VALVE TYPES: SELECTION, INSTALLATION AND OPERATION

Transcription

1 VALVE TYPES: SELECTION, INSTALLATION AND OPERATION Presenter: John Tonkin ABOUT THE PRESENTER: JOHN TONKIN th 2014 sees John's 44 year in engineering. Initially he had exposure to plant maintenance (steam, water, pneumatics, ash handling, boilers, turbines and pumping systems) and marine steam plant. A number of years in the selling, commissioning and trouble shooting of pumping systems were followed by nine years in the designing and presenting of training courses which covered the technicalities and marketing of pump sets, pipes, valves, diesel engines and basic electrical systems for pumping plant. An extended period followed in which John's career was focused on the marketing, selling and trouble shooting of pumping systems and submersible electric motors. Through his exposure to the international arena and the development and marketing of new products, John has gained a unique perspective of the fluid movement and control industry. A firm believer in the benefits of high-quality training, John has been at the forefront of training initiatives throughout his career. He can now offer your company the knowledge and skills he has gained over the years, presented in an interactive and practical manner. His courses have drawn a multitude of positive comments, many of which allude to his professional presentation style and the practical examples he offers throughout the training session Number of days: 4 Cost: $2800 This course is set at a fundamental to intermediate level and is aimed at individuals who have had some experience with valves but have not had the opportunity to be exposed to some of the finer details of these vital pieces of equipment. There are a number of practical examples and case studies that require the delegate to solve some algebraic equations and draw diagrams and graphs. To this end, he/she should have access to a calculator, (preferably scientific) a ruler and some coloured pens. As there will be discussions centred on computer software, it would be advantageous to have access to a laptop computer. We strive to tailor our training as close as possible to the delegate s real life experiences. We therefore encourage delegates to bring to the course data/material pertaining to any valve related problem or novel solution experienced back at the workplace. This adds a fresh and very rewarding aspect to the course for all concerned. KEY CONCEPTS Valve orifice, Cv, and other hydraulic concepts. Control valves (overview only). Gate, globe, pinch, diaphragm, ball, butterfly valves. Materials of construction. Air release, vacuum breaker and non-return valves. Actuators. WHO SHOULD ATTEND Piping Engineers and Designers Mechanical Engineers Process Engineers Plant managers and Engineers Oryx Engineering Grace Villamar Ext : Grace.Villamar@oes.com.qa

2 VALVE TYPES: SELECTION, INSTALLATION AND OPERATION Cont... COURSE OUTLINE DAY 1 Valve hydrodynamics and system hydraulics Valve inherent and installed flow characteristics Quick opening Linear Equal percentage When to use these characteristics Practical: Plotting the inherent characteristic of a diaphragm and a butterfly valve Flashing and choked flow Flashing defined Strategies for preventing/minimising flashing Choked flow defined Choked flow and the Critical pressure Drop (CPD) point Valve flow resistance The difference between head and pressure Valve K factors and their use in the calculation of losses in valves The equivalent length of pipe method of calculating losses in valves The Cv value of a valve and its application in valve sizing and loss calculation. The Kv value of a valve and its application in valve sizing and loss calculation. Valve and piping system interaction Overview of the calculation of friction loss in pipes A brief introduction to system resistance curves The influence of pipe resistance on valve throttling Practical: Calculating the total losses in a system that contains pipes and a number of valves of various sizes and patterns. Pressure transients (hammer in systems): A valve perspective Root cause of pressure transients Operational issues with regard to transients Ways to prevent or completely eliminate transients Air release valve: An overview of placement and sizing Practical: Delegates are taken through a worked example of the pressure rise due to transients. Classification of valves Linear actuation: Benefits, disadvantages and operational issues Rotary actuation: Benefits, disadvantages and operational issues Classification by size (dimensional) Classification by temperature and pressure rating Practical: Using the worked example in the previous practical, delegates select a suitable valve pressure rating from tables provided in the course material Cavitation and its implication in valves Vapour pressure and the destructive process of changes in fluid state Atmospheric pressure considerations Levels of cavitation: Incipient and constant Predicting cavitation conditions in valves using the sigma method Damage processes (pipes and valves): Vibration, erosion, corrosion and noise Strategies for eliminating or minimising cavitation damage Practical: Calculating the downstream pressure necessary to prevent a 600mm butterfly-throttling valve from cavitating. This valve was used to simulate the working head of a 1MW pump set In addition to a workbook, the resource material for this course will include material from selected manufactures and suppliers together with links to appropriate websites. Where appropriate, case studies based on in-field experiences will be included. Delegates are encouraged to raise problems they have had in the field with our course leaders in order to gain the maximum benefit from the program. Experience has shown that high levels of delegate participation ensure a rewarding experience for all participants.

3 VALVE TYPES: SELECTION, INSTALLATION AND OPERATION DAY 2 Valve components and materials of construction The valve body and bonnet Valve trim An overview of jointing gasket materials and stem packing Shell materials: Bronze, Iron (grey and bronze) Steel(carbon and alloy) Bolting Trim materials: Metallic and non metallic, ferrous and non-ferrous, alloys Definition of galling and how to prevent it Conditions of service and some of the consequences Fatigue Thermal shock High cycle rate loads Corrosion: Pitting, crevice, galvanic An overview of the prediction of remaining valve operating life Seat leakage rates Applicable specifications and their respective scopes ANSI/FCI MSS-SP61 API 598 Practical: Delegates are given a table of applications and they must match these with the most appropriate allowable leakage class. Gaskets and stem packing Flat, spiral wound and ring type joints An overview of bolt tightening sequence Packing materials: Braided, Moulded and die-formed Live loading stem seals: springs and Bellville washers Valve patterns for isolation and control Valve terminology: Body, bonnet, stem, ISRS, NRS, OS&Y etc The importance of recognising the two roles played by valves Requirements of an isolation valve Control valve applications Linear valves as controllers and isolators: Gate, globe, parallel slide knife gate, pinch needle, axial piston and diaphragm Rotary valves as controllers and isolators: Ball, butterfly and plug Non-return valves: Benefits, disadvantages and operational issues Practical: Delegates are given a diagram showing a piping system that requires the placement of appropriate valves in certain positions. This is a group exercise and it concludes with a general discussion of the completed system Valve maintenance routines Seat replacement Stem seal repacking Lubricant injection in ball valves Determining root cause of failure

4 VALVE TYPES: SELECTION, INSTALLATION AND OPERATION Day 3 Valve computer aided design System modelling programs The US Department of Energy s PSAT Valve software tool Manufacturer specific valve selection software programs The dangers of excessive "adjustment " of site data Valve selection software programs: Features, benefits and dangers Valve selection and sizing Considerations for the selection of valves Sizing isolating valves Valve specification sheets Sizing control valves: Too big, too small, just right Sizing control valves: Valve inherent characteristic Introduction to IEC/EN and IEC/EN and ISA S75.01 Throttling and pressure recovery Symbols used by the sizing equations specified in the IEC/EN and ISA Specs. Sizing equations for incompressible fluids Piping geometry factors Numerical constants Practical 1: Delegates are given a basic example of how to size a control valve for an application involving a pump, a heat exchanger and an incompressible liquid at a modest temperature Practical 2: An incompressible case study is presented to delegates for completion in groups. The activity ends with a report back session. Practical 3: Delegates are given a basic example of how to size a control valve for a super heated steam (pressure reducing) application Practical 4: A compressible fluid case study is presented to delegates for completion in groups. The activity ends with a report back session. Day 4 An introduction to pressure relief devices Basic terminology Code requirements Safety relief valves Rupture discs Buckling pins Valve actuators Input data requirements Energy sources: Pneumatic, Electrical, hydraulic Actuator types: Benefits, disadvantages and operational issues Stiffness, response, stroke lengths and torque Hysteresis and dead band Bench setting an actuator Basic actuator operation and maintenance Actuator sizing: Too big, too small, just right Limit switches Positioners The role played by a positioner Setting a positioner Smart vs. analogue positioners

5 About 2KG Training Leading engineering training firm 2KG Training has provided expert training to South African industry for almost a decade. Drawing on our international network of experienced professionals, 2KG Training provides training to the most exacting requirements in an exacting field. 2KG Training launched in 2005 with a focus on pumps, valves, and related systems. After establishing our presence in the field, we expanded our core offering of courses in order to meet demand from clients looking for our expert training in other aspects of the mechanical engineering discipline. Managing Director Harry Rosen is a past chairman of the South African Institution of Mechanical Engineering (SAIMechE) and an internationally-recognised expert on UNIDO Energy Efficiency projects. Mr Rosen embodies 2KG Training s insistence on experience and expertise in all aspects of our business. About Oryx Engineering Solutions Oryx Engineering Solutions (Oryx) is a progressive and newly established Qatari engineering services provider located in Ras Laffan Industrial City. Through Oryx s state-of-the-art facility or on-site teams they provide expertise in a number of technology areas: rotating & static equipment including pumps & valves, seals, welding and fabrication, and machining. Oryx works directly or through a number of strategic joint ventures and partnerships with leading companies, including: ABB Oryx Motors & Generators Service motors and generators, Aesseal Oryx for mechanical seals, Stork Oryx Turbo Machinery Services for turbines, gearboxes, control systems and the supply of associated auxiliary parts, and Furmanite for leak-sealing and on-site machining. Through this breadth of work Oryx recognises the importance of achieving maximum reliability and efficiency in the operation of these systems. This extends to the need for highest quality training and development for the industry. Our Training Offering In striving to deliver new value to the industry in Qatar, Oryx has now partnered with 2KG Training to bring world class engineering training to the country. Our reputation for comprehensive expertise is due to the stringent evaluation criteria used in selecting our trainers. Trainers are picked from a field of international experts, all of whom have at least twenty years of relevant experience. All our expert trainers have published books and journal articles in their disciplines, are affiliated with the relevant international associations and are actively involved with the standards committees. We currently offer the following accredited courses: Pump Operation and Maintenance Pump Efficiency Workshop Pumping Systems ASME B31.3 Process Piping ASME B31.1 Power Piping ASME Section VIII Div 1 Design, Fabrication, Inspection and Repairs of Pressure Vessels, ASME Section VIII Div 2 Design and Fabrication of Pressure Vessels ASME Section IX Welding and Brazing Qualifications Valves, Selection, Installation and Operations Piping Systems Compressors: Design, Operation and Maintenance Electricity for Mechanicals Bearings Mechanical Seals Flow Control Measurement API Advanced Storage Tanks: API650 & API653 Design, Maintenance and Inspection API ASME FFS1 Fitness for Service Power Generation: Steam and Gas Turbines Variable Speed Drives Vibration Analysis 1 Condition Monitoring and Reliability

6 REGISTRATION FORM Number of days: 4 Cost: $2800 How to register for the course: 1. Complete this registration form and fax it to Grace Villamar: Tel: Fax: Grace.Villamar@oes.com.qa 2. Acknowledgement will be ed to you. 3. Final confirmation and details will be faxed or ed to you approximately 7 days before the commencement of the seminar. Conditions of entry: 1. Cancellations are accepted in writing and without penalty, up to 14 working days prior to commencement of the seminar. 2. Cancellations in writing less than 14 working days prior to the seminar will be liable to pay 50% cancellation fee. 3. Less than 7 days, defaulter will be liable to pay 100% cancellation fee. 4. In case of insufficient applications for the workshop 2KG/Oryx Engineering reserves the right to cancel the seminar. Applicants will be informed and all fees will be refunded immediately. Delegate information: Title: Surname: Name: Full Company name: Job Title: Postal Address (to which invoice must be sent): Code: VAT number: Tel: ( ) Cell: fax: ( ) Contact/ Accounts information: Title: Tel: ( Surname: Name: ) Cell: Dietary Requirements: Normal Accommodation Requirements: fax: ( ) Vegetarian Halaal Yes No Please tick the course that you would like to attend. Qatar, Ras Laffan 2015 dates to be confirmed I have read and agreed to all the conditions of registration as stipulated in this brochure. Signature Date For more info and to register contact Grace Villamar on tel: Ext : 809 and Grace.Villamar@oes.com.qa Oryx Engineering Grace Villamar Ext : Grace.Villamar@oes.com.qa