Valve Type Acceptance Test Experiences API
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VALVE TYPE ACCEPTANCE TEST EXPERIENCES
API Meeting - SCOPV
Los Angeles, California
November 15, 2011
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What is Shell’s Type Acceptance Testing (TAT)?
Testing of a valve to its design limits on temperature and pressure
Seat testing with nitrogen and fugitive emission testing with heliumAmbient temperature
Maximum advertised temperature
Minimum advertised temperature
Ambient temperature
200 mechanical cycles including opening and closing torques
Acceptance criteria is based upon ISO 5208 (seat leakage) and ISO 15848 (FE)
TAT is part of a total valve qualification program complemented by:
Technical documentation review
Valve manufacturer technical audit (ISO 9001 methodology)
Valve design validation and verification
TAT EXPERIENCES
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TAT EXPERIENCES--2” 1500# SOFT-SEATED TRUNNION MOUNTED BALL VALVE
Unacceptable seat leakage due to o-ring/seat failure
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TAT EXPERIENCES--10” 1500# BOLTED BONNET GATE VALVE
Jammed wedge resulted in elongation of the stem. Instead of 4
threads per inch some parts of the stem only had 3 threads per inch.
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TAT EXPERIENCES--1” PN10 PLASTIC LINED PISTON CHECK VALVE
During high temperature seat testing the valve failed due to the wings of
the piston being deformed and the piston being hung in the seat guide.
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TAT EXPERIENCES--20” 600# EXPANDING GATE VALVE
During teardown of the valve it was discovered that the top part of
expanding gate wedge was deformed and pressed into top plate
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TAT EXPERIENCES--3” 300# GATE VALVE
Valve failed seat testing and during teardown it was discovered that
the stem threads were deformed after only 100 cycles
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TAT EXPERIENCES--8” 150# METAL SEATED BALL VALVE
During cycling of the valve, the opening/closing torque became very
high. During teardown it was discovered that the hard face overlay
was damaged and ball was scratched.
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TAT EXPERIENCES--4” & 10” 2500# TMBV
Excessive seat leakage was experienced during testing at ambient
temperature, due to lip seal damage. Valve design didn't give sufficient lip
seal housing clearance.
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TAT EXPERIENCES--10” 2500# TMBV
Actuator failure due to excessive valve torque at ambient temperature
due to bearing seizure & poor bearing design.
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TAT EXPERIENCES--10” 2500# TMBV
Excessive seat leakage at ambient temperature due to failure of metal
coating on ball and seat.
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TAT EXPERIENCES--10“ 600# BOLTED BONNET GATE VALVE
Damaged stem threads due to failure of the drive nut. The drive nut material was incorrect.
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TAT EXPERIENCES--6” 1500# PRESSURE SEALED GATE VALVE
Stem seal failure due to incorrect packing
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TAT EXPERIENCES--4” 150# TMBV
Valve had passed the testing portion of the TAT but during teardown it was found that their was interference between the ball and end pieces. The parts were within design tolerance, but the design had to be revised.
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TAT EXPERIENCES
Triple offset BF valve leaked at elevated temperature due to gasket
degradation. Gasket was only rated for 650°F while valve was advertised as
good to 800°F.
18” 600# ball valve wouldn’t open during final ambient test due sticking of
stem and galling from too tight of tolerances. Design had changed earlier to
open tolerance range, but drawings were not updated.
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TAT EXPERIENCES
Severe damage to stem and nut threads caused by galling between
316 SS stem & ductile iron nut.
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TAT EXPERIENCES
Explosive decompression during TAT.
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TAT EXPERIENCES
Stem stretched approximately 3.5” during mechanical cycling. Thread
external diameter was reduced from 2.4835” to 2.3755”.
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TAT EXPERIENCES--24“ 1500# BALL VALVEPEEK lip seal & spacer rings shrank during the low temperature testing (-58°F) which allowed the lip seal
to fall out into the valve bore. The lip seal and the spacer rings became trapped between the ball and
seats during the operation of valve creating seat sealing failure. Manufacturer changed lip seal spacer
ring material from PEEK to alloy 625.
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TAT EXPERIENCES
Severe cracking of high pressure steam non-return valve body
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TAT EXPERIENCES--10” 1500# METAL-SEATED TMBV
Excessive seat leakage after cycling at 575°F due to failure of tungsten
carbide coatings due to spring force being too high for 575°F
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TAT EXPERIENCES
Questions?
Thank you!