Rev 0 CVZ Oct.

2, 2014
UOP EXPERIENCE WITH SEVERE STICKING PROBLEMS WITH CAGE TRIM CONTROL VALVES
IN HOT RECYCLE GAS SERVICE

A summary of UOP’s experience with cage trim control valve sticking problems (inability to
move the valve plug) in hot recycle gas service is summarized in the table on the next page of
this memorandum.

UOP’s experience is that severe sticking (seizing) problems occur with cage trim valves in hot
recycle gas service at temperatures above 300 °C (572 °F).

At temperatures below 300 °C (572 °F) severe sticking problems have not been reported.
Positive reports of operation without sticking problems in hot recycle gas service have been
received for cage trim valves TV-7005 at Dalian, China, at 271 °C (520 °F), and HC-FV-016, at
Valero, Meraux, La. at 232 °C (449 °F).

Although severe sticking problems have not been reported in hot recycle gas service at
temperatures below 300 °C (572 °F), UOP has adopted a conservative approach of avoiding cage
trim control valves in hot recycle gas service at temperatures above 200 °C (400 °F).

For hot recycle gas service at temperatures above 200 °C, UOP recommends a top guided
Masoneilan 21000 series (or equal) globe style control valve because it avoids the close
clearances between trim parts that are a feature of a cage trim valve.

The primary factors that lead to sticking of cage trim valves in hot recycle gas service are the
following:

1. High temperature reduces the clearance between the plug and cage.

2. Scale or corrosion particles from upstream piping and heater exchangers obstruct the close
clearance between the plug and cage.

3. H2S may induce corrosion of nitrided CA6NM steel alloy, or of other alloys (particularly
nitrided alloys), and the accumulated layer of corrosion can obstruct the close clearance
between the plug and cage.

See the table on the next page of this memorandum for a summary of locations that have
experienced severe sticking problems with cage trim valves in hot recycle gas service.
 Rev 0 CVZ Oct. 2, 2014
UOP EXPERIENCE WITH SEVERE STICKING PROBLEMS WITH CAGE TRIM CONTROL VALVES
IN HOT RECYCLE GAS SERVICE

TABULATION OF LOCATIONS WITH CAGE TRIM VALVES IN HOT RECYCLE GAS SERVICE
THAT EXPERIENCED SEVERE STICKING PROBLEMS
Location Midor, Egypt Dalian, China CEPSA, Huelva, Spain
UOP Project Number 555027 928238 939992
Process Unit Unicracking Unicracking Unicracking
Control Valve Service Recycle Gas to Recycle Recycle Gas to Recycle Recycle Gas to Recycle
Gas Heater Gas Heater Gas Heater
Temperature °C 366 (SOR) to 405 (EOR) 364 (SOR) to 416 (EOR) 352 (SOR) to 407 (EOR)
Temperature °F 691 (SOR) to 761 (EOR) 687 (SOR to 781 (EOR) 666 (SOR) to 765 (EOR)
Pressure, bar (g) / psig 172.5 bar (g) / 2500 psig 170 bar (g) / 2465 psig 132 bar (g) / 1915 psig
Gas Composition
Mole % H2 90 97 94
Mole % light hydrocarbon 6 to 7 3 6
Mole % H2S 3 to 4 0.007 % with RG 0.01 % with RG Scrubber;
(no recycle gas scrubber) Scrubber; 0.70 % if 0.8 % if RGS is out of
RGS is out of service; service; higher during
higher during sulfiding. sulfiding
Date of Initial Unit Startup July, 2001 August, 2008 June, 2010
Dates (approximate) of January 2002 October 6, 2008 July 26, 2010
reports of sticking April, 2002 Sept. 23, 2013 (a few
June, 2002 days after restarting unit)
On stream time before About five months One or two months after One or two months after
1st sticking event initial startup initial startup
On stream time between About 60 days A few days after No second event reported
1st and 2nd sticking event restarting unit in Sept.,
2013.
On stream time before About 60 days No third event reported No second or third event
2nd and 3rd sticking event reported
Valve Model (cage trim) Masoneilan 41000 series Masoneilan 41000 series Fisher HPD
Plug Material; CA6NM Nitrided 347SS 316, CoCr-A S&G;
Cage Material CA6NM Nitrided 347SS, hard chrome F22, ion nitrided
plated
Reported cause of sticking See Notes 1, 2, and 3 See Notes 1 and 2 See Notes 1 and 2
problems
Resolution of Sticking See Note 4 See Note 5 Resolution has not been
Problem reported.

1. The high normal operating temperature reduced the clearance between the plug and cage.
2. Scale particles from upstream piping and heater exchangers obstructed the close clearance between the plug and
cage.
3. At the operating temperature, H2S induced corrosion of the nitrided CA6NM trim. The accumulated layer of
corrosion obstructed the close clearance between the plug and cage.
4. Cage trim valves were later replaced with Masoneilan 21000 series top guided control valves. No problems
were reported with the 21000 series control valves.
5. In September, 2013, after the third severe sticking event, the cage trim control valves were removed and
replaced.