Regulator "STAR"

3D model cover

Regulator "STAR"

The next step in development of control and anti-surge equipment for pipeline transport.

We have created it with consideration for most demanding requirements in the industry sector.

Gazprom Organization Standard 2–4.1–212–2008:

7.4.2 Selection of type and nominal diameter of control valves shall be carried out in accordance with requirements to its maximum design flow capacity (Kv) (Cv in case of imported valves)
7.4.7 The design of the flow path of the valve provides a straight-line symmetric gas flow trajectory that maximally excludes sudden changes in direction (the principle of axial flow is preferred).

The 'STAR' regulator features completely new operational characteristics. Primarily, its flow path geometry maintains consistent flow direction throughout the entire regulation zone, solving existing problems through symmetrical central throttling of the flow area.

STAR regulator operation diagram

Schematic cross-section of movable and fixed throttling elements (TE): a) fully open position; b) flow area adjustment. The diagram demonstrates another fundamental advantage — complete absence of central flow path obstructions. Another critical design feature is maintaining constant flow area throughout the entire path. The diagram shows a D=200mm regulator's flow section.

Regulator cross-section schematic

The symmetric central throttling method resolves all major operational challenges: 99% pipeline capacity utilization; perfect flow axial symmetry throughout regulation range; elimination of flow direction changes. We've implemented the 'smooth pipe' principle in flow regulation for the first time, resulting in exponential reduction of compensation costs. This creates substantially more efficient, economical and predictable regulation. The throttling element positioning methodology enables extremely precise adjustment through simple means, preserving gas kinetic energy from compressor stations or wellhead pressure. Maintaining gas flow kinetic energy that would otherwise be lost to regulator design limitations leads to directly proportional operational cost reductions — substantial savings impacting transportation budgets.

Specifications

Key characteristic of the gas pipeline valves is that their flow factor is 1.5 to 3 times higher than for analogous equipment of other manufacturers.

Energy loss reduction

Energy losses have been reduced by 5% owing to ideal axisymmetric design of the flow part, whereas energy losses for cage-guided valves exceed 60%.

The flow part heat-up

The world's first control valves with intrinsic heat-up function. This option is critical for equipment operating under low temperatures.

Reversal of flow

The only type of control valves featuring equivalent reversal of flow direction of gas, steam, or liquid. Characteristics of reversal flow remain the same.

Self-cleaning

The design minimizes damage to control valves by sand, welding burr, or other foreign inclusions. Repair interval is 2 times longer than for other types of control valves.

Repairability

Repair control valves without dismounting. Repair and mounting take several hours to several days. Equipment of other manufacturers is repaired up to half a year in factory conditions.