fugitive emissions standards & laboratory test …...common valve test standards • api 624,...
TRANSCRIPT
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Fugitive Emissions Standards & Laboratory Test Methods
for Valves
By: Greg JohnsonPresident, United Valve
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50 Years in 50 Seconds
1964 Houston air pollution Measuring air pollution in 1974
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50 Years in 50 Seconds
“The air is greener in Pasadena”
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50 Years in 50 Seconds
Not anymore!
Thanks to the the end-users, valve manufacturers,
valve service companies, leak abatement firms,
packing manufacturers and everyone who had a
hand in cleaning our air!
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The past 20 years
• End-users pushed the
valve manufacturers
through the API
• Initial tests were based
upon Method 21
• First US industry valve test
standard was
ANSI/ISA SP93.00.01 in
1999
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Testing standards
• MSS created a
packing test
standard in 1997
• First API test
standard – API 622,
packing test, 2006
• API 624, 2014
• API 641, 2016
• ISO 15848-1, 2006
First United Valve FE test- 2001
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What Makes a Valve Low-
emissions capable?
• FE containment Packing
• Little or no stem run-out
• Correct stem & stuffing box
finishes
• Correct dimensions &
tolerances of all packing
chamber components
• Proper torque on packing
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Dimensions & tolerances are critical for FE
containment
Stem
1) Diameter
2) Straightness
3) Runout
4) Finish
5) Cylindricity
Packing gland
1) ID
2) OD
Packing
1) ID
2) OD
3) For API, Must be
RP622
Bonnet
1) ID
2) OD
3) Finish
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Why We Test
• Repeatability is still a major
issue in low-cost manufacturing
countries
• Legacy designs do not address
the dimensions and tolerances
needed for Low-E packing
efficacy
• Some manufacturers still don’t
know how to achieve
repeatable Low-E compliance
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Common Valve Test Standards
• API 624, “Type Testing of Rising Stem Valves
Equipped With Graphite Packing for Fugitive
Emissions”
• API 641, “Type Testing of Quarter-turn Valves
for Fugitive Emissions”
• ISO 15848-1, “Industrial Valves- Measurement,
test, qualification procedures for fugitive
emissions” (type testing)
• End-user “type testing”
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API 624 – for Multi-turn valves
• Next edition (2nd) due out in 2018
• 3 thermal cycles @ 500o F
• 310 Mechanical cycles
• Both static and dynamic leakage
measurements
• Gasket leakage above 50 ppm
cause for rejection
• Maximum test pressure 600 psig
• Required by API 600, API 602, API
603, API 623 & RP591
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API 624 – for Multi-turn valves
Testing a 20” class 900 gate valve
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Typical API 624 set-ups
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Test software GUI interface
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API 641 – for Quarter-turn valves
• First edition 2016
• 3 thermal cycles
• 610 Mechanical cycles
• Both static and dynamic
measurements
• Multiple categories or “groups”
• Maximum test pressure 600 psig
• Not yet required by API ¼ turn design
standards API 599, API 608, API 609
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API 641 – for Quarter-turn valves
Testing ball valves to API 641
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ISO 15848-1
• “Cafeteria” style multiple classifications
– Tightness classes
– Endurance classes
– Temperature classes
• Primarily a helium procedure, but
methane is allowed
• Very popular for valves to be used in
the EU and China
• Used for valves that don’t fall under API
standards & testing criteria
• Used for control valves because of high
number of cycles
• ISO 15848-2 is a production test for
valves originally qualified to 15848-1
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Cryogenic FE testing
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Failure Modes
• Catastrophic bushing failure
– Galling & lock-up
– Total removal of threads because of poorly
machined components
• Stem scoring due to poorly machined or
out-of-tolerance parts
• Gross gasket leakage
• Lubricant dripping down from bushing
• Gross packing leakage due to poor
dimensions or tolerances
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Bushing Failure
Original bushing After threads gouged out
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Dripping lubricant
Not an issue when valves were tested in the stem
horizontal position
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Dimensions & tolerances are
extremely important
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Large linear valve issues
• Stem & flow horizontal – not good
• Potential for substantial FE leakage
• Side-loading of packing
• API 624 requires a stem vertical test
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API 624 – large valves
Component misalignment causes leaks
Yoke
Stuffing box
Backseat bushing
Disc to stem alignment
Body & disc guides
Yoke bushing or actuator mount
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Stem Horizontal Issue
Gravity
This side of packing can be over-
compressed
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API 624 – large valves
in horizontal service
Yoke bushing or actuator mount
Yoke
Stuffing box
Backseat bushingBody & disc guides
Stem to disc
“T-head” alignment
Cumulative errors in dimensions & tolerances are
can cause catastrophic packing failures
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Horizontal issues (cont.)
What about low emissions valves in
horizontal orientations? Some
Suggestions:
-Total misalignment of stem should be
less than 0.020” for most low E packings
to work.
-Double check all dimensions and
relational parts geometry
-Assemble or actuate the valve in the
stem vertical position
-Confirm damage free movement of stem
(cycle open and close)
-Optional: Perform an EPA method 21
type test- a low pressure gas test looking
for bubbles at the packing area
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A word about testing facilities
• All testing facilities are not created
equal
• It is not just equipment and
technicians
• Engineering experience and real-
world valve expertise are very
important
• End-user concern if “low-cost-
country” testing is allowed
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IMHO & Looking into
the crystal ball
• Helium will replace methane
as the test gas
• API will create a full-featured
type test standard that will
include high temperature FE
testing at working pressures
• API will create a helium
production test standard
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Questions?
The ultimate in leaky valve containment!