vw0903_safety_tyco.pdf
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OIL &GAS /REFINERY www.valve-world.net 74 March 2009 Valve programme for India Safety relief valves for the world’s largest single location refinery In completing the state-of-the-art, globally competitive refinery at Jamnagar, India within 36 months, from concept to commissioning during December 2008, Reliance Petroleum Limited has set a new global benchmark for building a grass-root refinery. Tyco Sanmar Limited, a Joint Venture between Tyco International Limited, USA – the world leader in fluid control products – and Sanmar Engineering Corporation, India – one of the largest manufacturers of engineered valves in India - , was the preferred supplier chosen by Reliance for the complete package of safety relief valves for both the existing and new refinery at Jamnagar. By Deepesh Nanda and Nilesh Doshi, Tyco Sanmar Ltd. Courtesy: Reliance Petroleum Limited website T he relationship between Reliance and Tyco Sanmar dates back to Reliance’s initial projects in the petrochemical sector. From Reliance’s first Jamnagar refinery in 1997 to the recent Jamnagar Export Refinery Project (JERP) – Tyco Sanmar has supplied a whole range of safety relief valves to Reliance Refineries.Work on JERP started in 2006, and with it started an exciting journey of technical selection in coordination with the world’s major engineering consultants, manufacturing, ASME-Sec-VIII Conventional Valve What is a safety relief (Pressure Relief) valve? A safety relief valve is a pressure relieving device designed to protect a pressurized vessel or system during an overpressure event. An overpressure event refers to any condition, which would cause pressure in a vessel or system to increase beyond its maximum allowable working pressure (MAWP). The basic spring operated safety relief valve(SOSRV) has been developed to meet the need for a simple, reliable, system actuated device to provide overpressure protection.The picture shows the construction of a conventional SOSRV.The valve consists of a valve inlet or nozzle mounted on the pressurized system, a disc held against the nozzle to prevent flow under normal system operating conditions, a spring to hold the disc closed, and a body/bonnet to contain the operating elements.The spring force is adjustable within its design range to vary the pressure at which the valve will open. What is a Pilot Operated Pressure Relief Valve ? A Pilot Operated Pressure Relief Valve (POSRV) is a Pressure Relief Valve in which the major relieving device is combined with and is controlled by a self actuated auxiliary Pressure Relief Valve(Pilot). Pilot operated pressure relief valve replace the spring with a small sophisticated controller or ‘pilot’ which reacts to pressure similar to a conventional valve and controls the opening and re-closing of main valve. With this combination, premium performance can be obtained. Generally, POSRVs, when compared to direct spring operated valves, will be more resistant to leakage (tighter), available in a wider range of sizes and pressure ratings, appropriate for solving many difficult applications. ASME-Sec-VIII Pilot Operated Safety Relief Valves testing and supply of around 3,500 safety relief valves for the 580,000 barrels per stream day (BPSD) refinery project. Application engineering of safety relief valves Senior project managers and application engineers fromTyco Sanmar worked closely with the technical consultants of the JERP project in the UK, USA, Canada and India to offer the optimal solution for the varied applications in the refinery.This activity was complex considering that we were working on multiple sizing and selection options for 3,500 safety relief valve installations. Given the size, scale and complexity of the refinery, there were many unique selections of safety relief valves. Here we would like to highlight some specific selections that resulted in better performance and significant cost savings for the customer.
Transcript of vw0903_safety_tyco.pdf
OIL & GAS / REFINERY
www.valve-world.net74 March 2009
Valve programme for IndiaSafety relief valves for the world’s largest single location refinery
In completing the state-of-the-art,globally competitive refinery atJamnagar, India within 36months, from concept tocommissioning during December2008, Reliance Petroleum Limitedhas set a new global benchmarkfor building a grass-root refinery.Tyco Sanmar Limited, a JointVenture between TycoInternational Limited, USA – theworld leader in fluid controlproducts – and SanmarEngineering Corporation, India –one of the largest manufacturersof engineered valves in India - ,was the preferred supplier chosenby Reliance for the completepackage of safety relief valves forboth the existing and new refineryat Jamnagar.
By Deepesh Nanda and Nilesh Doshi,Tyco Sanmar Ltd.
Courtesy: Reliance Petroleum Limited website
The relationship between Reliance andTyco Sanmar dates back to Reliance’sinitial projects in the petrochemical
sector. From Reliance’s first Jamnagarrefinery in 1997 to the recent JamnagarExport Refinery Project (JERP) – TycoSanmar has supplied a whole range of safetyrelief valves to Reliance Refineries.Work onJERP started in 2006, and with it started anexciting journey of technical selection incoordination with the world’s majorengineering consultants, manufacturing,
ASME-Sec-VIIIConventional Valve
What is a safety relief (Pressure Relief) valve?A safety relief valve is a pressure relieving device designedto protect a pressurized vessel or system during anoverpressure event.An overpressure event refers to anycondition, which would cause pressure in a vessel orsystem to increase beyond its maximum allowableworking pressure (MAWP).The basic spring operated safety relief valve(SOSRV) hasbeen developed to meet the need for a simple, reliable,system actuated device to provide overpressureprotection.The picture shows the construction of aconventional SOSRV.The valve consists of a valve inlet ornozzle mounted on the pressurized system, a disc heldagainst the nozzle to prevent flow under normal systemoperating conditions, a spring to hold the disc closed, anda body/bonnet to contain the operating elements.Thespring force is adjustable within its design range to varythe pressure at which the valve will open.
What is a Pilot Operated Pressure Relief Valve ?A Pilot Operated Pressure Relief Valve (POSRV) is a Pressure Relief Valve in whichthe major relieving device is combined with and is controlled by a self actuatedauxiliary Pressure Relief Valve(Pilot).Pilot operated pressure relief valve replace the spring with a small sophisticatedcontroller or ‘pilot’ which reacts topressure similar to a conventionalvalve and controls the opening andre-closing of main valve.With thiscombination, premium performancecan be obtained. Generally, POSRVs,when compared to direct springoperated valves, will be more resistantto leakage (tighter), available in awider range of sizes and pressureratings, appropriate for solving manydifficult applications.
ASME-Sec-VIII Pilot Operated Safety Relief Valves
testing and supply of around 3,500 safetyrelief valves for the 580,000 barrels perstream day (BPSD) refinery project.
Application engineering of safetyrelief valvesSenior project managers and applicationengineers fromTyco Sanmar worked closelywith the technical consultants of the JERPproject in the UK, USA, Canada and India to
offer the optimal solution for the variedapplications in the refinery.This activity wascomplex considering that we were working onmultiple sizing and selection options for 3,500safety relief valve installations. Given the size,scale and complexity of the refinery, there weremany unique selections of safety relief valves.Here we would like to highlight some specificselections that resulted in better performanceand significant cost savings for the customer.
OIL & GAS / REFINERY
www.valve-world.net March 2009 75
11.. PPiilloott OOppeerraatteedd SSaaffeettyy RReelliieeff VVaallvveessKeeping in view the stringent emissionregulation requirements and to achieve zeroflare, a large number of Pilot OperatedSafety Valves have been selected for JERP.These valves have also offered the flexibilityof operating the equipment at greater than90% (and less than 95%) of the set pressureof the equipment thus enhancing theoperating efficiency of the plant.
22.. DDuuaall AAccttiivvee PPiilloott OOppeerraatteedd RReelliieeff VVaallvveessIn the Power Recovery System of theFluidized Catalytic Cracker (FCC) unit, thechallenge was to design a Dual Active PilotOperated Safety valve that would use onemain valve with two pilots operatingsimultaneously. The main valve is installed onthe air blower line. While the main valve iscommon, the two pilots are set at differentset pressures to safe guard the FCCRegenerator and the FCC Orifice Chamber.The pilot pick-up sense line was isolatedfrom the FCC catalyst through instrumentair purge thus preventing clogging of thepick-up and malfunctioning of the valve. Theadvantages include substantial reduction ofcosts for both the equipments (FCCRegenerator and the FCC OrificeChamber). Furthermore, a common pilotvalve eliminates costs associated withcorresponding inlet, outlet piping and otherrelated structural costs.
33.. OOvveerr--TT VVaallvveessIn the Coker plant, Tyco Sanmar hasmanufactured and supplied valves largerthan the API orifice for the Coker Drumand Fractionator. The inlet size of this spring-operated safety relief valve is 18” with an24” outlet. The advantage of this large sizevalve includes optimization of number ofinstallations, and associated cost saving ofinlet and outlet piping and overall structure.
Manufacturing and supplyGiven the magnitude of the supplyrequirements we expanded ourmanufacturing capacity to 1,200 safetyvalves per month. The assembly and testingfacilities were ramped up to manufacturethe large size valves like 18 AA 24 springoperated safety relief valves. The supplieswere made on time to meet the aggressivecommissioning schedule of the customer,thanks to the expanded plant capacity andto Sanmar’s 30,000 tons per annum (tpa)sand and investment casting steel foundrylocated in the same campus. The foundry’sadvantage to deliver a range of bodymaterials of construction (MOC) likecarbon steel, alloy steel, stainless steel andother special materials like Monel, Hast-C,HVD-1, C12, C12A, C5 and Inconelstrengthened the ability of Tyco Sanmar tobe a full portfolio supplier for the entirerange of safety relief valves. Themanufacturing plant is ISO 9001 certifiedwith Certification of Authorization from
ASME for Conventional Sec VIII & PilotValves with “UV” code stamp. The plant alsohas the Certification of Authorization fromPED for Conventional Sec VIII, Sec-I andPilot Valves with CE marking and IBR (IndianBoiler Regulation) certification for allConventional Sec-I & Sec-VIII valves. Testingcapabilities include PMI, DP, MPI,Radiography, Hydro & Pneumatic up to6000 psig, helium leak test, impact test. Alltests were also done with completetraceability.
Installation and commissioningDuring the establishment of the firstrefinery at Reliance Jamnagar, SanmarEngineering Corporation entered into aservice agreement with Reliance by which ateam of trained and dedicated engineerswould maintain the products at the Refinerycomplex on a round-the-clock basis. Thismodel has been successful and has beenextended for installation, commissioning andmaintenance services for Reliance’s JERPrefinery. On-site testing of the safety reliefvalves were done on a test bench suppliedby Tyco Sanmar for the JERP project beforefield installation and commissioning.
Spare parts programmeThe final task was to set up an optimalspares parts inventory programme basedon the interchangeability that a large installbase of safety relief valves from a singlevendor would offer. Tyco Sanmar worked inclose coordination with Reliance to createthis spares parts interchangeabilityprogramme to help optimize the spare’sinventory at the customer site and toprovide preventive maintenance.
About the authorsDeepesh Nanda is currently the marketing manager at Tyco Sanmar Limited. He is amechanical engineer and has been working for fourteen years in application, sales andmarketing of valves and related products at Sanmar Engineering Corporation. Nilesh Doshiis currently the Key Account Manager for Reliance Petroleum Ltd at Tyco Sanmar Limited.He is a mechanical engineer with 24 years of experience in the application and specificationof valves for petrochemical and other process industry customers. Tyco Sanmar Ltd., is aconstituent of Sanmar Engineering Corporation (SEC). SEC is one of the largestmanufacturer of engineered valves (Joint ventures with Crane, Fisher, Tyco), sealing systems(JV with Flowserve) and safety systems (JV with BS&B) serving the energy and processindustries in the Indian market. SEC is part of the Sanmar Group which includes SanmarMetals Corporation and operates one of the largest steel foundries in India with other steelfoundries located in Mexico and USA and iron foundries in India and Germany.
Dual Active Pilot Operated Safety Relief Valves
18 x 24 Over-T valves manufactured by TycoSanmar Ltd for JERP
