VALVE TYPE ACCEPTANCE TEST EXPERIENCES

API Meeting - SCOPV Los Angeles, California November 15, 2011

TAT EXPERIENCES
What is Shells Type Acceptance Testing (TAT)?

Testing of a valve to its design limits on temperature and pressure Seat testing with nitrogen and fugitive emission testing with helium

Ambient temperature Maximum advertised temperature Minimum advertised temperature Ambient temperature

200 mechanical cycles including opening and closing torques Acceptance criteria is based upon ISO 5208 (seat leakage) and ISO 15848 (FE) Technical documentation review Valve manufacturer technical audit (ISO 9001 methodology) Valve design validation and verification

TAT is part of a total valve qualification program complemented by:

TAT EXPERIENCES--2 1500# SOFT-SEATED TRUNNION MOUNTED BALL VALVE

Unacceptable seat leakage due to o-ring/seat failure

TAT EXPERIENCES--10 1500# BOLTED BONNET GATE VALVE

Jammed wedge resulted in elongation of the stem. Instead of 4 threads per inch some parts of the stem only had 3 threads per inch.

TAT EXPERIENCES--1 PN10 PLASTIC LINED PISTON CHECK VALVE

During high temperature seat testing the valve failed due to the wings of the piston being deformed and the piston being hung in the seat guide.

TAT EXPERIENCES--20 600# EXPANDING GATE VALVE

During teardown of the valve it was discovered that the top part of expanding gate wedge was deformed and pressed into top plate

TAT EXPERIENCES--3 300# GATE VALVE

Valve failed seat testing and during teardown it was discovered that the stem threads were deformed after only 100 cycles

TAT EXPERIENCES--8 150# METAL SEATED BALL VALVE

During cycling of the valve, the opening/closing torque became very high. During teardown it was discovered that the hard face overlay was damaged and ball was scratched.

TAT EXPERIENCES--4 & 10 2500# TMBV

Excessive seat leakage was experienced during testing at ambient temperature, due to lip seal damage. Valve design didn't give sufficient lip seal housing clearance.

TAT EXPERIENCES--10 2500# TMBV

Actuator failure due to excessive valve torque at ambient temperature due to bearing seizure & poor bearing design.

TAT EXPERIENCES--10 2500# TMBV

Excessive seat leakage at ambient temperature due to failure of metal coating on ball and seat.

TAT EXPERIENCES--10 600# BOLTED BONNET GATE VALVE

Damaged stem threads due to failure of the drive nut. The drive nut material was incorrect.

TAT EXPERIENCES--6 1500# PRESSURE SEALED GATE VALVE

Stem seal failure due to incorrect packing

TAT EXPERIENCES--4 150# TMBV

Valve had passed the testing portion of the TAT but during teardown it was found that their was interference between the ball and end pieces. The parts were within design tolerance, but the design had to be revised.

TAT EXPERIENCES
Triple offset BF valve leaked at elevated temperature due to gasket

degradation. Gasket was only rated for 650F while valve was advertised as good to 800F.

18 600# ball valve wouldnt open during final ambient test due sticking of

stem and galling from too tight of tolerances. Design had changed earlier to open tolerance range, but drawings were not updated.

TAT EXPERIENCES
Severe damage to stem and nut threads caused by galling between 316 SS stem & ductile iron nut.

TAT EXPERIENCES
Explosive decompression during TAT.

TAT EXPERIENCES
Stem stretched approximately 3.5 during mechanical cycling. Thread external diameter was reduced from 2.4835 to 2.3755.

TAT EXPERIENCES--24 1500# BALL VALVE

PEEK lip seal & spacer rings shrank during the low temperature testing (-58F) which allowed the lip seal to fall out into the valve bore. The lip seal and the spacer rings became trapped between the ball and seats during the operation of valve creating seat sealing failure. Manufacturer changed lip seal spacer ring material from PEEK to alloy 625.

TAT EXPERIENCES
Severe cracking of high pressure steam non-return valve body

TAT EXPERIENCES--10 1500# METAL-SEATED TMBV

Excessive seat leakage after cycling at 575F due to failure of tungsten carbide coatings due to spring force being too high for 575F

TAT EXPERIENCES

Questions? Thank you!