velan abv - rotary control ball valve...
TRANSCRIPT
KEY-C: Identity Card
Valve Type: Quarter turn Rotary Ball Valve
Design Standard: API 6D & B16.34
Size: from 3” up to 48”
Pressure Class: from 150# – 2500#
Construction: Forged Body & Caged Ball Trim
Service:Flow Control /Level ControlPressure ControlAntisurgeFast BlowDown operation
Standard Body Materials:- Carbon Steel / Stainless Steel /Duplex & specialAlloys
Standard Trim Materials:- Stainless Steel + Tungsten Carbide on Seat AreasMaterials comply to NACE/ MR0175
Fire Safe: API 6FA/607 and ISO 10497
24”x20” ASME 150 Bronze Mat.2014 - Project TEN FPSO / End User: Tullow Ghana / EPC: MODEC
Control valves Overview
The main common control valve was Globe
type
Still today Globe valves represent 70 % of
control valves
The Globe valve was used for all type of
applications
Due to low valve capacity, line sizes are big
Valves are now part of complex automation
system
Controllers are becoming Digital
Accuracy & Repeatability are key features
Processes require severe controls (with
high pressure & high velocity)
The correct valve selection & sizing is
fundamental for each process
Noise Limitation shall be considered
Historically Today
Rotary Control Ball valves improve performances of conventional LargeSize Single Seated Globe valves
KEY- C: Benefits
Higher capacity
Higher rangeability
More Compact package
Low Noise & vibration
Better wear resistance
Tight shutoff capability
Longer intervals between maintenance
Longer service life
Why?
Single Seated Globe Valves Limitations
Low Flow Capacity & limited Cv
High Pressure loss across the valves
Low regulation ratio
High risk of Cavitation and Flashing,under severe conditions
No Noise & vibration abatement device
High Risk of stem leakage
Not suitable for Fugitive Emission
Request of periodic maintenance
High Forces for valve shutoff
Plug obturator & Rising Stem design lead to:
Cavitation
Flashing
Ideal Control Valve
P1
V1
Vvc
Inlet Outlet
V2
P2
Pvc
VALVE
Pressure
Velocity
CavitationPv
Flashing
Optimal Curve
Pressure recovery
STD Ball Valve for Control ServicePressure & Velocity profile across Ball Valve
Full Bore - extremely high Cv
Min pressure Drop at fully open position
Easy installation: Std Face to Face andbidirectional mode
Ideal solution for tight shut off
Rotary stem increases valve reliability
Poor control between 10-50% of thestroke under severe conditions
Risk of Cavitation and Flashing
High Noise
Advantages
Disadvantages
KEY-C Valve for Control ServicePressure & Velocity profile across KEY-C Valve
Full Bore - extremely high Cv
Min pressure Drop at fullyopen position
Easy installation:Std Face to Face and bidirectional mode
Ideal solution for tight shut off
Rotary stem increases valve reliability
VERY GOOD Control between 10-50%of the stroke
Reduction of Risks of Cavitation andFlashing
LOW Noise
Advantages
KEY-C Trim: Working Principle
KEY-C trim has a multistage design, composed bya series of holed plates, partializing the pressuredrop
KEY-C trim guides the flows path to self dissipatethe kinetic energy, limiting the velocity,preserving the mechanical integrity and reducingthe noise
The gap between plates are expansion chambers,which gradually allow the flow to pass through thevalve without increase its velocity
Multi holes increase the total number of passagesreducing the Noise through the valve
KEY-C Trim: Optimization
KEY-C Trims are optimized using themost advanced CFD simulationtechnologiesSeveral cases were analyzed to reachthe optimal configuration,considering:
Number of holes in the plates
Hole diameter
Plate number
Plate distance
Plate inclination
Additional holes for gas expansionanalysis
Pressure Drop Control Velocity check
Torques determination Noise prediction
KEY-C: Valve Characteristic
Valve Characteristic according to: IEC 534-2
ISA S75.01 & S75.02
Noise level calculated according to:
VDMA 24422 (liquid)
IEC 534-8-3 (gas)
Typical Inherent Characteristic Curve
FL- Liquid pressure recovery factoris an important characteristic of acontrol valve, which shows the pressurerecovered from the vena contracta tothe valve outlet relative to the generalpressure drop across the valve
The closer the FL is to 1.0, the lessthe pressure recovery is.
KEY-C: Features in Detail
Unidirectional FlowValve with one seat
upstream
DPE Seat forbidirectional
tightnessTrunnion mounted
design for sustaininghigh pressure drops& torques reduction
Metal to Metal seats,with TC coating
performed betweenball and seatscontact area toincrease wear
resistance
Emergency sealinginjection on seat
and stem foremergency purpose
Stem Packing forLow Fugitive
Emission
Leakage rateaccording ANSI/FCIClass IV, Class V &
Class VI
Mounting Flange as perISO 5211 for an easy
interface with actuators
Cycle of Operations
Ste
msealle
akag
e
KEY-C: Summary Comparison
Rated Cv KEY-C >> Rated Cv Globe
Rangeability is much higher compareto globe
Thigh shutoff capability
With KEY-C Valves, same controlconditions can be reached with 2SIZE less than Globe valve
Actuator size is also smaller
After 5000 operations, the stemleakage from KEY-C is 40 times lessthan Globe
Longer intervals between maintenance
Longer service life
!! TOTAL COST SAVING 40% !!
Common Globe SingleSeated Solution
KEY-C AlternativeSolution
KEY-C: Case of Study
Project: HAIL Surface facilities
EPC:
Valve Application: Flow Control
KEY-C: Case of Study
Project: HAIL Surface facilities
EPC:
Valve Application: Flow Control
Common Globe SingleSeated Solution
KEY-C AlternativeSolution
Common Globe SingleSeated Solution
KEY-C AlternativeSolution
KEY-C: Case of Study
Project: HAIL Surface facilities
EPC:
Valve Application: Flow Control
KEY-C: Case of Study
Project: HAIL Surface facilities
EPC:
Valve Application: Flow Control
Common Globe SingleSeated Solution
KEY-C AlternativeSolution
Dimensions Saving:
FtoF: from 708 mm to 404 mm 42%height: from 1594 mm to 1049 mm 35%
Weight Saving:
from 664 kg to 420 kg 38%
Price Saving:
from 15.000 Euro to 9.500 Euro 40%
KEY-C: Actuation
16” ASME 900 CS Body / SS TrimPneumatic Double Acting SY Actuator withSmart Positioner2012 - Project Xinjinang Hutubi Gas Field
Main common Quarter Turn Actuators types:
Pneumatic Scotch Yoke Spring Return / Double Acting
Hydraulic Scotch Yoke Spring Return / Double Acting
Rack and Pinion for small valves
Electric control actuator
Manually operated (e.g. Laminating flow control)
! IMPORTANT !
Not all actuator types are suitable for control duty, due totheir poor control features as:
large Hysteresis / low Accuracy / low Repeatability
LIMITS of common SY Actuators
Nonlinear characteristics
Minimum torques in the middle of the stroke
Low efficiency due to the high internal friction
on prismatic joints
Stick slip effect
Low mechanical Efficiency
No useful for heavy duty cycles
Scotch Yoke limits arise when rotary valves are used for control service since the fluid-dynamicsbehavior contributes highly to increasing the valve torques along the stroke
Disadvantages SY Transmission
ALTO: Adaptive Linear Torque Output
Linear Torque Characteristic
Constant & High Efficiency
Wide Torques range
Pneumatic & Hydraulic configuration
Spring Assisted for Emergency Action
True modular design for maximumflexibility
Full range of override options: manual,geared, and hydraulic
The revolution of Simplicity
Innovative transmission system based on the principle to drive a
pulley by two anchored cables, ensuring the development of a linear
torque throughout the valve stroking cycle & high reliability on heavy
duty cycles
PATENTED
ALTO: Working Principle
Supply Mode Fail Mode
The ALTO transmission system converts the cylinder’s linear motion into a quarter-turn rotation by creating aconstant transmission ratio and constant mechanical efficiency along the entire stroke
The fluid pressure supply in the cylinder, puts tension on thecable and produces a clockwise quarter-turn rotation of thepulley along with the compressing the antagonist spring
In the case of an emergency, the supply fluid is released fromthe cylinder, allowing the antagonist spring to produce acounterclockwise quarter-turn rotation of the pulley.
ALTO: Features in Detail
ENP on cylindertube to ensureperfect dynamicseal, corrosionresistance, and
low friction
A rotatable elementconfigured to control
the position ofquarter turn valves
Two antagonistpreloaded cablesanchored on thepulley, to avoidany Backlash
Rolling bearingsinstead ofbushing toincreaseefficiency
Few elementsunderload,all slidingfrictions
eliminated
Coated spring forminimal bindingand corrosion
inhibition
Springs are guided andsupported to reducewear and to ensureproper alignment forintense repeatability
task
Two lateral ports for easy checkinspection and maintenance
Centre Body with a robust &compact construction, designed
for maximum rigidity andtoque transferinterface inaccordance with ISO 5211
Two externally adjustabletravel stop, mounted directly
on the Centre Body, toensure a correct alignment of
the valve obturator in theopen and closed positions
Designed to be the simplest, but efficient and safe
ALTO: Benefits
Q0° Q90°Stroke
Torq
ue
D S.M.
ALTO ActuatorScotch Yoke Actuator
Torques Characteristic comparison between PCA andconventional Scotch Yoke Actuator. PCA Actuatorprovides big advantages in terms of Safety Marginsalong the whole stroke, maximizing this contribution
in the middle.
Linearity increases Torques S.M. during running stroke
Actuators Size Reduction
Better matching with Butterfly Torques Curve
High Efficiency (Rolling << Sliding friction)
High Accuracy
High Repeatability
Zero Backlash
Low complexity
Rolling friction instead of Sliding friction
Few elements underload
Requirements for Control Applications
Requirements for Longer Life & less Maintenance
30%
ALTO: Case of Study 1
Actuator Sizing
Valve: KEY-C 10” ASME 300
S.M. 30%
Safety position: CLOSE
Option I: Common SY Actuator
Option II: ALTO Actuator
the fluid-dynamics behaviorcontributes highly to increasingvalve torques along the stroke
Nm
ALTO: Testing Results
Linearity Torque @ Stroke
Actuator has been tested in accordance with EN15714
Endurance Test: 100.000 cycles under load successfully performed
ALTO: Specifications
Design temperature
Standard range: -29°C to 100°C
Low temperature: down to -60°C
High temperature: up to 148°C
Design pressure
Pneumatic cylinder: up to 12 barg
Hydraulic cylinder: up to 210 bargNo standard pressure ranges are available upon request
Supply mediaInstrument air, nitrogen, or sweet gasNACE compliance for sour gas applications
Torque rangeSingle acting spring return: up to 50.000 Nm
Certifications/approvals
Actuator sizing as per API 6DX
Designed in accordance with EN15714
Pressure components as per ASME VIII
IP66 per EN60539 (IP68 upon request)
Compliance with PED 97/23/EC
Compliance with ATEX
SIL 3 Certified (upon request)
ALTO: Control System
X - Pneumatic supply connectionY - Pneumatic connection to actuatorZ - Electric connection to SOV coilK - Electric connection to the positioner
Controls packages full customizable for the most criticalpneumatic and hydraulics applications:
Filter regular (Al and SS316)
Relief valve (SS316)
Check valve (SS316)
Solenoid valve, auto reset or manual reset (Al and SS316)
Pilot valve (Al and SS316)
Quick exhaust valve (SS316)
Unidirectional and bidirectional flow regulator (SS316)
Booster (Al and SS316)
SMART positioner for regulation
Working with the latest control technology in
accordance with international standards
ALTO: Summary Comparison
Pneumatic & Hydraulic conf. Available Available
Modular Solution Yes Yes
Assembly Configuration Horizontal Horizontal
Spring Assisted Yes Yes
Design Complexity Low Medium
Torque Range Wide Wide
Torque Characteristic Linear U curve
Efficiency Constant 97% 70-90%
Control Accuracy GOOD POOR
Zero Backlash Yes No
Reliability High Medium
Maintenance Low Medium
KEY-C: Applications in Oil & Gas
Separation & Treatment System: Level & Pressure control and blowdown
Compressor Surge Prevention / Recirculation Valve
Metering Station FCV and PCV’s
Pig Launcher & receiver: Pig Back pressure control
Crude Oil Loading Arms Control Valve
Common Requirements:
Larger than 3” valve size
High Pressure drop to control
Pressure rating ASME 300 and over
High cavitation risk with high potential noise
Large mass flow to manage
Accurate flow control required
Tight shutoff capability
KEY-C: Projects Reference List
REFERENCES VALVE CLASS VALVE SIZE
CUSTOMERCONTRACTOR
ENGEND USER PROJECT DESTINATION YEAR
Min
Max
Min
[in
ch
]
Max
[in
ch
]
TO
T.
QN
T
SOLBERG & ANDERSEN AKER - SRU Unit Ghana GHANA 2010 ASME 150 ASME 150 6 6 6
INTEGRACION DE SISTEMAS COTEMAR - Offshore platform MEXICO 2010 ASME 150 ASME 600 2 4 3
SOLBERG & ANDERSEN AKER PETROBRAS FPSO – MV22 BRAZIL 2010 ASME 300 ASME 300 8 8 4
FORTUNE CONTROLS - - - UAE 2010 ASME 600 ASME 900 4 8 3
AKER SOLUTION AKER SOLUTIONS UN-RIO / ATP - ROPlatform P-62
BRAZIL 2010 ASME 150 ASME 150 8 8 3
AKER SOLUTION AKER SOLUTIONS UN-RIO / ATP - RO Platform P-58 BRAZIL 2010 ASME 150 ASME 150 8 8 4
SOLBERG &ANDERSEN BW OFFSHORE FPSO Waimea BRAZIL 2011 ASME 150 ASME 150 6 6 1
SOLBERG &ANDERSEN AIBEL STATOIL Offshore Platform NORWAY 2011 ASME 2500 ASME 2500 2 2 1
TANGENT CONTROLSXinjinang Hutubi Gas
FieldCHINA 2012 ASME 600 ASME 900 12 16 5
ENDRESS + HAUSER CONSORCIO LPGLPG PROJECT
ECUADORECUADOR 2012 ASME 300 ASME 300 6 12 26
VALEX ENGINEERING Gas Storage CHINA 2012 ASME 600 ASME 600 12 16 3
VALEX ENGINEERING GangQing Pipeline 3# CHINA 2013 ASME 600 ASME 600 10 10 1
VALEX ENGINEERING WATANG CHINA 2013 ASME 600 ASME 600 4 4 1
MRC SAAS MODEC GHANA LTD Platform JUBILEE GHANA 2014 ASME 300 ASME 300 8 8 2
MODEC Offshore MODEC Tullow Ghana FPSO TEN GHANA 2014 ASME 150 ASME 150 24 24 1
MRC SAAS MODEC GHANA LTD Platform JUBILEE GHANA 2014 ASME 300 ASME 300 8 8 2
MODEC Offshore MODEC PETROBRAS FPSO MV-29 BRAZIL 2015 ASME 150 ASME 600 6 20 26