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com
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ScienceDirect
ScienceDirect
Available online at www.sciencedirect.com
Procedia Engineering 00 (2017)000–000
www.elsevier.com/locate/procedia
ScienceDirect
Procedia Engineering 00 (2017)000–000
www.elsevier.com/locate/procedia
Procedia Engineering 206 (2017) 1831–1838

International Conference on Industrial Engineering, ICIE 2017

International Conference on Industrial Engineering, ICIE 2017
Wedge Gate Valves Selected during Technological Pipeline
Wedge Gate Valves
Systems Selected
Designing duringLife
Service Technological
AssessmentPipeline
Systems Designing Service Life Assessment
M.M. Zakirnichnaya, I.M. Kulsharipov*
M.M. Zakirnichnaya, I.M. Kulsharipov*
Ufa State Petroleum Technological University, 1, Kosmonavtov st., Ufa 450062, Russia
Ufa State Petroleum Technological University, 1, Kosmonavtov st., Ufa 450062, Russia

Abstract
Abstract
Wedge gate valves are widespread in petroleum refining industry. Manufacturers assign resources based on the valve body
calculation
Wedge gateresults
valvesunder the current in
are widespread regulatory
petroleum andrefining
technical documentation.
industry. Previous
Manufacturers studies
assign have determined
resources based on thethatvalve
the wedge
body
gate
calculation results under the current regulatory and technical documentation. Previous studies have determined that the regard,
valves fail before the appointed time. In some cases wedge gate valves cease to provide the locking tightness. In this wedge
there was a fail
gate valves need to adjust
before he wedgetime.
the appointed gate In
valves
sometechnical resource
cases wedge with account
gate valves cease tofor the wedge
provide resources,
the locking changing
tightness. under
In this the
regard,
operating
there was parameters influence.
a need to adjust he wedge gate valves technical resource with account for the wedge resources, changing under the
Hydrodynamic calculations
operating parameters were performed taking into account technological parameters using FLOWVISION. Based on these
influence.
results,
Hydrodynamic calculations were (SSS)
wedge stress-strain state calculations
performed were
taking into performed
account using FSIparameters
technological (fluid-structure interaction) technology.
using FLOWVISION. Based onOnthesethe
basis of SSS assessment the wedge number of cycles to failure was determined using a FE-SAFE module.
results, wedge stress-strain state (SSS) calculations were performed using FSI (fluid-structure interaction) technology. On the
The wedge
basis of SSSSSS calculations
assessment ODB-file
the wedge numberwereof imported to FE-SAFE
cycles to failure module. The
was determined usingset calculationmodule.
a FE-SAFE parameters: the dimension of
physical
The wedge quantities, the wedgeODB-file
SSS calculations metal physical
were and chemical
imported properties,module.
to FE-SAFE loadingThe
cycle.
setAfter calculating
calculation the wedge
parameters: the hooks number
dimension of
of cycles to failure were obtained.
physical quantities, the wedge metal physical and chemical properties, loading cycle. After calculating the wedge hooks number
The calculation
of cycles results
to failure wereshowed
obtained. that the wedge gate valves technical resource is primarily affected by the operating parameters
such calculation
The as the flowresults
rate and
showedpipeline system
that the wedge pressure. The technical
gate valves tested valves resource
resource values are
is primarily less than
affected by thethose indicated
operating by the
parameters
manufacturer.
such as the flow Therate
results
and show the system
pipeline need to pressure.
adjust theThe
valves assigned
tested valves resource
resourcetaking
valuesinto
are account
less thanthethose
operating parameters
indicated by the
influence on theThe
manufacturer. wedge.
results show the need to adjust the valves assigned resource taking into account the operating parameters
© 2017 The
influence Authors.
onAuthors.
the wedge. Published by Elsevier B.V.
© 2017 The
Peer-review Published by
under responsibility of Elsevier Ltd. committee of the International Conference on Industrial Engineering.
the scientific
© 2017 The
Peer-review Authors.
under Published
responsibility by
of Elsevier
the B.V. committee of the International Conference on Industrial Engineering
scientific
Keywords: technological
Peer-review pipeline systems;
under responsibility of theZKL2 300-25
scientific wedge gateofvalve;
committee ZKL2 250-25Conference
the International wedge gate valve; Abaqus software
on Industrial suite;
Engineering.
FLOWVISION
Keywords: software suite;
technological FE-SAFE
pipeline systems;module; fluid-structure
ZKL2 300-25 interaction
wedge gate (FSI). 250-25 wedge gate valve; Abaqus software suite;
valve; ZKL2
FLOWVISION software suite; FE-SAFE module; fluid-structure interaction (FSI).

* Corresponding author. Tel.:+7-927-955-66-41; fax: +7-347-242-09-13.

E-mail address:author.
* Corresponding kim102@mail.ru
Tel.:+7-927-955-66-41; fax: +7-347-242-09-13.
E-mail address: kim102@mail.ru
1877-7058 © 2017 The Authors. Published by Elsevier B.V.
Peer-review
1877-7058 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the International Conference on Industrial Engineering .
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering .

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.
10.1016/j.proeng.2017.10.721
1832 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838
2 M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000

1. Introduction

Technological pipeline systems used in the oil refining industry include a large number of structural elements,
including the shut-off valve. According to the Valve Central Design Bureau standard valves designed to fluid flow
shut off and is classified as repairable, restorable items with regulated restore discipline, with the assigned operation
duration. Therefore, in its accompanying operational documentation must necessarily be given technical and
operational characteristics, such as the assigned resource (in cycles) and the designated service life (in years). At the
same time the valves new product range development by manufacturer design team including all the necessary
complex calculations carried out for the working medium of water at a temperature of 20 °C and contains data about
the resources assigned only on the valve body calculations results.
An analysis of the results of periodic audits of valves that operate businesses are forced to resort to restore most
of the block valves of plastic deformation of the saddle and wedge hooks destruction [1]. This indicates that the
existing methods of residual life of purpose in the design of valves do not ensure the safety of its structural elements
within the designated service life and need to be adjusted based on actual operating parameters.
In studies [2-4], it was determined that the wedge deviation from the vertical in the valve passage section closing
process and non-alignment in its seat contributing to occurrence of plastic deformation occurs at a certain working
operating parameters combination. In addition, there are a number of conditions under which wedge maximum
equivalent stresses are above permitted (Fig. 1) [5-7]. As a result, wedge gate valves fail ahead of time, which can
lead to an emergency situation, therefore, a large economic loss due to downtime during unplanned repairs, negative
environmental consequences and casualties.

Fig. 1. Examples of stress distribution: (a) at the wedge hooks in the valve opening process; (b) the wedge hooks destruction.

In this connection there was a necessity of the adjustment method for calculating the wedge gate valves resource
taking into account the wedge stress-strain state.
As the objects of study ZKL2 250-25 (DN – 250 mm., PN – 2.5 MPa) and ZKL2 300-25 (DN – 300 mm., PN –
2.5 MPa) wedge gate valves were selected as the most common in refineries. [8]

2. Hydrodynamic calculations

Hydrodynamics calculations were performed using a FLOWVISION software package (SP) to assess the process
parameters impact on the wedge gate valve structural elements [1-3]. FLOWVISION is designed and suitable for
liquid and gas flows three-dimensional modeling in the technical and natural objects, as well as the flow
visualization of computer graphics methods [9-11].
Wedge gate valve fluid flows through the flow passage hydrodynamics calculation were carried out for the model
of "incompressible fluid". Gasoline, kerosene, diesel, fuel oil: As the transported liquids four main fractions
obtained by refining were selected. The liquid was set in view of changes in the physical properties (density and
viscosity) with temperature. Temperature ranges taken within the application temperature selected for the study of
the fractions. Liquid flow rate was taken in accordance with the recommended limits of change in velocity of the
fluid process piping from 0.5 to 3 mps.
 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838 1833
M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000 3

Calculations were made for a pressure in the range of 0.6 to 2.5 MPa according to the characteristics designated
by the manufacturer for the test valve.
To determine the difference between the maximum pressure on the wedge and the pressure in the system layer
"Filling" to the variable "Pressure" in the valve cross-sectional plane was created (Fig. 2). It was found that the
pressure on the wedges increases as closing the flow cross section, and reaches its maximum value when the degree
of closure of 95% (Fig. 3).

Fig. 2. "Filling" layer to the variable of "Pressure".

Fig. 3. Dependence of the difference between the maximum pressure on the wedge and a system pressure for ZKL2 300-25 from the valve flow
passage opening degree (working medium – water, flow rate of 1.5 mps).

Calculations have shown that when the flow passage closure degree of 50% or more of the stationary vortices are
formed behind the wedge further in the cross section, which are most clearly present in the 95% closure embodiment
(Fig. 4, d). The increase in the valve flow passage diameter influences the nature and number of vortex shedding
zones slightly. So, for ZKL2 250-25 valve vortex formation zone occurs at a distance 1,25d axis of the wedge
symmetry (d – flow passage diameter, mm), while for ZKL2 300-25 valve – on 0,88d distance (Fig. 5). Vortex
formation and fluid flow recycling that occur in the area of the flow passage narrowing (Fig. 6), due to the fact that
when passing through the obstacle in the form of a wedge of fluid flow changes direction and partially reverse flow
occurs. Returning to the main flow, the fluid involved in the recirculation zone converts recirculation to vortex.
It was found that with temperature increasing the pressure difference increases too, but the impact of temperature
on the maximum differential pressure value on the wedge and the pressure in the system is negligible. For example,
the difference in water pressure at a flow rate of 1.5 mps speed reaches 160.2 kilopascals at a temperature of 20 ° C
and 160.9 kilopascals - at a temperature of 100 ° C. The difference between the maximum pressure differential (at
plus 100 ° C) and minimum (plus 20 ° C) is 0.43%.
1834 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838
4 M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000

The dependence of the difference between the maximum pressure on the wedge and the pressure in the system
for all test valve flow section diameters and the working environments is similar (Fig.s 4, 5).
(a) 10%; (b) 40%; (c) 50%; (d) 75%; (e) 95%

Fig. 4. Example of the flow rate vector field graphical representation in the valve symmetry plane during closing the flow section (working
medium – water, flow rate of 1.5 mps).

Fig. 5. Example of the flow rate vector field graphical representation in the ZKL2 300-25 gate valve symmetry plane at closing the flow section
up to 95% (working medium – water, flow rate of 1.5 mps).

3. Stress-strain state assessment

Structural elements stress-strain state calculation taking into account the wedge gate valve liquid hydrodynamic
flow in the wedge closing process was realized using FSI-technology in the Abaqus SP, which is widely used to
evaluate the oil refining equipment elements stress-strain state [12-18]. Wedge moving process and its deformation
 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838 1835
M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000 5

was simulated in the Abaqus SP. The transported fluid movement was simulated in the FlowVision SP. Software
packages interaction carried through MP-manager.
The valve movable part – wedge – geometry imported to Abaqus SP. After importing the wedge geometry
material from which made a wedge – steel 20L physical and mechanical properties assigned in PROPERTY module.
Boundary conditions (fixing conditions) in the wedge hooks field assigned in the LOAD module. Interface surface
required in co-execution assigned in the ASSEMBLY module. Finite elements meshing performed in the MESH
module.
Then the INP-file containing the finite element coordinates mesh representing the moving body was generated.
The wedge gate valve flow passage 3D-model was imported to FlowVision SP. The substance - oil, the physical
model - incompressible fluid, boundary conditions - inlet, output, wall, imported moving body - wedge - on the basis
of INP-file received from Abaqus SP were assigned. Finite-difference grid was created.
To identify co-execution by the program at INP-file project in STEP Abaqus SP module the appropriate lines
were added.
Next prepared project files run on calculation using the MP-manager, which specifies the path to the settlement
file, chose step exchange between software systems. Progress calculation tracked via the application "module results
show" that allows to visualize the calculation process in the locking body - wedge movement course (Fig. 6). The
pressure distribution nature on the wedge surfaces, and fluid flow lines are consistent with the previous studies.

Fig. 6. The working fluid streamlines and pressure distribution on the wedge surface during the calculation at 30% closing the flow section.

After the execution process completion Abaqus SP project ODB-file was obtained. It contains data about the
wedge SSS change for a single operation cycle (the moving process from a state of "Open" to the state "Closed").
These values can be visualized in VISUALIZATION module (Figure 7, a).

4. Resource assessment

Abaqus SP FE-SAFE module was selected to evaluate the technical resource. It is used for analyzing fatigue life
of metal components under the complex cyclic loading influence. FE-SAFE combines the finite element analysis
(finite element analysis) results for different loading conditions from the Abaqus SP with a cyclic loading history
and predicts the service life, using the resulting ODB-file [19-23].
After the ODB-file import, the data to calculate the wedge gate valves fatigue life analysis selected in the
SELECT DATASETS TO READ dialog box. In AVAILABLE POSITIONS column the type of calculation by the
finite element mesh – ELEMENTAL was chosen. It makes a mark that will take into account the geometry of valve
three-dimensional model and the resulting interaction between the ring surface and wedge - DETECT SURFACE
and GEOMETRY MODEL. As the QUICK SELECT parameter STRESSES was chosen.
In MODELS PROPERTIES dialog assigned physical quantities measurement unit required during the
calculation.
Assigned service life calculation in the FE-SAFE module was carried out within the framework of data multi-axis
analysis concerning the different ways of load (pressure) applications on a wedge. In each case, the elastic stresses
were used for calculating. Analysis Type assigned after importing the loads (* .amc) file, which contains the
accompanying cyclic loading amplitude.
The path to the file * .amc was specified in LOADED DATA FILES dialog box.
1836 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838
6 M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000

The calculation for WHOLE GROUP was selected for the interaction of increments several preset values in the
SUBGROUP SELECTION dialog box.
The SURFACE FINISH DEFINITION module was used to select surface finish. The surface roughness (Ra) for
the settlement was accepted 0.4 mm. Valve metal physic-chemical properties assigned using MATERIALS
DATABASES base.
The residual stress was assigned to be zero. As the output FE-SAFE displays the number of cycles to failure. The
number of cycles to failure calculating visualization is possible in Abaqus after importing the results file (Fig. 7, b).

Fig. 7. (a) wedge surface equivalent stresses distribution at an operating pressure of 2.5 MPa; (b) calculation results visualization example in
Abaqus SP VISUALIZATION module.

Fig. 8. The number of cycles to failure dependence of the fluid flow rate for ZKL2 250-25 valve different operating pressure values (operating
environment - fuel oil, medium temperature +100 ° C).

Fig. 9. The number of cycles to failure dependence of the medium temperature at ZKL2 250-25 different working medium flow rates (operating
environment - fuel oil,operating pressure – 1.0 MPa).
 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838 1837
M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000 7

The calculation results showed that the wedge safe operation resource in the first place affected by such operating
parameters as the pressure and flow rate in pipeline (Fig. 8) while the temperature effect is negligible (Fig. 9). If you
change the valve flow passage diameter, dependence of the number of cycles to failure of the fluid flow rate are
similar in character (Fig. 10). For example, fig. 11 shows the dependence of the wedge hooks number of cycles to
failure of liquid flow rate for the ZKL2 300-25 valve for different mediums. It is evident that the wedge safe
operation resource below the values specified by the manufacturer (Table 1).

Fig. 10. The number of cycles to failure dependence of the fluid flow rate for different ZKL2 300-25 valve operating pressure values (operating
environment – fuel oil, medium temperature +100 ° C).

Fig. 11. Dependence of the number of cycles to failure of the fluid flow rate for different media ZKL2 300-25 (working pressure – 1.0 MPa).

Table 1. ZKL2 300-25 wedge gate valve assigned resource powered by the manufacturer catalogs.

Manufacturer ZKL2 300-25 valve assigned life, cycles*

Murom Industrial Valves Plant, JSC 2500

Ural Pipeline Valves Plant, LLC 2500

Blagoveschensk Pipeline Valves Plant, JSC 2500

“Palur” Regional Gas Company 3000

YarGasArmatura, LLC 3000
PenzTyazhArmatura, JSC 3000

5. Conclusion

Studies have shown that the wedge safe operation resource value obtained with the operating parameters
influence, such as medium density and viscosity, temperature, pressure and flow rate, in some cases less than the
1838 M.M. Zakirnichnaya et al. / Procedia Engineering 206 (2017) 1831–1838
8 M.M. Zakirnichnaya, I.M. Kulsharipov / Procedia Engineering 00 (2017) 000–000

safe operation resource values obtained as a valve body calculation results. This leads to premature wedge failure
and, therefore, requires the entire valve unscheduled repairs. So when assigning a gate valves safe operation
resource is necessary to realize additional wedge resource calculation based on the operating parameters.

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