Masoneilan 215X1 Series UOP Lock Hopper Over Travel Control Valve
Overview
The Masoneilan 215X1 Series is a high-capacity globe control valve that Baker Hughes designed in conjunction with UOP for one very specific and very demanding duty: severe on-off service inside the Lock Hopper control systems of the Continuous Catalyst Regeneration Platforming process. In that service the technical specification points to high pressure drop conditions in hydrogen with alumina (Al2O3) dust particles, and the valve must still seal tightly in repeated on-off cycling. Baker Hughes built the Masoneilan 215X1 on the proven construction of its 21000 Series unbalanced single-ported valves and added an over travel plug so that the soft seat is never exposed to the full pressure drop.
As the official trusted supplier for Masoneilan, Seven Star LLC supplies the Masoneilan 215X1 to refineries and petrochemical plants across the Sultanate of Oman and the GCC. Catalytic reforming units in the region depend on reliable lock hopper sequencing, and our instrumentation division in Muscat helps maintenance and process engineers match the valve, actuator and accessory package to the sequence they run.
Over Travel Seating Principle
The defining feature of the Masoneilan 215X1 is its dual seating arrangement. The plug sub-assembly carries a primary hard metal seat and, behind it, a secondary PTFE soft seat. On closing, the hard seating surfaces touch first. The plug then continues through a short over travel of approximately 0.25 inch (6.4 mm) while a set of disk springs inside the plug compresses, and only at the end of that movement does the soft seat come into contact. The result is two layers of protection: Class IV leakage from the hard seat alone and ASME Class VI leakage once the soft seat is engaged.
On opening, the sequence reverses. The hard seat remains on the seat ring while the soft seat retracts into the plug shank, so the instant the valve begins to crack open the soft seat is already out of the flow path. High differential pressure is therefore taken across the metal seat, which is hardfaced for the purpose, and the soft seat is protected from erosion by catalyst dust. Typical shut-off pressures of up to 400 psig (2800 kPa) can be achieved with the Masoneilan 215X1 over travel trim, and the flow direction is flow-to-close.
Engineering Design of the Masoneilan 215X1
The body of the Masoneilan 215X1 is a high-capacity globe pattern in carbon steel (ASTM A216 grade WCC) with a bolted bonnet in carbon steel (ASTM A515 grade 70), rated ASME Class 300 with raised-face flanges. Top entry construction means the plug sub-assembly and trim can be lifted out of the body without removing the valve from the line, which keeps maintenance access simple. The seat ring is threaded 316 stainless steel with a hardfaced seat, and the body gasket is a 316L spiral-wound gasket with flexible graphite filler.
Heavy top guiding supports the plug along the whole stroke through a large 440C stainless steel guide bushing, which controls vibration, keeps stroking repeatable and reduces trim wear. The plug shank is Stellite 6, the plug tip and insert retainer are 17-4 PH stainless steel in condition H900, the soft seat insert is PTFE and the disk springs are 17-7 PH stainless steel. A Masoneilan 215X1 is normally fitted with a Model 87 or 88 spring-diaphragm actuator, selected for air-to-close or air-to-open action, using PTFE packing within the stated temperature range of minus 20 to 450 degrees Fahrenheit.
Key Features
These features, taken from the Baker Hughes technical specification, explain why the Masoneilan 215X1 is specified for lock hopper duty rather than a general-purpose globe valve:
- Over travel seating of about 0.25 inch (6.4 mm) closes the soft seat only after the hard seat has made contact, so the soft seat does not carry the pressure drop.
- Dual seating gives ASME Class VI shut-off with the soft seat and Class IV leakage with the hard seat alone, as listed in the technical specification.
- The Masoneilan 215X1 uses heavy top guiding with a large bushing that supports the plug over its full stroke and limits vibration damage in repeated on-off cycling.
- Solid Stellite and 17-4 PH stainless steel components resist the wear produced by alumina dust in high-pressure hydrogen service.
- Typical shut-off pressures up to 400 psig (2800 kPa) are achievable with the over travel trim design.
- Simple top-entry body and plug sub-assembly construction allows easy access to and removal of trim components.
- The design is based on the 21000 Series unbalanced single-ported valve and has a long record in UOP Lock Hopper systems installed in refineries worldwide.
- Low emissions packing, air sets, solenoids and switches are available as accessories and options to complete the on-off package.
Industrial Applications
Baker Hughes states that the Masoneilan 215X1 is used in severe on-off service within the UOP Lock Hopper control systems that form part of the Continuous Catalyst Regeneration Platforming process. The duty is high pressure drop in hydrogen service with alumina dust particles. In Oman and the wider GCC, this is relevant to refineries that operate UOP Continuous Catalyst Regeneration Platforming units, and the manufacturer notes a long history of successful operation in numerous UOP Lock Hopper systems installed in refineries around the world.
In Oman and the GCC, Seven Star LLC supplies the Masoneilan 215X1 together with the actuators and instruments that surround it. Maintenance teams can specify the Masoneilan Type 87/88 pneumatic spring-diaphragm actuators that drive the valve, pair it with the Masoneilan SVI3 digital valve positioner where positioning feedback is wanted, and review the related single-port family through the Masoneilan 21000 Series seal kit.
Technical Specifications
The table below summarises the published data for the Masoneilan 215X1 from the Baker Hughes technical specification (Rev. B, 08/2020). Please refer to the full document for the materials list, dimensions and weights.
| Parameter | Specification |
|---|---|
| Model | Masoneilan 215X1 Series UOP Lock Hopper over travel control valve |
| Body type | High-capacity globe, top-entry, bolted bonnet |
| Valve sizes | 1, 1.5 and 2 inch (DN 25, 40 and 50) |
| Rating and ends | ASME Class 300, raised-face flanges |
| Rated Cv | 12 (1 in), 25 (1.5 in), 45 (2 in) |
| Travel | 0.8 inch (20.3 mm) |
| Trim | Over travel plug, primary hard metal seat plus secondary soft seat, threaded seat ring, heavy top guided, full area |
| Flow direction | Flow-to-close |
| Characteristic | Modified linear |
| Seat leakage | Class VI (soft seat), Class IV (hard seat) |
| Temperature range | Minus 20 to 450 °F (minus 29 to 232 °C), PTFE packing |
| Body and bonnet materials | Carbon steel |
| Actuator | Model 87 (air to close) or 88 (air to open) spring-diaphragm, size 10 or 16, optional handwheel |
| Body weight | 36 lb (16 kg) at 1 in, 49 lb (22 kg) at 1.5 in, 57 lb (26 kg) at 2 in |
Related Masoneilan severe-service and single-port valves include the Masoneilan 21000 Series top-guided globe control valve and Masoneilan PXR single-seated globe control valve.
Request a Quote for Masoneilan 215X1
A request for quotation for the Masoneilan 215X1 should give the valve size, differential pressure, hydrogen or catalyst service details, actuator action and any accessory requirements such as solenoids or limit switches. Seven Star LLC then confirms the configuration, checks regional availability and provides the Baker Hughes technical specification for download from this page. In Oman and the GCC, we deliver genuine products with manufacturer documentation and local support.
- Datasheet Masoneilan 215X1 Series Control Valve Technical Specifications (Rev. B, 08/2020) Download
Masoneilan control valves and actuator series
The globe valve listing centers on the 21000 series, including the cryogenic version with extension bonnet, and the 41005 cage-guided series in high pressure, API 6A and VRT anti-cavitation executions. The 80385 and 80386 are three-way combining and diverting valves. Rotary products include the 35002 Camflex II and the 37002 MiniTork II butterfly control valve. Actuators cover spring-diaphragm, cylinder and rack-and-pinion designs, among them the 5A cylinder actuator for Camflex II. Masoneilan also makes pressure regulators, SVI digital valve positioners and displacer-type level instruments, and offers Lo-dB trim for noise control.Where Masoneilan valves are used
Throttling duty on steam, hydrocarbons, gas and water is the daily work of these valves: feedwater and steam conditioning in power plants, separator and compressor loops in gas processing, high pressure drop letdown, cryogenic service in LNG and air separation, and general flow, pressure and level control in refineries and chemical plants.Ordering Masoneilan valves and spare parts: what we need
For spare parts the serial number is decisive, since the factory record behind it lists trim, materials and actuator. Send a clear nameplate photo with serial number, model number, size and pressure class. For a new valve add the process data: fluid, inlet and outlet pressure, temperature, minimum, normal and maximum flow, required leakage class, fail position, air supply and control signal.Browse Masoneilan products by category: Control Valves, Valve Actuator, Regulators, Valve Positioner, Level Transmitter.
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