4 Valves - The Good The Bad and The Ugly Rev 2

bad Valves: The good, the bad and the ugly
Real life cases

Jonas kerlund September 2010
Purpose
To promote the use of modern analysis tools in the qualification process.
Valves: The good, the bad and the ugly 21 April 2010 Det Norske Veritas AS. All rights reserved. 2
DNV an independent foundation

An independent foundation established in 1864
Our Purpose To safeguard life, property and the environment Our Vision Global impact for a safe and sustainable future
Highly skilled people across the world
300
offices
Valves: The good, the bad and the ugly 21 April 2010 Det Norske Veritas AS. All rights reserved.
100
countries
5
9,000
employees
Valve failures in general
Failure modes
Leakage Jamming Self opening Body failure Actuator/stem failure
Causes
Surface damage Thermal expansion / distortion Erosion Galling Flow effects Porosity/surface roughness
ISO 10423: Wellhead and christmas tree equipment

ANNEX F: Performance Verification Procedures: F.1.9 Temperature testing
- The heating for maximum temperature testing may be applied internally in the through-bore or externally.
Operational thermal gradients in the valve body are not captured properly in testing
F.2.3.3.3 Dynamic test at maximum rated temperature

- starting against full differential pressure. Pressure shall be maintained at 50% of the initial test pressure.
Force/stroke curve completely different during test
Flow induced issues

Will my gate valve close?
- Could be a challenge if dry gas runs through it and your actuator design is marginal. - Have you considered the forces from the fluids passing through a restriction?
F.2.3.3.3 Dynamic test at maximum rated temperature

- starting against full differential pressure. Pressure shall be maintained at 50% of the initial test pressure.
What do I have to overcome to close the valve?

Friction between seat and gate Friction in stem and actuator Control system return pressure vs. Cavity pressure Spring force
The force balance
Ffr_gate Ffr_act Freturn Fspring Fprocess
Closing condition:
fr _ gate
fr _ act
return
spring
process
Tools to use for reliable actuator force prediction

Multiphase flow solver
- To model the entire well and find the differential pressure across the valve while closing it
CFD (Computational Fluid Dynamics)

- Used to calculate the force balance on the gate for different levels of closing
Physical testing
- Friction between gate and seats
FEA (Finite Element Analysis)

- Local effects
Differential pressure on gate

250
200
150 Upstream pressure Downstream pressure Differential pressure (P1-P2) Differential pressure (as tested)
100
50
0 100 %
OPEN
90 %
80 %
70 %
60 %
50 %
40 %
30 %
20 %
10 %
0%
CLOSED
Pressure (bar)
Friction increases
The force balance

120
100
80
60 Opening Force Counterforce 20
40
0 100 %
OPEN
90 %
80 %
70 %
60 %
50 %
40 %
30 %
20 %
10 %
0%
CLOSED
Force (kN)
Advice
Thorough analysis considering the entire system to establish force balance Relying on grease might be dangerous
Thermal/structural issues
I just opened my gate valve, but I changed my mind and I want to close it again. Will it close?
- Certainly, if you are not in a hurry.
F.1.9 Temperature testing

- The heating for maximum temperature testing may be applied internally in the through-bore or externally.
Temperature field in a typical gate valve

Clearance
120
100
80
Temperature
Gate
60
Seat
40
Body
20
0 0 -20 100 200 300 400
Time
500
600
700
800
Temperature effect on gate valve clearance
0.6 0.4 0.2 0
tjam
0 100 200 300 Time 400 500 600 700 800
Clearance change
-0.2 -0.4 -0.6 -0.8 -1 -1.2
In operation As tested Limit
Clearance _ change l
cavity
l 2 l
gate
seat
Possible solutions
Added clearance Obvious, but not always desired Block insulation Reduces temperature gradient
Advice
Hand calculations typically overestimate the clearance change at steady state and underestimate the change during a transient event.
Flow induced issues

Will my ball valve stay open?
- Sorry, if you havent considered this effect.
Simulation model, 10% closed

Torque acting on a ball valve
P P
Velocity and pressure contours
Torque
Ball valve; 10 closed

Massflow [kg/s] 400.0 300.0 200.0 100.0 0.0 0 -100.0 -200.0 -300.0 -400.0 Time [s] 2 4 6 8 10 Torque [Nm]
Possible solutions
Lockdown mechanism Gearboxes often used
Observed Qualification Practices

Failure modes and failure mechanisms not systematically identified Limited use and validation of analytical models through the test program Actual operating environment often not tested Design / qualification by Trial and Error Technology Qualification performed as an after thought => Schedule and budget overruns & poor reliability or cancelled project
Qualification Procedure For New Technology DNV RP-A203

Objective:
To provide a systematic approach ensuring that the technology functions reliably within specified limits
Scope:
Applicable for: components, equipment and assemblies used in hydrocarbon exploration and exploitation offshore
Benefits of the Qualification Procedure

Systematically identifies failure modes Improves the end users confidence in the system Increase the likelihood of delivering on time
It reduces the risk cost during operation by reducing uncertainties and increasing reliability
Traceability of qualification efforts Allows quicker re-qualification for new operating conditions
Conclusions
A valve tested according to ISO 10423 does not necessarily work properly under the same conditions in operation.
Design codes often consider components, not systems.

Modern simulation tools gives us the possibility to accurately find the conditions governing the valve operating envelope. Multidisciplinary collaboration is needed to fully understand the valve operating conditions. DNV RP-A203 contains a systematic approach to determine and assess failure modes.
CFD
FEA
PHYSICAL TESTING
QUALIFICATION MANAGEMENT
MECHANICAL DESIGN
PROCESS DESIGN
Safeguarding life, property and the environment

www.dnv.com

4 Valves - The Good The Bad and The Ugly Rev 2

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4 Valves - The Good The Bad and The Ugly Rev 2

Uploaded by

Copyright:

Available Formats

bad Valves: The good, the bad and the ugly

Real life cases

To promote the use of modern analysis tools in the qualification process.

DNV an independent foundation

Highly skilled people across the world

Valve failures in general

ISO 10423: Wellhead and christmas tree equipment

F.2.3.3.3 Dynamic test at maximum rated temperature

Flow induced issues

F.2.3.3.3 Dynamic test at maximum rated temperature

What do I have to overcome to close the valve?

The force balance

Ffr_gate Ffr_act Freturn Fspring Fprocess

Tools to use for reliable actuator force prediction

CFD (Computational Fluid Dynamics)

FEA (Finite Element Analysis)

Differential pressure on gate

The force balance

60 Opening Force Counterforce 20

F.1.9 Temperature testing

Temperature field in a typical gate valve

0 0 -20 100 200 300 400

Temperature effect on gate valve clearance

0.6 0.4 0.2 0

-0.2 -0.4 -0.6 -0.8 -1 -1.2

In operation As tested Limit

Flow induced issues

Simulation model, 10% closed

Torque acting on a ball valve

Velocity and pressure contours

Ball valve; 10 closed

Observed Qualification Practices

Qualification Procedure For New Technology DNV RP-A203

Benefits of the Qualification Procedure

Design codes often consider components, not systems.

Safeguarding life, property and the environment

You might also like