Valves for Refining Applications

Engineered Solutions for the Refining Industry

MOGAS severe service ball valves have proven successful
in these processes and more:
Atmospheric Distillation
Vacuum Distillation
Continuous Catalytic Reforming (CCR)
Visbreaking
Fluidized Catalytic Cracking (FCC)
Fixed Bed Hydrotreating
Fixed Bed Hydrocracking
Ebullated Bed Hydrocracking
Delayed Coking
Gasification
Deasphalting
MOGAS — Your Partner in the Process
Proven Reliability. Engineering Expertise. Dependable Service.

The refining industry has undergone many changes, from the methods of processing to the length of time that they operate
their process units. These changes, along with the emergence of low sulfur fuel specifications, the requirement to process
lower grade crude and the need to convert more bottom-of-the-barrel residuals, has put an extreme demand on isolation
and control valves. Unreliable and unpredictable valves in emergency situations can cause enormous monetary losses and
have devastating consequences for personnel. MOGAS has responded to these challenges by developing a combination of
diverse trim configurations and high quality coatings for use in high temperature, high pressure, erosive, corrosive, viscous
and coking / asphaltene applications.

FUEL GAS AMINE

OTHER REFINERY FUEL
GASES TREATING
SULFUR PLANT SULFUR
GAS MEROX LPG
PROCESSING TREATING BUTANES

LIGHT
NAPHTHA
HYDROTREATING ISOMERIZATION ISOMERATE

HEAVY
CRUDE OIL

CONTINUOUS
NAPHTHA CATALYTIC
ATMOSPHERIC DISTILLATION

HYDROTREATING REGENERATION REFORMATE

JET FUEL / KEROSENE
JET FUEL / DIESEL
KEROSENE MEROX
HYDROCRACKER

TREATING HYDROCRACKED
GASOLINE

DIESEL OIL
HYDROTREATING DIESEL

ATMOSPHERIC
GAS OIL
ALKYLATION ALKYLATION

HYDROTREATING FCC GASOLINE

CATALYTIC
FLUIDIZED
CRACKING

FCC FEED
ATMOSPHERIC

HYDROTREATING
BOTTOMS

LIGHT VACUUM
GAS OIL FUEL OIL
DISTILLATION
VACUUM

COKER NAPHTHA
HEAVY VACUUM
DELAYED
COKING

GAS OIL

VACUUM RESIDUUM
PETROLEUM COKE

VACUUM VISBREAKING FUEL OIL

RESIDUUM
DEASPHALTING ASPHALT
AIR
AIR GASIFICATION SYNFUEL

KEY

SEPARATION TREATING UPGRADING CRACKING

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Valves for Refining Applications

Severe plant conditions can quickly turn into severe consequences

for your business. That’s why companies worldwide turn to
MOGAS Industries — the leading provider of severe service
ball valves. Combining over four decades of experience with
the most advanced manufacturing practices available, MOGAS
helps ensure process integrity, uptime reliability and personnel
safety. The result — immediate business efficiencies and lower
total cost of ownership in the long term. In short, MOGAS valves
perform in the harshest environments so your company can too.

Valves for Refining Applications

Key Features Size (in) Pressure Class Body Materials Maximum Temperature
ISOLATOR 2.0 1 to 4 150 to 600 F316, F9, F53, A105, Ambient to 650° F
Low Pressure Isolation Valves Ti Gr 12 (to 343° C)
• full bore
• 2-piece forged body
• bi-directional
• blowout-proof stem

CA-HO1 1 to 3 900 to 4500 300 Series, Carbon 651 to 1100° F

Heavy Oil Valves Steel, Chrome (343 to 593° C)
• engineered specifically for Molybdenum
heavy oil applications
• 2-piece forged body
• blowout-proof stem

C-Series 4 to 36 300 to 4500 300 Series, Carbon 651 to 1500° F

Customizable Isolation Valves Steel, Chrome (343 to 815° C)
• engineered specifically for Molybdenum
customer application
• 2-piece or 3-piece forged
body
• blowout-proof stem

RSVP / iRSVP 1/2 to 4 300 to 4500 F22, A105, F91 Ambient to 1100° F
Vent and Drain Valves (to 593° C)
• integrated vented body
• quarter-turn, non-rising
stem
• rigid mounting bracket

FlexStream 1 to 42 300 to 4500 300 Series, Carbon Ambient to 1100° F

Control Technology Steel, Chrome (to 593° C)
• velocity control Molybdenum
• variable characterization
• high rangeability
• precision modulation

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Design Flexibility
C-Series Valve Adapts to Applications

Common Features for the MOGAS C-Series Valve Line

1 Floating ball design 6 8

• Rotating ball does not displace volume or solids
• Straight-through bore path protects sealing surfaces
5
2 Pressure-energized sealing
• Seat springs maintain constant sealing contact
between ball and seats
• Allows for thermal expansion of trim
6
• Metal seats wipe sealing surface of ball clean 2
during operation 3

3 Wide seat sealing surface 4 1

• Matched ball and seat sets provide total sealing
contact for reliable isolation
• Greater sealing contact area withstands minor
4
scratches or abrasions
7
4 Independent replaceable seats
• Minimizes maintenance and repair costs

5 Blowout-proof stem design

• One piece design meets industry safety standards
• Withstands severe service torques and maximum
working pressures
Application Specific Options
6 Dual-guided stem design Seat designs Engineered for maximum performance in
• Pressure-energized inner stem seals serve as application-specific conditions
thrust bearing and lower stem guide
Live-loaded packing Ensures constant packing energization
• Valve stem bushing serves as upper stem guide
• Eliminates lateral movement of valve stem Prevents stem packing leaks and risk of
• Prevents media migration fugitive emissions
• Prevents stem packing leaks and risk of Body Gaskets Pressure energized body gasket available
fugitive emissions to meet industry codes
Materials Application-specific materials available,
7 Forged body & end connections including exotics
• Greater wall thickness in critical areas provides Extends valve life
longer valve life
Coatings Application-specific coatings provide
• 2 or 3-piece designs
enhanced erosion and corrosion resistance

8 Heavy-duty mounting flange Liners and inlays Liners and inlays can be applied to the
through-bore or wetted surfaces
• Machined after attaching to ensure precise stem
alignment Purge ports Purge ports are available for recommended
• Provides structural support for operator mounting periodic maintenance
• Provides visual inspection for confirmation of End connections Available end connections include flanged,
ball position welded, hub/clamp or RTJ

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Ball Valve Advantages
Compared to Gate and Globe Valves

When it comes to valve types, there are distinctive

differences in design, intent and purpose. Whether
a valve has rotary operation or linear action is a
critical part of the longevity and performance
of the valve in severe services. Exposed sealing
mechanisms versus protected sealing surfaces
Quick quarter-turn operation with
can make a big difference. Commodity valves smooth rotational movement
manufactured for clean environments at ambient
or low temperatures are simply not engineered
to withstand the strenuous demands of extreme
operating conditions.

Straight-through bore path

Serious industrial Ball Valve Advantages

processes require Recessed seats are protected from continual exposure
to the process flow
serious valve choices. Ball is wiped clean with each operation of the valve

Understanding the
Rotates on own axis, thus no volumetric displacement
fundamental differences
in valve types can assist Packing area is protected from potential media erosion, maintaining
integrity of stem seal area while reducing risk of fugitive emissions
with those important
decisions. Non-rising stem design meets EPA VOC packing leakage standards for
greater number of cycles

Pressure-assisted sealing

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 Vertical rising stem creates
continuous wear deterioration and Vertical rising stem creates continuous wear
friction to packing area deterioration and friction to packing area

Sealing components Turbulent and interrupted flow path

exposed to media

Gate Valve Disadvantages Globe Valve Disadvantages

Sealing components in the line of flow lead to potential wear and Damage to sealing surfaces due to exposure of the seats when the
corrosion attack valve is open

Geometry of the exposed sealing surface wears and loses the ability Sealing trough / rib erodes over time and can capture flow particles
to hold tight seal

When operated, flow path is interrupted causing volumetric When operated, flow path is interrupted causing volumetric
displacement of the process fluid which must occur from behind the displacement of the process fluid which must occur from behind the
plug back into the flowstream plug back into the flowstream

Multi-turn rising stems can pull destructive catalyst and pipe scale up Multi-turn rising stems can pull destructive catalyst and pipe scale up
through the interior diameter of packing area leading to possible through the interior diameter of packing area leading to possible
hazardous atmospheric leaks hazardous atmospheric leaks

A sliding stem valve will not provide the length of service life or A sliding stem valve will not provide the length of service life or
number of cycles due to the stem moving through the packing box number of cycles due to the stem moving through the packing box
along with the process fluid along with the process fluid

Relies on vertical thrust by the stem to drive the sealing plug Torque seated to activate seal — thermal cycling relaxes stem
into the seat

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Application Guide
Industry Expertise

Distillation — Atmospheric and Vacuum

In atmospheric distillation, the pipe still process takes the raw desalted crude and
heats it up in the crude furnace until it is partially vaporized. This allows for the
separation process to begin in the crude tower where several side streams are
taken off at different boiling points.

In vacuum distillation the vacuum flasher provides a separation of atmospheric

crude tower residue to produce heavy, medium and light vacuum gas oil and non-
distillable products, such as vacuum residue.

A refinery fire is always a dangerous event, but a fire that reaches the large
amounts of crude contained in the main tower and related side strippers can
quickly go from dangerous to catastrophic.

As a leading provider of critical service valves, MOGAS has worked with several
oil companies to create a reliable emergency bottoms isolation system. In a fire-
related emergency, this system isolates the tower and strippers—and the highly
flammable product they contain—from the source of the fire. Located at the top of a major refinery,
these MOGAS valves were chosen for their
performance and low maintenance. Due to
their location, reliability was a critical part of
Continuous Catalytic Reforming (CCR) the installation decision.

The CCR process is primarily used in the refinery to improve the research octane
number of the motor gasoline pool. It can also be configured for the production
of aromatics for a petrochemical complex. A catalytic dehydrogenation reaction
converts paraffins into iso-paraffins and naphthenes into aromatics. Hydrogen is
a byproduct produced within this process and used in other parts of the refinery.

The leading licensor of this process has over 600 units installed globally, and has
specified MOGAS isolation valves in its Schedule A specifications. This process
package has evolved from a semi-regenerative to a continuous process, thus
increasing the performance demands placed on the catalyst movement valves.

MOGAS has developed spray coatings that can cycle up to 50,000 times with
no degradation in shutoff performance, which led to MOGAS being the preferred
choice of the leading licensor of this process.

MOGAS has also developed a spring-loaded packing design to eliminate

potential fires caused by hydrogen leakage within the process operating unit.

Visbreaking
The MOGAS C-Series valve, with its engineered trim configuration, gives 100
percent reliability during the visbreaking process, which reduces downtime
significantly over gate designs. In applications where heavy coking occurs,
MOGAS offers an intermittent and continuous purge system to remove the coke
build-up. Installed between the lockhopper and lift
engager at a major southwest refinery, these
3-inch ASME 300 class metal-seated isolation
valves cycle at least three times an hour. These
valves replaced another manufacturer’s design
that lasted only two months.

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Application Guide
Industry Expertise

Fluidized Catalytic Cracking (FCC)

The FCC process is used for converting higher molecular weight hydrocarbons
into value-added products. The conversion occurs in the presence of a catalyst
that converts hydrotreated gas oils and fractionator bottoms into gasoline, C3 /
C4 olefins and light cycle oils.

MOGAS has developed valve designs to handle the powdery ultra high
temperature catalyst fines present during the removal process from the
regenerator. In some cases the catalyst is carried over into the fractionator and is
very erosive to gates and globe style valves. MOGAS’ full-ported ball valves with
special coatings have outperformed these designs lasting throughout the entire This CA-DRI 8-inch ASME 300 class valve
handles catalyst at 1425° F (774° C). It is the
four- to five-year run times. major isolation valve between the third stage
and fourth stage cyclone separator.

Fixed Bed Hydrotreating

High pressures and temperatures are required to break the sulfur and nitrogen
molecular bonds that occur in residual, gas oil and diesel streams. In heavy metal
crude processing refineries, a guard reactor system is typically put in place to
prevent poisoning of the hydrotreating catalyst. The catalyst in the guard reactor
has to frequently be removed due to collection of heavy metals on the catalyst.

Two licensors of fixed-bed hydrotreating process have developed unique

methods of loading the guard reactors with fresh catalyst without taking the unit
off-line. These guard reactor systems require catalyst withdraw and addition This CA-1AS 6-inch ASME 300 class feed
isolation valve is a critical part of the
valves, which MOGAS can provide. emergency shutdown system.

Fixed Bed Hydrocracking

The fixed bed hydrocracking process has the largest installed base of the two
reactor types. The reactor will typically have multiple beds of catalyst. This
catalyst cannot be removed as it is in the ebullated-bed process. Therefore, the
run times are limited to approximately two years before catalyst performance is
affected by coke build-up.

MOGAS has worked with several licensors of fixed-bed hydrocracking process

technology to improve the performance of isolation applications in an attempt to
make the overall process unit more reliable and safer to operate for the 600 to Located in a frigid Scandinavian environment,
this large bore ASME 4500 class ball valve is
700 operating process units throughout the world. installed on the outlets of the hydrogen heater.

Ebullated Bed Hydrocracking

MOGAS valves operate in 100 percent of the ebullated bed hydrocracking
units throughout the world, and has been working with the two ebullated bed
hydrocracking technology licensors for over 20 years. MOGAS has been involved
in the development of coatings and valve designs that can operate in arduous
duty service conditions with 100 percent reliability for the entire projected four to
five year run time.

This experience, performance record and continuous improvement has made

MOGAS the preferred valve vendor for this process technology. These 12-and 16-inch ASME 2500 class valves are
installed at the letdown station of a European
refinery responsible for producing 115,000 bpd.

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Application Guide
Industry Expertise

Delayed Coking
Coking is a batch process that requires frequent operation of the isolation valve
system during the coke drum switching operation.

MOGAS’ simple floating ball design provides trouble-free operation in this heavy
coking application, unlike complicated trunnion designs that provide several high
tolerance areas for coke to build-up and cause torque to increase significantly
from start of run to end of run of the unit.

Our floating ball design requires much less steam during purging operations than
the typical trunnion designs, saving thousands of dollars annually in energy costs. This midwestern refinery has four 20-inch ASME
300 class MOGAS ball valves in overhead vapor
service. Several are in their second decade of
As a continuous improvement to the company’s design, MOGAS has taken service.
data from the field to determine the exact amount of service duty that should be
applied to actuator and valve stem sizing. This helps avoid valve and actuator
failure from increased torque due to coke build-up.

Gasification
MOGAS has worked with the leading licensor of the gasification process globally
to develop trim and coating technology to increase the operational reliability of
critical isolation valves.

MOGAS’ most recent achievement was to extend the lockhopper valve system
for de-slagging operations. This achievement improved performance from six
months to five years with over 50,000 cycles of operation without any related This 16-inch ASME Class 600 valve was
installed for 550° F at 1095 psig (290° C at
valve or actuator failures. 75 bar g) lockhopper isolation service. Several
of these valves withstood over 50,000 cycles.

Deasphalting
Deasphalting is the process of removing asphalt, metals and sulphur from
petroleum fractions. Removing asphaltenes prevents coke build-up on catalyst
in downstream unit processing. It produces asphalt (asphaltenes, hard and soft
resins) and deasphalted oil (DAO) as final products. This refining process can be
considered a carbon rejection process, since asphaltenes that are removed have
relatively low hydrogen-to-carbon (H:C) ratios. Since asphaltene yields increase
as operating temperatures increase, deasphalting is a severe service that requires
rugged valve designs and engineered coatings.

The MOGAS C-Series full-ported valve design can be used in all asphaltene and This large bore 24-inch metal seated ball
valve was one of several chosen for a tar
deasphalted oil services with 100 percent reliability. In applications where heavy sands upgrade project. Ability to meet the
asphaltene build-up occurs, MOGAS offers an intermittent and continuous purge stringent deadline was crucial to the success
of the start-up.
system to remove the asphaltene.

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Purge System
Alleviates Coke Build-up

Purging has been demonstrated to be effective in numerous field applications Purge Benefits
at minimizing the ill effects of coke formation. MOGAS highly recommends and
offers purge systems designed specifically for valves in high-fouling applications • Reduces operating torques from
to maximize the valve’s operating service life. start of run to end of run in critical
isolation valves
MOGAS purge solutions have worked so reliably that some companies have • Provides lubrication preventing
incorporated it into their best practices design manual. excessive frictional forces on
coating surface of ball and seats
resulting in reduced repair costs
• Keeps coke build-up on ball in a
soft condition allowing for optimal
cleaning by scraper seats
• Proper sequencing allows for warm
up avoiding temperature shock to
control valves
HP LP
• Allows isolation of redundant line
for safe repair of instruments and
control valves
• Eliminates coking in control valve
station allowing for safe venting
and draining of high pressure
reactor effluent liquid and vapor

Purge locations shown are for illustration purposes only; actual purge
locations will be determined based on application-specific data.

Industry Codes & Standards

The following partial list of industry codes and standards are referenced in the
manufacturing of MOGAS valves: API, ASTM, ATEX, CRN, DIN, FCI, GOST-R,
ISA, ISO, NACE, NBBI, PED, SIL, TA-Luft, TUV.

For a complete list, download our Design Conformance Standards from our
Media Centre at www.mogas.com

ASME Title API Title

B16.5 Steel Pipe Flanges & Flanged Fittings 598 Valve Inspection & Test
B16.10 Face to Face & End to End Dimensions of Valves 607 / 6A Fire Test for Quarter Turn Valves
B16.11 Forged Fittings Socket Welding and Threaded 6D Specification for Pipeline Valves
B16.25 Butt-welding Ends
B16.34 Valve – Flanged, Threaded & Welded End
NACE Title
FCI 70-2 Control Valve Seat Leakage
MR-0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
Refining Environments
MSS Title
SP-25 Standard Marking System for Valves, Flanges & Unions
British Title
SP-55 Quality Standard for Steel Castings for Valves, Flanges & Fittings Standard
SP-61 Pressure Testing of Steel Valves BS 6755 Testing of Valves
Part 1 – Specification for Production Pressure Testing Requirements
Part 2 – Specification for Fire Type Testing Requirements

© Copyright 09/30/2017 MOGAS Industries, Inc. www.mogas.com Valves for Refining Applications

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Service
Global Capabilities

Factory Service
Authorized Repair Center
Valve Automation Center

Service Excellence in Action

We provide exceptional When you select MOGAS products, service is a big part of what comes with
them. The MOGAS commitment to service means more than basic repairs. It also
service for unique means timely access to our knowledgeable and experienced team of experts—
anytime, anywhere in the world. And when our team becomes part of your team,
locations—everyday, you can trust that we will do everything we can to come through for you.

everywhere. When you have a problem, our technical advisors get to the root of it. They will
look at your entire application to accurately identify and solve the issue. Using a
comprehensive approach helps you improve equipment reliability and operational
efficiency, as well as reduce costs. Our core services include:

Project Support Repair, Refurbish & Customization

• Installation, startup and • 24-hour emergency response
commissioning • Troubleshooting
• Shutdown planning and • Valve performance analysis
implementation • 3D finite analysis
• Procurement and contract • High pressure testing
management • Online repair documentation

Preventive Maintenance
Catalyst particulates and harsh solids are • Complete system inspection
easily handled by MOGAS valves. This valve
was checked as part of a routine maintenance
• Routine maintenance, valve
program and then was put back into service. repacking
• Valve asset management

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Asset Management Plan
Optimize Your Investment

Getting more value for every dollar is now more important than
ever. To help minimize your total cost of ownership while
truly benefiting from predictive maintenance, MOGAS offers the
MORE™ Asset Management Plan—a totally customizable valve
purchase and service plan. Whether you buy a few valves or
several hundred valves, you can choose from a variety of options
to help optimize your investment.

On-site Services
• Start-up and commissioning assistance
• Field support and troubleshooting
• Quarterly walkdowns
• Major shutdown planning • Technical Assistance

Managed Inventories • Dependable Operation

• Revolving dedicated inventory (located and managed at
MOGAS facility) • Preventive Maintenance
• On-site inventory (for emergency use)
• Data Collection
Walkdown Evaluations
• On-site inspection of installed valves • Proactive Communications
• Customized reports
• Value Pricing
Valve Management Program (Online)
• Initial setup, input, links to P&ID and maintenance
reports
• Repair history
• Performance analysis reports
• Incident reports
• Valve repair cost
• Valve torques
• Revised bills of material
• Revised drawings
• Predictive / preventive maintenance recommendations

Certified Training
• Lunch-n-learns
• Valve installation & operation (hands-on)
• Maintenance & troubleshooting

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Confidence for Tomorrow
A Warranty is Not a Performance Guarantee

CONFIDENCE
PREDICTABILITY
RISK FREE DECISIONS
IMPROVED SAFETY
ENHANCED RELIABILITY
LESS DOWNTIME
ANTICIPATED BUDGETS

Only from MOGAS

Continuous years of research and development, design innovation,
advanced manufacturing techniques and field experience allow
us to offer an application-specific PERFORMANCE GUARANTEE
on our metal seated isolation and control valves…plus a lifetime
warranty on materials and workmanship.

Valves for Refining Applications © Copyright 09/30/2017 MOGAS Industries, Inc. www.mogas.com

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Severe Service MOGAS Industries, Inc.
Headquarters
The MOGAS Definition 14204 East Hardy Street
Houston, TX, USA 77039-1405
Phone: +1.281.449.0291
• Extreme temperatures
Fax: +1.281.590.3412
• High pressures E-mail: [email protected]

• Abrasive particulates
Europe
• Acidic products Phone: +44 (0)116.279.3367
• Heavy solids build-up
China
• Critical plant safety Phone: +86 (0)10.84549478
• Large pressure differentials
Australia
• Velocity control Phone: +61 (0)8.9456.3533
• Noise control
Middle East
Phone: +971 (0)4.889.5667

For other MOGAS locations

or a distributor in your area,
visit us online at
www.mogas.com

© Copyright 09/30/2017 MOGAS Industries, Inc. www.mogas.com

MOGAS Industries reserves the right to make modifications, alterations or
updates to this document. Check our website for the most current information.
Refining Brochure (EN)