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Magnum Valves Running Strong For Tosco
Dresser-Rand engineers knew the innovative
design of the Magnum valve would set new benchmarks for reliability,
longevity, and affordability on all models of reciprocating compressors.
And, for Tosco Corporation, the Magnum valve has done just that –
performing continuously for nearly two years.
 Tosco
Corporation’s Woodriver, Illinois, oil refinery was experiencing
frequent compressor valve failures on two of its reciprocating process
compressors. The failures were identified as broken sealing elements and
springs that were failing primarily because of a process gas commonly
contaminated with liquids and debris.
Tosco, with corporate headquarters in Old
Greenwich, Connecticut, is the largest independent refiner and marketer of
petroleum products in the United States. The company is also the nation's
largest operator of company-controlled convenience stores.
As a critical component to refinery
operation, the compressors are responsible for compressing hydrogen in
three stages – as a feed gas to various refinery processes and a single
stage on vent gas service. With no spare compressor available, unscheduled
downtime is costly and highly visible in a marketplace where supply is
tight.
“Improving compressor reliability, as
well as making minor modifications to the compressor cylinders which would
allow an increase in capacity, was crucial to Tosco,” said Mike Sikora,
rotating equipment engineer for the company.
Engineers from Dresser-Rand’s revamp and
valve engineering teams conducted an engineering performance review of the
units. Based on the results, Dresser-Rand determined the existing
compressors and electric motor drivers were capable
of satisfying the desired increased capacity requirements. The Magnum
valve was perfect for this application.
With a precision-guided valve element and
springs, the Magnum valve increases the reliability of moving parts for
long-term operation and can be configured for a wide range of operating
conditions and virtually any gas process – from gases ranging in
molecular weight from 2 to 71, speeds from 327 to 1,000 RPM, and pressures
ranging from 35 to 4,000 psig. The Magnum valve also employs
a unique grid pattern that balances seat and guard areas with the lift
area.
Dresser-Rand completed the upgrade, which
included the removal of existing inlet valve cap pockets, and the
modification of valve covers to accommodate the new
valve design.
Since installation, Dresser-Rand’s Magnum
valves have been running continuously for nearly two years at the
Woodriver refinery. Prior to the installation of the Magnum valves, the
compressors ran an average of 11 months between valve failures.
“In addition to the valves being more
reliable, the compressors are noticeably quieter and the discharge
temperatures are down an average of 5-10 degrees,” added Sikora.
“Needless to say, we [Tosco] are very satisfied with the increased run
time, as well as Dresser-Rand’s responsiveness.”
As a result of the upgrade, Tosco has
recently contracted Dresser-Rand to apply Magnum valves and O-ring valve
cover upgrades to a non- Dresser-Rand reciprocating compressor.
After being installed in more than 100
cylinders around the world in both lubricated and non-lubricated service,
the Magnum valve continues to demonstrate that it is clearly an innovative
engineering design that is a step ahead of the rest.
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