Pipeline Valve Technology : A Practical Guide

This book covers the life cycle of pipeline valves, the largest and most essential valves in offshore pipeline engineering. Discussing the design process, testing, production, transportation, installation, and maintenance, the book also covers the risk analysis required to assess the reliability of these valves. Pipeline valves require particular attention to ensure they are safely designed, installed, and maintained, due to the high stakes. Failure would result in environmental pollution, the destruction of expensive assets, and potential loss of life. Proper installation and upkeep require specialist processes throughout the life cycle of the valve. This book is a key guide to these processes. Beginning by looking at the design of pipeline valves, this book details how conserving weight and space is prioritized, how materials are chosen, how thickness is calculated, and how leakage is minimized. It then discusses production and specific welding techniques to bond dissimilar materials, alongside casting and machining. Building on other discussions in the text with case studies and questions and answers for self-study, this book is the ideal guide to pipeline valves. This book will be of interest to professionals in the industries of offshore oil and gas, material engineering, coatings, mechanical engineering, and piping. It will also be relevant to students studying coating and welding, or mechanical, piping, or petroleum engineering. Cover Half Title Title Page Copyright Page Table of Contents Preface Acknowledgment Author Biography Chapter 1: Introduction and General Features 1.1 Introduction 1.2 General Features 1.2.1 Valve Types 1.2.2 Bore Requirement 1.2.3 Access to the Valve Internals 1.2.4 Connection to the Pipeline 1.2.5 Metallic Seats 1.2.6 Trunnion-Mounted Ball 1.2.7 Design Standards 1.2.8 Valve Operator 1.3 Cross-section Drawing and Part List Questions & Answers Bibliography Chapter 2: Material Selection 2.1 Introduction 2.2 Material Selection 2.2.1 Body and Bonnet 2.2.2 Valve Internals (Trim) 2.2.3 Bolting (Bolts and Nuts) 2.2.4 Pup Piece and Transition Piece 2.2.5 Seal 2.2.6 Stem Bearing 2.2.7 Spring 2.3 Coating Questions & Answers Bibliography Chapter 3: Double Isolation and Bleed Concept 3.1 Introduction 3.2 Pipeline Valves DIB Concept 3.3 DIB Effects on the Valve Design 3.4 DIB2 and Valve Marking Questions & Answers Bibliography Chapter 4: Design for Weight Reduction 4.1 Introduction 4.2 Design for Weight Reduction 4.2.1 Wall Thickness Calculation and Validation 4.2.1.1 Wall Thickness Calculation 4.2.1.2 Wall Thickness Validation 4.2.1.2.1 Finite Element Analysis 4.2.1.2.1.1 Load Combination and Scenarios 4.2.1.2.1.2 Modeling and Analysis 4.2.1.2.2 Load Test (Bending Moment Test) 4.2.2 Cylindrical Nuts Questions & Answers Bibliography Chapter 5: Seat Scrapers and Flushing Ports 5.1 Introduction 5.2 Wax Dissolution in Seats 5.2.1 Sealant Injection Fittings 5.2.2 Flushing Ports 5.2.3 Flushing Fluid 5.2.4 Flushing Procedure 5.3 Particles Ingress Prevention in Seats Questions & Answers Bibliography Chapter 6: Manufacturing Process 6.1 Introduction 6.2 Pipeline Valves Manufacturing Processes 6.2.1 Kick-off Meeting and Engineering 6.2.2 Purchasing or Manufacturing Raw Materials 6.2.2.1 Casting 6.2.2.2 Forging 6.2.3 Welding 6.2.4 Machining 6.2.5 Inspection and Quality Control 6.2.6 Assembly of Valves 6.2.6.1 Body and Bonnet Bolts Tightening 6.2.6.2 Marking 6.2.7 Testing 6.2.8 Coating or Painting 6.2.9 Preservation and Packing 6.2.10 Final Inspection 6.2.11 Shipment Questions & Answers More pictures Bibliography Chapter 7: Welding Technology 7.1 Introduction 7.2 Valve End Connections 7.2.1 Standard ASME Flange 7.2.2 Mechanical Joint (Hubs and Clamps) 7.2.3 Compact Flange 7.2.4 Wafer Connection 7.2.5 Threaded Connection 7.2.6 Welded Connections 7.2.6.1 Socket Weld 7.2.6.2 Butt Weld 7.3 A Case Study of Welding Between Pipeline Valves and Two Oil and Gas Export Pipelines 7.3.1 Pipeline Material Selection 7.3.2 Pup and Transition Pieces 7.3.3 Weld Joint NDTs 7.3.4 Pipeline Valves Welding 7.3.5 Welding Qualification at the Construction Yard Questions & Answers Bibliography Chapter 8: Actuation 8.1 Introduction 8.2 Actuators’ Sources of Power 8.2.1 Pneumatic Air 8.2.2 Hydraulic 8.2.3 Electrical 8.3 Actuator Choices for Pipeline Valves 8.3.1 Scotch and Yoke Actuator 8.3.2 Linear Actuator 8.3.3 Electrical Actuator 8.4 Actuator Selection for Pipeline Valves 8.5 Actuator Selection Case Study Questions & Answers Bibliography Chapter 9: Testing 9.1 Introduction 9.2 Test Procedure 9.3 Test Preparation 9.4 Test Setup 9.5 Type of Tests 9.5.1 Hydrostatic High-Pressure Body or Shell Test 9.5.1.1 Safety Relief Valve Test 9.5.2 Hydrostatic High-Pressure Seat or Closure Tests 9.5.3 Hydrostatic Functional and Torque Measurement Tests 9.5.4 Hydrostatic Cavity Tests 9.5.4.1 Both Seats Are SR 9.5.4.2 Double Isolation and Bleed (DIB1) 9.5.4.3 Double Isolation and Bleed (DIB2) 9.5.5 Backseat Test 9.5.6 Air or Gas Low-Pressure Seat or Closure Tests 9.5.7 High-Pressure Gas Body or Shell Test 9.5.8 High-Pressure Gas Seat or Closure Test 9.5.9 Drift Test 9.5.10 Electrical Continuity Test 9.5.11 Fire Test 9.5.11.1 Fire Test According to API 6FA 9.5.11.2 Fire Test for Pipeline Valves 9.5.11.3 Fire Thermal Simulation and Analysis Case Study 9.6 Actuators Testing 9.6.1 Hydraulic Actuators Testing 9.6.2 Electrical Actuators Testing Questions & Answers Bibliography Chapter 10: Preservation and Packing 10.1 Introduction 10.2 Preservation Types 10.2.1 General Preservation 10.2.2 Internal Preservation 10.2.3 External Preservation 10.3 Packing Questions & Answers Bibliography Chapter 11: Handling, Lifting, and Transportation 11.1 Handling 11.2 Lifting 11.3 Transportation Questions & Answers Bibliography Chapter 12: Installation, Operation, and Maintenance 12.1 Installation and Operation 12.1.1 Storage Before Installation 12.1.2 Valve Installation and Operation on the Pipeline 12.2 Maintenance 12.2.1 Emergency Sealant Injection 12.2.1.1 Sealant Injection on Seats 12.2.1.2 Sealant Injection on Stem 12.2.2 Minor External Leakage Repairs 12.2.2.1 Sealant Injection Fitting 12.2.2.2 Vent and Drain Blind Flanges 12.2.2.3 Modular Valves on the Seat Flushing Ports 12.2.3 Major External Leakage Repairs 12.2.4 Internal Leakages Questions & Answers Bibliography Chapter 13: Safety and Reliability 13.1 Introduction to Shutdown Systems 13.2 Safety Integrity Level 13.2.1 SIL Case Study for a Pipeline Valve 13.3 Failure Mode and Effect Analysis 13.3.1 FMEA Case Study for Pipeline Valves 13.4 Results and Discussion Questions & Answers Bibliography Index The e-book+ version of the book, Pipeline Valve Technology, complements the other versions of the book. The e-book+ version provides the user with additional questions and answers at the end of each chapter to gauge and enhance the user's understanding. The book covers the life cycle of pipeline valves, the largest and most essential valves in offshore pipeline engineering. Discussing the design process, testing, production, transportation, installation, and maintenance, the book also covers the risk analysis required to assess the reliability of these valves.Pipeline valves require particular attention to ensure they are safely designed, installed, and maintained, due to the high stakes. Failure would result in environmental pollution, the destruction of expensive assets, and potential loss of life. Proper installation and upkeep require specialist processes throughout the life cycle of the valve. This book is a key guide to these processes. Beginning by looking at the design of pipeline valves, this book details how conserving weight and space is prioritized, how materials are chosen, how thickness is calculated, and how leakage is minimized. It then discusses production and specific welding techniques to bond dissimilar materials, alongside casting and machining. Building on other discussions in the text with case studies and questions and answers for self-study, this book is the ideal guide to pipeline valves.This book will be of interest to professionals in the industries of offshore oil and gas, material engineering, coatings, mechanical engineering, and piping. It will also be relevant to students studying coating and welding, or mechanical, piping, or petroleum engineering.