Hi
We are facing a strange phenomena for the steam control valve to Flare tip 86FC004. It is MP steam with 20 barg and 320 C. It is injected in two different zones at flare tip as per attach. Normally, this valve operating with 0.3% - 0.5 % opening ! giving flow of 1200 Kg/Hr. We cannot maintain this valve at auto mode because of this narrow operating window of opening. Strangely, the outlet pressure of this valve is 0.5 barg!! I cannot imagine how it is reaching the tip with this very low pressure! we changed the PG and conducted pressure survey to check this low pressure value and we endup by same 0.5 barg all time! In the data sheet it should be 6 barg almost! So for resizing the valve we couldn't know which outlet pressure should be used!
We tried to increase this control valve FC004 opening by following steps:
1- Pinch off the manual block valves on downstream of the control valve to build up higher downstream pressure to the Control valve: the downstream block valve was closed gradually, there was no major change in the flow of FC004 or smoke appearance. When the valve fully closed,the flow dropped to half and pressure gauge red zero barg. We confirmed that the block valves are not passing as well as FC004. When FC004 is fully closed the flow was reading 600 Kg/hr. Then we decided to close the valve of orifice fully where this valve should be fully open normally to keep a minimum flow to flare. We noticed no change in this 600 Kg/hr with fully open or close at orifice valve. So we become sure that this small valve 2" is passing.
2- In next day we decided to do something else;
- It was agreed to pinch the two globe valves (4” and 2”) at downstream of 86FC004 to increase FC004.MV to maintain the same flow. As per below pic, we tried to close 4” valve fully and closing 2” valve partially. The downstream pressure at outlet of FC004 increased from 0.5 barg into 9 barg, yet the flow reading dropped minorly <100 KG/H with the same opening of 0.3%. Then, we fully closed FC004 and the flow dropped from 1280 to almost 800 KG/H.
- Because we didn’t notice any big difference in the steam flow after pinching these globe valves, we returned 2” valve in almost open position while we kept 4” partially close to maintain the outlet pressure at FC004 at 3.5 barg currently.
- Then, we fully closed FC004, the pressure at the PG dropped to almost zero while FC004 dropped to ~ 630 KG/H. So we confirmed there is no passing found in this valve FC004.
- Then, we closed the valve of orifice where no change was noticed in the flow whether the valve is open or close. So, susceptibly it is passing.
We found it hard to accept 0.5 barg as the outlet pressure of FC004 while the pressure at outlet valve of pilot gas is 1.5 bar.
What's the issue? What are we missing here?!