Valves 101. Gobind Khiani, P.Eng, Fluor Canada Ltd Fluor. All Rights Reserved.

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1 Valves 101 Gobind Khiani, P.Eng, Fluor Canada Ltd. 2014

2 Disclaimer The contents of this presentation are intended for educational purposes only and do not replace independent professional judgment. They do not constitute advice and should not be relied upon in making (or refraining from making) any decision. Statement of fact and opinions expressed are those of the speaker alone and are not the opinion or position of his/her employers, past or present, nor those of the professional bodies and committees in which he/she participates. 1

3 Safety Topic: Valve Size can Change Handling 2

4 Definition of a Valve: Any device that stops, starts or changes the direction or magnitude of any fluid flow or its pressure How? By adjusting the closure element of the valve. 3

5 Manual and Automatic Manually Operated Valves Start and stop flow (gate, ball, plug, butterfly) Regulate and throttle flow (globe) Regulate pressure (choke) Automatically Operated Valves (Check Valves) Prevent back flow (check valve) Relieve excess pressure (relief valves) 4

6 Valves can be grouped by how they close onto the seat Manually Operated Valves 1. Closing-down valves: globe, y-pattern globe (Linear) 2. Slide Valves: wedge, slab, parallel slide gate (Linear) 3. Rotary Valves: ball, plug, butterfly (Quarter-turn) 4. Flex-body: pinch, diaphragm Automatically Operated Valves (Flow or pressure makes the valve operate) 1. Check Valves: swing, tilting disc, lift, duo, ball check, non-slam check 2. Pressure Relief Valves 5

7 Valve Types Gate Valve Check Valve Globe Valve Pig Ball Choke Valve Ball Valve 6

8 Valve Industry Standards per API API 594 Check Valves: Flanged, Lug, Wafer and Butt-welding API 598 Valve Inspection and Testing API 600 Steel Gate Valves-Flanged, Butt-welding Ends, Bolted Bonnets API 623 Steel Globe Valves Flanged, Butt-welding Ends, Bolted Bonnets API 602 Gate, Globe and Check Valves for Sizes DN100(NPS4 ) and Smaller for the Petroleum and Natural Gas Industries API603 Corrosion-resistant, Bolted Bonnet Gate Valves Flanged and Butt-welding Ends API 607 Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic Seats API608 Metal Ball Valves Flanged, Threaded, and Welding Ends API 609 Butterfly Valves : Double flanged, Lug and Wafer-type API622 Type Testing of Process Valve Packing for Fugitive Emissions API 623 Steel Globe Valves Flanged and Butt-wedling Ends, Bolted Bonnets 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 CURRENTLY UNDER DRAFT API 6D Specification for Pipeline and Piping Valves API 6FA Specification for Fire Test for Valves 7

9 Gate Valve On / Off Fully Open or Closed Sizes Available: ¼ 48 Routine Maintenance Can be Lubricated Stroke valve if possible when lubricating Inspect Packing Area Inspect for Leakage or Corrosion Especially in the bonnet area Inspect for Bent Stem 8

10 Globe Valve Throttle / Block Fully Open or Closed Throttling Application Sizes Available: ¼ 24 Routine Maintenance Can be Lubricated Stroke valve if possible when lubricating Inspect Packing Area Inspect for Leakage or Corrosion Especially in the bonnet area Inspect for Bent Stem 9

11 Pressure Seal Bonnet Gate or Globe Applications Sizes Available: 2 24 Routine Maintenance Can be Lubricated Stroke valve if possible when lubricating Inspect Packing Area Inspect and Tighten Draw Bolts Inspect for Leakage or Corrosion Inspect for Bent Stem 10

12 Forged Steel Valves Sizes Available: ½ 2 Gate, Globe & Check Valves Flanged ends from 150# to1500# Screwed/socket ends from - 800#, # # 11

13 Check Valve Prevents Backflow / Allows Flow in One Direction Reverse Flow or Gravity or Spring Assist will Close Valve Sizes Available:½ 36 Some Designs Packing Box and Outside Counter Weight Piston, Swing, Tilting Disc, Lift Type and Ball Swing Check Valve 12

14 Dual Disc Check 13

15 Non Slam Check Valve 14

16 Diaphragm Valve A valve used for throttling or adjusting flow Closes by Means of a Flexible Diaphragm Attached to a Compressor. When the compressor is Lowered by the Valve Stem onto a Weir, the Diaphragm Seals and Cuts Off Flow. Handles Corrosive, Erosive and Dirty Services 15

17 Ball Valves Trunnion / Floating Comparison Trunnion Designed for high pressure and/or large diameter applications in production and transmission No size limit Seat moves to ball Lower torque Lower actuation cost Double block and bleed capability Trunnion Ball Valve Floating Designed for smaller size and application in production and process Limited to 12 bore size and smaller Ball moves to downstream seat to seal Economically priced 16 Floating Ball Valve 16

is Positively Retained Cannot be removed with valve in service Standard Stem Sealant Injection Fittings Secondary Seat

18 Typical Trunnion Details Seat is Set into Deep Groove In its steel retainer, protected from erosion and from materials Pressure Actuated Seat Provides positive seal under all conditions Standard Adapter Flange For ease of automation Stem is Positively Retained Cannot be removed with valve in service Standard Stem Sealant Injection Fittings Secondary Seat Sealant Injection fittings with check valves. Ball is Held Fast by Trunnion But free to turn easily at any pressure 17

19 Floating Ball Valve (also known as Floater) 18

20 Body Style Variations Top Entry 3 Piece Unibody (End Entry) 2 Piece Cast 19

Butterfly Valve Block or Throttle Fully Open or Closed Throttling Application Sizes Available: 2 36 Routine Maintenance Typically CAN NOT be Lubricated Stroke valve if

21 Butterfly Valve Block or Throttle Fully Open or Closed Throttling Application Sizes Available: 2 36 Routine Maintenance Typically CAN NOT be Lubricated Stroke valve if possible when inspecting Gearbox Typically cannot be Lubricated without disassembly Inspect Packing Area Inspect for Leakage or Corrosion Attention to two-piece body / body seam 20

22 Triple Off-Set Butterfly 21

Plug Valve Typically Block Fully Open or Closed Special Designs for Throttling Application Sizes Available: ½ 20 Most Applications are Teflon Sleeved Valves Routine Maintenance

23 Plug Valve Typically Block Fully Open or Closed Special Designs for Throttling Application Sizes Available: ½ 20 Most Applications are Teflon Sleeved Valves Routine Maintenance Non-sleeved lube-types can be lubricated Stroke valve if possible when inspecting Gearbox Typically cannot be Lubricated Inspect Packing Area Inspect for Leakage or Corrosion 22

24 Three-Way Valve Block Fully Open or Closed in one Port Typically used for Multi product transfer applications Sizes Available: 2 12 Routine Maintenance Typically CAN NOT be Lubricated Inspect Packing Area Inspect for Leakage or Corrosion 23

25 Design Specifications Three key points should be considered when specifying a valve: 1. How to Identify and Order Valves: Example 1. Size of Connection 6 2. Pressure Class 600# 3. Type of Connection RF 4. Port (if necessary) Full Port 5. Body Type Top Entry 6. Valve Type Ball Valve 7. Body Material A352 LCC 8. Trim Material A105/ENC Trim 9. Seat/Seal/Packing Nylon Seat 10. Special Service Double Block and Bleed 11. Actuation Manual Gear Op 12. Service Conditions 22% H2S 45 C 24

26 Design Specifications Cont d 2. Identify its corresponding API Standard, ie: Forged Steel Valve to API 602. API specifications for valves sets the minimum standards the valve has to comply to. 3. Canadian Registration Number (CRN). The above three key areas will set minimum standards of quality and conformance. This is extremely important should you ever have to deal with indemnity issues resulting from any catastrophic failure. 25

27 Main Valve Component Parts 1. Body 2. Bonnet/Top Plate/End Caps 3. Trim (internal parts) 4. Packing and Seals 5. Means of Actuation WE WANT TO CONTAIN THE MEDIUM WITHIN THE PRESSURE CONTAINING PARTS OF THE VALVE TO PREVENT: A. Leakage to Atmosphere. B. Leakage Downstream when in the closed position. 26

28 Valve Body Materials Temperature Comparisons METAL FORGING CASTING TEMP- TEMP+ Cast Iron A F 410 F Ductile Ir. A F 650 F Carbon St. A105 A216 WCB -20 F 850 F Low Temp. CS A350 LF2 A352 LCC -50 F 650 F 1 ¼ Moly A182 F11 A217 WC6-20 F 1000 F 2 ¼ Moly A182 F22 A217 WC9-20 F 1050 F 304ss A182 F304 A351 CF8-425 F 1500 F 316ss A182 F316 A351 CF8M -425 F 1500 F 347ss A182 F347 A351 CF8C -425 F 1500 F Monel A296 M F 900 F Alloy 20 A296 CN7M -50 F 300 F NOTE: Check Code such as ASME B31.3 for Temperature requirements 27

29 Things To Consider When Selecting Valve Types Service temperature Service conditions Media Abrasives Corrosives Flow rates Size/envelope dimensions Weight and support requirements Actuation Repairability/long service life Field serviceability Special considerations Double block and bleed Firesafe Pigging Requirements Standards ANSI, API, ASTM CRN, CSA, ISO Operability Fugitive emission considerations Supply availability Price 28

30 An Important Aspect in Selection of Valves Is CV Factors Coefficient of Volume (CV) is the amount of Gallons Per Minute of water flowing past the valve, required to create enough friction to lose one psi of pressure. (i.e.: pressure drop ) 29

31 Trims: Defined per API th Edition The trim is comprised of the following: stem body seating surface gate seating surface bushing, or a deposited weld, for the backseat and stem hole guide small internal parts that normally contact the service fluid, excluding the pin that is used to make a stem-to-gate connection (this pin shall be made of an austenitic stainless steel material) NOTE: The definition may be different depending on valve type/standard applicable, the above is for Gate Valves only

32 Trim Selection What is the media, what is the temperature, what is the operating pressure, what are the maximum design conditions? Is the media corrosive, abrasive, clean, dirty? Will there be high pressure drops? What type of trim do I need to stand up to these conditions? Over the years, valve trim has evolved into a limited number of materials which have the necessary balance of physical and chemical properties to give good performance in a wide variety of applications. 31

33 Factors Determining Trim Selection 1. Physical Properties 2. Erosion Considerations 3. Corrosion Considerations 4. Ease of Casting/Forming/Machining 5. Relative Cost 32

34 API Trims (Common trims for gate valves) per API th Edition API Trim 1 F6 (13 Chrome) Seat/disc/stem API Trim 5 HF (Hard Face) Seat & disc (full Stellite) API Trim 8 F6 Disc/stem & HF Seat API Trim 9 Monel Seat/Disc/Stem API Trim SS Seat, disc & stem API Trim SS Disc/stem & HF Seat API Trim 13 Alloy 20 Seat/disc/stem API Trims do not designate Body Materials. 33

35 A few Common Trim Types for All Metal (Gate, Globe & Check Valves): Bronze mild service (commercial water) 316 ss general service/moderate corrosive 410 ss general service/moderate erosive 17-4 ss general service/corrosive & erosive Stellite 6 erosive/high temp Inconel X high temp strength for springs Monel very corrosive/salts/reducing env. Hastelloy very corrosive/acids/oxidizing env. Titanium very corrosive/chlorides/brines 34

36 Common Trim in Gate, Globe & Check Valves Trim 1(not commonly used)13cr Trim 5 HF/HF/13Cr Trim 8 HF/13Cr Trim Trim 12 HF/316 Trim 16 HF/HF/316 35

37 Trim material per API th Edition Table 8- Nominal Seating Surface, Stem and Backseat Bushing or Weld-deposit Materials and Hardness Trim # Normal Trim Seat Surface Hardness (HB) Minimum a Seat Surface Material Type b Seat Surface Typical Specifications Grade Stem / Brushing Backseat Brushing Cast Forged Welded m Material Type b Typical Specifications Type Stem hardness (HB) Hardness (HB) 1 F6 Note c 13Cr ASTM A217 (CA15) ASTM A105 (F6a) AWS A5.9 ER410 13Cr ASTM A276-T410 or T min 275 max 250 min Note d 18Cr-8Ni ASTM A351 (CF8) ASTM A182 (F304) AWS A5.9 ER308 18Cr-8Ni ASTM A276-T304 Note d Note d 3 F310 Note d 25Cr-20Ni NA ASTM A182 (F310) AWS A5.9 ER310 25Cr-20Ni ASTM A276-T310 Note d Note d 4 Hard F6 750 e Hard 13Cr NA Note f NA 13Cr ASTM A276-T410 or T min 275 max 250 min 5 Hardfaced 350 e Co-Cr A g NA NA AWS A5.13 or R CoCrA 13Cr ASTM A276-T410 or T min 275 max 250 min 5A Hardfaced 350 e Ni-Cr NA Na Note h 13Cr ASTN A276-T410 or T min 275 max 250 min 6 F6 and Cu-Ni 250 i 13Cr and ASTM A217 (CA15) ASTM A182 (F6a) AWS A5.9 ER410 13CR ASTN A276-T410 or T min 275 max 250 min 175 i CuNi NA Note k NA NA NA NA NA 7 F6 and 250 i 13Cr and ASTM A217 (CA15) ASTM A182 (F6a) AWS A5.9 ER410 13Cr ASTN A276-T410 or T min 275 max 250 min Hard F6 750 i Hard 13Cr NA Note f NA NA NA NA NA 8 8A F6 and Hardfaced F6 and Hardfaced 250 i ASTM A217 (CA15) ASTM A182 (F6a) AWS A5.9 ER410 ASTN A276-T410 or T min 275 max 250 min 13Cr and Co-CR A g NA 350 i NA NA AWS A5.13 E or R CoCrA NA NA NA 250 i 13Cr and ASTM A217 (CA15) ASTM A182 (F6a) AWS A5.9 ER410 13Cr ASTN A276-T410 or T min 275 max 250 min 350 i Ni-Cr NA NA Note h NA NA NA NA 9 Monel Note d Ni-Cu Alloy NA MFG Standard NA Ni-Cu Alloy MFG Standard Note d Note d Note d 18Cr-8Ni ASTM A351 (CF8M) ASTM A183 (F316) AWS A5.9 ER316 18Cr-8Ni-Mo ASTM A276-T316 Note d Note d Monel and Hardfaced 316 and Hardfaced Note d NA Ni-Cu Alloy MFG Standard Note Ni-Cu Alloy and d Note d NA MFG Standard Trim 5 or 5A 350 i See Trim 5 or 5A NA NA NA NA Note d 18Cr-8Ni-Mo AWS A5.9 ER316 18Cr-8Ni-Mo ASTM A276-T316 Note d Note d ASTM A351 (CF8M) ASTM A183 (F316) 350 i Trim 5 or 5A See Trim 5 or 5A NA NA NA NA 13 Alloy 20 Note d 19Cr-29Ni ASTM A351 (CN7M) ASTM B473 AWS A5.9 ER320 19Cr-29Ni ASTM B473 Note d Note d 14 Alloy 20 and Hardfaced Note d 19Cr-29Ni and ASTM A351 (CN7M) ASTM B473 AWS A5.9 ER320 19Cr-29Ni ASTM A276-T304 Note d Note d 350 i Trim 5 or 5A NA NA Trim 5 or 5A NA NA NA NA 15 Hardfaced 350 e Co-Cr A g NA NA AWS A5.13 E or R CoCrA 18Cr-8Ni ASTM A276-T304 Note d Note n 16 Hardfaced 350 e Co-Cr A g NA NA AWS A5.13 E or R CoCrA 18Cr-8Ni-Mo ASTM A276-T316 Note d Note n 17 Hardfaced 350 e Co-Cr A g NA NA AWS A5.13 E or R CoCrA 18Cr-10Ni-Cb ASTM A276-T347 Note d Note Hardfaced 350 e Co-Cr A g NA NA AWS A5.13 E or R CoCrA 19Cr-29Ni ASTM B Note Fluor. All Rights Reserved. Note n

38 Common Trim Types for Soft Seat (Ball) Valves: 316 ss Ball & Stem general service / moderate corrosive c/w PTFE Seat, Viton, or Nitrile O-ring; PTFE or Graphite Packing A105 ENC Ball & Stem general service c/w PTFE Seat, Viton, or Nitrile O-ring; PTFE or Graphite Packing There are a variety of seat and O-ring materials available for soft seated valves, selection depending upon service conditions. *Before buying check with manufacturer 37

39 Soft Seats and Seals Seat (Soft seated valves only) PTFE /RPTFE Nylon PEEK PCTFE Gasket O-rings Packing 38

40 Seat MATERIAL PTFE RPTFE PCTFE CHEMICAL RESISTANCE The best corrosion resistance. Inapplicable to fluorine and fused alkali metals under high pressure and temperature. Reinforced PTFE Corrosion resistance after PTFE. Does not resist to toluene, carbon tetrachloride, trifluoro, ethyl acetate, and diethyl ether under high temperature. For low temp. application. PEEK Nylon Series All chemical solvents except concentrated sulfuric acid, hydrofluoric acid, and nitric acid. Hard so will wear Resists to oils, hydrocarbons, esters, bases, alcohols, ethers, ketones, detergent s. Does not resist to concentrated acids and polar solvents 39

41 Ball Valves Seat Variations(Quarter Turn) 40 40

42 Pressure/Temperature Rating 41 41

43 Material of Construction Bronze ASTM B584 ASTM B61 ASTM B62 Forged Brass ASTM B283 Cast Iron ASTM A126 Class B Ductile Iron ASTM A536 Gr Non-Metallic FRP Teflon Carbon Steel / Chrome ASTM A216 WCB ASTM A217 WC6 ASTM A217 WC9 ASTM A217 C5 ASTM A217 C12 and 12A Stainless Steel ASTM A351 Gr. CF8M ASTM A351 Gr. CF8 42

44 Applicable Standard: Valves Size and Pressure Temperature Rating ASME B16.34 Minimum Wall Thickness ASME B16.34 Listed Material ASME B16.34 End Connections ASME B16.5 ASME B16.47 ASME B16.25 ASME B16.11 End-to-End ASME B16.10 Joint Design ASME B16.34 Other in ASME B16.34 Minimum Hydrostatic Examination NDE Procedure Acceptance NDE level 43

45 Definition of Double Block and Bleed(DBB) and Double Isolation and Bleed(DIB) per API6D 24 th Edition 44

46 Fire Safe Standards Fire Safe Standards tests valves under simulated fire conditions and defines how a valve is supposed to react under these conditions, and hopefully will do the same under an actual fire. It looks at rapid heating and cooling, method of measuring temperature, test pressures, cycling, open and closed positions and allowable leak rates under these conditions. API-607 (for plants and facilities) is a new standard so that everyone could test to the same spec for soft seated valves. There have been several revisions, the latest being the 4th edition. The 4th edition is more strict in its requirements than the previous 3rd edition. Not all manufacturers have met this new standards. 45

47 Fire Safe Standards Cont d API 6FA - This standard is more commonly used for fire safe Trunnion ball valves, & it s recognized (also used internationally), for pipelines, gathering systems, terminals, etc. The standard used to be identical to API 607 until the arrival of the 4th edition. EXES A - Exxon has their own fire burn test. They have additional requirements to API or BS such as rapid cooling and more stringent allowable leakage rates. BS-6755 British Standard Institute - has been re-worded so its now similar to API 607 3rd edition. ISO European specification. Like British standards, the specification was very much like API 607 till the latest revision. 46

48 CRN Numbers (Canadian Registration Number) CSA B51 Fitting & Valve Registration is Mandatory by Code Provincial Jurisdiction Changes in Design etc. Require Re-Registration Renewal Required Every 10 Years Operator s Responsibility Registration in the Province of Alberta is ABSA (Alberta Boilers Safety Association) 47

49 ASME/ANSI Pressure Classes to material group 1.1(per ASME B ) 150# = 285 PSI Maximum Operating Pressure 300# = 740 PSI Maximum Operating Pressure 600# = 1480 PSI Maximum Operating Pressure 900# = 2220 PSI Maximum Operating Pressure 1500 = 3705 PSI Maximum Operating Pressure 2500# = 6170 PSI Maximum Operating Pressure 800# = 1975 PSI (*Interpolated) *800# is an interpolated pressure class equivalent to 1975 psi, and is commonly used with API 602 forged steel gate, globe, and check valves, and to reflect 2,000 psi. Maximum Pressures are at Ambient Temperature. As Temperature Rises, The Pressure Envelope Decreases! 48

50 Compatibility Chart Pipe, Fittings, Flanges & Valves PIPE WELD FITTINGS SCRD & SW FITTINGS FLANGES VALVES (FORGED) VALVES (CAST) SA-106B SA-234 WPB SA-105 (N) SA-105 (N) SA-105 (N) SA-216 WCB SA-333 GR 6 SA-420 WPL6 SA-350 LF2 SA-350 LF2 SA-350 LF2 SA-352 LCB SA-352 LCC SA-312 T316 SA-403 WP316 SA-182 F-136 SA-182 F-316 SA-182 F-316 CF8M *This chart shows the most common piping components that require material match-up. Studs and Nuts Service Stud Nut Sweet B7 2H Sour B7M 2HM Sweet Low Temp L7 GR 4 Sour Low Temp L7 7M NOTE: We do not differentiate A105 and A105N for all intensive purposes. We tend to specify A105N for normal service and A350LF2 Class 1 for low temperature service as a best practice 49

51 Pressure/Temperature Ratings The following charts show how temperature affects the maximum allowable pressure rating. Pressure/Temperature Ratings ASME(ANSI) B A216 WCB Temp F 150# 300# 600# 900# 1500# 2500# -20 to

52 Pressure/Temperature Ratings Cont d Pressure/Temperature Ratings ASME(ANSI) B A352 LCC Temp F 150# 300# 600# 900# 1500# 2500# -20 to

53 Pressure/Temperature Ratings Cont d Pressure/Temperature Ratings - ASME/ANSI B A351 CF8M Temp F 150# 300# 600# 900# 1500# 2500# -20 to

54 Nomenclature Nominal Pressure Class Nomenclature ANSI CLASS NOMINAL PRESSURE CLASS 150 PN PN PN PN PN PN 420 NOTE: PN Means pressure. The numerical part of the designation approximates the maximum cold working pressure rating in bars (100 kpa) Typical Pressure Combinations for Valves and Fittings(approx values only refer ASME) PRESSURE CLASS ANSI/ASME MAXIMUM OPERATING PRESSURE FITTING RATING PSI (FORGED STEEL) FLANGE RATING ANSI/ASME VALVES WOG RATING-MFR THRD/SW PSI VALVES ANSI B16.34 THRD/SW FLANGED VALVE RATING CL CL CL 800 CL 150 CL Cl CL 800 CL 300 CL CL CL 800 CL 600 CL CL CL CL 900 CL psi CL CL 1500 CL 1500 CL ** CL ** CL 2500 CL 2500 * Based on A105/A216WCB pressure ratings. Maximum allowable pressure varies with each specific material. ** Does not fully meet ANSI Class 2500# NOTE: The temperature rating of valves are limited by the specific seat and seal material used. 53

55 Testing of Valves Standard pressure tests API 6D, ASME B16.34, API598 Shell Body / bonnet / bolting Stem packing Teflon w/injectable packing Graphite Seat Leakage determined visually Soft seats Zero leakage Metal-seated API 598 Optional testing Cryogenic (cold box) Using gas and liquid nitrogen High pressure gas Fugitive On-going testing to specific customer requirements High pressure gas Helium Ambient Temperature Compliance with 1990 US Clean Air Act EPA Method PPM Effective PPM Effective 1997 Testing with Methane Teflon Packing Systems Ambient Graphite Packing Systems 600 F / 315 C 54

56 Valve Certification Certification versus Traceability EN b = 3.1 Testing done by someone other than mfg. EN a & c = 3.2 Witnessed testing or certification by a third party. Bodies, bonnets Fully traceable using heat numbers Cores, Seats, Stems, etc. Made from traceable material but not maintained throughout mfg process (meets 3.1). (EN10204 Metallic products Types of inspections documents) 55

57 Time to ask Questions 56

Gate, Globe and Check Valves

Gate, Globe and Check Valves 1 COMPANY OVERVIEW Ringo Válvulas (RV) is located in the industrial city of Zaragoza, Spain. Since its establishment RV has designed and manufactured its own cast and forged