Ivs2017 final presentation session12_strategies to api 624 qualification

Strategies to API 624 Qualification
Pramod Kalyani
Kalson Engineering Solutions,
INDIA
IVS 2017 • 2nd International Conference on Valve and Flow Control Technologies
May, 24th and 25th 2017
1

AGENDA
2
Requirements of API 624
Planning for In-house Test Bench
Design Assembly Guideline
Third Party Labs for final Verification.

AGENDA
3

Methane a significant contributor to global warming
• Methane is a key component of natural gas and is 25 times stronger
than carbon dioxide when it comes to trapping heat in the atmosphere.
Read more at: https://phys.org/news/2015-08-methane-oil-gas-industry.html#jCp
10/04/2017 IVS 2015 • International Conference on Valve and Flow Control Technologies 4

VALVES a significant contribute to VOC

EPA CONSENT DECREE & API 624

• EPA implements “consent decrees” on refinery and chemical processing end users
-Include fines for emissions over established limits
-Requires implementation of LDAR (leak detection and repair) programs
-Leads to low FE-requirements for valves and sealing systems
• EPA Consent Decree New Equipment Upgrade Requirement
-Newly installed valves must be Low-E
-Repack or replace with Low-E for Valves that leak above 250 PPMv (Chemical)
-Repack or replace with Low-E for Valves that leak above 500 PPMv (Refinery)
• Industry defines low FE products by Complying to API FE Test Standard,
-API 622: Type Testing of Valve Packing for FE Released in August 2006, 2nd edition
October 2011
- API 624: Type Testing of Valves Equipped with Graphite Packing for FE Released in
February 2014.
EPA CONSENT DECREE & API 624

REQUIREMENTS OF API 624
Title and Edition
Type Testing of Rising Stem Valves Equipped
with Graphite Packing for Fugitive Emissions,
First Edition
Date
Standard by the American Petroleum Institute,
02/01/2014
Pass Criteria
leakage throughout the test does not exceed 100
PPMv
Packing Adjustment None allowed

Media Methane 97% minimum purity
Temperature
500°F (260°C)
Optional Low Temperature Test at -20° F
Pressure 600 psig (41.4bar-g)
Number of Valve Stem
Actuations
310
Number of Thermal
Cycles
3

Leak Measurement
Method
EPA Method 21
Stem Orientation Stem is oriented in vertical position
Leak Measurement
Details
Leak measurements are sniffed using a detection
probe. Done with stem in static and dynamic states
Leak Measurement
Frequency
Every 50 actuations of the stem

API 624 ACTUATION- WE REFER API622
• The test valve may be equipped with a method of actuation capable
of stroking the stem to simulate the mechanical cycle of a valve at
the rate of 3 mm to 5 mm (0.04 in. to 0.20 in.) per second.
• The method of actuation should not impose additional side loads on
the stem or packing.
• Running torque values shall be recorded on the first and last cycle of
testing.
11

API624 VALVES QUALIFIED
All valves of the same basic design as the test valve may be deemed
to have been type tested, subject to the following additional limitations:
• For API 602 valves, a NPS ¾ class 800 test valve may be used to
qualify all valves NPS 1 and smaller valves up to and including class
800.
• For API 602valves, a NPS 1-1/2 class 800 test valve may be used to
qualify all valves NPS 1-1/4 through NPS 2-1/2 up to and including
class 1500.
12

For all other valves, a test valve may be used to qualify valves from
two nominal sizes smaller to one nominal size larger and one pressure
class lower than the test valve.
13
API624 VALVES QUALIFIED

API624 VALVES QUALIFIED-REQUALIFICATION
Any change in valve stem sealing system design including, but not
limited to, packing material, packing manufacturer, or packing
type/model requires a re-qualification.
If the location of the valve manufacturing facilities is different than
what is listed on the API 624 certificate, the purchaser may request
requalification
14

Valve shall be disassembled and
components; including stem, packing,
stem nut, gland follower, and stuffing
box; shall be inspected and condition
documented.
Sealing components shall be
photographed in accordance with
section 9.4.
15
API624 Post-test Inspection

API624 Post-test Inspection
16

API624 Recording and Documentation
As a minimum, test results shall be provided on the Fugitive
Emissions Test Report provided in Appendix A.
Valves qualified by this standard shall be clearly and
permanently marked as “API 624”.
17

AGENDA
18

IN-HOUSE TEST BENCH API624 FE TEST
Sr.No Component Description Qty
1 Valve Holding Structure including Crane for support 1
2 Motor/Electric Actuator 1
3 Limit Switches Non-Contact Type (Open Close) 2
4 Torque Transducer 1
5 Heating Jacket 1
6 Leakage Monitoring Device with Calibration Set up 1
7 Test Gas Methane 97% Purity 1
8 Purging Nitrogen Gas 1
9 Piping and regulator set 1
10 Data Logger 1
11 Thermocouples for temperature measurement 3
Figure 1. Technician uses Method 21 to monitor
leakage. Photo courtesy of GreatWeld Engineering
Pvt.Limited,India.

Leak Measurement Devices based on API 624 and EPA
Method 21.

Leakage Detection Techniques
The following point detection techniques were identified
 Ionization/Ion Mobility
 Spectrometry.
 Flame Photometry.
 Infrared Spectroscopy.
 Electrochemistry.
 Colorimetric.
 Surface Acoustic Wave.
 Photoionization Detection.
 Thermal and Electrical Conductivity.
 Flame Ionization.
 Polymer Composite Detection Materials
21

Leak Measurement Devices based on API 624 and EPA
Method 21.
Standard API624 EPA Method 21
Monitoring
Instrument
Detector type
Section7.
Flame Ionization
Section 3.1.1.
Detector types which may
meet this requirement include, but are not
limited to, catalytic oxidation, flame
ionization, infrared absorption, and
photoionization.
Device Make Thermo-Scientific
TVA2020
SENSIT® GOLD G2
Price ~12000$ ~2500$

23
Methane Leak Detection Principle-FID

Methane Leak Detection Principle-Electrochemistry
24

AGENDA
25

# Aspect Description Illustration Advantages
1 Fine
Threads
with Close
Tolerance
▪ Threaded Ring-Bonnet prefer a fine
thread pitch and closer tolerance.
▪ Fine Threading and Closure
Tolerance will improve centering
and reduce side loads on stem
and packing.
2 Controlled
and
Reduced
Diametrical
clearance
▪ Try to have minimum diametrical
clearance in following mating parts
▪ Stem Nut-Threaded Ring-
Bonnet.
▪ Stem-Bonnet
▪ Bonnet-Body
▪ Bonnet-Packing-Stem (radial
clearance to 0.1)
▪ Bonnet-Backseat-Stem
▪ Closer and tight tolerances
between mating parts will
improve guide and bearing
support to Stem and better
alignment during dynamic mode.
▪ Tighter clearance requirements
between Stem and Packing Gland
than API 600 may be required.
Design Guideline

3 Stem to Bonnet
Stem Housing
Support
▪ Additional Spacer between Stem
and bonnet
▪ Reduce Stem Contact with Bonnet
stem housing will reduce
possibility of valve stem scoring.
4 Packing Bolt
Location
▪ Eye bolt distance from center of
Stem try to keep minimum.
▪ Material of bolt / nut B7
▪ Closer positioning of packing bolt
improved force distribution and
sealing performance.
Design Guideline

5 Backseat Design ▪ Provide Guide at the end to ensure
better alignment or centring
▪ Provide Tack weld
▪ Better Centering of Backseat.
▪ Improved support to Stem.
▪ Tack Weld ensures no loosening of
backseat.
6 Stem ▪ Provide Hard Chrome Plating 20
m
▪ Tempering temp-450C hardness 30-
40HRC.
▪ Good Surface Finish is Key.
▪ Runout, Circularity, and
Straightness tolerances to be
achieved.
▪ Thread tolerance can be changed to
5C instead of 2G
▪ When the stem or Stem is closing
the valves, bending, shifting,
twisting can
occur so stem to be designed with
adequate strength.
▪ Improved surface finish, hardness
and controlled Circularity, Runout
and Straightness will improve
sealing performance.
Design Guideline

Design Guideline
7 Stem Nut-Stem
Lubrication
▪ Stem is oriented in vertical position
which can allow yoke bushing
grease to travel down stem to
packing area.
▪ Selection of proper Stem & Stud
grease becomes critical due to
thermal parameters.
▪ DUALCO GSVL grease claims to
have bulky viscosity with extreme
pressure lubricant with excellent
high and low temperature
properties.
8 Bolt
Lubrication
• Apply anti-seize lubricant to gland
stud threads, nuts, and hardened
washers.
▪ JET LUBE 550 eXtreme is good
anti-seize lubricant which you
might consider.

Design Guideline
9 Tightening
Torque Packing
Gland Bolt &
Nut.
Overtightening
might result in
Stem failure at
high
temperature;
Inadequate
tightening result
in packing
consolidation.
▪ Get formula for torque from
Packing manufacture (not all the
same)
▪ Use a calibrated torque wrench
▪ Torque alternately between gland
nuts to not cock the gland which
could cause valve stem scoring or
uneven loading of the packing set.
▪ Ensure proper levelling of gland
load
▪ Hardened washers should be
utilized under the gland nuts .
Arrow Illustrate force
transmission.
▪ Ensures No substantial increase in
packing friction at high temperature
thereby no increase in stem torque.
▪ No packing consolidation and
hence no leakage.
▪ To maintain even gland load on the
packing set over time, a live-load
spring assembly also can be used.

Packing Gland Assembly Guideline
1
0
Packing Gland
Assembly &
Proper leveling
of Gland load
▪ 5 rings only need to seal, more
rings less sealing
▪ Seat each ring individually This
procedure eliminates the need to re-
pack or re-torque and vastly
enhances the life of the seals.
▪ If the gland follower is not long
enough to reach the bottom of the
stuffing box, a tamping tool or an
extension ring must be used during
this installation step.
▪ Actuate the valve multiple times
▪ Retighten with torque wrench
▪ If any movement of the nuts
(consolidation), repeat actuation
steps until no movement at the
recommended torque.
▪ This will help to have uniform
gland load and better sealing
performance.

AGENDA
32

Third Party Labs for final Verification
1. YARMOUTH RESEARCH AND TECHNOLOGY, LLC
o 434 WALNUT HILL ROAD, NORTH YARMOUTH, ME 04097 USA
o PHONE: (207) 829-5359
o INFO@YARMOUTHRESEARCH.COM
o WWW.YARMOUTHRESEARCH.COM
2. UNITED VALVE
o 9916 Gulf Freeway, Houston, TX 77034-1045
o 1-888-715-5093
o 713-944-9852
o Fax: 713-944-5964
o WWW.UNITEDVALVE.COM

CONCLUSION
• We covered briefly requirement of API 624 and strategies which will
be helpful in API 624 compliance. This is just my experience and I
am sure there would be other strategies which might also be helpful.
• I would solicit reader’s judgement and wisdom to interpret and apply
my experience to develop in house test setup for API 624 FE test
and design modifications if necessary to pass the test.

Ivs2017 final presentation session12_strategies to api 624 qualification

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