By John An &#; Polymer Concepts Technologies, Inc. (PCTI)
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Attention to each of the valve seal applications mentioned above can help reduce the risk of equipment failure. Here are a few more things to consider.
Flammable fluids are a real hazard for the oil and gas industry, so fire-safe valves and valve sealing materials are worth considering. Products designed to API 6FA specification meet the test and evaluation requirements for valves exposed to clearly-defined fire conditions.
Flammable fluids are a real hazard for the oil and gas industry, so fire-safe valves and valve sealing materials are worth considering. Products designed to API 6FA specification meet the test and evaluation requirements for valves exposed to clearly-defined fire conditions.
The seal materials used in the cryogenic valves tend to become brittle and shrink making them difficult to seal over time. Materials soften in high temperature and pressure environments. Material degradation can cause product integrity challenges. Valves designed to API 6A and ISO standards offer the most comprehensive temperature, pressure, and fugitive emission protection.
The seal materials used in the cryogenic valves tend to become brittle and shrink making them difficult to seal over time. Materials soften in high temperature and pressure environments. Material degradation can cause product integrity challenges. Valves designed to API 6A and ISO standards offer the most comprehensive temperature, pressure, and fugitive emission protection.
API-standard valves that perform at 15-25 ksi and 350-400°F are best suited for subsea applications as the combination of high pressure and temperature with corrosive and toxic fluids rapidly degrades the valve material. Since there is no tolerance for leakage, designing the right sealing system for the valve stem is a top priority.
API-standard valves that perform at 15-25 ksi and 350-400°F are best suited for subsea applications as the combination of high pressure and temperature with corrosive and toxic fluids rapidly degrades the valve material. Since there is no tolerance for leakage, designing the right sealing system for the valve stem is a top priority.
Let us review three common valve seal applications, and then answer four questions about what to consider when selecting them.
Let us review three common valve seal applications, and then answer four questions about what to consider when selecting them.
In a natural gas environment where cryogenic temperatures are the norm, it is critically important that polymer seals are compatible with the task. There is a heavy focus on controlling fugitive emissions, so natural gas valves and their sealing components face even greater scrutiny.
In a natural gas environment where cryogenic temperatures are the norm, it is critically important that polymer seals are compatible with the task. There is a heavy focus on controlling fugitive emissions, so natural gas valves and their sealing components face even greater scrutiny.
The nature of valves used in extremely demanding applications earns them the designation of severe-service valves. The function of severe-service valves is defined and driven by higher temperature and pressure requirements to satisfy the industry&#;s desire for increased production efficiency. Valves and their sealing components work harder as the industry goes deeper on land and offshore.
The nature of valves used in extremely demanding applications earns them the designation of severe-service valves. The function of severe-service valves is defined and driven by higher temperature and pressure requirements to satisfy the industry&#;s desire for increased production efficiency. Valves and their sealing components work harder as the industry goes deeper on land and offshore.
1. What is the role of hardware and surface finish in valve seal performance?
It is very important to have proper gland designs to achieve optimum seal performance. The hardware conditions are critical to seal performance, such as gland styles and sizes, tolerances, extrusion gap, lead-in chamfers, surface finish, and surface hardness. A proper lead-in chamber will prevent seal damage during installation. When sealing at high pressures and/or temperatures, the extrusion gap behind the seal becomes critical. It should be held to a minimum to prevent or minimize extrusion of the seal material. Having a smooth sealing surface significantly reduces abrasive wear and enhances sealing ability. We recommend the 8 RMS and 16 RMS for the dynamic and static surfaces, respectively. High surface hardness (55 to 65 Rc) is recommended to make the sealing surface impervious to erosion and abrasion. Hardware can be either coated or plated to achieve the proper surface hardness.
2. How are oil and gas valve seals tested?
Testing is critical because of the cost of failure. The valves and sealing materials used in oil and gas applications must be tested and validated. Validation begins with establishing a high level of competence via finite element analysis (FEA), which is a simulation of how the seal design and material behave in the application based when subjected to the pressure and temperatures they will experience in the field. The FEA analysis is backed by in-house or third-party testing in conjunction with OEM testing. Finally, application experience provides an additional layer of performance assurance. Many seal manufacturers have a long history of working with some of the most difficult and challenging applications in other severe-service industries, such as space exploration, with similar seal design parameters.
3. What should a design engineer know about seals and sealing materials for valves on wellhead equipment?
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The common type of valves used in the oil and gas industry are ball valves, control valves, butterfly valves, safety valves, cryogenic valves, and gate valves. The seal materials are determined based on the operating conditions, such as media, temperature, speed, and pressure. The seal performance can be significantly improved by considering or developing the materials with low friction and excellent heat and wear properties. Designing highly engineered bi-directional stem packing assemblies with proper seal materials should meet the leakage, friction, and seal life requirements under extreme conditions; e.g., 25,000 psi, +500°F, abrasive and corrosive wellbore fluids, and reciprocating shaft.
4. Are there any technological advances on the horizon for valve seal manufacturing?
We see a general industry trend in the use of a combination of newly developed materials and custom designed seals with certain configuration. The seal configurations can be face seals, radial seals, and fully-contained bump seals (or anti-blowout seals) which are used for static or dynamic conditions. The use of energizers and custom spring designs are also on the rise. PCTI has a proprietary Polycon material technology and process. This technology allows the company to provide sealing solutions for extreme operating environments characterized by temperatures ranging from -450° to 600°F, system pressures up to 30,000 psi, and intensely abrasive and corrosive media.
Regardless of the application, severe-service valves and seals are important for oil and gas industry. When equipment fails, it has a significant impact on human safety, the environment, and the total cost of downtime and repair. Valve-related equipment failure can be significantly reduced or eliminated with the proper seal selections.
When we delve into the world of valve standards, it&#;s like opening a time-tested manual that has shaped the way we interact with our most fundamental utilities. The American Petroleum Institute (API), the International Organization for Standardization (ISO), and the American National Standards Institute (ANSI) aren&#;t just acronyms; they&#;re the backbone of an industry that thrives on precision.Valve standards, including those outlined by the American Society of Mechanical Engineers and others, serve as the guardians of efficiency and safety in a high-pressure environment where there is no room for error. The balance between flow control and tight shutoff is often a matter of a few turns of a gate valve or the seamless operation of solenoid valves.And yet, it&#;s not just about turning a ball valve in a piping system or ensuring the correct pressure ratings; it&#;s about a legacy. A legacy that&#;s woven by standard organizations and the hands of skilled workers in the valve industry across the United States and beyond ensures every component fits its intended use, from a butterfly valve in a suburban home to a complex array of control valves in a refinery.
Valve standards are not just a collection of guidelines&#;they are the epitome of what it means to channel force through the conduits of civilization. High temperatures, the caustic flow of natural gas, and the very essence of process control rest upon these standards. From ASTM International to the Fluid Control Institute, every standardization society contributes a threat to this tapestry.Whether it&#;s a relief valve in a pressure vessel or a pinch valve in the fittings industry, the standards dictate the performance. The pressure ratings, temperature ratings, and even the specific standards for test procedures are all part of a larger narrative&#;a narrative that emphasizes proper functionality and overall performance.
Every check valve and ball valve that makes its way into a pipeline transportation system is a testament to a manufacturer&#;s adherence to these standards. It&#;s not merely about compliance; it&#;s about upholding a tradition of excellence and safety. Major standard organizations dictate that a standard valve isn&#;t just another piece of metal; it&#;s a vessel for engineering prowess.Imagine a stainless steel valve designed for hydraulic fluid control&#;a piece that must withstand the relentless pressure and flow rate demands. It&#;s here that international standard organizations like the American Society play a critical role, setting the stage for what becomes the industry norm.
ISO (EN -1) stands as a monolith in the international standard landscape. It is not merely about ensuring that a globe valve can execute flow control, but that every nuance, from its material to its structural integrity, can meet the stringent requirements set forth by a global consortium.In this intricate dance of metals and mechanics, terms like &#;standard valve&#; and &#;international valve and instrument&#; are not just thrown around&#;they are venerated. The specifications within ISO encompass an array of valve types, each with its own unique role in the fluid control symphony.
Diving deeper, ISO doesn&#;t just set the stage; it dictates the script by which every valve performance is judged. Testing materials, flow rates, and tight shutoff parameters are not just line items&#;they are the chapters of a story that each valve must tell flawlessly.The testing procedures and acceptance criteria within ISO are akin to the rehearsals of an orchestra&#;each instrument must play its part, and each valve must adhere to its role, ensuring the harmony of functionality and safety.
Test ProcedureStandard DivisionValve Type ApplicableISO Rate AZero leakage for soft seated valvesBall Valves, Butterfly ValvesISO Rate BVery slight leakage allowedGate Valves, Globe ValvesISO Rate CLimited leakage acceptableCheck Valves, Plug ValvesISO Rate DLeakage rate as agreed upon by customer and manufacturerSpecial Purpose ValvesAPI 598 is like the vigilant overseer of the valve world. It doesn&#;t simply suggest; it demands that every valve be put through the paces of rigorous inspection and testing. When a valve manufacturer embarks on this journey, it&#;s with the understanding that every check valve, gate valve, and globe valve will face the test of fire and pressure.It&#;s a meticulous process where pressure relief valves and safety valves are subjected to scenarios far beyond their intended use. The purpose? To guarantee that when a valve claims to meet the API standard, it&#;s not just a badge&#;it&#;s a promise.
Meanwhile, API 6D is the script for a specific cast&#;the pipeline valves. These are the gatekeepers of the natural gas industries, the sentinels of the pipeline transportation systems. In the realm of high pressure and high stakes, API 6D is the rulebook that every player knows by heart.This is where specifications translate to safety and efficiency. The valve industry, much like the United States itself, is built on a foundation of standards, and API 6D ensures that this foundation is rock-solid.
Standard CodeStandard NameAPI 598Valve Inspection and TestingAPI 600Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas IndustriesAPI 602Compact Steel Gate Valves &#; Flanged, Threaded, Welding, and Extended-Body EndsAPI 607Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic SeatsAPI 609Butterfly Valves: Double-flanged, Lug- and Wafer-typeAPI 6DSpecification for Pipeline and Piping ValvesAPI 6ASpecification for Wellhead and Christmas Tree EquipmentIn the complex orchestra of valve standards, ANSI conducts with a steady hand. It doesn&#;t seek to overshadow ISO or API; instead, it enhances, integrates, and solidifies. The American National Standards Institute&#;s guidelines weave through the fabric of valve specifications, ensuring that every thread&#;be it for a solenoid valve or a pressure vessel&#;is strong enough to hold the immense pressures they are subjected to.ANSI standards, often seen as a bridge between the robust American Society of Mechanical Engineers&#; regulations and the global reach of the International Organization for Standardization, ensure a harmony that allows for seamless international cooperation and technological exchange.
The selection and application of a valve are pivotal decisions that resonate throughout the life span of a piping system. Whether it&#;s a stainless steel ball valve or a cast iron butterfly valve, the ANSI standards ensure that these components not only meet the minimum requirements but also fit elegantly into the grand design of a facility&#;s process control architecture.
Standard CodeStandard NameANSI/FCI 70-2Control Valve Seat LeakageANSI B16.34Valves &#; Flanged, Threaded, and Welding EndANSI B16.10Face-to-Face and End-to-End Dimensions of ValvesANSI B16.5Pipe Flanges and Flanged FittingsANSI B16.25Buttwelding EndsANSI B16.1Cast Iron Pipe Flanges and Flanged FittingsANSI/ISA 75.01Specification for Process Control ValvesANSI/ISA 75.02Control Valve Response Measurement from Step InputsThe world of valves is as varied as the applications they serve. From the humble gate valve to the more complex control valve, each has its role, its personality, if you will. And for each, there&#;s a set of standards that define its existence and ensure its performance.
The specificity of test standards for different valve types is crucial&#;it ensures that a ball valve meant for a cryogenic application doesn&#;t falter when faced with the extreme cold, or a globe valve for a steam system maintains integrity under the relentless heat.
The story of valve standards is ever-evolving, much like the technology and industries they serve. The American Society of Mechanical Engineers, the American Petroleum Institute, and the International Organization for Standardization, along with many others, continue to adapt and refine their standards to meet the challenges of new materials, new processes, and new environmental considerations.In this dynamic field, a seasoned engineer&#;s insight is invaluable. A lifelong accumulation of knowledge, tempered by experience and an unwavering commitment to quality and safety, ensures that the valves of today not only meet current standards but are ready to evolve with the standards of tomorrow.As we close this chapter on valve standards, we look ahead to the next with anticipation and confidence that the industry&#;s commitment to excellence will continue to fuel innovation and safety in equal measure. The keyword is not just &#;standard&#;&#;it&#;s &#;evolution&#;.If you still have some questions about those standards, talk to Dombor and we will offer professional help.
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