Ivs2017 final presentation session12_strategies to api 624 qualification
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The document discusses strategies for qualifying valves according to API 624 standards for fugitive emissions. It outlines the requirements of API 624, including test parameters like medium, temperature, pressure, number of actuations and thermal cycles. It also discusses planning an in-house test bench, guidelines for valve design to improve performance, such as reducing clearances and adding stem supports. Third party labs can be used for final verification.
Ivs2017 final presentation session12_strategies to api 624 qualification
- 1. 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 2017 1
- 2. AGENDA IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies May, 24th and 25th 2017 2 Requirements of API 624 Planning for In-house Test Bench Design Assembly Guideline Third Party Labs for final Verification.
- 3. AGENDA IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies May, 24th and 25th 2017 3 Requirements of API 624 Planning for In-house Test Bench Design Assembly Guideline Third Party Labs for final Verification.
- 4. 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
- 5. VALVES a significant contribute to VOC 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 5
- 6. EPA CONSENT DECREE & API 624 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 6
- 7. • 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 7 EPA CONSENT DECREE & API 624
- 8. REQUIREMENTS OF API 624 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 8 Title and Edition Type Testing of Rising Stem Valves Equipped with Graphite Packing for Fugitive Emissions, First Edition Date Standard by the American Petroleum Institute, 02/01/2014 Pass Criteria leakage throughout the test does not exceed 100 PPMv Packing Adjustment None allowed
- 9. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 9 Media Methane 97% minimum purity Temperature 500°F (260°C) Optional Low Temperature Test at -20° F Pressure 600 psig (41.4bar-g) Number of Valve Stem Actuations 310 Number of Thermal Cycles 3 REQUIREMENTS OF API 624
- 10. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 10 Leak Measurement Method EPA 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 REQUIREMENTS OF API 624
- 11. 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
- 12. 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
- 13. 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
- 14. 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
- 15. 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
- 17. 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
- 18. AGENDA IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies May, 24th and 25th 2017 18 Requirements of API 624 Planning for In-house Test Bench Design Assembly Guideline Third Party Labs for final Verification.
- 19. 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 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 19 Figure 1. Technician uses Method 21 to monitor leakage. Photo courtesy of GreatWeld Engineering Pvt.Limited,India.
- 20. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 20 Leak Measurement Devices based on API 624 and EPA Method 21.
- 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
- 22. 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$ 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 22
- 23. 23 Methane Leak Detection Principle-FID
- 24. Methane Leak Detection Principle-Electrochemistry 24
- 25. AGENDA IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies May, 24th and 25th 2017 25 Requirements of API 624 Planning for In-house Test Bench Design Assembly Guideline Third Party Labs for final Verification.
- 26. # 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 26 Design Guideline
- 27. # Aspect Description Illustration Advantages 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 27 Design Guideline
- 28. # Aspect Description Illustration Advantages 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 28 Design Guideline
- 29. Design Guideline # Aspect Description Illustration Advantages 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 29
- 30. Design Guideline # Aspect Description Illustration Advantages 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 30
- 31. Packing Gland Assembly Guideline # Aspect Description Illustration Advantages 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 31
- 32. AGENDA IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies May, 24th and 25th 2017 32 Requirements of API 624 Planning for In-house Test Bench Design Assembly Guideline Third Party Labs for final Verification.
- 33. 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 INFO@YARMOUTHRESEARCH.COM 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 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 33
- 34. 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. 10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 34
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