valves
TRANSCRIPT
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VALVESVALVES
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VALVE DEFINITION
VALVES ARE MECHANICAL DEVICES SPECIFICALLY DESIGNED TO:
•DIRECT
•START
•STOP
•MIX
•REGULATE
FLOW, PRESSURE OR TEMPERATURE OF A PROCESS FLUID
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• Valves can be designed to handle either LIQUID or GAS applications.
• Industrial Valves : Size 0.5” Nominal Dia (DN15) to 48” (DN1200).
• 90% of Valves are 4” (DN100) or smaller in size.
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SERVICEVacuum to over 13,000 psi (897 bar)
MATERIALS OF CONSTRUCTIONIron, Steel, Plastic, Brass, Bronze (or) a
number of special Alloys
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HISTORY
• In 1712, Englishman Thomas Newcomen invented a simple Iron Plug Valve, to regulate the flow of steam to the piston – The first known application of a Throttling valve.
• Corliss Steam Engine unveiled in 1876 was designed with Self-acting Control Valves.
• Invention of Crude oil as an inexpensive and plentiful form of power in early 19th century spawned the creation of Petroleum Refinery, Petrochemicals, Process Industries, Paper, Food, Beverage Industries creating need for various types of valves.
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VALVE CLASSIFICATION
a) Function classifications:• ON-OFF (Block valves) – Block or allow
flow• Non-return (Check valves) – Allow flow to
travel in one direction• Throttling (Full open to full close) –
Regulation of flow (Can be used as ON-OFF also)
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b) Application Classification:• General Service valves (Manual or
Automated) – -46oC to 343oC, Class 150 to 600, Non-corrosive applications.
• Special service – Custom engineered – High pressure, high temperature, corrosive/erosive medium.
• Severe service – Valves with special features to handle volatile applications, very high pressure drops, severe cavitation, flashing, choking, beyond 593oC, liquid Sodium applications.
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c) According to motion:• Linear motion – sliding stem design.• Rotary motion – through quarter turn or 45o
range to open or block the flow.
d) According to Port size:• Full port valves• Reduced port valves
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Other types of Valves
• Block & Bleed valves – To prevent intermixing of fluids (Fin Fan cooler, wash water systems)
• Butterfly valves – Water applications (AWWA standards)
• Blow-off valves – Steam systems
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TERMS AND DEFINITIONS
• ANSI rating class – Numerical pressure design class defined in ASME B 16.5 and used for reference purposes.
• ANSI rating class is designated by the word ‘CLASS’ followed by a number. Ex: Class 150.
• Bi-directional valve – Valve designed for blocking the fluid in both downstream and upstream direction.
• Bleed – drain or vent.• Block valve – Gate, Plug or Ball valve that blocks
flow to downstream when in closed position
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• Locking device – Part or an arrangement of parts for securing a valve in the open and (or) closed position.
• NPS – Nominal pipe size.• PN – Numerical pressure design class as defined
in ISO-7005-1. (PN followed by a number). Ex: PN16.
• Pressure containing parts – Parts such as body, bonnet, gland, stem, gasket, bolting designed to contain pipeline fluid.
• Process wetted parts – Parts exposed directly to pipeline fluid.
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ABBREVIATIONS
BM Base Metal
CE
Carbon Equivalent =
{%C+(%Mn/6)+(%Cr+%Mo+%V)/5+(%Ni+%Cu)/15}
Limit: 0.43 – Heat analysis, 0.45 – Product.
DBB Double Block and Bleed
DN Nominal Size
HAZ Heat Affected Zone
HR Rockwell Hardness
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HV Vickers Hardness
MPD Maximum Pressure Differential
MT Magnetic Particle Testing
NDE Non-Destructive Examination
NPS Nominal Pipe Size
NP Nominal Pressure
WPS Welding Procedure Specification
PQR Procedure Qualification Record
WQR Welder Qualification Record
WM Weld Metal
PT Penetrant Testing
PWHT Post Weld Heat Treatment
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ANSI PRESSURE CLASSPOUNDS OF FORCE PER SQUARE INCH OF SURFACE AREA
NOMINAL PRESSURE – ALLOWABLE
PRESSURE IN BAR
150 16
300 40
600 100
900 160
1500 250
2500 400
4500 700
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VALVE SELECTION
• Valve co-efficient or Flow co-efficient
Cv = Flow X m sqrt Sp. Gravity at flowing temperature / pressure drop
Cv = One US gallon (3.78 litres) of 60oF (16oC) water that flows through an opening (valve) during 1 minute with a 1 psi (0.1 bar) pressure drop
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END CONNECTIONS
• Threaded (1.5” and smaller sizes) (NPT)
• Flanged End (2” and larger) – Integral, separable
• Welded End (Class 900 and higher) – Socket welded (2” and smaller), Butt welded (3” and higher)
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PRESSURE CLASSES
• Six standard classes – 150, 300, 600, 900, 1500 or 2500 – As per B 16.34 standard
• Special classes – 15, 4500 Etc.
• Intermediate classes – Ex. 3300 (CS valve for 150oC, 450 bar)
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Casting Quality Factors
• ASME Codes / B 16.34
Especially for corrosive, high pressure, high temperature applications
• Level – 1
• Level – 2
• Level – 3
• Level indicates severity levels of imperfections
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Casting imperfections include
• A – Gas porosity
• B – Sand, slag inclusions
• C – Shrinkage
• D – Cracks
• E – Hot tears
• F – Inserts
• G – Mottling
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Examination of Steel castings are done as per
• ASME Sec:VIII Div:1 Mandatory Appendix:7
• ANSI B 16.5
• ANSI B 16.34
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Radiographic examination standardsThickness Standard
Up to 2” (51 mm)ASTM E 446
(Std Reference Radiographs)
2” – 4.5” (51-114 mm)ASTM E 186
(Std Reference Radiographs)
4.5” – 12” (114mm-305mm)
ASTM E 280
(Std Reference Radiographs)
Above 12”ASTM E 280 / UT exam is
done
RT spotsAs per sketch in B 16.34
standards
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VALVE MANUFACTURING
• Valve design• Pattern development• Establish methoding process with Statistical
Quality Control• Pilot casting• Tests / Acceptance standards• Fix quality factors• Machining of castings
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• Bought out items (other items like stem, gasket, packing, fasteners, hand wheel, disc, yoke, seat ring)
• Assembly
• Testing
• Marking / Punching
• Despatch
• VTR / Release note of TPI
• Spares, valve key Etc.
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MATERIAL
• Carbon Steel – up to 425oC
• Chrome-Moly Steel – Corrosive, H2S environment
• SS - >535oC, high temperature, corrosive applications
• A216 WCB (CS), A217 C5 (AS), A351 CF8M, CF3M (SS)
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TRIM MATERIAL
API 600 Trim No.
Service StemBody seat
ringWedge
Back seat bush
8MP / LP Steam
SS 410 RC22 max
Body MOC +
HF
Body MOC + 13% Cr
RC22 max
SS 410 RC22 max
12Corrosive
serviceSS 316
Body MOC +
HF
Body MOC + SS 316 RC22
max
SS 316 RC22 max
5 HP Steam Both body seat / wedge is Stellited.
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MATERIAL TESTING
• Chemical composition – basic, alloying elements
• Mechanical properties – UTS, YS, % elongation, hardness Etc.
• Special properties – Impact, high corrosion resistant properties Etc.
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Various Heat Treatment processes conducted in valve manufacturing
• Normalizing
• Hardening
• Annealing
• Tempering
• Solution Annealing
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EXAMINATIONS
• Visual
• Liquid Penetrant
• Magnetic particle examination
• Radiography
• Ultrasonic examination
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TEST PROCEDURE – API 600• Gate valve : Shell
BackseatAir seatHydro seat
• Globe valve : ShellBackseatAir seatHydro seat
• Check valve : ShellHigh pressure closure testLow pressure closure testLow pressure air seat test
(optional)
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REPAIR
• Weld repairs should be approved by TPI / Client
• WPS / PQR / Welder qualifications – check
• NDT
• Post weld heat treatment
• Tests as above
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Gasket Selection
• Purpose : Prevent leakage from joint
Prevent leakage to atmosphere
Allow function of internal mechanism• Material / : CAF, Spiral Wound, Ring Joint type
types
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PACKING
Any soft material encased in a bonnet or in a body used to seal a valve closure elements stem or shaft is called packing. It is held by a packing follower or guides.
Ex: Graffoil, Impregnated Graffoil Etc.
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CLOSING ELEMENTS
• GATE
• GLOBE
• BALL
• PLUG
• BUTTERFLY Etc.
TYPES OF OPERATION• MANUAL
• GEAR OPERATED
• ACTUATOR OPERATED
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COMMON VALVE PROBLEMS
• High pressure drop – Result in cavitation, flashing, choked flow, high noise levels, vibrations.
• Water hammer effects – Due to sudden stoppage of flow, shock waves are generated, avoid sudden pressure surges.
• Erosion, Corrosion• Defects, leaks (Gland leaks)• Operational issues – closing, opening Etc.
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ACCREDITATIONS
• API – Monogram
API – 6D for Gate, Plug, Ball, Check valves
• ISO – 9001
• ISO – 14000
• IBR / EIL, TDC, TPI approvals
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Purchasing Issues
• Valve data sheet• Drawing• Specifications• QAP• Stage / Final inspections• Storage, Installation• Spares• Warranty, Guarantee issues• Vendor surveys for enlistment
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INSTALLATION
• For best performance, it is recommended that Gate, Globe valves are installed in vertical position with the stem operating end at the top, horizontal or at an angle in between.
• Swing check valves can be installed in vertical or horizontal pipelines. However, in vertical pipelines the flow should always be in the upward direction.
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• Swing check valves should never be installed at the outlet of a Reciprocating pump – as the pulsating flow will damage internals of the valve.
• Gate valves have bi-directional capabilities and can be installed in any direction.
• Globe valves to be installed in the direction of arrow.
• Check valves are unidirectional. Flow direction and arrow direction should coincide.
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OPERATION• GATE VALVES : Should be fully open or fully
closed. Throttling will cause wire drawing at seating area leading to damage, leak. Clockwise: close, anticlockwise: open.
• GLOBE VALVES : Used for throttling. It is advisable not to use Globe valves for flow control below 10% of full opening. Clockwise: close, anticlockwise: open.
• CHECK VALVES : All are swing type which automatically open by the velocity pressure of flow and close by the gravitational force when flow reverses or stops.
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Maintenance Issues
• Periodical cleaning, flushing, greasing
• Check gear box, actuator mechanisms
• Installation issues
• Online leak arresting (clamps, cold repairs Etc.)
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PARTS
• Disc and Seat that directly affect the flow
• Stem that moves the Disc
• Body and Bonnet that house the Stem / internal parts
• Operator that moves the Stem
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DESIGN / TESTING CODES
VALVE DESIGN TESTING
GATEAPI 600, BS 1414,
DIN 3202 API 598, ANSI B 16.34,
BS 6755,
DIN 3230
GLOBE BS 5352
CHECKBS 5352 (Forged) /
BS 1868 (Cast)
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Other relevant Standards include:
• API 6D – Petroleum & Natural Gas Industries – Pipeline Transportation Systems – Pipeline Valves
• ASME B 16.5 – Pipe flanges and flanged fittings (1/2” to 24”)
• ASME B 16.10 – Face to face and end to end dimensions of valves
• ASME B 16.25 – Butt welded ends
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• ASME B 16.34 – Flanged, threaded and welding ends.
• ASME B 16.47 – Large Dia steel flanges (26” to 60”)
• NACE TM 0284 – HIC testing
• NACE MR0175 – Sulfide Stress Cracking resistant metallic materials for oil field equipment
• API 6 FD / API 607 – Fire safe testing of valves
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PRESERVATION
• End caps
• Water ingress
• Check prior to installation
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Special Applications
• NACE – MR0175
• IBR – FORM - III C
• AWWA Stds. – Water applications
• Custom designed – PAREX rotary valves
• Cryogenic applications – very low temperatures : N2, LPG (-180oC)
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TRACEABILITY
• Manufacturer Name Plate
• Heat No. / Lot No. / Sl. No.
• Size / Rating
• W.O. No.
• VTR / Release Note of TPI
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Famous / Approved Manufacturers
• AUDCO
• KSB
• FOURESS
• SANMAR
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COST ASPECTS
• Size, Rating
• Additional Features (Gear, Actuator)
• Special Requirements (NACE, RT Quality)
• Location of Supplier vs. User
• Mandatory Requirements
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QUESTIONS / VALIDATION:
• What is a Valve?• What is the purpose of a Valve?• What are types of Valves?• What are the Design/Testing standards?• What NDT are done in manufacturing stage?• What is AWWA Std? Where is it applicable?• What is Cv?• What are Appurtenances for valves? Name any 03.• What are different types of ends of valves?• What are NACE application Standards?• What is an IBR valve? What is the Form No.?
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THANK YOUTHANK YOU