{"dataset":"Process Unit Valve Strategy Dataset","id":"process-units","description":"Unit-level valve strategy across refining, gas-processing, petrochemical, utility and safety-system process units - critical valve points, isolation philosophy, the equipment and fluids each unit involves, and governing standards.","publisher":"Vajra Industrial Solutions","publisherUrl":"https://www.vajravyuh.com","sourcePage":"https://www.vajravyuh.com/process-units","downloadUrl":"https://www.vajravyuh.com/data/process-units.json","license":"Free to use with attribution to Vajra Industrial Solutions (vajravyuh.com)","citation":"Vajra Valve Data Commons - Process Unit Valve Strategy Dataset, Vajra Industrial Solutions, vajravyuh.com/data","disclaimer":"Engineering reference data for valve service; indicative only. Ratings and limits depend on concentration, temperature and service conditions. Verify against the governing standard and a qualified engineer before procurement.","recordDescription":"One record per process unit with its critical valve points, equipment/fluid relationships and standards.","fields":["slug","name","abbreviation","category","industries","equipmentSlugs","fluidSlugs","criticalValvePoints{point, categorySlug, reason}","valveStrategy","standards"],"recordCount":12,"records":[{"slug":"crude-distillation-unit","name":"Crude Distillation Unit","abbreviation":"CDU","category":"refining","industries":["Oil & Gas Refining"],"equipmentSlugs":["centrifugal-pump","shell-and-tube-heat-exchanger","distillation-column","storage-tank"],"fluidSlugs":["crude-oil","naphtha","diesel-fuel","hot-oil","steam"],"criticalValvePoints":[{"point":"Furnace inlet/outlet isolation","categorySlug":"gate-valves","reason":"High-temperature crude service ahead of the fired heater; thermal cycling drives the gate-valve selection."},{"point":"Column side-draw control","categorySlug":"control-valves","reason":"Product-cut flow control off each fractionation tray."},{"point":"Overhead reflux and relief","categorySlug":"safety-valves","reason":"Column overpressure protection sized for loss of overhead condensing."}],"valveStrategy":["Column and exchanger-train isolation is planned around the multi-week turnaround, not routine maintenance - valve population per column runs into the hundreds","High-temperature crude and hot-oil circuits demand pressure-seal or bolted-bonnet gate valves rated for continuous thermal cycling","Desalter and wet-crude sections need corrosion-resistant trim (salt/chloride exposure) distinct from the dry fractionation sections"],"standards":["API 650","ASME Section VIII","API 520","API 521","API 600"]},{"slug":"vacuum-distillation-unit","name":"Vacuum Distillation Unit","abbreviation":"VDU","category":"refining","industries":["Oil & Gas Refining"],"equipmentSlugs":["centrifugal-pump","shell-and-tube-heat-exchanger","distillation-column"],"fluidSlugs":["hot-oil","bitumen-asphalt","vacuum-service","steam"],"criticalValvePoints":[{"point":"Vacuum column feed","categorySlug":"gate-valves","reason":"Full-bore isolation for viscous hot residue with minimal flow restriction."},{"point":"Ejector / vacuum system isolation","categorySlug":"butterfly-valves","reason":"Large-bore, low-pressure-drop isolation on the vacuum-generating steam ejector train."}],"valveStrategy":["Vacuum-service valves need positive sealing against inward air leakage, not just process containment - a leaking valve breaks the vacuum and derates the whole unit","Residue and slop-wax lines run hot and viscous - full-bore, minimum-obstruction valve selection prevents plugging"],"standards":["API 521","ASME Section VIII","API 600"]},{"slug":"fluid-catalytic-cracking-unit","name":"Fluid Catalytic Cracking Unit","abbreviation":"FCC","category":"refining","industries":["Oil & Gas Refining","Petrochemical"],"equipmentSlugs":["centrifugal-compressor","shell-and-tube-heat-exchanger","separator-pressure-vessel"],"fluidSlugs":["hot-oil","naphtha","propylene","steam"],"criticalValvePoints":[{"point":"Wet gas compressor anti-surge","categorySlug":"control-valves","reason":"Prevents surge on the erosive, high-molecular-weight wet-gas stream."},{"point":"Regenerator/reactor relief","categorySlug":"safety-valves","reason":"Fire-case and blocked-outlet overpressure protection on the highest-temperature vessels in the unit."},{"point":"Main fractionator bottoms","categorySlug":"gate-valves","reason":"Hot, solids-bearing slurry service demanding abrasion-tolerant trim."}],"valveStrategy":["Catalyst-slide and standpipe valves see continuous erosive duty - hard-faced or ceramic-lined trim is standard practice, not an upgrade option","Main air blower and wet-gas compressor isolation follows severe-service rotating-equipment practice with anti-surge protection","Regenerator and reactor overpressure protection is a fire-case-driven relief study, not a routine PSV sizing exercise"],"standards":["API 617","ASME Section VIII","API 520","API 521","API 6D"]},{"slug":"hydrotreating-unit","name":"Hydrotreating Unit","abbreviation":null,"category":"refining","industries":["Oil & Gas Refining"],"equipmentSlugs":["reciprocating-compressor","centrifugal-pump","shell-and-tube-heat-exchanger","separator-pressure-vessel"],"fluidSlugs":["hydrogen","hydrogen-sulphide","diesel-fuel","naphtha"],"criticalValvePoints":[{"point":"Reactor feed/effluent isolation","categorySlug":"gate-valves","reason":"High-pressure hydrogen service ahead of and after the catalyst reactor."},{"point":"Recycle gas compressor isolation","categorySlug":"ball-valves","reason":"DBB isolation for the sour, high-pressure recycle-hydrogen loop."},{"point":"Sour water / amine interface","categorySlug":"control-valves","reason":"Level control on the high-pressure separator handling H2S-laden condensate."}],"valveStrategy":["High-pressure hydrogen embrittles susceptible steels - material selection follows hydrogen-service guidance (ASME B31.12) alongside standard pressure-class rules","NACE MR0175 / ISO 15156 sour-service material limits apply to every wetted part downstream of the H2S-forming reactor section","Recycle-gas compressor and make-up hydrogen isolation are DBB by default given the flammability and pressure of the service"],"standards":["NACE MR0175 / ISO 15156","ASME B31.12","API 6D","ASME Section VIII"]},{"slug":"amine-treating-unit","name":"Amine Treating Unit","abbreviation":null,"category":"gas-processing","industries":["Oil & Gas Refining","Gas Processing","Fertilizer"],"equipmentSlugs":["centrifugal-pump","distillation-column","shell-and-tube-heat-exchanger"],"fluidSlugs":["amine","hydrogen-sulphide","co2","natural-gas"],"criticalValvePoints":[{"point":"Rich/lean amine exchanger isolation","categorySlug":"gate-valves","reason":"Corrosive rich-amine service demands upgraded trim over the lean side."},{"point":"Acid gas outlet","categorySlug":"control-valves","reason":"H2S/CO2 acid-gas flow control to the sulfur recovery unit or flare."},{"point":"Amine circulation pump isolation","categorySlug":"check-valves","reason":"Non-return protection on the continuously circulating amine loop."}],"valveStrategy":["Every wetted valve in the acid-gas path is sour-service rated per NACE MR0175, including the lean/rich amine exchanger and control valves","Amine solution is corrosive to carbon steel at the rich-amine (CO2/H2S-loaded) end - stainless trim is standard even where the body stays carbon steel","Control-valve trim in the rich-amine flash and stripping sections sees cavitation-prone flashing duty"],"standards":["NACE MR0175 / ISO 15156","API 6D","ASME Section VIII"]},{"slug":"sulfur-recovery-unit","name":"Sulfur Recovery Unit","abbreviation":"SRU","category":"gas-processing","industries":["Oil & Gas Refining","Gas Processing"],"equipmentSlugs":["shell-and-tube-heat-exchanger","storage-tank"],"fluidSlugs":["hydrogen-sulphide","co2","natural-gas"],"criticalValvePoints":[{"point":"Molten sulfur draw-off","categorySlug":"gate-valves","reason":"Steam-jacketed, full-bore valves to prevent sulfur solidification and plugging."},{"point":"Acid gas feed isolation","categorySlug":"ball-valves","reason":"Sour-service isolation ahead of the reaction furnace."},{"point":"Tail gas incineration line","categorySlug":"butterfly-valves","reason":"Large-bore isolation to the thermal oxidiser / incinerator."}],"valveStrategy":["Molten sulfur is solid below roughly 115-120C - lines and valves need steam or electric tracing, and valve selection favours full-bore, self-draining designs that will not plug on a trace failure","Acid-gas and tail-gas paths carry the same sour-service material rules as the amine unit upstream","Reaction-furnace refractory-lined piping limits valve placement to cooler sections of the train"],"standards":["NACE MR0175 / ISO 15156","API 6D","ASME Section VIII"]},{"slug":"lng-liquefaction-train","name":"LNG Liquefaction Train","abbreviation":null,"category":"gas-processing","industries":["LNG","Gas Processing"],"equipmentSlugs":["centrifugal-compressor","shell-and-tube-heat-exchanger","storage-tank"],"fluidSlugs":["lng","natural-gas","nitrogen"],"criticalValvePoints":[{"point":"Main cryogenic heat exchanger isolation","categorySlug":"ball-valves","reason":"Cryogenic ball valves with extended bonnets isolate the coldest section of the train."},{"point":"LNG storage tank inlet/outlet","categorySlug":"gate-valves","reason":"Cryogenic gate valves for tank filling and send-out."},{"point":"Boil-off gas relief","categorySlug":"safety-valves","reason":"Cryogenic safety relief valves protect against tank and line overpressure from boil-off."}],"valveStrategy":["Extended-bonnet, cryogenic-rated valves (BS 6364) are mandatory below the pre-cooling stage - standard-bonnet valves cannot maintain stem-packing integrity at cryogenic temperature","Boil-off gas (BOG) handling requires valves rated for the same cryogenic range even during upset venting","Thermal-cycling fatigue on start-up/shutdown - far more frequent in LNG service than steady continuous plants - drives seat and bellows life"],"standards":["BS 6364","API 6D","ASME B31.3","API 598"]},{"slug":"hydrogen-generation-unit","name":"Hydrogen Generation Unit","abbreviation":"SMR","category":"petrochemical","industries":["Oil & Gas Refining","Fertilizer","Hydrogen","Chemical"],"equipmentSlugs":["shell-and-tube-heat-exchanger","separator-pressure-vessel"],"fluidSlugs":["hydrogen","natural-gas","steam","co2"],"criticalValvePoints":[{"point":"PSA cycle valves","categorySlug":"ball-valves","reason":"High-cycle-life valves switching adsorber beds many times per hour."},{"point":"Reformer feed/effluent","categorySlug":"gate-valves","reason":"High-temperature alloy-steel isolation on the reforming furnace circuit."},{"point":"Hydrogen product relief","categorySlug":"safety-valves","reason":"Overpressure protection on the high-pressure hydrogen product header."}],"valveStrategy":["Hydrogen embrittlement governs metallurgy selection per ASME B31.12 across the whole high-pressure hydrogen circuit","PSA (pressure swing adsorption) purification cycles valves through frequent, fast open/close duty - cycle-life rating matters more than static seat performance","Reformer tube inlet/outlet manifolds run at high temperature - alloy steel valves with appropriate creep-strength ratings"],"standards":["ASME B31.12","ASME Section VIII","API 520","API 521"]},{"slug":"demineralised-water-plant","name":"Demineralised Water Plant","abbreviation":"DM Plant","category":"utilities","industries":["Power","Refining","Chemical","Pharmaceutical"],"equipmentSlugs":["centrifugal-pump","storage-tank"],"fluidSlugs":["demineralised-water","caustic-soda","hydrochloric-acid","sulphuric-acid"],"criticalValvePoints":[{"point":"Regeneration chemical dosing","categorySlug":"diaphragm-valves","reason":"Corrosion-resistant, lined valves for caustic/acid regeneration chemicals."},{"point":"Resin bed isolation","categorySlug":"butterfly-valves","reason":"Frequent-cycling isolation for the ion-exchange or RO train sequencing."},{"point":"Product water isolation","categorySlug":"ball-valves","reason":"SS 316L construction to protect boiler-feed or high-purity water quality."}],"valveStrategy":["Regeneration chemical lines (caustic, HCl or sulphuric acid) need lined or high-alloy valves distinct from the product-water side","Product DM water for pharma or high-purity boiler feed favours SS 316L construction to avoid contamination and corrosion product carryover","Resin-bed isolation valves see frequent cycling on the regeneration sequence - this is a duty-cycle selection question, not a static one"],"standards":["ASME B31.3","AWWA C504"]},{"slug":"effluent-treatment-plant","name":"Effluent Treatment Plant","abbreviation":"ETP","category":"utilities","industries":["Chemical","Refining","Pharmaceutical","Textile","Steel","Water Treatment"],"equipmentSlugs":["centrifugal-pump","separator-pressure-vessel"],"fluidSlugs":["slurry","caustic-soda","sulphuric-acid","demineralised-water"],"criticalValvePoints":[{"point":"Sludge / slurry transfer","categorySlug":"pinch-valves","reason":"Abrasion-tolerant isolation for solids-laden effluent streams."},{"point":"Equalisation basin isolation","categorySlug":"butterfly-valves","reason":"Large-bore, variable-pH-tolerant isolation across basins."},{"point":"Chemical dosing (pH correction)","categorySlug":"diaphragm-valves","reason":"Corrosion-resistant metering of acid/caustic dosing chemicals."}],"valveStrategy":["Solids-bearing sludge and slurry lines favour knife-gate or pinch valves over standard gate/ball designs","Variable and often unpredictable pH across equalisation basins pushes toward lined or duplex trim rather than a single carbon-steel default","Low-pressure, high-reliability requirement - the ETP rarely has redundancy, so valve availability drives selection more than performance headroom"],"standards":["ASME B31.3","AWWA C517"]},{"slug":"fire-water-system","name":"Fire Water System","abbreviation":null,"category":"safety-systems","industries":["Oil & Gas Refining","Chemical","Petrochemical","Power","LNG","Marine"],"equipmentSlugs":["centrifugal-pump","storage-tank"],"fluidSlugs":["seawater","demineralised-water"],"criticalValvePoints":[{"point":"Ring-main sectional isolation","categorySlug":"gate-valves","reason":"Supervised (tamper-monitored) OS&Y gate valves so isolation status is always known."},{"point":"Deluge system actuation","categorySlug":"control-valves","reason":"Fast-acting deluge valves for fixed fire-protection systems on vessels and tanks."},{"point":"Hydrant and monitor isolation","categorySlug":"gate-valves","reason":"Manual isolation at each hydrant/monitor point across the ring main."}],"valveStrategy":["Normally-open isolation valves are supervised (tamper-switch monitored) so an inadvertently closed valve is alarmed, not discovered during a fire","Deluge and monitor valves need fail-open or fail-safe actuation independent of plant power/instrument air where the spec demands it","Corrosion allowance is generous by design - seawater or long-standing stagnant water rewards conservative material selection over minimum-cost selection"],"standards":["NFPA 24","NFPA 20","API 607"]},{"slug":"flare-system","name":"Flare System","abbreviation":null,"category":"safety-systems","industries":["Oil & Gas Refining","Petrochemical","Gas Processing","LNG"],"equipmentSlugs":["separator-pressure-vessel"],"fluidSlugs":["natural-gas","hydrogen-sulphide","hydrogen"],"criticalValvePoints":[{"point":"Knock-out drum liquid drain","categorySlug":"control-valves","reason":"Automatic liquid-level draw-off from intermittent, often sour flare condensate."},{"point":"Purge gas control","categorySlug":"control-valves","reason":"Maintains positive purge flow to the flare tip to exclude air ingress."},{"point":"Header isolation (where fitted)","categorySlug":"gate-valves","reason":"Car-sealed or interlocked-open valves so the flare path is never inadvertently blocked."}],"valveStrategy":["Flare header isolation is avoided by design wherever possible - the header must always have a path to atmosphere; where isolation exists it is car-sealed or interlocked open","Knock-out drum liquid level and drain valves must handle intermittent, often sour or pyrophoric condensate","Water-seal and purge-gas control valves maintain a positive purge to keep air out of the flare tip - control-valve reliability here is a safety function, not a process one"],"standards":["API 521","API 537","ASME Section VIII"]}]}