4 - Valves and Operators Maintenance

Ch 3 Valves & Operators Maintenance
Chapter 3
Valve and Operator
Maintenance
Kuliah MS4102 Perawatan Mesin 1
3.1. General
• Valves are mechanical devices specifically designed to direct,
start, stop, mix, or regulate the flow, pressure, or temperature
of a process fluid.
• Berdasarkan atas fungsinya, aplikasinya, dan rancangannya,
valve dapat dibedakan ke dalam beragam kelas styles, sizes,
dan ragam pressure.
• Tipe yang umum ditemukan adalah plug, ball, globe, butterfly,
dan gate valves.
• Valve dapat dibuat dari berbagai material seperti: steel,
steel iron,
iron
plastic, brass, atau sejumlah material paduan khusus lainnya.
• Komponen-komponen utama sebuah valve diberikan pada
Gbr. 3.1

• The internal
elements of a valve
are collectively
referred to as a
valve's trim.
• The trim typically
includes a disc,
seat, stem, and
sleeves needed to
guide the stem.
• A valve's perfor-
mance is
determined by the
di and
disc d seatt
interface and the
relation of the disk
position to the
seat.
Gbr. 3.1 Basic components of a valve
Types
Gb 3.2
Gbr. 32
Ball Valve
Gbr. 3.3 Gbr. 3.4

Butterfly Valve Plug Valve
Gbr. 3.5
Globe Valve
Gbr. 3. 6
Gate Valve
Gbr. 3.7 Pinch Valve
open throttling closed
Gbr. 3.8 Diaphragm Valve

Gbr. 3.9
Berbagai macam
check valve
Gbr. 3.10 Pressure Relief Valve (PRV)

Gbr. 3.11
Manual Valve Gbr. 3.12
Control Valve
Table 1. Types of Valves Used in hydrocarbon Pipeline Transmission Systems (Seiders, 2004)
Material/
Design Features Port Function Body Style Remarks
Manufacture
Gate Rising stern Full port Shut-off Cast Cast Steel
Non-rising stern Reduced port Forged Forged Steel
Thru conduit Fabricated Cast iron
Slap gate
Wedge gate
Expanding gate
Ball Floating ball Full port Shut-off All welded Cast Steel Ball valve design is inherently a
thru conduit valve
Trunion Reduced port Split/Flanged body Forged Steel Special ball valve designs are
Mounted ball used for flow or pressure
Top entry Cast iron control
Butterfly Shut-off Flanged Cast Steel Special butterfly valve designs

are used for flow or pressure
Control Mounted between flanges Forged Steel Cast control
iron
Plug Full port Shut-off Cast used Special plug valve designs are
used for flow or pressure
Reduced port Control Forged steel control
Cast iron
Globe Control
Check Clapper One-way Flanged/Wedled Cast steel

Thru-conduit, clapper Mounted between flanges Forged steel
Plug or ball Cast iron
Pressure Relief/Safety Cast steel

relief
Pressure Relief/Safety Forged Steel

safety Cast Iron

Valve Standards/Applicable Codes
• API (6D, 6FA, Specification Q1, RP 591, 594, 598,

599,, 600,, 602,, 605,, 606,, 607,, 608,, 609,, RP 621))
• ASME/ANSI (B16.5, B16.10, B16.20, B16.25, B16.34,
B31.4, B31.8)
• British Standards Institution (BS 1414, BS 1868, BS
1873, BS 2080, BS 5351, BS 5840, B 6755 1 & 2))
• ISO (5210,
(5210 5211,
5211 9001)
• NACE MR 01.75
• MSS (SP-6, SP-25, SP-55, SP-61, SP-66, SP-92)
3.2. Valve Maintenance Requirement
Coding and Color
• Industryy practice
p is g
generally
y to label and color-code all
identifiable mainline valves.
• There is no unified color-coding utilized by the industry, and
each company selects its own colors.
• Valve labels are more unified and generally the following
symbology is adopted by the industry (Table 1)

http://www.smithvalve.com/tec
hnical/documents/Valve-Color-
Coding.PDF

Table 2 Valve Labeling - Acronyms
Valve Description Valve Code

Block valve/valve BLK/V
Bypass valve (station) BV
Bypass check valve (station) BCV
Check valve CV
Control station valve CSV
Pressure control valve PCV
Station discharge valve SDV
Station suction valve SSV
Receiving scraper trap check valve TRCV
Receiving scraper trap valve TRV
Sending scraper trap check valve TSCV
Sending scraper trap valve TSV
Unit check valve UCV
Unit discharge valve UDV
Unit suction valve USV
Crossove valve XV
Valve Inspection and Schedule
 Codes and regulation require that every pipeline valve be
inspected and partially operated at least once each calender
year, i.e., this is mandatory, not optional.
 The
Th iindustry’s
d t ’ generall practice
ti iis tto iinspectt mainline
i li valves
l
and side valves, including remotely operated valves, at least
twice a year at intervals not exceeding 7,5 month.
 The inspection and maintainance usually includes:
• Checking valve for general appearance, condition and
leaks.
• Lubricating the valve and parts.
• Checking valve support and pipe support.
• Performing any required maintenance works as per MI.
Valve Inspection and Schedule (cont’d)
• Operating all valve from full open to close, if practical.
• Correcting all deficiencies or problems found during the
routine inspection.
• Verifying valve proper operating position upon completion
of the inspection and maintenance.
 Pipeline inspection usually proceeds with the supplier/user
given prior notice of the intent to operate any valve that affect
the flow of fluid in a major facility.
 All valves are to be locked except p those within the confines of
an approved area, building or other enclosue that is locked.
 Record keeping, which must include remote valve
maintenance/test report.

Gbr. 3.13 Exploded view of a manual ball valve

Keterangan
(1) Body
(2) Plug
(3) Top cap
(3A) Top
T cap bolt
b lt
(5) Sleeve
(6) Diaphragm
(11) Thrust collar
(12) Adjuster
(12A) Adjuster bolt
(13) Wrench
(17) Grounding spring
(19) Stop collar Gbr. 3.14
(19A) Stop collar retainer Exploded view of
a manual plug
valve
(1) Body
(1A) Hex head cap
screw
(1B) Hex nut
(1C) Bushing
(2) Disk
(3) Retainer plate
(4) & (4A) socket head
screw
e
(5) Gland at top
(5A) O-ring inboard
(5B) O-ring outboard
(6) Spring
(7) Bearing
(8) Ring-stem wedge
(9) Ring-stem
compression
(10) Liner
((11)) Seat energizer
g
(12) Gland at bottom
(13) Plate mounting
(14) Stem extension
(15) Spacer
(16) Bracket
(17) Stud
Gbr. 3.15 Exploded view of a lines, split-body, (18) Hex nut
(19) & (20) washer
concentric disk butterfly valve.
Preventime Maintenance Treatment
To prevent damage, the following procedures is generally
followed:
 Pre-shipment:
p
• After hydrostatic testing, the valve needs to be cycled to the
full open position.
• Valve is packaged properly to prevent grease from leaking
out and to prevent the air, water spray from entering the
valve’s body
• Sealant system is to be filled by means of injecting a light
grade synthetic valve lubricat.
• All body vent/drain valve need be in the close position.

Preventime Maintenance Treatment(cont’d)
 Shiping and Receiving:
• To protect from corrosion, valve may be coated with a light
varnish to protect external surface and with a light oil or
grease all inernal surfaces.
• End covers is used to keep water and airborne
contaminants from internal surface.
• The shipper/receiver need to verify that end covers are
intact, the shipping
pp g ggrease has not leaked out that water
has not leaked into the valve body.
• The shipper/receiver should not remove the end caps
unless internal damage is supected.
 Valve Handling:
• Valve need to be handled properly during loading/
unloading and during transportation.
transportation
• Preparation consists of crating/uncrating the vavle,
protecting/removing the protective end covers and placing
in on the ground to be externally painted or coated before
welding into the pipeline.
• Valves should be lifted byy means of external sling
g attached
to the valve at the position as indicated by the
manufacturer.

 Installation:
• Prior to installation, it is required that all varnish coating be
removed carefully.
• Case NO OPERATOR: all exposed valve stems must be
cleaned and wrapped with a plastic waterproof covering
and taped to secure.
• Case WITH OPERATOR: it is critically important to ensure
the valve and operator from flexing.
• Special care must be taken to ensure that valve body does
not overheat and damage body or internal elastomers
(Teflon seals and O-rings).
• After installation it is important to ensure that the stem
system is energized to ensure smooth opeation.
 Hydrostatic Testing:
• Hydrostatic test pressure must never be applied against a
closed valve unless the valved is rated for the maximum
test pressure.
• Prior to pressurizing the pipeline, all ball valve must be
rotated to the half closed/open position to prevent the
possibility of a pressure differential in the valve body.
• Valve must not be allowed to remain in this position for an
extended p period of time  the elastomers in the seat ringg
become deformed  severe seat leakage.
• Follow the SOP for hydrostatic testing as required by code
or regulation.
• Upon completion of successful hydostatic test, valve must
be returned to the full open position.
 Pipeline Commissioning:
• Sand, dirt, pebbles and rocks, sand blasting material, hand
tools and timbres are some of the manyy contaminants
normally discovered in valve bodies, pig receivers and
scrapper/filter devices during pipeline commissioning during
pipeline commisioning/after startup.
• Minor valve seat leakage is often the result of tiny scratches
to the seating surfaces caused by these contaminants.
• Experience
p indicates that a valve with even minor scratches
will leak under high pressure, particularly in gas pipeline.
• These scratches may continue to erode into large leak path
if PM program is not in place.
• Some PM procedure are described by Sealweld (1992,
2003).
The following is checklist of items needing attention:
SHIPMENT/RECEIVING
− Unloaded from truck and lifted properly
− Set onto wooden pallets Stem positioned – pointing up
− Document received
− External examination: visual–no damage
− Internal damage–remove end caps and inspect
− Ball in full open
p p position
− Open and closed positions clearly marked on top
− Inject lubricant into seat sealant fittings
Approximately 1 oz/inch of valve size
Plus riser pipe quantities of 2 oz/foot

SHIPMENT/RECEIVING (cont’d)
− Collect shipping grease from inside of valve body
− Level space between seat ring and ball with #911
− Replace and caps and secure
− Stem seal energizer to max
max. 33,000
000 psi and holding
− Gear box and bearings lubricated
− All threaded connections lubricated
− External Coating Applied Properly
No Coating Material on Valve Stem
No coating material on External Fittings
WELDING PROCEDURES
− Seat sealant system topped up after welding
− All metal caps on sealant fittings tightened
− All body vent/ drain fittings closed
POWER OPERATOR INSTALLATION

− Authorized representative on–site
− Document/manuals and training received
− Valve stops set properly and marked
HYDROSTATIC TEST
− Fill pipeline with water, with all valves in full open
− Position, before building pressure, stops pumps
− Ball rotated to half–closed /open position
− Start water pump and build pressure to 50% MOP
− Valve and flanges examined for leakage
− Start pump and build pressure to full test pressure
− Hydrostatic test passed
− Pipeline drained
− Body cavity drained
− Ball returned to fully open position
− Seat sealant system topped up, caps tightened
Example of Valve Maintenance Activities
Valve PM activities while In-situ valve wellhead

valve in operation service and maintenance
Valve maintenance truck
Valve maintenance training

3.3. Valve Inspection and Testing (API 598)
Scope of API 598
– Scope of works:
• Inspection
• Examination
• Supplementary examinations
– Seat:
• Resilient-seated*
• Non
Non-metallic-seated
metallic seated (e.g. ceramic)
• Metal-to-metal-seated
– Valve types:
• Gate valve
• Globe valve
• Plug
g valve
• Ball valve
• Check valve
• Butterfly valve
– Resilient seats, include:
• Soft seats
seats, both solid and semi solid grease type (e
(e.g.
g
lubricated plug)
• Combination of soft and metal seat
• Any other type valve designed to meet resilient seat
leakage rates by the standard
• The test requirements cover both required and optional

pressure tests at the valve manufacturer’s plant.
• The tests consist of:
– Shell test
– Backseat test
– Low-pressure closure test
– High-pressure closure test
– Visual examination of castings
– High-pressure pneumatic shell test
3.4 Inspection, Examination & Supp. Exam.
• At the manufacturer’s plant
– The p
purchaser will specify
p y in P/O to p
perform witness test at
manufacturer’s plant.
– Purchaser’s inspector shall have free access to any part of
the plant, concerning the valve’s manufacturing whenever
work on the order is underway.
• Outside the valve manufacturer’s plant
– Shell components may be manufactured at other
locations.
– If so, and if specified in P/O, purchaser will inspect at
those locations.
• Examination
– Visual examination for all casting of bodies, bonnets, covers,
and closure elements to ensure conformance with MSS SP-
55.
55
– Valve manufacturer shall examine to assure the compliance
to this standard and the referenced standard (e.g. API std
600, according to the valve types).
– All examinations shall be performed in accordance with
written procedures that comply with the applicable
standards.
• Supplementary examinations by the manufacturer are required

and witnessed by the purchaser’s inspector, if specified in P/O,
such as:
– Magnetic particle
– Radiography
– Liquid penetrant
– Ultrasonic examination

3.5 Pressure Tests
Test equipment
– Shall only apply pressure load, no other external forces that
may affect seat leakage allowed.
– End-clamping is allowed for valves designed to function
between mating flanges, e.g. wafer check and butterfly
valves!
Types of Test required

– For NPS ≤ 4 and pressure rating ≤ 1500
Valve Type
Test Butterfly and
Description Gate Globe Plug Check Floating trunnion-
trunnion
Ball mounted Ball
Shell Required Required Required Required Required Required

Backseata Required Required NA NA NA NA
Low-pressure Required Optional Requiredb Alternativee Required Required
closure
High-pressure Optional Requirede Optionalb Required Optional Optional
closure
l d
a The backseat test is required for all valves that have backseat features, except for bellows seal
valves.
d The high-pressure closure test of resilient-seated valves may degrade subsequent low- pressure
service.
e For power-operated globe valves, the high pressure closure test shall be performed at 110%
design differential pressure used for sizing the power operator.
– For NPS > 4 and pressure rating > 1500
Valve Type
Butterfly and
Test Gate Globe Plug Check Floating trunnion-
D
Description
i ti mounted dBBallll
Ball
Shell Required Required Required Required Required Required
Backseata Required Required NA NA NA NA
Low-pressure Optional Optional Optional Alternativeb Required Optional
closure
High-pressure Required Requirede Required Required Optional Required
closured
a The backseat test is required for all valves that have backseat features, except for bellows seal
valves.
d The high-pressure closure test of resilient-seated valves may degrade subsequent low- pressure
service.
e For power-operated globe valves, the high pressure closure test shall be performed at 110% design
differential pressure used for sizing the power operator.
Test fluid
– For shell, high-pressure backseat, and high-pressure
closure tests: Air, inert gas, kerosene or water or
noncorrosive liquid with viscouscity ≤ water’s
water s.
– For low-pressure closure and low-pressure backseat tests:
air and inert gas.
– Test fluid temperature ≤ 125oF (52oC), or as specified in
P/O.
– If air or gas is used,
used the manufacturer shall demonstrate the
adequacy of the leakage detection method.

Test Pressures
– Shell test
Shell Test Pressure (Min.)
Valve type Class
psig barg
150 400 26
Ductile Iron
300 975 66
Cast Iron:
NPS 2-12 125 350 25
NPS 14-48 265 19
Cast Iron:
NPS 2 2-12
12 250 875 61
NPS 14-48 525 37
Steel
150 – 2500 Per ASME B16.34
Flanged and Butt-weld
800 1.5 pressure rating at 100oF
Screwed and socked-weld 150 – 2500 Per ASME B16.34
Table ANSI Pressure Class vs. Nominal Pressure*)

ANSI Pressure Class Nominal Pressure (PN)
(pounds of force per square
(allowable pressure in bar)
inch of surface area)
150 20
300 50
400 64
600 100
900 150
1500 250
2500 420
4500 700
Note:
PN is an approximation to the corresponding ANSI pressure class, and should not be
used as an exact correlation between two standards.
Other test pressures

Minimum test pressure
Test
psig Bar
Valves Except Butterfly and Check

High-pressure closure and backseata b
Low-pressure closure and backseata 60-100 4-7
Butterfly Valve
High-pressure closure c -
Low-pressure closure 60-100 4-7
a The backseat test is required for all valves that have this feature
b 110% of MAP at 100oF in accordance with the applicable specification
c 110% of design differential pressure at 100oF in accordance with the applicable specification
Other test pressures (cont’d.)

Minimum test pressure
Test
psig Bar
Check Valves
High-pressure closure and backseata
Class 125 (Cast Iron)
NPS 2-12 200 14
NPS 14-48 150 11
Class 250 (cast iron)
NPS 2-12 500 35
NPS 14-24 300 21
Class 150 (ductile iron) 250 17
Class 300 (ductile iron) 640 44
b
Carbon, alloy, stainless st., & special alloys -
Low-pressure closure and backseata 60 - 100 4-7
(as in shell test)

Test Duration
Minimum Test Duration (second)

Shell Clos e
Closure
Valve Size Check Valves Other Check Valves Other
Backseat
(NPS) (API Std 594) valves (API Std 594) Valves
≤2 60 15 15 60 15
2½-6 60 60 60 60 60
8 – 12 60 120 60 60 120
≤ 14 120 300 60 120 120
The test duration is the period of inspection after the valve is fully prepared and is under full
pressure
Test Leakage
– For shell and backseat tests, no visible leakage is permitted
• Liquid: No drop, wetted of the external surfaces.
• Gas: no leakage shall be revealed by the established
method.
– For low and high pressure closure tests:
• Visual evidence of leakage through the disk, behind the
seat rings, or past the shaft seal is not permitted.
• Structural damage is not permitted
permitted.
• Plastic deformation of resilient seats and seals is not
considered structural damage.

Allowable rate for leakage of test fluid past the seats
Metal –Seated Check

All Metal – Seated Valves Except Check
Valves
All Resilient Liquid Testa Gas Test
Valve Size Liquid Gas
Seated (drop per (bubbles per
(NPS) Test Test
Valves b minute) minute)
≤2 0 0b 0b c d
2½-6 0 12 24 c d
8 – 12 0 20 40 c d
≤ 14c 0 28 56 c d
a For liquid test, 1 ml is equivalent to 16 drops

b There shall be no (visible) leakage for the specified minimum test duration
c The maximum permissible leakage shall be 3 ml per minute per inch of nominal pipe size
d The maximum permissible leakage shall be 1.5 SCF of gas per hour per inch of nominal pipe size
e For check valve larger than NPS 24, the allowable leakage rate shall be per agreement
3.6 Test Procedures
• General
– Valves shall be free from injectable sealant to the seat of
packing
ki area.
– When liquid is used for test fluid, the valves shall be free
from air.
– Required protective coating, e.g. paint, which may mask
surface defects, shall not be applied before inspection or
pressure testing.
t ti
– When closure testing valves, the applied closure force shall
be as specified in the applicable standard, no excessive
closure force allowed.

• Shell test
– Valve ends closed,
– Valve partially open,
– The
e pac
packing
gg gland
a d tight
g e enough
oug too maintain
a a testes p
pressure,
essu e,
– Test pressure, as specified earlier.
• Backseat test
– Valve ends closed,
– Valve fully open,
– Packing gland loose
loose,
– Test pressure, as specified in std. or catalogue or 110%
MAWP at 100oF.
• Low pressure closure test

– Sealing surfaces clean and free from oil, grease and sealant.
– This does not apply to a valve that uses lubricant as its
primary seal
seal.
– Procedure:
• For both direction closure  pressure shall be applied
successively for each side.
• For one direction  pressure only in one direction
(pressure direction)
direction).
• Any leakage at the seat, is observed using water or soap.

• High-pressure closure test

– Procedure is the same as Low-pressure closure test.
– When liquid test fluid is used, leakage is observed by the
drops.
drops
3.7 Certification and Retesting
• Certification:
– Valve’s manufacturer shall submit a certificate of compliance
with the P/O.
P/O
• Retesting
– A completed valve is required to be retested unless
specified, and may be waived by written certification by the
manufacturer that the valves have been inspected, tested
and examined for conformance with the standard’s
requirements.
– Painted valves need not have paint removed for retesting.
– Stored valves shall be commercially cleaned before retesting
and shipment.

3.8 Purchase Order
• If required, the following can be specified in P/O
– Inspection by the purchaser at the valve manufacturer’s plant,
– Inspection by the purchaser outside the valve manufacturer’s plant,
– Address for inspection notices
notices,
– Any supplementary examination required,
– Type of backseat test,
– High-pressure closure test,
– High-pressure pneumatic shell test,
– Test fluid temperature for low temperature valves,
– Use of wetting g agent
g in the test water,
– Certificate of compliance.
• If API 598 is used for valves not covered by the standard, the
purchaser will specify the extend to which the standard is to be
applied


References
 Mohitpour, Jason Szabo and Thomas Van Hardeveld, “Pipeline
Operation & Maintenance: A Practical Approach”, ASME, New
York 2005
York, 2005.
 Skousen, P.L., Valve Handbook, McGraw-Hill, USA, 1998.
 Fisher, Control Valve Handbook, Fisher Control International,
USA, 2001.

4 - Valves and Operators Maintenance

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Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 1

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 2

Ch 3 Valves & Operators Maintenance

Gbr. 3.3 Gbr. 3.4

Ch 3 Valves & Operators Maintenance

Gbr. 3.7 Pinch Valve

open throttling closed

Gbr. 3.8 Diaphragm Valve

Kuliah MS4102 Perawatan Mesin 6

Kuliah MS4102 Perawatan Mesin 7

Ch 3 Valves & Operators Maintenance

Gbr. 3.10 Pressure Relief Valve (PRV)

Kuliah MS4102 Perawatan Mesin 8

Ch 3 Valves & Operators Maintenance

Butterfly Shut-off Flanged Cast Steel Special butterfly valve designs

Check Clapper One-way Flanged/Wedled Cast steel

Pressure Relief/Safety Cast steel

Pressure Relief/Safety Forged Steel

Kuliah MS4102 Perawatan Mesin 10

Valve Standards/Applicable Codes

• API (6D, 6FA, Specification Q1, RP 591, 594, 598,

Kuliah MS4102 Perawatan Mesin 11

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 12

Kuliah MS4102 Perawatan Mesin 13

Ch 3 Valves & Operators Maintenance

Valve Description Valve Code

Kuliah MS4102 Perawatan Mesin 15

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 16

Gbr. 3.13 Exploded view of a manual ball valve

Ch 3 Valves & Operators Maintenance

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 20

Kuliah MS4102 Perawatan Mesin 21

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 22

Ch 3 Valves & Operators Maintenance

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 26

Kuliah MS4102 Perawatan Mesin 27

Ch 3 Valves & Operators Maintenance

POWER OPERATOR INSTALLATION

Valve PM activities while In-situ valve wellhead

Ch 3 Valves & Operators Maintenance

Valve maintenance truck

Valve maintenance training

Kuliah MS4102 Perawatan Mesin 30

Kuliah MS4102 Perawatan Mesin 31

Ch 3 Valves & Operators Maintenance

• The test requirements cover both required and optional

Kuliah MS4102 Perawatan Mesin 33

Ch 3 Valves & Operators Maintenance

Kuliah MS4102 Perawatan Mesin 35

Ch 3 Valves & Operators Maintenance

• Supplementary examinations by the manufacturer are required

Kuliah MS4102 Perawatan Mesin 36

Kuliah MS4102 Perawatan Mesin 37

Ch 3 Valves & Operators Maintenance

Types of Test required

Shell Required Required Required Required Required Required