Valves

Users Perspective &

Expectations
Petroleum Refinery and Petrochemicals

By P.K.Shrivastava
(Reliance Engineering Associates Limited)

Introduction

Reliance has recently completed major projects

comprising
of
integrated
Petroleum
Refinery
&
Petrochemical complex ( JERP )along with Deep Sea Oil &
Gas production systems ( KGD6 ).
Installed and put into operation more than 350,000 valves
Similar quantum of valves are in use in the existing plants
of RIL group companies which are being maintained .
Used almost all types of valve, viz. Gate, Globe, Check,
Butterfly, Ball, Plug etc. Valves for new projects are
procured from domestic as well as international markets.
(Onshore scope is about 60% for cast steel valves & 5% for
forged valves)

Valve Vendor evaluation checklist

Almost all the valves are procured directly from
the manufacturers. The vendors were evaluated
on the following checkpoints prior to consideration
for Order placement :

Design Capability & Technical tie-up/back ups

Range of valves manufactured (Size/MOC & service
wise)
ISO 9001 accreditation & API monograms
List of Satisfactory clients
Service tenure of the valves
Manufacturing capacity (including inspection facilities,
Hydro/Pneumatic testing facilities, painting, material
identification facilities, etc.)
Casting sourcing procedures

Types of Valves Used

Types of Special Valves Used

Over and above the basic types of valves specified in the
earlier slide, following special valves are used :
Metal seated triple offset butterfly valve for general
hydrocarbons service in the size range of 10 to 72
Nozzle check valves Plate type check valves for gas /air
services
Cryogenic Gate /Globe /Ball valves with extended
spindles
Angle Valves
Needle Valves

Plate type Check Valve

The major advantages of the plate type check
valves are :
Reliable and rapid closing action upon or
before flow reversal
Minimal pressure drop
Long service life even in pulsating flow
environments
Low maintenance
Low Noise
Smooth operation at different duty points
Variable installation position
Compliance with international Standards and
directives

Material of Construction used

Body Construction types used

Sizes of Valves used

64%

15%
12%
6%

2%

1%

Material of Construction used in

KGD6 Onshore Application

Size-Range of valves used in KGD6

Onshore Application

Size Range

UOM

Carbon Steel

Duplex SS

SS

LTCS

6Mo SS

Total

1/2" - 1.1/2"

Each

7924

144

1717

3277

72

13134

2"-10"

Each

6682

290

1814

3951

165

12902

>10"

Each

429

51

72

560

Problems Experienced
While there has been some perceived improvement as
compared to the quality of valves procured in our earlier
Petroleum / Petrochemical projects, there is sufficient
scope for the enhancement in the design and overall
quality system for the domestic suppliers to focus on.
Major observations related to design and quality of the
valves have been illustrated in the subsequent slides.
These findings have been summarized on the basis of the
problems reported at Jamnagar site from the recently
commissioned Jamnagar Export Refinery Project.

Problems encountered in Globe Valves

In case of unidirectional Globe valves designed for flow from over the

disc and tested in the same direction Problems were experienced with
large size (>10) valves which could not take the test pressure in the
conventional direction. These sort of cases pose operational hazards
because these valves may not block the flow from both directions. Our
suggestion in this regard is to design the valve, with suitable disc profile
and stem material, such that these could hold the pressure from both the
directions.
In case of unidirectional Globe Valves, It may also be noted that the
valves designed for flow from under the disc are inherently suitable for
flow from both the sides; however, the reverse is not possible unless the
valves are designed and tested from both the directions. The subsequent
slide comprising of a typical globe valve design in accordance to BS 1873
shall lend more clarity to this point.

Problems encountered in Globe Valve

Problems encountered in Globe Valves

Gland

Leakage

Leakage from Seat / Bonnet joints identified during

hydrotest prior to plant start-up.
Operational / functional problems during project start-up
Mismatch in body MOC identified during PMI tests at site
Broken stems
Gear Box problems
It may be noted that this sort of problems identified prior to
plant start-up had a major impact on meeting the project
schedule at the eleventh hour.

Sample case of Problem encountered in

a Globe Valve used in By-pass line
One sample case of a failure encountered in a 12 Class 300
Globe valve in a Control Valve By-pass line is worth
mentioning as the leakage of the fluid (LCGO) through its
gland led eventually led to a fire as shown below :

Sample case of Problem encountered in

a Globe Valve used in By-pass line
The major observations on dismantling this valve are listed below:
There were no gland packing which could have been blown away
during the leak and subsequent fire.
The guide rod at the bottom was missing The construction was flimsy
even the weld to disc appeared inadequate as checked on another
valve of same make.
The bush on which the back seat sits could be opened by hand
indicate poor fabrication practice.
The body/bonnet gasket was of grafoil only instead of spiral wool
SS316 as per data sheet.
The stem didnt bend and no scoring marks at gland area.
The disc was in position and remote possibilities of its rotation on its
own and flow reduction.
There was also no proof of third party inspection of this valve during
hydro-test at the Vendor shop. The inspected valves scope did not
mention this valve as part of third party inspection.

Sample case of Problem encountered in

a Globe Valve used in By-pass line
The snaps of the valve internals specified below will give
a better insight to the findings of the failure of the globe valve :

Problems encountered in Gate Valves

Gland Leakage and Leakage thru bonnet stuffing box found on
account of broken packing rings.
Damaged Wedge seating area & damaged guides accounting for
problematic wedge movement. There were also cases screwed seat
rings which should actually have been seal welded.
Operational / functional problems during project start-up
Mismatch in body MOC identified during PMI tests at site
Castings were not of radiographic quality as Pin-holes in bonnet /
Blow holes in body were commonly observed.
Gear Box problems
Body flange thickness was often found to be on the lower side
when compared with the dimensional standards. Problems were
also faced at site related to the bolting of the flanges as the same
were not machined properly.

Problems encountered in Gate Valves

Casting Defects - Blow holes found on new valve bodies

Problems encountered in Gate Valves

Casting Defects - Blow holes found on new valve bodies

Problems encountered in Ball Valves

Gland Leakage & Leakage through sealant connections.
Gearbox body movement during operation.
Development of cracks near the handle
No Operation Handle free rotation / Bent spindle
Other operational problems like noise/friction during
operation.
It is to be noted that these problems of ball valves were all
identified in sizes of 10 only.
In case of ball valves for sizes up to 3/4 installation at site
was problematic as the mating flange studs were fouling
with valve body bolting .

Problems encountered in Ball Valves

Crack near the

handle

Improper bolting
leading to
improper gasket
compression

Problems encountered in Butterfly Valves

Problem of improper lining on body/seat/disc for
large size valves (>24 NPS), e.g.. Many cases of
liners not extended to the flange face were identified
Frequent problem of damaged liners, improper
bonding of liner with body/disc
Effective bonding procedure for the EPDM lining on
body/disc to be developed
Metallurgical issues need to be addressed due to
highly corrosive nature of seawater. It may be noted
that Cu-based alloys cause problem of galvanic
corrosion in the CS pipelines with saline service

Problems encountered in Butterfly Valves

Soft Seat coming out of

position during opening
after hydrotest of a 42
butterfly valve
Poor quality of coating on
the disc, coating could not
take even a gentle tapping
by hand. Lining problems
also exist with body lining.

Problems encountered in Butterfly Valves

Case of a recent Valve Rubber Lining Failure encountered in
JERP

Problems encountered in Butterfly Valves

Bolting not possible at tapped holes.
Damaged liners & lining problems leading to
leakage from seat.
Seat passing even at low pressures.
Automatic Valve closure without any manual
intervention when left in open condition.
Operational / functional problems which can pose a
severe threat specially in the Fire water lines during
emergencies.
These problems were identified in valves in the size range
from 12 to 72.

Problems encountered in Check Valves

Wafer type design is not recommended for hydrocarbon
services on account of associated leakage hazard in case of
accidental fire (due to differential expansion of studs on high
temperature services and studs getting exposed to external
fire) on account of which there was a requirement of Dual
Plate Double Flanged Check Valves where we faced a
problem of sourcing the same from domestic market.
As a minimum, where the flanged design is not possible as
per API594 due to dimensional limitations, extended face to
face dimensions to accommodate fastening of the bolts to be
looked into
Retainer-less design should be developed to meet low
fugitive emission requirements and also to preclude any
leakage hazard
Rubber lined check valves pose similar problems of
damage to body/disc lining, as explained in the previous
slides for lined butterfly valves

Problems encountered in Check Valves

Typical Check Valve designs (API 594) required / Supplied
Required
Double
Flanged
Design

Supplied
Wafer Type
Design

Suggested Solid Lug

Design where
dimensional
limitations are
involved

Problems encountered in Check Valves

Seat leakage, Leakage from damper, leakage of hyd oil
thru damper were some common leakage problems faced
pertaining to Check Valves during the start-up of the
Jamnagar Export Refinery Project.
Pin hole / Blow-Hole observed in the valve body.
Mismatch in body MOC identified during PMI tests at site
Operational / Functional problems
Spring & Shaft failure of Nozzle check Valve on the outlet
of reciprocating compressor on account of fluctuation of
fluid flow.

Sample case of problems in 16",

600# ,Dual Plate Check Valve
The following observations in a 16", 600# ,Dual Plate Check
Valve (Body and Disc -SA216 WCB+STL6 Overlay) operating
in a Pump discharge line is worth mentioning
A through and through hole at 1 to 2 oclock position was
observed at back side of valve disc.
The water jet impingement through disc hole also further
eroded the valve body.
Radiography of the whole disc was carried and casting
defects like shrinkage cracks, porosity and sand inclusion
were observed. Taking cue from these findings similar
checks were carried on other valves of the same make for
this project where the findings were similar at other discs at
similar location.
The snaps of these valve in the next slide will lend more
clarity to this case

Sample case of problems in 16",

600# ,Dual Plate Check Valve

Spring & Shaft failure of Nozzle check

Valve

Quality System
The existing system of Quality Control & management at the
Vendors place seems inadequate/deficient, particularly
when it comes to large scale production of quality valves.
There have been many instances of failure at various levels
of manufacturing, as mentioned below:
Mix up of metallurgy in alloy steel valves. Many cases have been
noticed at the PMI tests conducted at site where the body/bonnet
metallurgy are different between what was specified in the requirement
and the actual receipt at site. This indicates lack of traceability at shop
level and may result in severe accidents once installed in
Petrochemical / Petroleum sites involving a fair degree of hazardous
services.
Lack of traceability of trim materials metallurgy
Perceived failure/inadequacy of final inspection at manufacturer shop
level by qualified inspectors using fool-proof inspection techniques.

Quality System
The instances Multiple Failures of valves during hydrotest
at site (seat/body) are very high, and this causes concern on
shop level testing
Improper packaging and preservation system before
dispatch, which results in damages to valves rendering them
unsuitable for application on receipt at site in the course of
which the project schedule completion gets affected.
Casting Defects have been a major concern. Radiographic
quality castings should be a norm. Whereby Castings are
out-sourced to other foundries, qualified vendors quality
control inspector should supervise the entire process to
ensure the quality of the castings.
Radiography/NDE facilities for higher rated valves having
high thickness need to be developed

Valve Installation SOP work-flow

Design Development & Facility

Enhancement Scope
With the increasing plant capacities, current technologies
require large size and high rated valves for which there is
limitation on available capacity in India. Subsequent to
execution of many Mega Projects, we feel that there is a need
for more R&D for the development of high performance valves
and valves having special feature, as specified below :
Dual plate wafer type check valves with retainer-less design
to address fugitive emission issues
Dual plate check valves with double flanged/solid lug type
design
Swing check valves cast-in hinge arrangement
Large size swing check valves with actuated/hydraulic
dampening devices

Design Development & Facility

Enhancement Scope
Triple offset butterfly valves in large sizes (>54 NPS)
Triple offset butterfly valves with solid metal disc-seat ring
Large size (>24 NPS) butterfly valves for seawater service,
requiring rubber lining
Improved Competiveness & Capacity for forged valves
Guided disc feature must be included in all Globe valves
Development of Ball and Spring type check valves
UWL certification of valves
Design of valves with extension spindle
Chain wheel operated valves
Limitation in availability of ball valves manufacturing facilities
Development of Nozzle Check Valves
Improvement in Site Support System

Future Projects & Our Expectations

Keeping in view the fast track nature of projects, we expect
the Domestic Valve industry to come forward with the three
pronged challenges of :
Manufacturing quality valves in the shortest possible
delivery lead time.
Competitive pricing without compromising on quality
(lest, India may loose out on the market like China).
Effective Service after sales, which can go a long way
in the smooth commissioning of the projects.

Thank You