VALVE TYPE ACCEPTANCE TEST EXPERIENCES

API Meeting - SCOPV

Los Angeles, California
November 15, 2011
 TAT EXPERIENCES

ƒ What is Shell’s Type Acceptance Testing (TAT)?

ƒ Testing of a valve to its design limits on temperature and pressure

ƒ Seat testing with nitrogen and fugitive emission testing with helium
ƒ Ambient temperature
ƒ Maximum advertised temperature
ƒ Minimum advertised temperature
ƒ Ambient temperature

ƒ 200 mechanical cycles including opening and closing torques

ƒ Acceptance criteria is based upon ISO 5208 (seat leakage) and ISO 15848
(FE)
ƒ TAT is part of a total valve qualification program complemented by:

ƒ Technical documentation review

ƒ Valve manufacturer technical audit (ISO 9001 methodology)
ƒ Valve design validation and verification
TAT EXPERIENCES--2” 1500# SOFT-SEATED TRUNNION MOUNTED BALL VALVE

Unacceptable seat leakage due to o-ring/seat failure

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.
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.
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
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
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.
 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.
TAT EXPERIENCES--10” 2500# TMBV

Actuator failure due to excessive valve torque at ambient temperature

due to bearing seizure & poor bearing design.
TAT EXPERIENCES--10” 2500# TMBV

Excessive seat leakage at ambient temperature due to failure of metal

coating on ball and seat.
TAT EXPERIENCES--10“ 600# BOLTED BONNET GATE VALVE

Damaged stem threads due to failure of the drive nut. The drive nut
material was incorrect.
TAT EXPERIENCES--6” 1500# PRESSURE SEALED GATE VALVE

Stem seal failure due to incorrect packing

 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.
 TAT EXPERIENCES

ƒ 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.

ƒ 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.
TAT EXPERIENCES

Severe damage to stem and nut threads caused by galling between

316 SS stem & ductile iron nut.
TAT EXPERIENCES

Explosive decompression during TAT.

TAT EXPERIENCES

Stem stretched approximately 3.5” during mechanical cycling. Thread

external diameter was reduced from 2.4835” to 2.3755”.
 TAT EXPERIENCES--24“ 1500# BALL VALVE
PEEK 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.
TAT EXPERIENCES

Severe cracking of high pressure steam non-return valve body

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
TAT EXPERIENCES

Questions?

Thank you!