Emerson’s Fisher® Control-Disk™ valves improve throughput and reduce variability at INEOS Chlor plant

fisher_control-disk_hires

Fisher Control-Disk


High resolution image



Emerson Process Management grants accredited media full permission to reproduce these images according to the following guidelines:  Images cannot be used to promote or sell any product or technology, nor can they be used in advertising or brochures or other sales materials.  We understand that you will give our company a credit line as follows: "Courtesy of Emerson Process Management."









Enhanced butterfly valves help plant in Runcorn, United Kingdom,  avoid six unplanned shutdowns and save an estimated $600,000 USD.

MARSHALLTOWN, IOWA (January 18, 2011) -- INEOS Chlor, a major European producer of chlor-alkali and chlorine derivatives, reduced process variability by 5% at its plant in Runcorn, United Kingdom, by replacing traditional butterfly valves with Fisher® Control-Disk™ valves from Emerson Process Management. The reduced variability enabled the plant to increase throughput, avoid several unplanned shutdowns that could have cost as much as $600,000, and achieve a 96% Overall Equipment Effectiveness rating for the unit where the valves were installed.

“For a plant this size, even a modest reduction in variability can have a significant payback," said Barry Makepeace, INEOS Chlor control & instrumentation engineer. "The Control-Disk valve applications not only saved us money, but also enabled us to optimize process control without sacrificing flow capacity or needing to re-pipe.”

The Runcorn plant had previously used traditional butterfly valves to control the temperature and flow of cooling water to the primary condensers. Tight control is essential because if the condensers’ temperature is too low, there will be residual chlorine in the system, which has to be removed. If the temperature is too high, there is an increased risk of a safety trip or plant shutdown. Each trip and subsequent unplanned shutdown can cost INEOS Chlor up to $100,000 USD.

Unfortunately, the traditional valves had a small control range and a large deadband, which reduced their ability to respond to temperature changes. In the previous 12 months, the plant had experienced 23 trips leading to a significant loss of production.

Working with Emerson valve experts, INEOS Chlor replaced four traditional butterfly valves with the new Fisher Control-Disk design. Its effective control range (15% to 70% of travel) approaches that of a segmented ball valve. Tighter, more reliable valve control enabled plant operators to optimize temperature set points and avoid at least six unplanned shutdowns—saving the plant up to an estimated $600,000.

Media:
• Contacts: Emerson Global Media Contacts

Additional resources:
• Join the Emerson Exchange 365 Community
• Connect with Emerson via X Facebook LinkedIn YouTube

About Emerson 
Emerson (NYSE: EMR) is a global technology and software company providing innovative solutions for the world’s essential industries. Through its leading automation portfolio, including its majority stake in AspenTech, Emerson helps hybrid, process and discrete manufacturers optimize operations, protect personnel, reduce emissions and achieve their sustainability goals. For more information, visit Emerson.com.

Please enable JavaScript to use this website.