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Engineer Specified Valves

Aplicaciones en Seminario Tecnico


Servicio Severo Bogota 2012
Project Objectives

The Projects Objectives

Standardize and Optimize Design for a Long Term Safe and


Economic Operation

Successful Valve Selection Process proven by


Operability, Sealing Integrity and Availability

Combined with: Optimum CAPEX and OPEX


Design Optimization

Project Design Optimization

Overall Cost Efficiency

Life Cycle Optimization


High Integrity Valves
For Critical Isolation in Demanding
Services;
Applications in the Pipeline Industry
Manufacturing Capacity:
Size, Pressure Class &
Weight;
SizeRange 1/2 - 110
ANSI Pressure Classes ANSI 150 - 4500
API Pressure Classes API 2000 - 20,000
Max Weight Capacity 148 Tons
Main Materials of Construction Utilized

1. Carbon / Low Temperature Carbon Steel


2. Low Alloy Steel
3. Austenitic & Super Austenitic Stainless Steel
4. Ferritic / Martensitic Precipitation Hardening S.S
5. Duplex St. & Super Duplex
6. Titanium, 6MO, Incoloy 825, Monel
7. High Nickel Alloys
8. Non Ferrous Materials
Hard Facing & Corrosion Barriers

StelliteHard Facing
Tungsten Carbides Hard Facing
Chromium Carbides Hard Facing
Ceramic Hard Facing
Inconel 625 Overlay or Cladding
Nickel / Monel Overlay
316 Stainless Steel Overlay
Soft Sealing Components

Pressure Temperature Limitations for Soft Sealing Components


PetrolValves Modeling
42" Class 900 - Gate Valve
Example of Active PetrolValves Clients

BP - America PEMEX
ExxonMobil ICA Fluor Daniel
Shell PDVSA
Aramco BP - Colombia
YPF/Repsol BP Trinidad
TotalFinaElf
Petrobras
MustangEngineering Williams
Pan American Energy
Techint
Project Highlights

Pigap Project - Venezuela


High Pressure Gas Injection
Ball, Globe, T.C. Gate Valves
1850 Valves supplied
$12 Million (USD)
Engineer Specified Valves Seminar

Pipeline

APPLICATIONS
PIPELINE APPLICATIONS

ESDVs
Launchers & Receivers
Double Block & Bleed
Primary Isolation
Secondary Isolation
By Pass
Blowdown
PIPELINE
APPLICATIONS

ISOLATION VALVES

Through Conduit Types


Full Bore Ball

Double Expanding Gate


Slab Gate
Non-Through Conduit
Expanding Parallel Slide
Wedge Gate
Reduced Bore Ball
Globe Valves
Typical Double block and bleed Valve designs
For pipeline Applications
API-6D
Valve Type Seat Design Characteristic Design
Block Direction

Single Point Self Relieving (5) Yes One block on each direction

Two block on each direction


Ball,
Sealing Double Piston (5) Yes (Limitations on Ratings and Services)
Trunnion (1)
Multipoint Self Relieving (6) Yes One block on each direction

Sealing Double Piston (6) Yes Two block on each direction

Slab Gate (1) Same as Trunnion Ball Yes Same as Trunnion Ball

Expanding Double Expansion (4) Yes Two block on each direction

Gate (2)
Single Expansion (3) Yes (3) Two block on each direction
PIPELINE & VALVE PROBLEMS

Coating failure on ball surface


PIPELINE & VALVE PROBLEMS

Debris abrasion on Seat Insert


PIPELINE & VALVE PROBLEMS

Metal debris damage to ball and seat insert


PIPELINE & VALVE PROBLEMS

EDP (Explosion Decompression Damage)


PIPELINE & VALVE PROBLEMS

O-Ring damage (possibly due to temperature or incorrect compound selection)


PIPELINE & VALVE PROBLEMS

Seat & Body ORing damage


PIPELINE & VALVE PROBLEMS
Swarf blistering and seat damage
PIPELINE & VALVE PROBLEMS
Corrosion Seat Pocket & Seat Ring Damage
PIPELINE & VALVE PROBLEMS
Corrosion - Incorrect Storage (new
uninstalled valve)
PIPELINE & VALVE PROBLEMS

Severe metal debris abrasion damage


VALVE PROBLEMS

Construction debris damage to ball


Debris from Pigging Operations
Engineer Specified Valves Seminar

BALL VALVES
56" Class 300

Ball Valve Technology

Design Optimization
Types Awareness
Component Awareness
BALL VALVE TYPES

SIZE RANGE:
ANSI - to 80

API6A - 1-13/16 to 30

API6D - to 80

PRESSURE CLASS:

ANSI - 150 /300 /400 /600 /900 /1500 /2500 /4500

API6A - 2000 /3000 /5000 /10000 /15000 /20000

API6D - 150 / 300 / 600 / 900 / 1500 / 2500


BALL VALVE TYPES

VALVE EXECUTION:
Three piece
Side entry
Top Entry
Welded Body
Wellhead Service
Floating Ball
Tandem Block
Soft seated Options
Metal seated Options

END CONNECTIONS:
Flanged,
Buttweld,
Socket weld
Hub.
BALL VALVES TYPES

Full Bore Ball Valves:

Main Advantages

Low Friction Losses


Pigability
REDUCED BORE BALL VALVES

Main Advantages
Offers cost savings for Non Pigable
applications

Single Reductions
Double Reductions
Custom Reductions
HP Reduced
Bore
Metal Seated
Floating Ball
Valve
DUPLEX / INCONEL CLAD TANDEM BALL VALVES

Tandem Full & Reduced Bore Ball Valves with Inconel 625 Cladding
TOP ENTRY BALL VALVES

Advantages
Serviceable In Line
Reduced Leak Potential
Reduced Down Time
Turn Function
Disadvantages
Special Tooling Required
Special Machinery
Many Spares Required to Support
High Life Cycle Cost
Susceptible to Entrained Solids
ENGINEER SPECIFIED VALVES

Valve Specifications
Body & Bonnet Material
Ball Materials
Seat Ring Materials
Stem Material
Bonnet Gasket Material
Soft Sealing Materials
Elastomeric Seals (AED)
Gland Packing Material
End Connections Type
Operator Type
ENGINEER SPECIFIED VALVES

TRUNNION MOUNTED BALL VALVES

PETROLVALVES BALL VALVES


trunnion mounted range offers high
integrity isolation. The high strength stem
is supported in Teflon / PTFE
impregnated steel bearings or hard faced
bearings and thrust control components.
The trunnion Stem as an integral or 2
piece assembly offers complete anti-
blowout protection.

Trunnion mounted stems absorb the


thrust from Line pressure. PTFE
bearings eliminate the need of
lubrication, they facilitate operations
and torque values are optimized during
valve cycling.
Slab
DISEOS DE ASIENTOS SUAVES

INSERTO SUAVE
ANILLO
METALICO
Secondary Seals

Single vs. Multiple point of contacts

Self relieving vs. double piston effect


Typical Primary and Secondary
Seat Sealing System Designs

Single Piston Effect Typical Seat Carriage


Typical Primary and Secondary
Seat Sealing System

PetrolValves preferred Seat


Single Piston Effect Sealing System
Typical Primary and Secondary
Seat Sealing System

Seat Design Variables Single Piston Effect Typical Seat Carriage


Soft Seals CARBON STEEL

Fire Seals
Pressure Energized
Mechanically Energized
Multi-Point Seals
Single Point Seals Single Piston Effect
Back-UpSingle Piston Effect 316 SST OVERLAY
Springs
Hard Facing Stellite,
Tungsten Carbide, Chromium
Carbide
Typical Primary and Secondary
Seat Sealing System

Seat Design Variables Single Piston Effect Typical Seat Carriage


Soft Seals
Fire Seals
Pressure Energized
Mechanically Energized
Multi-Point Seals
PetrolValves Preferred Seat
Single Point Seals Single Piston Effect Sealing System
Back-UpSingle Piston Effect Inconel 625 Overlay
Springs
Hard Facing Stellite,
Tungsten Carbide, Chromium
Carbide
Single point seal O-ring
Multipoint vs single point seal
Multipoint vs single point seal
SEAT DESIGN

Double Block and Bleed Valve


All PetrolValves valves are equipped with a pressure energised seat ring (at low
pressure positive sealing is guaranteed by springs behind the seat)

March 2001
SEAT DESIGN

Self Relieving Seat


Overpressure in the body cavity is automatically relieved by the seat

March 2001
Double Piston O-rings Seals
Double Piston O-rings Seals
EMERGENCY SEAT SEALING
PACKING (STEM)SEALS

EMERGENCY STEM SEALING


On request valves in size 2 inch (50 mm) and larger
can be provided for the injection of sealant to
establish an emergency seal in the stuffing box to
stem area. This seal offers an ability to control an
external emission in the event that normal
adjustments of the gland are no longer possible.
BUTT WELD END CONSIDERATIONS
Engineer Specified Valves Seminar

DOUBLE EXPANDING GATE VALVES


42" Class 1500

Double
Expanding
Gate Valves
True Double Block Applications
for Large Abrasive Content in Media
& Long Term High Integrity Isolation
DEGV
SPECIAL DOUBLE EXPANDING GATE VALVES

Extremely Special Duplex Valves


DOUBLE EXPANDING GATE VALVES

Features & Benefits:


High Integrity Isolation
True Double Block & Bleed
No Special Tools Required
No Elastomeric or Plastics Parts
Easily Serviced Reduced Time
Only: Bonnet Gasket & Packing
required to support a refurbish Op.
All main parts are interchangeable
DOUBLE EXPANDING GATE VALVES

Closed Position

WORKING PRINCIPLE
DEGV - close
DOUBLE EXPANDING GATE VALVES

Open Position

WORKING PRINCIPLE
DEGV open
DOUBLE EXPANDING GATE VALVES

Closure Member Wedge Segments Design & Construction

The Standard PETROLVALVES Female Segment


EXHIBIT
A3
DOUBLE EXPANDING GATE VALVES

Operational Advantages
Less overall weight with one valve for Double Block & Bleed applications
Negligible pressure drop
Block, bleed, and drain in the open or close position, while valve is in service
Test seat seal reliability prior to shutdown
Bi-directional flow (complete size & range)
Performs regardless of pressure origin
upstream
downstream
body cavity
DOUBLE EXPANDING GATE VALVES

Operational Advantages (cont)


Downstream seat is not continuously exposed to:
Erosion.
Abrasion.
High Temperature.
Sediment, Scale or Other entrained solids
Fire safe construction
Piggable design
PV seat design (patent) results in low contact between mating surfaces and
offers extended life of seat sealing surfaces
Body cavity isolated when Open or Closed
Can accommodate any kind of load generated by the adjoining pipeline
without affecting seat seal performance and operability
Axial thrust
Bending moment
DEGV's Isolation Principals

Upstream Pressure Upstream + cavity Upstream + downstream Body cavity Pressure


Pressure Pressure (valve closed) (valve closed)

Down stream Downstream + cavity Upstream + downstream


Pressure Pressure Pressure (valve open)
FEA & DESIGN OF DOUBLE EXPANDING GATE VALVES

DESIGN

FEA analysis
Valve body mesh

Body/bonnet model:
17,000 elements
27,000 nodes
82,000 degrees of freedom

December 2000 Super SAP- 3D CAD DRAW


FEA & DESIGN OF DOUBLE EXPANDING GATE VALVES

DESIGN

FEA analysis with pressurised body


Valve body/bonnet stress distribution

Valve body/bonnet displacements

December 2000
FEA & DESIGN OF DOUBLE EXPANDING GATE VALVES

DESIGN

FEA analysis with pressurised body + bending moment

Valve body displacements

Bonnet displacements

December 2000
FEA & DESIGN OF DOUBLE EXPANDING GATE VALVES

DESIGN

FEA analysis of trim components

Valve trim mesh


Valve trim stress plot
Valve trim displacements

December 2000
HARD FACINGS FOR DOUBLE EXPANDING GATE VALVES

Metal Hard facing Options

Tungsten Carbides Hard facing


up to 750 f
Chromium Carbides Hard facing
up to 1200 f
Ceramic Overlay
up to 1300 f

HVOF

Application process
HARD FACINGS FOR DOUBLE EXPANDING GATE VALVES

HVOF (High Velocity Oxygenated Fuel)


NDT FOR DOUBLE EXPANDING GATE VALVES

NDT
Non Destructive Material Test
(Standard and Requested)
RT/UT/MT on body and bonnet
UT on billets (forged body)
LP on finished surface
Other test available upon request
Non Destructive Pressure Test
Shell& Bi-Directional Seat Gas testing
High / Low temperature test
Other Test
PerformanceTest (cycling/endurance test)
Bending moment

Background: Hyperbaric Testing


MAINTENANCE FOR DOUBLE EXPANDING GATE VALVES

Maintenance Advantages
Extended Operating Cycles / Less Down Time Due to
PetrolValves Design:

Both Seats Protected with Valve in Open Position


against Media Dynamics During Operations

Minimal Seat Surface Contact Pressure during Cycling

PV Centralizer design Minimizes Friction during Cycling

Logistics Advantage to Support Valve with Spare Parts

No Special Tooling Required to Dis-Assemble Valve


MAINTENANCE FOR DOUBLE EXPANDING GATE VALVES

Maintenance Advantages
No Special Machinery Required for Refurbishment

Fully Serviceable In Line (Top Entry Access)

All Trim Components Easily Renewed

Reduced Refurbishment Time

Small Requirement for Spare Parts to Support in Field

Expensive Components Always Re-usable


DOUBLE EXPANDING GATE VALVES

General Advantages
Longer Valve Life Cycle
Reduced Life Cycle Costs
Longer Operations Periods Between Turnarounds
Long Term High Integrity Isolation Continuity
Designed for Easy Field Serviceability
World Wide Service Presence
Dedicated Spare Parts Available to PV Service
Global Field Technical Support
Trained Product Specialist Field Service Engineers
Engineer Specified Valves Seminar

EXPANDING PARALLEL SLIDE GATE VALVES

Expanding Parallel
Slide Gate Valve

Single Expanding Gate Valve


Single Expanding Gate Segments
SINGLE EXPANDING GATE VALVES
TRUE DOUBLE BLOCK & BLEED VALVE TYPES

Only Two Valve Types Meet the Requirements of Norsok: Single & Double Expanding
Gate Valves
Single Expanding Gate Valves Double Expanding Gate Valves
EXPANDING PARALLEL SLIDE GATE VALVES

True Double Block & Bleed Isolation + 100% Fire Safe

Soft Seat insert option


Metal Seated Options
Screw in Seat Rings with
Threaded Pocket Soft Seals
Seal Welded Seat Ring Option
In Line Lapping of Metal Seats
New Seats install without the
need to perform any re-fitting
Exercises in line or in the Workshop
Less Spare Parts Required for
Refurbishment Exercises.
Reduced Refurbishment Time
No special Tooling or Machinery
Required to Support Field
Refurbishment Exercises.
Single expanding Gate
Typical ANSI
300
Bolted Bonnet
Parallel Slide
Gate Valve
Norsk Hydro Oseberg Project

5.1/8" API 5,000 Slab Gate with FSC Hydraulic Act


Norsk Hydro Oseberg Project

5.1/8" API 5,000 Slab Gate with FSC Hydraulic Act


High
performance
ball valve
Buried Service
Engineer Specified Valves Seminar

DOUBLE BLOCK & BLEED VALVES


Double Block and Bleed
(Extracts from API-6D and Norsok Standards)
API-6D, Section 1, Scope.

1.3. Definitions (page 6).

Bidirectional Valve: A valve designed for sealing in either direction.

Block Valve: A gate, plug or ball valve that prevents flow or leakage into the
downstream conduit when in the close position. Valves shall be single or double seated,
bidirectional or unidirectional.

Double Block and Bleed Valve: A valve with two seating surfaces which, in close
position, provides blockage of flow from both valve ends when the cavity between the
seating surfaces is vented or drained. A means shall be provided for draining or venting
the cavity between the seating surfaces.

Unidirectional Valve: A valve designed for sealing in one direction only.


API-6D, Section 5, Tests. - 5.3. Hydrostatic Seat Test (page 27) and,
API-6D, Appendix C, Supplemental Test Requirements.
- C3. Air Seat Test (page 45).
- (Also see Supplement 2 for Revisions)
c. Block Valves.
1) Unidirectional. Close valve and apply pressure to the
appropriate end of the valve.
2) Directional. Close valve and apply pressure successively to
each end of the valve.
d. Double Block and Bleed Valves. The test sequence is optional;
however, both of the following tests shall be performed.
1) Close valve, open body vent, apply seat test pressure to one
end of the valve. Release pressure and repeat test for the other
end of the valve.
2) Close valve, open body vent, apply seat test pressure
simultaneously to both end of the valve.
NORSOK

Double Block & Bleed. Two barriers with a bleed between the
barriers. Typical arrangement is two block valves with a bleed
valve in the middle. Double block and bleed as defined in ISO DIS-
14313, and adopted by some valve manufacturers, is not according
to the definition in this NORSOK standard. A single valve is
acceptable as double block and bleed only if the force acting on the
seal faces is independent of system pressure, and if a bleed
connection is provided between the two seal faces (typically a
double expanding gate valve). Further, such a valve must be
lockable in closed position to avoid malfunction or maloperation.
For more information Go to: http://www.nts.no/norsok then, go to
NORSOK Standards P-Process p-001, Process Design, Rev
4, Oct 1999 Definitions Double block and Bleed.
Typical Double block and bleed Valve designs
For pipeline Applications
API-6D
Valve Type Seat Design Characteristic Design
Block Direction

Single Point Self Relieving (5) Yes One block on each direction

Two block on each direction


Ball,
Sealing Double Piston (5) Yes (Limitations on Ratings and Services)
Trunnion (1)
Multipoint Self Relieving (6) Yes One block on each direction

Sealing Double Piston (6) Yes Two block on each direction

Slab Gate (1) Same as Trunnion Ball Yes Same as Trunnion Ball

Expanding Double Expansion (4) Yes Two block on each direction

Gate (2)
Single Expansion (3) Yes (3) Two block on each direction
DOUBLE BLOCK & BLEED VALVES

CONFORMING TO API
Double Expanding Gate

Thru Conduit Slab Gate


Reduced & Full Bore Ball
Expanding Parallel Slide Gate Valve

TRUE DOUBLE BLOCK & BLEED VALVES


Double Expanding Gate Valve

Expanding Parallel Slide Gate Valve


TRADITIONAL DOUBLE BLOCK & BLEED ARRANGEMENT

DOUBLE BLOCK & BLEED IN ACCORDANCE WITH API

Typical Field API Double Block & Bleed Arrangement.

VENT
Pool
TRADITIONAL DOUBLE BLOCK & BLEED ARRANGEMENT

DOUBLE BLOCK & BLEED IN ACCORDANCE WITH API

Typical Field API Double Block & Bleed Arrangement.

VENT
MODERN DOUBLE BLOCK & BLEED ARRANGEMENT

TRUE DOUBLE BLOCK & BLEED

Typical Field Double Block & Bleed Arrangement.


COST, SPACE & WEIGHT SAVING SOLUTIONS

One Double Expanding Gate Valve Substitutes 2 Ball Valves

Up-Stream Seal Down-Stream Seal


Engineer Specified Valves Seminar

Questions & Answers


INSIDE ANSI
SIZE SIZE INSIDE API- API 6D
DIAMETER 70-2 (1000
(inches) (Metric) DIAMETER *** 5208 Rate B ** Rate D
(API-6D)* PSID)

(ml/min (ml/min (ml/min


(mm) (INCHES)
) ) )

2 50 49 1.93 0.03 0.31 0.96

3 80 74 2.91 0.04 0.46 1.46

4 100 100 3.94 0.06 0.61 1.97

6 150 150 5.91 0.09 0.91 2.95

8 200 201 7.91 0.12 1.21 3.96

10 250 252 9.92 0.15 1.52 4.96

12 300 303 11.93 0.18 1.83 5.96

14 350 334 13.15 0.20 2.14 6.57

16 400 385 15.16 0.23 2.44 7.58


410 SST vs 316 SST
Mechanical Properties

Material 0,2% yield Tens Elong Reduct Hard


strength min ile ation in 50 ion in area ness
Designa
tion (Mpa/psi) Strength mm min Max.
min. min (2inch) (%) Brinel
(psi) (%) min. min. l
min.
410 sst
60k 414/600 85 18 35 390
00 000 Hb
316 sst (204 c)

30k 205/300 75 54 80 217


Rb
00 000 200 F 200 F
(95)
HVOF PROCESS
HVOF COATING