ivs2017 final presentation session12_strategies to api 624 qualification

Strategies to API 624 Qualification

Pramod Kalyani

Kalson Engineering Solutions,

INDIA

IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies

May, 24th and 25th 20171

AGENDA



Requirements of API 624

Planning for In-house Test Bench

Design Assembly Guideline

Third Party Labs for final Verification.

AGENDA







Methane a significant contributor to global warming

• Methane is a key component of natural gas and is 25 times stronger

than carbon dioxide when it comes to trapping heat in the atmosphere.

Read more at: https://phys.org/news/2015-08-methane-oil-gas-industry.html#jCp

10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 4

VALVES a significant contribute to VOC


EPA CONSENT DECREE & API 624


• EPA implements “consent decrees” on refinery and chemical processing end users

-Include fines for emissions over established limits

-Requires implementation of LDAR (leak detection and repair) programs

-Leads to low FE-requirements for valves and sealing systems

• EPA Consent Decree New Equipment Upgrade Requirement

-Newly installed valves must be Low-E

-Repack or replace with Low-E for Valves that leak above 250 PPMv (Chemical)

-Repack or replace with Low-E for Valves that leak above 500 PPMv (Refinery)

• Industry defines low FE products by Complying to API FE Test Standard,

-API 622: Type Testing of Valve Packing for FE Released in August 2006, 2nd edition

October 2011

- API 624: Type Testing of Valves Equipped with Graphite Packing for FE Released in

February 2014.


EPA CONSENT DECREE & API 624

REQUIREMENTS OF API 624


Title and Edition

Type Testing of Rising Stem Valves Equipped

with Graphite Packing for Fugitive Emissions,

First Edition

DateStandard by the American Petroleum Institute,

02/01/2014

Pass Criterialeakage throughout the test does not exceed 100

PPMv

Packing Adjustment None allowed


Media Methane 97% minimum purity

Temperature500°F (260°C)

Optional Low Temperature Test at -20° F

Pressure 600 psig (41.4bar-g)

Number of Valve Stem

Actuations310

Number of Thermal

Cycles3



Leak Measurement

MethodEPA Method 21

Stem Orientation Stem is oriented in vertical position

Leak Measurement

Details

Leak measurements are sniffed using a detection

probe. Done with stem in static and dynamic states

Leak Measurement

Frequency Every 50 actuations of the stem


API 624 ACTUATION- WE REFER API622

• The test valve may be equipped with a method of actuation capable

of stroking the stem to simulate the mechanical cycle of a valve at

the rate of 3 mm to 5 mm (0.04 in. to 0.20 in.) per second.

• The method of actuation should not impose additional side loads on

the stem or packing.

• Running torque values shall be recorded on the first and last cycle of

testing.

11

API624 VALVES QUALIFIED

All valves of the same basic design as the test valve may be deemed

to have been type tested, subject to the following additional limitations:

• For API 602 valves, a NPS ¾ class 800 test valve may be used to

qualify all valves NPS 1 and smaller valves up to and including class

800.

• For API 602valves, a NPS 1-1/2 class 800 test valve may be used to

qualify all valves NPS 1-1/4 through NPS 2-1/2 up to and including

class 1500.

12

For all other valves, a test valve may be used to qualify valves from

two nominal sizes smaller to one nominal size larger and one pressure

class lower than the test valve.

13

API624 VALVES QUALIFIED

API624 VALVES QUALIFIED-REQUALIFICATION

Any change in valve stem sealing system design including, but not

limited to, packing material, packing manufacturer, or packing

type/model requires a re-qualification.

If the location of the valve manufacturing facilities is different than

what is listed on the API 624 certificate, the purchaser may request

requalification

14

Valve shall be disassembled and

components; including stem, packing,

stem nut, gland follower, and stuffing

box; shall be inspected and condition

documented.

Sealing components shall be

photographed in accordance with

section 9.4.

15

API624 Post-test Inspection

API624 Post-test Inspection

16

API624 Recording and Documentation

As a minimum, test results shall be provided on the Fugitive

Emissions Test Report provided in Appendix A.

Valves qualified by this standard shall be clearly and

permanently marked as “API 624”.

17

AGENDA







IN-HOUSE TEST BENCH API624 FE TEST

Sr.No Component Description Qty

1 Valve Holding Structure including Crane for support 1

2 Motor/Electric Actuator 1

3 Limit Switches Non-Contact Type (Open Close) 2

4 Torque Transducer 1

5 Heating Jacket 1

6 Leakage Monitoring Device with Calibration Set up 1

7 Test Gas Methane 97% Purity 1

8 Purging Nitrogen Gas 1

9 Piping and regulator set 1

10 Data Logger 1

11 Thermocouples for temperature measurement 3


Figure 1. Technician uses Method 21 to monitor

leakage. Photo courtesy of GreatWeld Engineering

Pvt.Limited,India.


Leak Measurement Devices based on API 624 and EPA

Method 21.

Leakage Detection Techniques

The following point detection techniques were identified

Ionization/Ion Mobility

Spectrometry.

Flame Photometry.

Infrared Spectroscopy.

Electrochemistry.

Colorimetric.

Surface Acoustic Wave.

Photoionization Detection.

Thermal and Electrical Conductivity.

Flame Ionization.

Polymer Composite Detection Materials

21

Leak Measurement Devices based on API 624 and EPA

Method 21.

Standard API624 EPA Method 21

Monitoring

Instrument

Detector type

Section7.

Flame Ionization

Section 3.1.1.

Detector types which may

meet this requirement include, but are not

limited to, catalytic oxidation, flame

ionization, infrared absorption, and

photoionization.

Device Make Thermo-Scientific

TVA2020

SENSIT® GOLD G2

Price ~12000$ ~2500$


23

Methane Leak Detection Principle-FID

Methane Leak Detection Principle-Electrochemistry

24

AGENDA







# Aspect Description Illustration Advantages

1 Fine

Threads

with Close

Tolerance

▪ Threaded Ring-Bonnet prefer a fine

thread pitch and closer tolerance.

▪ Fine Threading and Closure

Tolerance will improve centering

and reduce side loads on stem

and packing.

2 Controlled

and

Reduced

Diametrical

clearance

▪ Try to have minimum diametrical

clearance in following mating parts

▪ Stem Nut-Threaded Ring-

Bonnet.

▪ Stem-Bonnet

▪ Bonnet-Body

▪ Bonnet-Packing-Stem (radial

clearance to 0.1)

▪ Bonnet-Backseat-Stem

▪ Closer and tight tolerances

between mating parts will

improve guide and bearing

support to Stem and better

alignment during dynamic mode.

▪ Tighter clearance requirements

between Stem and Packing Gland

than API 600 may be required.


Design Guideline


3 Stem to Bonnet

Stem Housing

Support

▪ Additional Spacer between Stem

and bonnet

▪ Reduce Stem Contact with Bonnet

stem housing will reduce

possibility of valve stem scoring.

4 Packing Bolt

Location

▪ Eye bolt distance from center of

Stem try to keep minimum.

▪ Material of bolt / nut B7

▪ Closer positioning of packing bolt

improved force distribution and

sealing performance.


Design Guideline


5 Backseat Design ▪ Provide Guide at the end to ensure

better alignment or centring

▪ Provide Tack weld

▪ Better Centering of Backseat.

▪ Improved support to Stem.

▪ Tack Weld ensures no loosening of

backseat.

6 Stem ▪ Provide Hard Chrome Plating 20

m

▪ Tempering temp-450C hardness 30-

40HRC.

▪ Good Surface Finish is Key.

▪ Runout, Circularity, and

Straightness tolerances to be

achieved.

▪ Thread tolerance can be changed to

5C instead of 2G

▪ When the stem or Stem is closing

the valves, bending, shifting,

twisting can

occur so stem to be designed with

adequate strength.

▪ Improved surface finish, hardness

and controlled Circularity, Runout

and Straightness will improve

sealing performance.


Design Guideline

Design Guideline


7 Stem Nut-Stem

Lubrication

▪ Stem is oriented in vertical position

which can allow yoke bushing

grease to travel down stem to

packing area.

▪ Selection of proper Stem & Stud

grease becomes critical due to

thermal parameters.

▪ DUALCO GSVL grease claims to

have bulky viscosity with extreme

pressure lubricant with excellent

high and low temperature

properties.

8 Bolt

Lubrication

• Apply anti-seize lubricant to gland

stud threads, nuts, and hardened

washers.

▪ JET LUBE 550 eXtreme is good

anti-seize lubricant which you

might consider.


Design Guideline


9 Tightening

Torque Packing

Gland Bolt &

Nut.

Overtightening

might result in

Stem failure at

high

temperature;

Inadequate

tightening result

in packing

consolidation.

▪ Get formula for torque from

Packing manufacture (not all the

same)

▪ Use a calibrated torque wrench

▪ Torque alternately between gland

nuts to not cock the gland which

could cause valve stem scoring or

uneven loading of the packing set.

▪ Ensure proper levelling of gland

load

▪ Hardened washers should be

utilized under the gland nuts .

Arrow Illustrate force

transmission.

▪ Ensures No substantial increase in

packing friction at high temperature

thereby no increase in stem torque.

▪ No packing consolidation and

hence no leakage.

▪ To maintain even gland load on the

packing set over time, a live-load

spring assembly also can be used.


Packing Gland Assembly Guideline


1

0

Packing Gland

Assembly &

Proper leveling

of Gland load

▪ 5 rings only need to seal, more

rings less sealing

▪ Seat each ring individually This

procedure eliminates the need to re-

pack or re-torque and vastly

enhances the life of the seals.

▪ If the gland follower is not long

enough to reach the bottom of the

stuffing box, a tamping tool or an

extension ring must be used during

this installation step.

▪ Actuate the valve multiple times

▪ Retighten with torque wrench

▪ If any movement of the nuts

(consolidation), repeat actuation

steps until no movement at the

recommended torque.

▪ This will help to have uniform

gland load and better sealing

performance.


AGENDA







Third Party Labs for final Verification

1. YARMOUTH RESEARCH AND TECHNOLOGY, LLC

o 434 WALNUT HILL ROAD, NORTH YARMOUTH, ME 04097 USA

o PHONE: (207) 829-5359

o [email protected]

o WWW.YARMOUTHRESEARCH.COM

2. UNITED VALVE

o 9916 Gulf Freeway, Houston, TX 77034-1045

o 1-888-715-5093

o 713-944-9852

o Fax: 713-944-5964

o WWW.UNITEDVALVE.COM


CONCLUSION

• We covered briefly requirement of API 624 and strategies which will

be helpful in API 624 compliance. This is just my experience and I

am sure there would be other strategies which might also be helpful.

• I would solicit reader’s judgement and wisdom to interpret and apply

my experience to develop in house test setup for API 624 FE test

and design modifications if necessary to pass the test.
