Vanessa Triple Offset ValvesVanessa Triple Offset Valves

IGNACIO ROMERO – Emerson Automation SolutionsLatin America Butterfly and Triple Offset Valves Business Development Manager

Part 1 Safety Instrumented Systems

Part 2 Emergency shutdown

Part 3 Vanessa TOV

Part 4 Storage tank emergency shutdown

Part 5 References

AGENDA

Safety InstrumentedSystems

• Safety Integrity Systems (SIS) are designed to

• protect personnel, equipment and the environment by mitigating the likelihood and severity of the potential risk

• prevent or reduce hazardous events by taking the process to a safe state when predetermined conditions are violated

• IEC 61508/61511 standards set up the key provisions for its implementation

• Sub-systems of SIS are:

• Safety Related Systems

• Safety Interlocks

• Emergency Shutdown Systems (ESD)

• Fire & Gas Systems (FGS)

• Instrumented Protective Systems (IPS)

• Burner Management Systems (BMS)

• High Integrity Pressure Protection System (HIPPS)

PROTECTING PERSONNEL, EQUIPMENT & THE ENVIRONMENT

EmergencyShutdown

Due to more stringent health, safety and environment (HSE) requirements, tank farm operators are increasingly adopting triple offset valves (TOVs) for critical emergency systems

• An SIS, in this case we will consider Emergency Shutdown System (ESD) only, consists of multiple SIF (Safety Instrumented Functions)

• Each Safety Instrumented Function has a Safety Integrity Level (SIL) rating – SIL applies to the devices that make up the Safety Instrumented Function (e.g.: valve + actuator + controls)

• Based on the probability of failure, there are four SIL classes: • SIL 0/none – lowest risk

• SIL 1 – 80% of the Safety Integrity Functions (SIFs)

• SIL 2 (Low-Med-High) – 20% of SIFs

• SIL 3 – < 1%

• SIL 4 – highest risk

• Higher reliability/plant availability is achieved by using proper safety components (design), installing such components as per manufacturer’s guidelines and testing them both at initial startup as well as at specified intervals or after any modification

SIL CLASSES

The different components of an emergency shutdown system imply different levels of probability of failure

• Ball valves have symmetric designs in respect to the pipe axis and therefore their behavior is independent from flow direction and ΔP – they do not intrinsically support a specific safety function

• they require higher contribution from the actuation to be moved from their “stable” and “balanced” operating condition, with the underlying risk of failing when the emergency signal is triggered

• The use of PTFE seats to provide tighter shut-off may increase the variability of torque demand overtime. This implies that actuation needs to be often oversized to ensure longer term reliability

STANDARD VALVES ON PROTECTIVE SERVICES

• With the presence of significant pipe stresses ball valve trims tend to suffer due to the bending of the body and the compression of the ball against the seat, often causing stickiness and leakage

• To overcome such issue, operators must set up dedicated supports to offload such vibrations from the valve body incurring into further costs

Protective valve services have been historically handled by automated ball valves

• The adoption of TOVs in storage-tank safety systems is driven by basic design principles applied to emergency valves

• This is why an inherently safer design such as Vanessa TOVs', coupled with appropriate automation and controls, can help contribute towards a safer system altogether

ADOPTING TOVs IN ESD FUNCTIONS

• Critical developments in the management of safety integrity, in response to several serious accidents, have triggered a search for more reliable valve solutions

• Automated Vanessa TOVs are capable of achieving the Safety Integrity Level (SIL) 3 according to safety standard IEC 61508, and they are increasingly being selected to handle several functions within emergency systems: Vanessa TOVs provide the rapid isolation of the vessel in response to an emergency signal

With an accurate valve, material and actuator selection, the asymmetric behavior of Vanessa TOVs' trim significantly minimizes systematic failure

Vanessa TOVs

CONE-TO-CONE SEALING

Vanessa uses a sealing system consisting of stationary seat and a rotating sealing surface sharing an identical shape: an inclined conic section

CONTACT BETWEEN SEALING ELEMENTS

Vanessa features a non-rubbing design that produces a single, instantaneous contact line between sealing elements as soon as closed position is reached

Valve Size

Seat tests with WATER

Isolation Valves Control valves

Test pressure = 1.1 * design ΔpANSI/FCI 70-2 or IEC 60534-4

Test pressure: 45÷60 psig ≈ 3÷4 barg OR design Δp ±5%[4]

mm inch

EN 12266-1 or ISO

5208 Leak Rate A ≈

API 598 Resilent

Seated (Liq.)[1]

EN 12266-1 or ISO

5208 Leak Rate B (Liq.)

EN 12266-1 or ISO

5208 Leak Rate C (Liq.)

API 598 Metal Seated

(Liq.)[2] Leakage Class VI[4]

Leakage Class V

(Liq.),

e.g.: Class 300[5]

(Test press. = 740 psig≈ 51 barg)

Leakage Class IV

(Liq.),

e.g.: Class 300[6]

(Test press. = 50 psig ≈

3.5 barg)

80 3" 0 0.05 0.14 0.38

Not Applicable

1.1 172.1

200 8" 0 0.12 0.36 1.00 3.0 2289.1

300 12" 0 0.18 0.54 1.50 4.4 6554.3

600 24" 0 0.36 1.08 3.00 8.9 29630.6

900 36" 0 0.54 1.62 4.50 13.3 77830.6

Valve Size

Seat tests with AIR or nitrogen gas

Isolation Valves Control valves

Test pressure: 60÷100 psig ≈ 4÷7 bargANSI/FCI 70-2 or IEC 60534-4

Test pressure: 45÷60 psig ≈ 3÷4 barg

mm inch

EN 12266-1 or ISO

5208 Leak Rate A ≈

API 598 Resilent

Seated (Gas)[1]

EN 12266-1 or ISO

5208 Leak Rate B

(Gas)

EN 12266-1 or ISO

5208 Leak Rate C

(Gas)

API 598 Metal Seated

(Gas)[3] Leakage Class VI[4] Leakage Class V (Gas)

Leakage Class IV

(Gas),

e.g.: Class 300[6]

(Test press. = 50 psig ≈

3.5 barg)

80 3" 0 1.4 14.4 12 bubbles/min ≈ 0.8 0.9 14.1 5729

200 8" 0 3.6 36.0 32 bubbles/min ≈ 2.1 6.75 37.6 76181

300 12" 0 5.4 54.0 48 bubbles/min ≈ 3.1 16.0 56.4 218121

600 24" 0 10.8 108.0 96 bubbles/min ≈ 6.3

Not Applicable

112.8 986084

900 36" 0 16.2 162.0144 bubbles/min ≈

9.4169.2 2590148

If not specified otherwise, the leak rate values are expressed in ml/min.

ALLOWABLE LEAKAGE RATES - STANDARDS

Valve Size

Seat tests with WATER

Isolation Valves

Test pressure = 1.1 * design Δp

mm inchesEN 12266-1 or ISO 5208 Leak

Rate A ≈ API 598 Resilient Seated (Liq.)

API 598 Metal Seated (Liq.)

80 3" 0 0.38

200 8" 0 1.00

300 12" 0 1.25

600 24" 0 3.00

900 36" 0 4.50

BIDIRECTIONAL ZERO LEAKAGE

Valve Size

Seat tests with AIR or nitrogen gas

Isolation Valves

Test pressure: 60÷100 psig ≈ 4÷7 barg

mm inchesEN 12266-1 or ISO 5208 Leak

Rate A ≈ API 598 Resilient Seated (Gas)

API 598 Metal Seated (Gas)

80 3" 0 12 bubbles/min ≈ 0.8

200 8" 0 32 bubbles/min ≈ 2.1

300 12" 0 48 bubbles/min ≈ 3.1

600 24" 0 96 bubbles/min ≈ 6.3

900 36" 0 144 bubbles/min ≈ 9.4

Vanessa metal-to-metal TOVs perform zero* leakage to API 598 resilient seated (the most stringent for isolation valves)

EN 12266-1 or ISO 5208 Leak Rate B and C (Liq.) also available

*Zero Leakage means no visible leakage when tested at high pressure with water and low pressure with air according to existing

international standards

Vanessa Series 30,000 ESD Function

• When ΔP is acting on the shaft side, it generates a torque that is contributing to keep the valve closed

• When ΔP is acting on the disc side, the valve will tend to open instead

• When the valve is open, the offset shaft produces a large region of low velocity flow whenever the flow is coming from the shaft side, therefore generating a large pressure differential between the upstream and the downstream of the disc – this dynamic effect (known as dynamic torque) will also push the valve to close

ASYMMETRICAL TRIM DESIGN

The asymmetry of the valve triggers different behavior depending on installation – this increases the reliability of the valve when actuation fails

TOV KEY BENEFITS• The metal-to-metal non rubbing design supports

quick acting

• Depending on the safety function, the operating speed for valve closing or opening can be as low as 1 second

• Thanks to their non-rubbing quarter turn rotation, TOVs are capable of opening / closing in extremely short times compared to other valve design in view of extremely low running torque requirements

TOVs offer intrinsically higher Safety Integrity Levels (SIL) compared to other conventional ball valves.

QUICK ACTING

• Low and constant torque demand (running torque) across 90°of trim rotation ensures high safety factor when selecting typical standard scotch yoke actuation

• Operability remains reliable over time and across the whole trim travel

OTHER ADVANTAGES

• Non-rubbing metal-to-metal rotation• Higher reliability for emergency operations

• A valve unaffected by piping loads• Improved operability

• Higher reliability for emergency operations

• No need for external supports

• Ability to provide control function together with ESD

By eliminating contact between the metal seat and seal during opening-closing, Vanessa TOVs require minimum/no maintenance across most applications

MULTIPLE/COMBINED FUNCTIONALITIES

• Vanessa Series 30,000 valves are SIL 3 certified according to IEC 61508: 2010

• The valves were functionally assessed through proven in use data analysis and Design Review FMECA (Failure Mode Effects and Criticality Analysis) to determine SIL level in case of:

• deliver full stroke

• deliver tight shut-off for clean and unclean duties

• In addition, failures have been distinguished in

• Systematic and Random as requested by

• the IEC 61508:2010 safety standard

VANESSA SIL CERTIFICATION

Storage TankEmergency Shutdown

STORAGE – EMERGENCY SHUTDOWN

Main Vanessa TOV ESD tank valve functions:

• on inlet line (emergency close)

• on outlet line (emergency close)

• on overflow line (emergency open)

• venting (emergency open)

A single product fulfilling all storage tanks applications to provide significant cost benefits to users

STORAGE – EMERGENCY SHUTDOWN

Vanessa Series 30,000 offer intrinsically higher Safety Integrity Levels (SIL) compared to other conventional bidirectional ball and gate valves

HYDROCARBON STORAGE TANK

SIL-3 ARCHITECTURE AND CONTROL SYSTEM

STORAGE – EMERGENCY SHUTDOWN

• EMERGENCY VALVES INSTALLED ON STORAGE-TANK INLET AND OUTLET

• EMERGENCY VALVES INSTALLED ON STORAGE-TANK OVERFLOW LINE

Vanessa TOVs can be installed on both line loading/offloading and tanks

SAFETY INTEGRITY SYSTEMOPERATING SYSTEM

ESD: Emergency Shut DownDCS: Digital Control SystemROSOVs: Remotely Operated Shut-Off Valve

References

Adopting TOVs in place of standard process valves will significantly improve the safety standards of these operations.

TOVs were selected to create an independent emergency-close function and were separated from the newly installed MOVs. The signal to manage the ROSOVs is generated independently from the standard operating

devices for normal loading, offloading and inventory activities.

In response to the recommendations by the investigating commission, TOVs were adopted to improve safety by introducing a ROSOV as the first tank-body valve

In a large storage tank farm in India, a fuel leakage and a consequent fire resulted in several deaths and a significant number of injuries.c

SIL UPGRADES – CASE 1

Safety can be improved by adopting Vanessa Series 30,000 triple offset valves

STORAGE – EMERGENCY SHUTDOWN

Jubail refinery has adopted TOVs as emergency shutdown valves

Depending on the risks arising from handling specific fluids, the refiner has increased the level of safety by combining different types of actuation with fail-close/fail-last functions with TOVs.

To comply, several tank operators have switched from gate to non-rubbing torque seated metal-to-metal TOVs.

These valves must now be automated and controlled from the outside of the tank dyke. Personnel and the DCS should be able to remotely set the valves in a fail-safe position.

In The Netherlands, for example, new rules were introduced on the use of firesafe, fail-safe valves as the first shut-off valves installed on the tank wall, i.e., first tank-body valves.

In 2005, The results of the investigation carried out by the Health and Safety Commission in the UK after the Buncefield Oil Depot incident were used as a guideline across several countries to review layouts and safety

regulation in tank farm facilities.

SIL UPGRADES – CASE 2

Safety can be improved by adopting Vanessa Series 30,000 triple offset valves

PROJECT NAME CUSTOMER NAME LOCATION TYPE OF PLANT QUANTITY BODY STYLE SIZE RANGE (FROM/TO)PRESSURE CLASS

RANGE (FROM/TO)

SHAYBAH NGL (1,2,4)

SAUDI ARAMCO SAUDI ARABIA NGL PLANT 86 DF 12”-68” CLASS 150-900

SAUDI KAYANSAUDI KAYAN

PETROCHEMICAL COMPANY

UAE OLEFINS PLANT 76 DF & LUG 10”-42 CLASS 150-600

WASIT SAUDI ARAMCO SAUDI ARABIA GAS PLANT 54 DF 8”-64” CLASS 150-600

SOUTH HOOK LNG TERMINAL

SOUTH HOOK UK LNG TERMINAL 53 DF 8”-32” CLASS 150

YAMAL LNG YAMAL RUSSIA LNG TERMINAL 49 DF 4”-40” CLASS 150-900

ARZEW GNL SONATRACH ALGERIA LNG PLANT 31 DF & BUTTWELD 8”-52” CLASS 150-600

BARZAN ONSHORE

RASGAS QATAR GAS TREATMENT 30 DF 46”-80” CLASS 150

ICHTHYS ONSHORE LNG

FACILITIESINPEX AUSTRALIA LNG PLANT 28 DF 20”-52” CLASS 150-600

FREEPORT LNG LIQUEFACITON

FREEPORT LNG USA LNG TERMINAL 22 DF 12”-14” CLASS 900

TERMINAL ISOLATION

ENBRIDGE PIPELINES

CANADAPIPELINE METERING

STATION19 DF 8”-24” CLASS 150-600

EXAMPLES OF ESD TM BALL VALVE REPLACEMENT

PROJECT NAME CUSTOMER NAME LOCATION TYPE OF PLANT FLUID QUANTITYSIZE RANGE (FROM/TO)

PRESSURE CLASS RANGE (FROM/TO)

SHAYBAH NGL (1,2,4) SAUDI ARAMCO SAUDI ARABIA NATURAL GAS HC LIQUID 668 6" TO 68"CLASS 150, 300, 600,

900

WASIT SAUDI ARAMCO SAUDI ARABIA GAS PLANT HC LIQUID 250 8" TO 64"CLASS 150, 300, 600,

900

SOUTH YOLOTEN GAS FIELD DEVELOPMENT

TURKMENGAS TURKMENISTAN NATURAL GAS HC GAS 126 10" TO 56"CLASS 150, 300, 600,

900

PORT & REFINERY AREA TANK FARM

SAUDI ARAMCO TOTAL REFINERY & PETROCHEMICAL

(SATORP)

SAUDI ARABIA OTHER HC LIQUID 40 14" TO 40" CLASS 150, 300

YIBAL KHUFFPETROLEUM

DEVELOPMENT OF OMAN (PDO)

OMAN OTHER HC LIQUID 48 8" TO 48"CLASS 150, 300, 600,

900

HELIUM 2 RASGAS QATAR OTHER HC GAS 6 6", 14" & 40" CLASS 150, 300

EXAMPLES OF TM BALL VALVE REPLACEMENTS

QUESTIONS?

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VanessaTriple Offset Valves