Hydrogen PSA Applications

Metso Products for PSA

견적 적용 모델

• Switch valves • On-off

- Soft-seated high-performance Jamesbury - Standard soft-seated high-
butterfly valves with high-cycle upgrades performance Jamesbury
- Spring-return actuators butterfly valves
- Positioner - Spring-return rack & pinion
actuators

MAPAG Type A
with model A/F actuator

2 © Metso
Metso PSA Valves
Critical Design Features
 Critical Design Features
Metso Products for PSA
Valve Assembly Configuration

Switch Valve Design

Optimized for Product , Feed, Equalization, and Tail
Gas Applications

Valve – Metso’s Jamesbury soft seated High Performance Butterfly

Valve configured for high cycle service.

Actuator – Metso’s B Series high cycle piston actuator designed for

rotary control and modified for maximum cycle life

Linkage – Mounting hardware provides proper alignment yet is

designed to remain reliable even when installed incorrectly

Positioner – Metso’s ND9000 digital valve controller. Specified to

limit initial flow volume through valve to prevent lifting of the
molecular sieve bed.

Together, these components form the most reliable PSA switching valves
available in the market.

© Metso
 Standard Features & Upgrades
Metso Products for PSA
Assembly Configuration

Standard valve
Valuable features for Hydrogen PSA service

+ Wafer-Sphere seat design

+ Wafer-Sphere seat material
+ High Cycle Life B-series Actuator
+ ND9000 Digital valve Controller

Upgrades for PSA service

Thoroughly tested in laboratory and field proven in PSA plants

+ Shaft bearings
+ No-play couplings and H-clips
+ Thrust bearings
+ Shaft seal & live-loading
+ Shaft materials
+ Disc pinning

5 © Metso
Standard Valve
Product Features
 Valuable Standard Features
Metso Products for PSA
Wafer-Sphere Seat Design

Wafer-Sphere® High Performance Butterfly Valve

• Double offset disc and shaft design eliminates seat
wear points.. Increases seat life
 Flexible Lip Seal compensates for temperature
and pressure changes
 Pressure energized - compensates for wear
 No additional o-ring or metal pieces required to
maintain bubble tight shutoff
 Full Bi-directional Sealing
 Wide sealing band DISC

 Enclosed and protected from flow erosion

SEAT
As Assembled…
 Seat is energized by the disc when closed
BODY
INSERT

7 © Metso
 Valuable Standard Features
Metso Products for PSA
Wafer-Sphere Seat Material

Xtreme® seat material provides maximum cycle life

• Jamesbury’s flexible lip design

relies upon the seat to return to it’s
original shape after loading

As Designed
• This maintains a tight seal between
the seat and disc

• The amount the seat recovers

determines:

• Maximum pressure rating

• Seat cycle life
As Assembled

9 © Metso
 Valuable Standard Features
Metso Products for PSA
Wafer-Sphere Seat Material

Permanent compression set versus temperature

Xtreme® returns closer to its original shape after loading
0.14

0.13
Permanent Deflection, inch

0.12

0.11

0.1

0.09

0.08
PTFE
0.07
Filled Xtreme seat는 PTFE에 비해
PTFE Seat의 복원률이 높음
0.06

0.05
Xtreme

0.04
100 150 200 250 300 350 400 450 500

Temperature, 0F

10 © Metso
 Valuable Standard Features
Metso Products for PSA
Wafer-Sphere Seat Material

More recovery yields higher pressure-temperature rating

• Xtreme® expands butterfly

valve pressure-temperature
range for full Class 300
body ratings from 2500F to
over 4000F.
• Over 60% increase in
temperature rating
• Xtreme® chemical
compatibility is superior to
glass and carbon filled
PTFE.

11 © Metso
 Valuable Standard Features
Metso Products for PSA
Wafer-Sphere Seat Material

More recovery yields greater cycle life

Wafer-Sphere Seat Cycle Life Comparison

(at full rated pressure)
3,500,000

3,000,000
3,000,000

2,500,000

2,000,000
Cycles

1,500,000

1,000,000 800,000

500,000
500,000
140,000
35,000
0
UHMWPE Virgin PTFE MTFE TFM Xtreme

Seat Material

12 © Metso
Standard Actuator
Product Features
 Valuable Standard Features
Metso Products for PSA
High Cycle Life Actuator

Series B High Cycle Life Actuator – Design Features

• Plastic covered seals

• No rubber sliding against metal
• No lubrication to dislodge and jam
pneumatic spools
• Oversized air ports for fast stroke speeds
• Wear resistant, high cycle bearings
• Safety contained spring cartridge
• Cycle life > 3 Million
• Operating pressure up to 10 bar / 140 psig
• Standard temperature range -20°C to 70°C
(-4°F to 160°F)
• High temperature rating up to
견적된 모델은 B series 모델이 아닌 VPVL (RACK AND PINION TYPE) 임 120°C (250°F) is available as option
• Low temperature rating down to -40°C
(-40°F) is available as option

14 © Metso
 Valuable Standard Features
Metso Products for PSA
High Cycle Life Actuator

Series B High Cycle Life Actuator – Design Features

Piston seal

Piston rod seal

Double Delta seal

Connection
Arm
bearings
Fiberglide Bearing
15 © Metso
 Valuable Standard Features
Metso Products for PSA
High Cycle Life Actuator

Series B High Cycle Life Actuator – Design Features

• Linkage in housing converts linear

piston movement to rotary output
motion

• Unlike scotch-yoke actuators, B-

series linkage dimensions are
optimized for seating and
unseating rotary control valves

• Smooth, stable, accurate control

positioning even from fully shut

• Snapping open or overshoot that

is typical for butterfly valves is
minimized

16 © Metso
 Shaft bearings
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
Shaft Bearings

• Shaft bearings are the key

part for butterfly valve
performance

• Worn shaft bearings will

cause:

• Seat leakage
• Packing leaks
• Shaft fatigue failure
• Inaccurate and
inconsistent control

24 © Metso
 Critical Design Features
Metso Products for PSA
Shaft Bearings

High-Cycle Bearing Laboratory Test Results in Actual Valve

Bearing weight
Bearing Load Surface Velocity PV Coefficient of
Bearing Picture loss Cycle life
P, psi V, fpm (psi - fpm) friction
(%)

EPI Hy-Load -
1st Generation Filled PTFE with
Standard Bearing
2,360 2.05 4,838 0.133 3.67 215,744
perforated stainless steel
backing

Norglide M -
Current Generation
Standard Bearing
Filled PTFE with bonded 2,373 2.10 4,983 0.115 2.20 398,699
stainless steel backing

Bronze Bearing -
1st Generation High SAE 660 lubricated with
Cycle Bearing
2,750 1.75 4,813 0.084 6.37 534,785
Mobilux EP1 grease
every 50,000 cycles

Rexnord Duralon -
2nd Generation High Woven PTFE fiber and
Cycle Bearing
2,360 1.95 4,602 0.203 1.80 519,764
Dacron liner with
fiberglass backing

FIBERGLIDE -
Current Generation Woven PTFE fiber and
High Cycle Bearings Dacron liner with bonded
2,344 2.34 5,479 0.061 0.40 1,268,207
stainless steel backing

Data from Metso Research & Development Laboratory tests

25 © Metso
 Shaft material
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
Shaft Material

Shaft Design Challenges for PSA

• Cyclic Pressure Swings in PSA plants generates high, reversing

bending stress in butterfly valve shafts when the valve is shut
• Akin to bending a piece of wire back and forth, which will eventually
break at the point of highest stress
• For PSA, standard shaft and bearings materials as well as typical disc
pinning methods are prone to fatigue failure
• The most fatigue resistant shaft materials are essential, especially for
equalization valves
• Clearances between parts are required to facilitate assembly, but the
clearances permit metal-to-metal rubbing called fretting
• Surface damage from fretting creates very high stress concentration,
leading to crack initiation and fatigue failure
• Shot-peening the shaft surface can extend the cycle life

© Metso
 Critical Design Features
Metso Products for PSA
Shaft Material

Wafer-Sphere standard disc pins – contact surface is in

compression for maximum torque capacity

Wedging action of pins

pushes shaft to opposite side
of bore and causes small gap

© Metso
28
 Critical Design Features
Metso Products for PSA
Shaft Material

Metso Experience with PSA Valves

Metso’s extensive experience results in clear issue identification and root
cause correction.

Identification of design improvement opportunity

• Analysis reveals 2 crack initiation points
• POINT A – Fretting against corner of pin
• POINT B – Fretting between shaft and disc

© Metso
 Critical Design Features
Metso Products for PSA
Shaft Material

Free Body Diagram - Shaft Downstream

RF RF

L1

PRESSURE

• L1 is the section of the shaft that is free to flex between the end of
the shaft bearing to the edge of the disc bore

© Metso
 Critical Design Features
Metso Products for PSA
Shaft Material

Free Body Diagram - Shaft Upstream

Gap caused by wedge pins increases
bending stress when pressure is PRESSURE
applied on shaft side of disc

L2

RF RF
L2 ≈ 2 x L1

y(deflection) = f (L3) so y is roughly 9 times greater shaft upstream

Bending stress increases by a factor of 3 as L increases, this is why bearing wear is critical to
shaft fatigue life
© Metso
 Critical Design Features
Metso Products for PSA
Shaft Material

Shaft Material Cycle Life Comparison

• Comparison of material fatigue reveals Inconel 718 provides greater fatigue life than the
standard shaft material 17-4PH cond. H1150M

PSA 전용 SHAFT 재질

© Metso
 Critical Design Features
Metso Products for PSA
Shaft Material

Shaft Material Cycle Life Comparison

• Fatigue curves are the median
• Typical range creates wide variation in fatigue life for the same conditions

Shaft material fatigue strength

160,000

140,000
17-4 PH H1150M
120,000
Alternating stress, psi

100,000

80,000

60,000

40,000

20,000

0
1 10 100 1,000 10,000 100,000 1,000,000 10,000,000 100,000,000

Number of cycles to failure

© Metso
 Disc Pins
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
Disc Pins

Wafer-Sphere standard disc pins generate gap clearances

to permit assembly permit fretting damage

Wedging action of pins

pushes shaft to opposite side
of bore and causes small gap

© Metso
35
 Critical Design Features
Metso Products for PSA
Disc Pins

Metso Design, Test and Analysis Capabilities

•Metso’s long history of collaborative The Solution

experience with the PSA industry has led to
•reliable
Metso’s experience
design andthat
solutions continuous developmentrequirements.
exceed specification of improvements to PSA valves has
led to
•The cost effective
solution is a newand
pinreliable
to shaftsolutions
interface design and a new pinning technique.
• The solution to eliminate clearances and fretting is a new pressed pinning technique

© Metso
 Critical Design Features
Metso Products for PSA
Disc Pins

Pressed and staked disc pins

37 © Metso
 Shaft Seal Packing
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
Shaft Seal Packing

Super PTFE Shaft Seals

25

• 25% Carbon Filled TFM

Virgin PTFE
20

• Less Initial Compression

% Compression
15

• Less Wear
10

• Longer Cycle Life Super PTFE

5

• Proven Problem Solver

0
0 500 1000 1500 2000 2500

Packing load, psi

Metso R&D Laboratory Test Results for Live-Loaded Packing

Number of Cycles at Packing Adjustment

Leakage would not stop with further
Virgin PTFE 5,565 82,212 170,997 233,349 613,277 1,087,590 tightening

Super PTFE 480,000 1,120,000+ No leaks at end of test

39 © Metso Test stopped to check electrical conductivity of packing so an adjustment was

made even though packing was not leaking
 Critical Design Features
Metso Products for PSA
Shaft Seal Packing

Live Loaded Shaft Seals

Visual indication – No torque wrench and
inconsistent tightening. Proper load when
washer is flush with top of cup

Fugitive Emissions Certification

• ISO 15848 class BH (Helium)
• TA-Luft (Helium)
• EPA Method 21 (Methane)
• ASME B31.12 (Helium)

40 © Metso
 No-Play Coupling
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
No-Play Coupling

High Cycle Actuator linkages

Jamesbury’s No-Play coupling designed
for high stress, fast cycle speed
applications

Jamesbury’s standard bracket design will support the weight of the actuator in any
mounting orientation plus the weight of a 200 lb person stepping on the assembly

© Metso
 Critical Design Features
Metso Products for PSA
No-Play Coupling

High Cycle Actuator linkages

Strong Clamping force prevents
shaft deformation that will occur
with slip fit adapters

Problems
with Slip-On
type coupling

© Metso
 Critical Design Features
Metso Products for PSA
No-Play Coupling

No-play Coupling - Modified for High Cycle Service (Optional)

Coupling half is pinned to both shafts to prevent relative movement if
technicians do not align shafts per procedure when installing actuator

Pins installed at assembly

Clearance holes pre-drilled in

coupling half before assembly

After assembly, smaller

holes are drilled in valve
shaft and actuator driver

Roll pins are pressed

into holes

High shear strength of roll

pins eliminate movement
of shafts within coupling
High fatigue strength bolts
Aircraft quality, stainless steel,
hi-collar lock washer under
screw head (not shown)

© Metso
 Thrust Bearing
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
Thrust Bearing

High-Cycle Life Thrust Bearings

• Standard bearing is chrome plated

stainless steel
• Standard bearing is harder and more wear
resistant than body and disc
• High cycle thrust bearing is PEEK and
Carbon Fiber filled PTFE
• 200x increase in cycle life over standard
Thrust Bearings bearing
• Bearing wears - prevents damage to disc
and body
• Low-cost option
• Increases valve and plant reliability

46 © Metso
Materials of Construction
Upgrades for PSA service
 Critical Design Features
Metso Products for PSA
Materials of Construction

Metso PSA Valve Options

• Unidirectional service – differential pressure applied in

preferred direction only:
• Shaft: 17-4PH cond. H1150M
• Disc pins: 17-4PH cond. H1150M
• Bearings: High cycle, shaft & thrust
• Seat: Xtreme
• Shaft seal: 25% Carbon filled TFM

• Bidirectional service – differential pressure can be

applied in both directions. Max. life with highest pressure
in preferred direction
• Shaft: Inconel 718 shot-peened
• Disc pins: 316L stainless steel
• Bearings: High cycle, shaft & thrust
• Seat: Xtreme
• Shaft seal: 25% Carbon filled TFM

• B-Series Actuator & ND9000 positioner

48 © Metso