Automatic Recirculation Valves

PUMPENSCHUTZVENTILE

Automatic Recirculation Valves

An automatic recirculation valve (ARV) is a multifunctional valve whose primary purpose is to ensure that a pre-determined minimum ow is assured through a centrifugal pump at all times. This is important as centrifugal pumps suffer from over heating and cavitation and can be permanently damaged if they run dry. uncovered allowing a minimum ow of liquid to be routed back to the pump.

One Valve, Many Functions

An automatic recirculation valve encompasses all of the hardware required in a conventional bypass system in a single housing. The valve consists of several key parts: the check valve running vertically from the pump inlet below to the outlet above, which not only protects against reverse ow, but provides excellent pulsation dampening of the uid. the bypass valve operates by sensing the main ow and automatically controlling the medium ow into the bypass line. This avoids the use of any electrical power, control wiring or the need for instrument air support.

ARV Design
SchuF Fetterolf manufactures several standard automatic recirculation valves as well as customised designs for special process requirements and severe operating environments. The standard SchuF SureFlo design is illustrated opposite.
Outlet (process side)

Spring

Check valve disc

Bypass

SureFlo Operating Principles

The automatic recirculation valve is installed Spindle in the pump discharge (hollow) line in the position of the main check valve that it replaces. The Inlet (pump side) valve opens as soon SureFlo design as the pump builds sufcient ow to move the internal valve disc in the main line into an open position. Decreasing ow through the valve causes the spring loaded disc to return to its seat closing the process outlet. Simultaneously, a bypass outlet is

Letdown unit

Features
n Modular design n Automatic bypass operation n Non return function n Pressure modulation in bypass n Self cleaning bore n Linear or customised pressure control

the pressure letdown unit located in the bypass section of the valve (on the right of the drawing) is designed to handle the required pressure drop from the process to the pump inlet. The automatic recirculation valve is therefore a check, bypass, minimum ow and pressure control valve in one body.

Centrifugal Pump Protection Scenarios

Centrifugal pumps transform mechanical energy into pressure energy by means of centrifugal force resulting from impeller rotation acting on the uid within the pump. The pump requires a minimum liquid ow in order to avoid overheating. If a predened minimum ow is not maintained, the pump can be permanently damaged. A number of different pump protection scenarios are reviewed below.

1) Non return scenario

The pump has no back-ow prevention and therefore product will ow back through it once it has stopped. A non return valve (NRV) is therefore usually placed after the outlet of the pump. A reservoir is used to take the pumps output when there is no process demand.

2) Continuous ow scenario
A manual bypass or leakage path can be added to allow the required minimum ow back to the pump inlet. This system is simple and effective, but is in constant operation and therefore is inefcient and costly (energy costs).

Reservoir Process

Reservoir Process

NRV

NRV Bypass

Tank

Pump

Tank

Pump

3) Control valve scenario

This comprehensive control valve solution is highly effective. In this scenario, a ow control valve is connected to a ow meter and allows the main line ow to be metered. As main line ow decreases the control valve opens to allow the correct minimum ow required. However, it is a highly capital intensive solution that requires ow metering equipment, control and non return valves. No reservoir is required.
Process

4) ARV solution
The previous approach stands and falls with the integrity of the control system and its associated cost. A safer system is to combine the non return valve, the bypass valve and the control valve into an interconnected unit, the so called automatic recirculation valve. This valve closes when there is no ow, automatically opening the bypass line, which is sized for minimum ow. When the main line takes ow but less than minimum, the bypass line and the main line are both partially open.

Bypass control valve

Flow meter

Process

NRV

ARV

Tank

Tank Pump

Pump

ARV Operating Conditions

1. Main Flow Only Bypass Closed
When the process associated with the pump is in the normal operating condition, the main line is open. The pressure created from the media ow is sufcient to compress the spring in the check valve disc and lift it from its seat to the fully open position. As the connected disc stem rises, the bypass exit in the stem funnel is moved against the valve body and the bypass system is closed. The recirculation ow is blocked, thus eliminating wasted energy. This is illustrated in gure 1. The bypass ow is therefore inversely proportional to the main pump ow. When the check valve is fully opened, the bypass is fully closed.

2. Combined Flow
As the ow requested by the process is reduced the pressure on the disc spring is lowered and the disc moves towards its seat. The check valve part of the automatic recirculation valve moves rst to a partially open position (illustrated in gure 2). In this position there is partial ow to the outlet and a minimum ow to the bypass is maintained.

3. No Main Flow Bypass Only

When no product is required by the process the valve disc returns to its seated position. There is insufcient ow to compress the spring and allow the disc to rise. In this position, the curved part of the hollow stem is now ush with the entrance to the bypass funnel. A predened minimum ow can now move from the pump through the bypass section and be recirculated to the front end of the pump. The centrifugal pump is protected from overheating or cavitation.

Figure 1

Figure 2

Figure 3

Outlet

Outlet

Outlet

Inlet

Inlet

Inlet

ARV Product Range

SureFlo
n For 1 to 10 inch pump applications n Fixed letdown in the bypass n Up to ASME 2500 # pressure class n Variable bypass delay n Fewer moving pieces n Cast housing in CS or SS material

HighFlo
n For 10 inch+ pump applications n Fixed letdown in the bypass n Better noise attenuation n Up to ASME 4500 # pressure class n Variable bypass delay n Forged or cast body

ControlFlo
n Size independent n High pressure design n Multistage letdown n Enhanced bypass sealing n Letdown varies with stroke n Enhanced noise attenuation n Forged or cast body in CS or SS material n Non return valve in bypass

BackFlo Pressure Regulator

n Used with ARV n Assures a dened backpressure n Eliminates ashing and cavitation n 1 to 8 inch pipelines n Up to ASME 2500# n Stainless steel, anged or butt weld

Product Range & Technical Data

Product Range Product Range
SureFlo HighFlo ControlFlo BackFlo

Description
1 inch (DN 25) to 10 inch (DN 250) pumps and up to ASME 2500# pressure class 10 inch (DN 250) to 16 inch (DN 400) and up to ASME 4500# pressure class for enhanced bypass sealing and multistage letdown to create a defined pressure differential in order to eliminate flashing and cavitation in special applications. Used with an automatic recirculation valve with special maritime body and trim material size and pressure class as required for special pump applications or unique operating environments and severe media

Maritime & Offshore ARV Custom designed ARV

Technical Data ARV

Application Size Body and bypass Valve Lining/Sleeves Trim materials

Standard Features

Optional Features

Spindle Spring Temperature Process sealing Pressure rating Connection types Heating jacket Bypass trim design Control Characteristics Installation Flow direction Other options

To protect pumps and ensure minimum flow conditions 1 to 16 as standard To 30 or larger as custom design Carbon or Stainless steel (316L) Duplex, Hastelloy or Titanium n/a Ceramic Stainless steel (316L) Duplex, Hastelloy, Ceramic, Inconel, Titanium or Tungsten Carbide for severe service applications Stainless steel 1.4404 (316L) as above Stainless steel Inconel X750 (2.4669) Minus 20 to 300C Minus 100C to 500C Metal to metal n/a All up to ASME 2500 (PN320) To ASME 4500# or higher on request Butt weld end or flanged (DIN or ASME) ISO, BS, JIS, NF on request n/a Full or semi jacketing Throttle plates Multi stage, hollow, or cage trim in bypass Linear Equal % Vertical Horizontal Flow to open, no reverse flow (integral n/a check valve) Maritime sea water service ARV design Valves conforming to NACE MR0175

ARV Business Benefits

n Protects the business investment in critical pump equipment n Saves power costs by eliminating the need for continuous recirculation to cool the pump n Includes reverse flow protection n Avoids additional investment in pressure reduction equipment n Needs no electrical wiring, plant or instrument air n Reduces downtime and is easy to maintain

Selected ARV Dimensions and Parts List

Dimension Table Inlet/Outlet Size
1"/1"; DN25/25 2"/2"; DN 50/50 3"/3"; DN75/75 4"/4"; DN100/100 4"/4"; DN100/100 4"/4"; DN100/100 6"/6"; DN150/150 6"/6"; DN150/150 8"/8"; DN200/200

Bypass Size
"; DN15 1"; DN40 3"; DN75 1"; DN40 2"; DN50 3"; DN75 3"; DN75 4"; DN100 3"; DN75

Pressure Class
ASME 150 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300

a in mm
188 283 277 297 297 297 357 357 524

b in mm
145 236 295 300 305 310 385 390 430

H in mm
271 425 420 450 450 450 520 520 795

The dimension table below is for illustrative purposes for automatic recirculation valves up to eight inches. SchuF can produce automatic recirculation valves in all sizes and pressure classes as required by the application or operating conditions.

SureFlo Parts List (High temperature design example) Part

10 20 30 40 50 60 70 80 90 100 110

b= b= DN

Description
Upper body Lower body Disc with spindle Spring guide Bypass body Control bushing Bush Spring guide Letdown unit Wire wound gasket Spring

Material
ASTM A217 WC1 ASTM A217 WC1 1.4404; 316L 1.4404; 316L 1.4404; 316L 1.4404; 316L 2.0550; Brass 1.4404; 316L 1.4404; 316L Graphite 2.4669; Inconel

40 80 HUB= Stroke= 10 110

a= a=

H= H=

100 30

60

20 70 90

DN 50

Nominal Size and Maximum Flow Examples Main Inlet/Outlet size

Max Flow GPM m3/h GPM m3/h

1
65 15

1.5
132 30

2
264 60

3
616 140

4
1,100 250

6
2,422 550

8
4,400 1,000

10
8,805 2,000

Bypass size
Max Flow

0.75
62 14

0.75
62 14

1
88 20

2
176 40

3
330 75

4
660 150

6
1,320 300

8
2,465 560

The above table is for illustrative purposes and is intended to give a quick estimate of the size of valve required based on main and bypass flow. The indicated flow values are based on fluids with a specific gravity of 1. For fluids with different specific gravity, please inquire with SchuF directly.

Control Trim and Control Valve Options

ARV Control Trim Options
SchuF offers a variety of automatic recirculation valve control trim options. Choice will depend on many factors such as the medium, the required pressure drop, solid contents and the nature of the process. The most common form of pressure control in the bypass line is achieved via a series of nozzle plates. The required pressure drop is achieved by varying the number, size and position of the nozzles in the bypass and the number of plates used.

Minimum Recirculation Control Valve

Despite the diversity of control options available for the automatic recirculation valve, there are still situations were an independent control valve may be the best option. Processes that require independent and variable control or where the media contains solid particles, crystals or is highly viscose generally require a separate control valve to protect the centrifugal pump. An example of a SchuF minimum recirculation control valve used in a severe application is shown below.

Flow
Flow Stellited Sealing Surface
Nozzle plates in bypass letdown unit

Stainless Steel

Ceramic Ram Stellite

For high pressure drop requirements, a single piece multistage disc and spindle is placed in the bypass.

Minimum circulation control valve

Multistage letdown disc in bypass

The control valve shown above was designed for a severe service pump application that included a high pressure drop (p 40 bar), 30% solid contents and signicant ashing. It has the following key features:

Pressure can then be reduced in 2, 3, or up to 6 stages. The disc contours can be varied for different media or letdown patterns. For applications where noise or vibrations are of concern a cage labyrinth design can be used in the bypass or integrated into the main line check valve design.

Key Features
n Flow to open (piston opens into the valve body) n Accelerating body geometry design n One piece disc and spindle n Linear or equal % control characteristics n Standard heavy yoke (ideal for vibrating service or high delta p ow) n Hard trim material to match process or medium conditions

Cage labyrinth letdown design

ARV Applications and Media

Automatic recirculation valves have the primary purpose of protecting pumps. They are found in most industries and can be used with a broad variety of pump applications:

ARV Applications
n General centrifugal pumps n Boiler feed water pumps n Cooling plant feed pumps n Crude oil pumps n Fluid gas pumps (for LNG, LPG etc.) n Process liquid pumps n Booster pumps n Seawater injection pumps n Fire ghting pumps
SureFlo in a boiler feedwater application

ARV Media and Industry Examples Industry

Chemical plant Chemical plant LNG plant Offshore Power plant Power plant Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery Renery

Medium
Various solvents Butadiene Fire- / Fresh- and Seawater (HP) Methanol / LDHI Demin. Water Filtered Water Drain Liquid Oil Hydrocarbon-uid Boiling Blowdown Water Kerosene Sour Water Fractionated Naphta Whole Naphta Vacuum Gas Oil Unstabilized Naphta Fractionated hydrocarbons Reux Naphta Premium Diesel Product Reux Naphta Boiler Feed Water LPG Whole Naphta Heavy Gas Oil Stabilized Naphta

P Class
PN 16 ASME 150 ASME 150 ASME 150 ASME 150 ASME 150 ASME 150 ASME 150 ASME 150 ASME 150 ASME 150 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300 ASME 300

Temperature Size
30 C -4 C -10/+20 C 35 C -10/+32 C 60 C 75 C 50 C 25 C 60 C -10/+20 C 60 C 275 C 84 C 243 C 131 C 354 C 99 C 242 C 99 C 121 C 42 C 108 C 353 C 40 C DN40; 1" DN50; 2" DN300; 12" DN50; 2" DN80; 3" DN100; 4" DN80; 3" DN80; 3" DN150; 6" DN150; 6" DN150; 6" DN80; 3" DN350; 14" DN300; 12" DN200; 8" DN200; 8" DN200; 8" DN150; 6" DN150; 6" DN150; 6" DN100; 4" DN100; 4" DN100; 4" DN100; 4" DN100; 4"

Automatic Recirculation Valve Data Sheet

Please use this data sheet to send your inquiries to us. Items marked in bold print indicate essential information.

Part 1 Company Information

Name: Company: E-mail: Title: Telephone: Fax:

Part 2 Order Information

General: Quantity: Tag No.: Valve Model: 78PS Automatic Recirculation Valve Application: Project Name: Projekt No:

Part 3 Valve and Process Information

Valve Information:
Valve Inlet Size (DN/Inch): Valve Outlet Size (DN/Inch): Bypass Outlet Size (DN/Inch): Materials Housing: Installation: Vertical or Horizontal Process: Medium: Density: Qmin = Q100 = Qmax = QBy = Valve Inlet Pressure Rating: Valve Outlet Pressure Rating: Bypass Outlet Pressure Rating: Materials Trim:

Process Information:

kg/m

Liquid or Gas: Op.Temp.:

PED Fluid Group 1 or 2: C Fluid Vapor Pressure: m Suction pr. PV: m Backpress. P1: Backpress. PN: Differential pr. (P1-PN):

(bara) (bar/psi) (bar/psi) (bar/psi) (bar/psi)

Pump Information:

m3/h HM = m3/h H100 = m3/h m3/h

Part 4 Please use the charts below to dene the information required in part 3
HO HM Pump curve H 100

Operating Point

P2 Q 100 Q max

Process
PN

Bypass
Q By

ARV

Head H

P1

Tank
Feed Q min

Pv

Pump Flow Q in m3/h

Q 100 Q max

Notes:

Send To: SchuF Fetterolf

E-Mail: valves@schuf.com Fax.:+49 6198 571200

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SchuF Fetterolf Valve Portfolio

SchuF Fetterolf has delivered over one million valves during its 100 year history to a wide variety of industries in over 75 countries worldwide. Headquartered near Frankfurt in Germany, the company has additional design and manufacturing centres in Brazil, India, Ireland, the UK and the United States. The SchuF group has sales and agent ofces covering almost every country in the world. We manufacture valve products that control, isolate, divert, and sample liquids, gases, powders, and slurries. Our product range of engineered, customised valves include:

Control Valves

Drain & Injection Valves

Piston Bottom Outlet Valves

Isolation Valves

Safety Related Valves

Line Blind Systems

Sampling Valves

Switching Valves

Angle Control Valve

IsoPlug - Lift Plug Valves

Line Sampling Valves Screw-in Sampling Valves Lethal Service Valves Wafer Sampling Valves Custom Sampling Systems

Y, R, & T Type Diverter Valves

Multistage Control Valve

Disc lowering Bottom Outlet

Y-Globe Valve

Changeover Valves Emergency Tank Safety Valves Emergency Shut down Valve

Multiport Diverter Valves

Cage Control Valve

Disc rising Bottom Outlet

Angle Isolation Valve

SwitchPlug Valve

Y Globe Control Valve

Steam Injection Valves

Special Gate Valves Custom Isolation Valves

m-Factory Diverter Valve

Automatic Recirculation Valves

Spray Rinse Valves

Custom Diverter Valves

Sample ARV Client List:

n Shell n Petrobras n Petronas n Conoco Phillips n Peru LNG n Sabic n Samsung n Fluor n Foster Wheeler n CBI n Malaysian Rening Company n BASF n General Electric n BP n Bayer n Exxon n Reliance n Rio Tinto

FUNCTIONAL &

RELIABLE

n Wilhelmshavener Rafneriegesellschaft
Model 78PS

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Worldwide

w w w. s c h u f . c o m w w w. s c h u f . d e

Fetterolf Corporation phone: +1 610 584-1500 fax: +1 610 584-5904 info@fetterolfvalves.com SchuF (USA) Inc. phone: +1 843 8813345 fax: +1 843 8816121 sales@schuf.us

SchuF Valve Technology GmbH phone: +353 (0)21 4837000 fax: +353 (0)21 4837030 sales@schuf.ie

G ER M ANY I ND IA

I RE L AND

USA

SchuF Chemieventile Vertriebs GmbH phone: +49 (0)6198 571100 fax: +49 (0)6198 571200 verkauf@schuf.de

Yo ur Loc al Agent:

B R AZ I L

SchuF Fetterolf do Brazil Ltda phone: +55 19 39369090 fax: +55 19 39353215 fbvendas@fetterolf.com.br

SchuF Speciality Valves India Pvt. Ltd. phone: +91 421 2264600 fax: +91 421 2362018 sales@schuf-india.com