will be at the refinery to ensure
a smooth deployment of the controllers.
Metso will also provide routine maintenance
services once operations commence.
For further information, please contact:
Sino-Venezuela Guangdong Petrochemical Company, China
Order of over 4,000 intelligent valves controllers
Metso has won a large order for intelligent valve controllers from Sino-Venezuela Guangdong Petrochemical
Company for its 20 million ton-per-year, heavy crude processing project. The preliminary estimated quantity is
over 4,000 units, including the Neles ND7000 series standard, intrinsically safe, and explosion-proof models.
The Sino-Venezuela Guangdong Petrochemical Company oil refinery project with a 5 km
footprint is located in the Jieyang
Nandahai Petrochemical Industrial Zone in Guangdong province. The project is slated to process 20 million tons of heavy crude
annually with 29 processing units, a 300,000-ton crude oil terminal and a 30,000- to 50,000-ton product terminal in what will be
the largest oil refinery project in China in terms of processing capability. Total project investment has reached USD 9.54 billion,
with PetroChina a 60% stakeholder and Petrleos de Venezuela S.A. of Venezuela holding a 40% stake. The raw material to be used
by the refinery is Merey-16 crude from Venezuela, which will be turned chiefly into petroleum, aviation fuel and diesel.
Neles (ND9300H) intelligent valve controller has received a marine
certicate from Bureau Veritas indicating that the unit has passed
that organizations requirements for steel ships.
To meet this level of certification, the ND9300H controller had to
pass a series of demanding corrosion and vibration resistance tests.
This level of certification means that the ND9300H is an excellent
high performance controller choice for severe offshore oil and gas
production applications.
As the demand for oil and gas increases, producers have been
moving their offshore operations to ever more demanding locations,
working at greater depths and under more severe weather conditions.
Metsos ND9300H can meet the high performance control require-
ments of these advanced offshore applications while standing up to
hard use as well as heat, cold, moisture, salt and other harsh conditions.
The ND9300H is a ruggedized, fully stainless steel enclosed intel-
ligent valve controller designed to withstand the harshest operating
conditions in the offshore
industry. It can be installed
on top of any valve rotary
or linear, big or small. The
ND9300H delivers superior control
performance with Metsos market-
leading diagnostic features as standard. With
the help of the marine-certified ND9300H intelligent valve
controller, oil and gas producers can further improve the safety and
reliability of their offshore production, easily and cost efficiently.
For more information please contact:
Marine-certied Neles intelligent valve
controller for severe oshore conditions
12 1/2014 results | valves
Metso has certified several flow control products to help process industry end-users
ensure that their plants comply with technical standard IEC 61511, Safety Instrumented
Systems (SIS), for the process industry sector.
Safety has always been an important and visible theme at Metso. Compliance with all
applicable standards is top priority, as Metso is continuously improving the performance
of all its products based on the field experience data collected from tens of thousands of
units installed worldwide.
According to Timo Torvinen, VP, Energy & Hydrocarbon sales and marketing, Metso:
In recent years, our customers, particularly in the energy and hydrocarbon industry, have
been looking for standardized best-in-class valve and controller technologies that can be
applied systematically both in process control and safety applications.
Third party certificates are in accordance with the newest version of IEC 61508.
Metso control and automated on-off valves provide complete solutions from a single
source supplier and are tested as an assembly to assure compatibility of crucial safety
loop components.
Furthermore, to improve use and servicing of critical safety loop components,
Metso has introduced new safety manuals for their valve and actuator series. These
provide the functional and safety-related information required to integrate and use
valves in safety systems in accordance with the IEC 61508 standard.
For further information, please contact: or
SIL certications for Neles ow control products
Metsos customer can condently apply the high performance
ow control products they have become familiar with on
the process side to critical safety applications as well.
The following products
can be used in safety loops
requiring Safety Integrity
Level SIL 3 classified automated
on-off valves:
Neles X and D series ball valves
Neles L6 and Mapag B-series
butterfly valves
Neles B-series actuators
Neles ValvGuard VG9000
intelligent safety solenoid
In applications where a control
valve can perform the safety action,
the following products can be
used in flow control loops requiring
SIL classified control valves:
Neles Finetrol eccentric rotary
plug control valve
Neles ND9000 intelligent
valve controller
Sierra Gordas desert mining project, Chile
Long-lasting seawater control
Sierra Gorda Sociedad Contractual Minera
(SCM) has chosen Metso to supply state-of-
the-art control and on-off valves to the Sierra
Gorda copper/molybdenum mining project
which is currently under construction in the
Atacama Desert in Antofagasta region, North
of Chile. The valves will be used to control
the flow of process and make-up water for a
variety of applications in the mine.
The Atacama Desert is one of the driest
regions on earth. Precipitation is extremely
rare and there is no surface water at the
project area. Therefore, the project will rely
heavily on sea water delivered via a 350
kilometer long pipeline from the Pacific
Ocean. To combat the highly corrosive
effects of seawater, Metso will provide
valves constructed of SMO254tm austenitic
stainless steel, which is highly resistant to
the effects of chlorides.
Metso will deliver 54 Neles V-port
segment control valves from 1 to 12,
on/off valves from 3 to 18 (with Series B1,
QPX pneumatic actuators or BIFFI electric
actuators) as well as numerous Jamesbury
ball valves. All of the valves are rated to
The Sierra Gorda mining facility is
expected to process 110,000 tons per day
(t/d) of mineral and its operations will
begin late in 2014. The anticipated life of
the project is 21 years and the equipment
supplied has a 25-year life expectancy.
For more information please contact:
13 results | valves 1/2014
The Neles PZ series of capping valves improves process
safety, enhances process reliability and eliminates unsched-
uled process downtime thanks to its proven technology.
Design features, like a preloading device mounted outside
the valve body, prevent chips and liquor from causing
hazards. Special interlocking systems, essential to plant
safety, help lower maintenance costs.
The Nymlla mills batch cooking process is a very
demanding application because magnesium bisulfite is
used as a cooking liquor. The local Metso sales and product
line teams were able to offer Stora Enso Nymlla mill a
solution that fulfilled their requirements by making a few
technical changes to the standard Neles PZ-series capping
valve design. These details were thoroughly discussed
with the customer. Technical compliance, together with
a proven track record in similar applications around the
world, helped Stora Enso Nymlla mill decide in favor of
the new capping valve solution.
The Nymlla mill specializes in producing high quality
office papers and has had a good working relationship with
Metso already for decades. Today, the whole mill with two
paper machines has an installed base of approximately
1,000 Metso valves. In addition, the mills PM 1 and 2
are equipped with Metsos automation system Metso
DNA, Metso IQ quality control system, NelesACE basis
weight valves and a range of profilers, which are fully
integrated with Metso DNA. The new capping valves
will also be connected to Metso DNA.
The valves for this project will be delivered
during 2014. All valves are scheduled for installa-
tion and commissioning by the end of the second
quarter of 2014. The delivery contains 5 Neles PZ capping
valves equipped with pneumatic actuators, control centers
and Neles SwitchGuard intelligent on/off valve controllers.
Long history in capping valves
The capping valve is one of the innovations for the pulp
and paper industry that originated from Metso. More than
1,500 capping valves in total have been delivered to batch
cooking applications worldwide.
The first capping valve deliveries to Sweden were made
during 1969, and Metso has continued its valve deliveries
and related services in the country since then.
For further information, please contact: or
improves safety and
reliability, and eliminates
Stora Enso Nymlla mill, Sweden
Automated solution for batch cooking
process with Neles capping valves
Stora Enso Fine Papers Nymlla mill in Sweden selected Metso as the supplier of new
capping valves for its batch digester line 1. In total, Metso will deliver 5 Neles PZ-series
capping valves to replace the mills old hydraulic cappers. This gives Stora Enso an automated
solution for its digesters replacing old valves and actuators that needed manual assistance
in the chip lling phase and increasing overall productivity.
14 1/2014 results | valves
Metsos valve solutions were chosen
because they meet the strictest standards
regarding leakage class and low fugitive
emission, says Steven Wang, Account
Manager, Automation, Metso.
The PO/AE integration project includes
plants for propane dehydrogenation, acrylate,
and acrylic acid resin, propylene oxide,
and polyhydric alcohols, as well as a LPG
storage cavern. Metso will supply ball valves
including its X series, D series stemball valves,
9000 series flanged valves, S6 series metal
seated high pressure valves, and the R-series
V-port segment control valves. Materials of
The valves will be used in the MDI integration project (diphenylmethane diisocyanate) at their
existing factory site and a new PO/AE integration project under construction in China (epoxy
propane and acrylic ester). This is the rst partnership between Metso and Yantai Wanhua,
which has invested approximately RMB 30 billion (USD 5 billion) in these two projects.
Yantai Wanhua Polyurethanes Limited, China
Superior tightness in difficult applications
construction range from WCB and CF8M
grade to Hastelloy, 316L and Monel per the
customers specification.
The key components of the MDI
project, which includes plants for producing
isocyanate, oxidized hydrogen chloride, and
nitrobenzene, require valves that deliver a
superior tightness in difficult applications
over long time and which promise control of
fugitive emissions. Metsos deliveries include
700, L6 Neldisc triple eccentric butterfly
valves that are engineered to accommodate
the projects unique requirements.
The Neldisc L6 series is a triple eccentric
butterfly valve with a metal seat. The trim
consists of a high-precision elliptical disc and
a chrome plated (Incoloy 825) seat, which is
attached to the casing with a stainless steel
clamp ring, making it easy to assemble and
dismantle for maintenance. Such metal seats
are more resistant to abrasion and more
tolerant of liquids at a high pressure and
temperature, all of which ensures a longer
operational life. When the valve is open, the
disc and seat are separated, which signifi-
cantly reduces abrasion between the sealing
components, reduces operational delays and
wear on sealing surfaces, and also lowers
valve torque. When the valve is closed, the
sealing is achieved through the elasticity
of the valve seat; assistance from pressure
generated by flowing liquid is not required,
meaning that a firm sealing can be achieved
even where the pressure differential is low.
For further information, please contact:
Metsos valve solutions were chosen because
they meet the strictest standards regarding
leakage class and low fugitive emissions.
Steven Wang, Account Manager
15 results | valves 1/2014
Green Energy Group in Kenya
Valves for geothermal power plant installation
Metso has already won its 10
repeat order from the Norwegian
company Green Energy Group AS for Neles rotary control
valves and triple eccentric disc valves. The valves were tested in
the companys pilot plant in Kenya, where the valves will control
the steamy process flow coming from the boreholes drilled into
the ground. The loosened soil from the ground can include silica
and sand, which sets special requirements on the valves to be
able provide accurate control ability in such rough conditions.
One of the challenges in these applications is the silica scaling.
Not many valves are able to operate in this type of environ-
ment, says Snorri Einarsson, Product Manager, Steam Systems,
Green Energy Group AS.
We have also benefited from Metsos Nelprof valve selection
program, which saves time since it is easy to use to calculate flow
characteristics. The next step will be to get all the plants hooked
Pearl GTL is a world-scale project located in Ras Laffan
Industrial City, 80 km north of Doha, Qatar. Pearl GTL
is the worlds largest source of gas-to-liquids (GTL)
products, with a design capacity of 140,000 barrels of
GTL products and 120,000 barrels natural gas liquids
and ethane per day.
Qatar Shell awarded a service contract to Metso supporting an
earlier delivery of valves and intelligent positioners to the Pearl
Gas to Liquids (GTL) Project in Ras Laffan Industrial City. Jointly
developed by Qatar Petroleum and Shell, Pearl GTL is the largest
GTL plant in the world and the largest energy project in the state
of Qatar. As part of the capital project, Metso delivered more than
two and a half thousand valves and twelve hundred ND9000
positioners. As the plant isdesigned to run 24/7, Shell is taking
the advantage of streamlining the spare part procurement
process to ensure competitive pricing and speedy order delivery.
The five-year Spare Parts Agreement with Metso covers more
than a thousand items.
According to Sami Alatalo, Metso Service Manager in Doha,
The agreement provides Shell and their service contractor with
a firm basis to plan valve service actions with delivery times and
agreed prices. A complete list of tag numbers maintained in the
Metso Doha office further ensures that the correct parts will be
available when and where needed on a day to day basis as well
as during the infrequent major shuts.
For further information, please contact:
Pearl GTL plant, Qatar
Spare part service contract
up to the Metso FieldCare Device and Asset Management
software to carry out predictive maintenance with live
monitoring of the valve performance, he continues.
Green Energy Group is famous for building up geothermal
power plants quickly due to its unique modular concept.
Traditional deployment of geothermal power plants takes
many years, from project start to power online, and requires
large investments to complete. Green Energy Group delivers
a unique power plant system that is prefabricated in ready
modules and commissioned on-site in weeks. In 2013 Green
Energy Group is delivering four geothermal power plants and
has received an order for five more plants for next year.
For further information, please contact:
Metso customer newsletter
for Neles, Jamesbury and
Mapag products
P.O. Box 304
FIN-01310 Vantaa, Finland
Tel +358 20 482 150

Radikal Advertising Helsinki Oy
2014 Metso Automation Inc.
All rights reserved.
All product names used herein
are trademarks of their respective
owners. Reproduction permitted
as source.
New service center in the Netherlands
Metso has opened a new service center in Waddinxveen, the Netherlands, near the Rotterdam-
Antwerp industrial area. The new service center supports our strategy to grow our valve and eld
device service business globally as well as strenghten capabilities within the Benelux region for
major petrochemical, energy, oil & gas and pulp & paper companies.
The new facility brings the total number of
Metsos automation service centers to 34 and
automation service hubs to 87. By combin-
ing intelligence with high quality servicing,
Metsos service centers all over the world
deliver customers secured plant availability
while optimizing total maintenance costs.
Our maintenance services range from
the servicing of individual Metso valves
all the way to maintenance and device
management solutions for complete plants.
We use intelligent solutions to service
valves and other field devices from Metso or
other manufacturers, explains Mikko Keto,
President, Services, Metso Automation.
The new service center in the
Netherlands is in line with our strategy to
continuously strengthen our global network
of Service Centers and service experts so
that we are close to our customers to best
support their business needs, he continues.
Metsos services portfolio
focuses on three main areas:
solving technical
and process issues
improving business
managing a business area
The Metso services mission is to
maximize the profitability of its customers
businesses. Metsos services portfolio
focuses on three main areas: solving
technical and process issues, improving
business performance, and managing a
business area.
Our services business is backed by Metsos
market-leading valve solutions, which
include control valves, automated on/off
and emergency shutdown valves, as
well as smart positioners and condition
For further information, please contact: