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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?
vanessavalves.emerson.com
VanessaTriple Offset Valves