PT.

Antogus Bona Sere (ABS)

1
 BYPASSES AND DRAINS
 A valve bypass is a small pipeline connecting the inlet and the outlet of a valve, going completely around the flow control element.
The bypass incorporates a small valve, usually a gate valve, that is normally closed. It is standard practice to attach the bypass at
the side of the main valve with the stems of both valves parallel, pointing vertically upward, as shown in Figure 16-1.
 Bypasses serve two purposes. First, by opening the by­pass valve the upstream pipeline pressure is reduced and the downstream
pipeline pressure increased, thereby reducing the decrease in pressure across the main valve, the fluid force on the flow control
element, and the force required to open the main valve. Second, on steam and other high-temperature services, opening the
bypass valve allows a small flow of hot fluid to warm the downstream pipeline before the main valve is opened, thereby reducing
thermal shock downstream. In both instances the bypass valve is normally closed after opening the main valve.

 MSS Standard SP-45 specifies the sizes of bypass lines for standard installations.
 A drain is a hole in the valve body, usually at the bottom, that is tapped and fitted with a pipe plug. It is used to empty fluid from a
depressurized valve and those parts of the connecting pipeline that are at a higher elevation. It is also used to drain fluid from
between the seats of double-seated valves in block-and-bleed operations and to relieve body cavity pressure. If draining is done
frequently, a pipe nipple and a small stop valve are installed instead of a pipe plug. To enable bypass and drain installation, valve
body castings made of steel and cast iron usually are designed with bosses at appropriate locations to provide sufficient material to
have the required thread length for a threaded connection, or to allow for the depth of a socket-weld socket and still have the
required valve shell wall thickness.
EXTENDED BODY VALVES
 Generally, valves are symmetrical end-to-end; that is, the flow control element is midway between the ends. Extended body valves
are the notable exception to this generalization. They are small, forged steel, gate and globe valves in which one end is substantially
extended. An extended body valve is shown in Figure 16-2. These valves are used in applications in which venting, draining, and
sampling connections are made directly on vessels, pipe headers, and so on.

2
 The valve shown in Figure 16-2 has a welded bonnet, but extended body valves are also made with bolted bonnets. There are a
number of options available for ends. The valve in Figure 16-2 has an integrally reinforced male couplet on the extended, or male,
end. The male couplet end is butt-welded directly to the wall of the header or vessel to which the valve is being attached. The small
ring extended from the end is inserted into a hole in the wall and acts as a backing ring for the attaching weld. Other extended end
options are the male pipe thread end and the male socket-weld end (equivalent to pipe). These are also shown in Figure 16-2. The
male pipe thread end is screwed into a transition piece, commonly known as a threadolet, that has been welded to the vessel or
header wall. Similarly, the male socket-weld end is fillet-welded into a transition piece, known as a sockolet, that has been welded to
the vessel or header wall. The short, or female, end of the extended body valve can be a threaded end or socket-weld end.

Figure 16-2 Extended body valve

DOUBLE-SEATED VALVES
 Valves with two seating surfaces, such as gate and ball valves, can trap pressurized liquids and gases in the cavity between the
seats when the valve is closed. This can have undesirable results. If the temperature of this trapped fluid is increased, the pressure
also increases. If the increase in pressure is great, damage or deformation of sealing materials, body-bonnet bolting, or the valve
shell can result. Although the number of applications in which this situation can occur is not great, these applications should be
recognized and one of the following preventive measures taken before the valve is put into service.
1. Drill a pressure equalization hole through the upstream side of the gate valve wedge or the ball valve ball. This makes the
valve unidirectional.
2. Install a small pipeline between the body cavity and the upstream end of the valve. This also makes the valve unidirectional.
3. Install a drain plug through the body cavity wall of the valve, and remove the plug when the valve is closed. This is only
feasible if the valve is rarely closed, and care must be taken to reinsert the plug before the valve is opened.

3
 4. Install a pressure relief valve through the body cavity wall of the valve.
 Some manufacturers of ball valves have recognized the need for cavity pressure relief and designed seat rings that move
slightly away from the surface of the ball when cavity pressure exceeds line pressure, allowing cavity pressure to relieve into the
valve bore.
 Even if cavity pressure build-up does not require special measures, if the valve is kept in the closed position, fluid trapped in the
valve body cavity remains under pressure after the piping system has been depressurized and even if the valve is removed from
the piping system. This valve can be a hazard during maintenance operations. If it is removed from service in the closed,
pressurized position and then is opened, or the bonnet unbolted, significant quantities of fluid will be released.

SOUR SERVICE VALVES

 Metallic materials in contact with sour environments (fluids containing water as a liquid and hydrogen sulfide gas with certain
partial pressures and concentrations, or sour crude oil with certain hydrogen sulfide gas concentrations and pressures) are
subject to a form of corrosion known as sulfide stress cracking (SSC). These sour environments occur frequently in oil
production and refining. The National Association of Corrosion Engineers (NACE) Standard MR-01-75 addresses in detail the
specific environments in which SSC must be considered in material selection. Sulfide stress cracking can be controlled through
the use of materials that have been properly heat treated and are of the appropriate hardness.
 Most manufacturers offer valves made of materials that meet NACE Standard MR-01-75 requirements; however, as in all
instances in which special requirements are invoked, these valves are not readily available in all sizes and pressure classes. In
addition, because there are different heat-treatment requirements for different materials, some manufacturers do not offer all
trim options on valves whose materials must meet NACE requirements. A prime example of this is the lack of availability of 13%
chromium stainless steel trim. In order to meet NACE requirements this martensitic stainless steel must undergo a three-step
heat-treatment process.
FIRE SAFE VALVES
 Despite the best preventive efforts, fires do occur in oil refineries and chemical plants.
In these instances, soft-seated valves, such as ball and butterfly valves, present a unique problem. During a fire temperature can rise
above the maximum operating temperatures of the materials used to make seats and seals, causing them to decom­pose or
deteriorate and sometimes producing disastrous results. If the valve was closed, it will no longer be closed. The effect of this
uncontrolled opening depends on the specific application; however, it is rarely beneficial. More importantly, loss of stem and
body seals produces leakage directly to the environment, and if the valve is in a service such as furnace fuel lines, LP-gas lines,
and petroleum and petrochemical piping systems, the leaking fluid literally adds fuel to the fire.
 In order to prevent such occurrences, designers of ball and butterfly valves have modified their designs to reduce leakage,
assuming the absence of the non-metallic seats and seals. For ball valves, the following modifications are typical:
1. On floating ball designs, a secondary integral metal seat is machined into the valve body adjacent to the soft seat. The
slotted stem-to-ball connection allows line pressure to move the ball downstream when in the closed position and bear
against this seat for closing.
2. Metal, spiral-wound graphite-filled gaskets are used as body seals in split body and top-entry valves, rather than the non-metallic
materials usually used.
4
 3. A backseat is machined in the body or cover of the valve that mates with an integral collar on the internally inserted
shaft to produce a metal-to-metal seal.
4. High-temperature graphite shaft packing is used in lieu of the non-metallic packing usually provided.
 The usual modification for butterfly valves is to encase the non-metallic seat ring in a metal carrier, which becomes a
secondary seating surface in the absence of the non-metallic material. Graphite shaft seals are also used instead of the usual
non-metallic seals.
 To verify the effectiveness of these measures, several standards, such as API 607, have been developed.
 API Standard 607 specifies a test that simulates typical plant fire conditions and stipulates criteria for evaluating valve
performance both during and after the test. Maximum internal and external leakage rates are specified. The Standard also
provides for extending the test results to other sizes and ratings of valves that have the same basic de­sign and the same
non-metallic materials. Valves that have satisfied the prescribed performance requirements can be certified by the
manufacturer as "Fire Tested per API 607.“
LOW FUGITIVE EMISSIONS VALVES
 The term fugitive emissions applies to leaks from process equipment such as pumps, valves, and compressors and from the
piping connections between them, as opposed to the controlled emissions from stacks and vents.
 Federal, state, and local agencies have issued regulations restricting the fugitive emissions of volatile organic compounds
(VOCs). VOCs can be loosely defined as
carbon-containing compounds that exist as a gas at ambient pressure and temperature. Some 149 different toxic VOCs are
covered by these regulations. For valves, leakage is determined by measuring the local VOC concentration at the valve
surface at a possible leak source (e.g., a packing gland or a body-bonnet joint) with an organic vapor analyzer. There is no
uniformity among federal, state, and local regulations as to the level of concentration that is unac­ceptable. However, currently
the 1990 US Environmental Protection Agency's Clean Air Act defines an unacceptable leak for valves as 500 parts per
million (ppm) or more of VOCs. Local and state regulations as to concentrations may be lower.

Valve manufacturers have taken several different approaches to reducing fugitive emissions, among which are the following:
1. Using specially engineered packing sets that have the capability to expand radially up to 1/8 inch upon gland
tightening to achieve improved leak-tight sealing against the stuffing box and the valve stem.
2. Redesigning stuffing boxes to achieve more uniform compression of the packing and better sealing. Design changes
include shorter, narrower stuffing boxes; tighter tolerances on stem or shaft diameter and straightness, and on stuffing
box diameter and concentricity; and improved finishes on stems, shafts, and stuffing boxes.
3. Using stuffing boxes with two sets of packing separated by a lantern ring and a leakoff connection for the detection of
a leak in the lower packing set. The upper packing set prevents leakage to the environment until the valve can be
repacked. The leakoff connection must be monitored.
4. Live-loading the packing gland by installing springs under the bolt nuts of the gland flange. These springs help
maintain packing compression after cycling and aging of the packing. A live-loaded butterfly valve is shown in Figure
5-2.
5
 3. Using stuffing boxes with two sets of packing separated by a lantern ring and equipped with an injector for the injection of
sealant between the sets of packing.
The injected sealant fills the leak paths at the outer diameter of the stem and the inner diameter of the stuffing box. This
seal must be maintained by replenishing the sealant periodically, and the sealant must be compatible with the fluid.
6. Using a metal bellows to seal the stem enclosure. A bellows seal globe valve is shown in Figure 16-3. The stem is encased
in a cylindrical bellows that has one end seal welded to the lower end of the stem and the other end seal welded to the
bottom of the bonnet. The bellows compresses as the valve is opened and expands as the valve is closed. The result is a
completely leak-tight assembly. Stem packing is retained as a back-up in the event of bellows failure. Metal bellows can
only be used with non-rotating stems.

When used on globe valves the stem must be driven by the yoke nut, as in a gate valve. Bellows seal valves have a history
of successful use in services in which fluid leakage to the atmosphere is unacceptable owing to toxicity, chemical
aggressiveness, radioactivity, and other health hazards. Bellows seals usually are found only on small forged steel valves.
They add substantially to the cost of a valve.
 All of these approaches, whether used separately or in combination, have been effective in reaching acceptable concentrations of
fugitive emissions, but only the last one—the bellows seal valve achieves zero fugitive emissions.