Pipeline Valve Technology This book covers the life cycle of pipeline valves, the largest and most essential valves in offshore pipeline engineering. Discussing the design process, testing, pro- duction, transportation, installation, and maintenance, the book also covers the risk analysis required to assess the reliability of these valves. Pipeline valves require particular attention to ensure they are safely designed, installed, and maintained, due to the high stakes. Failure would result in environmen- tal pollution, the destruction of expensive assets, and potential loss of life. Proper installation and upkeep require specialist processes throughout the life cycle of the valve. This book is a key guide to these processes. Beginning by looking at the design of pipeline valves, this book details how conserving weight and space is prioritized, how materials are chosen, how thickness is calculated, and how leakage is mini- mized. It then discusses production and specific welding techniques to bond dissimi- lar materials, alongside casting and machining. Building on other discussions in the text with case studies and questions and answers for self-study, this book is the ideal guide to pipeline valves. This book will be of interest to professionals in the industries of offshore oil and gas, material engineering, coatings, mechanical engineering, and piping. It will also be relevant to students studying coating, welding, mechanical, piping, or petroleum engineering. Pipeline Valve Technology A Practical Guide Karan Sotoodeh Seventh edition published 2023 by CRC Press 6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742 and by CRC Press 4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN CRC Press is an imprint of Taylor & Francis Group, LLC © 2023 Karan Sotoodeh Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, access www.copyright.com or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978- 750-8400. For works that are not available on CCC please contact [email protected] Trademark notice: Product or corporate names may be trademarks or registered trademarks and are used only for identification and explanation without intent to infringe. ISBN: 978-1-032-38056-8 (hbk) ISBN: 978-1-032-38060-5 (pbk) ISBN: 978-1-003-34331-8 (ebk) ISBN: 978-1-032-38085-8 (eBook+) DOI: 10.1201/9781003343318 Typeset in Times by SPi Technologies India Pvt Ltd (Straive) Contents Preface .......................................................................................................................xi Acknowledgment ....................................................................................................xiii Author Biography ....................................................................................................xv Chapter 1 Introduction and General Features .......................................................1 1.1 Introduction ...............................................................................1 1.2 General Features ........................................................................2 1.2.1 Valve Types...................................................................2 1.2.2 Bore Requirement.........................................................2 1.2.3 Access to the Valve Internals ........................................2 1.2.4 Connection to the Pipeline ...........................................5 1.2.5 Metallic Seats ...............................................................6 1.2.6 Trunnion-Mounted Ball ................................................7 1.2.7 Design Standards ..........................................................7 1.2.8 Valve Operator ..............................................................8 1.3 Cross-Section Drawing and Part List ........................................9 Questions & Answers .........................................................................12 Bibliography .......................................................................................15 Chapter 2 Material Selection...............................................................................17 2.1 Introduction .............................................................................17 2.2 Material Selection ....................................................................18 2.2.1 Body and Bonnet ........................................................19 2.2.2 Valve Internals (Trim) ................................................20 2.2.3 Bolting (Bolts and Nuts) ............................................22 2.2.4 Pup Piece and Transition Piece ..................................24 2.2.5 Seal .............................................................................25 2.2.6 Stem Bearing ..............................................................26 2.2.7 Spring .........................................................................26 2.3 Coating ....................................................................................28 Questions & Answers .........................................................................29 Bibliography .......................................................................................30 Chapter 3 Double Isolation and Bleed Concept ..................................................33 3.1 Introduction .............................................................................33 3.2 Pipeline Valves DIB Concept ..................................................35 3.3 DIB Effects on the Valve Design .............................................38 3.4 DIB2 and Valve Marking .........................................................43 Questions & Answers .........................................................................44 Bibliography .......................................................................................47 v vi Contents Chapter 4 Design for Weight Reduction .............................................................49 4.1 Introduction .............................................................................49 4.2 Design for Weight Reduction ..................................................50 4.2.1 Wall Thickness Calculation and Validation ................50 4.2.1.1 Wall Thickness Calculation ........................50 4.2.1.2 Wall Thickness Validation ..........................58 4.2.2 Cylindrical Nuts .........................................................65 Questions & Answers .........................................................................67 Bibliography .......................................................................................69 Chapter 5 Seat Scrapers and Flushing Ports .......................................................71 5.1 Introduction .............................................................................71 5.2 Wax Dissolution in Seats .........................................................72 5.2.1 Sealant Injection Fittings ............................................72 5.2.2 Flushing Ports .............................................................72 5.2.3 Flushing Fluid ............................................................75 5.2.4 Flushing Procedure .....................................................75 5.3 Particles Ingress Prevention in Seats .......................................76 Questions & Answers .........................................................................76 Bibliography .......................................................................................77 Chapter 6 Manufacturing Process .......................................................................79 6.1 Introduction .............................................................................79 6.2 Pipeline Valves Manufacturing Processes ...............................79 6.2.1 Kick-off Meeting and Engineering .............................79 6.2.2 Purchasing or Manufacturing Raw Materials .............80 6.2.2.1 Casting ........................................................80 6.2.2.2 Forging ........................................................82 6.2.3 Welding ......................................................................83 6.2.4 Machining ...................................................................84 6.2.5 Inspection and Quality Control ..................................86 6.2.6 Assembly of Valves ....................................................87 6.2.6.1 Body and Bonnet Bolts Tightening .............87 6.2.6.2 Marking .......................................................90 6.2.7 Testing ........................................................................91 6.2.8 Coating or Painting .....................................................92 6.2.9 Preservation and Packing ...........................................92 6.2.10 Final Inspection ..........................................................92 6.2.11 Shipment .....................................................................93 Questions & Answers .........................................................................93 Bibliography .......................................................................................96 Contents vii Chapter 7 Welding Technology ...........................................................................99 7.1 Introduction .............................................................................99 7.2 Valve End Connections ............................................................99 7.2.1 Standard ASME Flange ..............................................99 7.2.2 Mechanical Joint (Hubs and Clamps) ........................99 7.2.3 Compact Flange ........................................................100 7.2.4 Wafer Connection .....................................................101 7.2.5 Threaded Connection ...............................................102 7.2.6 Welded Connections .................................................103 7.2.6.1 Socket Weld ..............................................103 7.2.6.2 Butt Weld ..................................................104 7.3 A Case Study of Welding Between Pipeline Valves and Two Oil and Gas Export Pipelines.........................................106 7.3.1 Pipeline Material Selection ......................................106 7.3.2 Pup and Transition Pieces ........................................110 7.3.3 Weld Joint NDTs ......................................................114 7.3.4 Pipeline Valves Welding ...........................................115 7.3.5 Welding Qualification at the Construction Yard .....................................................116 Questions & Answers .......................................................................116 Bibliography .....................................................................................118 Chapter 8 Actuation ..........................................................................................121 8.1 Introduction ...........................................................................121 8.2 Actuators’ Sources of Power .................................................122 8.2.1 Pneumatic Air ...........................................................122 8.2.2 Hydraulic ..................................................................123 8.2.3 Electrical ...................................................................123 8.3 Actuator Choices for Pipeline Valves ....................................124 8.3.1 Scotch and Yoke Actuator .........................................124 8.3.2 Linear Actuator .........................................................125 8.3.3 Electrical Actuator ....................................................125 8.4 Actuator Selection for Pipeline Valves ..................................126 8.5 Actuator Selection Case Study ..............................................127 Questions & Answers .......................................................................131 Bibliography .....................................................................................134 Chapter 9 Testing ..............................................................................................135 9.1 Introduction ...........................................................................135 9.2 Test Procedure .......................................................................136 9.3 Test Preparation .....................................................................136 9.4 Test Setup ..............................................................................137 9.5 Type of Tests ..........................................................................139 viii Contents 9.5.1 Hydrostatic High-Pressure Body or Shell Test .........139 9.5.1.1 Safety Relief Valve Test ............................141 9.5.2 Hydrostatic High-Pressure Seat or Closure Tests ............................................................141 9.5.3 Hydrostatic Functional and Torque Measurement Tests ...................................................143 9.5.4 Hydrostatic Cavity Tests ...........................................143 9.5.4.1 Both Seats Are SR ....................................145 9.5.4.2 Double Isolation and Bleed (DIB1) ..........146 9.5.4.3 Double Isolation and Bleed (DIB2) ..........146 9.5.5 Backseat Test ............................................................147 9.5.6 Air or Gas Low-Pressure Seat or Closure Tests .......149 9.5.7 High-Pressure Gas Body or Shell Test .....................149 9.5.8 High-Pressure Gas Seat or Closure Test ...................150 9.5.9 Drift Test ...................................................................150 9.5.10 Electrical Continuity Test .........................................151 9.5.11 Fire Test ....................................................................151 9.5.11.1 Fire Test According to API 6FA ................152 9.5.11.2 Fire Test for Pipeline Valves .....................154 9.5.11.3 Fire Thermal Simulation and Analysis Case Study ................................................154 9.6 Actuators Testing ...................................................................157 9.6.1 Hydraulic Actuators Testing .....................................157 9.6.2 Electrical Actuators Testing ......................................158 Questions & Answers .......................................................................158 Bibliography .....................................................................................161 Chapter 10 Preservation and Packing .................................................................163 10.1 Introduction ...........................................................................163 10.2 Preservation Types .................................................................163 10.2.1 General Preservation ................................................163 10.2.2 Internal Preservation .................................................166 10.2.3 External Preservation ...............................................168 10.3 Packing ..................................................................................170 Questions & Answers .......................................................................170 Bibliography .....................................................................................171 Chapter 11 Handling, Lifting, and Transportation ..............................................173 11.1 Handling ................................................................................173 11.2 Lifting ....................................................................................174 11.3 Transportation ........................................................................176 Questions & Answers .......................................................................180 Bibliography .....................................................................................182 Contents ix Chapter 12 Installation, Operation, and Maintenance.........................................183 12.1 Installation and Operation .....................................................183 12.1.1 Storage Before Installation .......................................183 12.1.2 Valve Installation and Operation on the Pipeline ..........................................................183 12.2 Maintenance ..........................................................................185 12.2.1 Emergency Sealant Injection ....................................185 12.2.1.1 Sealant Injection on Seats .........................185 12.2.1.2 Sealant Injection on Stem .........................186 12.2.2 Minor External Leakage Repairs ..............................186 12.2.2.1 Sealant Injection Fitting ............................188 12.2.2.2 Vent and Drain Blind Flanges ...................188 12.2.2.3 Modular Valves on the Seat Flushing Ports ...........................................189 12.2.3 Major External Leakage Repairs ..............................190 12.2.4 Internal Leakages .....................................................192 Questions & Answers .......................................................................197 Bibliography .....................................................................................199 Chapter 13 Safety and Reliability .......................................................................201 13.1 Introduction to Shutdown Systems ........................................201 13.2 Safety Integrity Level ............................................................202 13.2.1 SIL Case Study for a Pipeline Valve ........................206 13.3 Failure Mode and Effect Analysis .........................................209 13.3.1 FMEA Case Study for Pipeline Valves.....................209 13.4 Results and Discussion ..........................................................212 Questions & Answers .......................................................................213 Bibliography .....................................................................................214 Index ......................................................................................................................217