Emissions Testing WebinarGreg Cole, Luke Norton, and Cameron Rapoport

February 12th, 2016

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Introduction Cameron Rapoport

Field Product Manager, Stationary Equipment Solutions Gregory Cole

Design Engineer II Lucas Norton

Design Engineer II

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Why test? Clean Air Act (CAA) – 1970

Method 21/LDAR – 1980s Fines/consent decrees

End-users develop testing OEMs develop testing API/ISO/TA-Luft develop standards Modern driving factors

Environmental Awareness Legislation

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API 622

Currently the Second edition (2011) “Type Testing of Process Valve Packing for Fugitive Emissions” 3 Test Sections

Emissions Test Corrosion Test Packing Materials Test

Emissions test rig based on 4” 300# Gate Valve Not valve specific Required for packing used in API 624 tested valves

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API 622 Emissions Test

1510 Mechanical Cycles 5 Thermal Cycles 6 Days

Test Pressure: 600 psig Test Temp: 500°F Methane

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API 622 (cont.)

Leak Detection Method: EPA Method 21 Static leakage readings Performance test, not Pass/Fail Allows for 500ppm Leakage and 1 Re-torque Corrosion test

Evaluates effect of inhibitor systems Uses replicated valve stem specimen (410 Stainless Steel)

Material test Weight loss, density, wet lubricant/PTFE content, leachable chlorides and

fluorides. Future

100ppm No re-torques Additional Test Rigs (different cross-sections)

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API 624

First Edition (2014) “Type Testing of Rising Stem Valves Equipped with Graphite

Packing for Fugitive Emissions” Type testing of a specific valve Intended for rising and rising/rotating block valves Is (or will be) required for API 600, 602, 603, and 623 valves Utilizes EPA Method 21 leak detection method Valve orientation: vertical Static and dynamic leakage measurements Tests leakage from body/bonnet connection and packing

stuffing box

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API 624 (cont.)

310 mechanical cycles 3 thermal cycles 4 days Test Temp: 500°F Test Pressure: 600 psig or

rated pressure per ASME B16.34 at 500°F

Methane 100ppm Zero re-torques

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API 624 Valves Qualified

API 602 NPS ¾ Class 800 tested valve

qualifies NPS 1 and smaller up to and including 800 class

NPS 1 ½ Class 800 tested valve qualifies NPS 1 ¼ through NPS 2 ½ up to and including 800 class

NPS ¾ Class 1500 tested valve qualifies NPS 1 and smaller in class 1500

NPS 1 ½ Class 1500 tested valve qualifies NPS 1 ¼ through NPS 2 ½ in class 1500

All other valves API 600, 603, 623 NPS 4 qualifies all valves up to

NPS 4 and one NPS larger for the tested pressure class, and one pressure class lower

Larger than NPS 4 qualifies valves two NPS smaller and one NPS larger for the tested pressure class, and one pressure class lower

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ISO 15848-1

Second Edition (2015) Test procedure for evaluation of external leakage of stem seal

and body joint of different valve designs intended for use where fugitive emissions standards are specified

Covers both Block and Control valves High and Low temperature testing High and Low cycling applications Various leakage classes Helium or methane as a test fluid. Test pressure dependent on valve pressure class Re-torques Allowed

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ISO 15848-1 (cont.)

Media: Helium Leakage Class (volumic):

AH: 1.78x10-7 mbar*l*s-1/mm BH: 1.78x10-6 mbar*l*s-1/mm CH: 1.78x10-4 mbar*l*s-1/mm

Valve type: Control Endurance Class:

CC1: 20,000 cycles CC2: 60,000 cycles CC3: 100,000 cycles

Media: Methane Leakage Class:

AM: 50ppm BM: 100ppm CM: 500ppm

Valve Type: Block Endurance Class:

CO1: 205 cycles CO2: 1,500 cycles CO3: 2,500 cycles

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ISO-15848-1 (cont.)

Temperature Classes -196°C -46°C Room temperature 200°C 400°C

Leak Detection Methods Vacuum (helium) Bagging (helium) Sniffing (helium and

methane)

Retorques 1 allowed per endurance class Must be recorded as a stem seal adjustment (SSA) in the report and

marking Marking

Example 1: ISO FE BH – CO1 – SSA1 – t200°C – CL300 – ISO15848-1 Example 2: ISO FE AM – CC2 – SSA2 – t200°C – CL150 – ISO15848-1 Example 3: ISO FE CH – CO3 – SSA3 – t400°C – (30/20) – ISO15848-1

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TA-Luft

“Technische Anleitung zur Reinhaltung der Luft” (Technical Instructions on Air Quality Control)

VDI 2440 Media: Helium Pressure: Class of valve Temp: max. operating temp of valve Mechanical cycles: “representative” Collection method: vacuum Acceptable leakage: 10-4 mbar x l/(s x m) up to 250°C, 10-2 mbar

x l/(s x m) at or over 250°C 1 retorque