VM 11 n04 Fall 2011 PDF

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WHERE VALVES ARE
USED: Pipelines
Actuators in Nuclear
Applications
Noise Reduction
Asset Management
2012 MARKET OUTLOOK:
Strength Against
Changing Winds
Fal l 2011 | VOLUME 23, NO. 4
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SPECIAL VALVEMAGAZINE.COM FEATURE
NUCLEAR INDUSTRY UPDATE
A representative from Areva, a nuclear and renewables energy company,
brings us up-to-date on whats happening around the world as a result of
the nuclear crisis in Japan.
42
42
38
38
Valve
M A G A Z I N E
Fal l 2011
VOLUME 23, NO. 4
C O L U M N S
Perspectives 4
A Brighter 2012
BY BILL SANDLER
Materials Q&A 46
Welding Procedure Specs
BY DON BUSH
Social Media 48
Online Valve Communities
BY JIM CAHILL
Maintenance & Repair 51
Asset Management
BY GARY OSTROWSKI
Conversation with 60
Ravi Krishnan on Doing Business in India
BY GENILEE PARENTE
D E P A R T M E N T S
Industry Capsules 6
VMA Calendar 10
Index to Advertisers 55
VMA and VRC Member Roster 58
ACTUATION IN
NUCLEAR POWER PLANTS
Actuators and the valves they operate face challenging
conditions in service to the nuclear industry. Heres specifics on
what is used and where.
BY PETE KUNDIN
34
34
VIBRATION ANALYSIS
PINPOINTS VALVE
NOISE SOURCE
A power plant in California faced public concern about a noise
generated by its system. Vibration analysis located the source.
BY DANIEL EILERS
14
14
MARKET OUTLOOK 2012
THE WINDS OF CHANGE
Market outlook speakers addressed both the forces of the
previous year, a year full of surprise gusts from unexpected
events, and what is to comea vastly different kind of
recovery than what has occurred in previous recessions. Still,
the news regarding valves and actuators was positive.
BY GENILEE PARENTE
WHERE VALVES ARE USED:
PIPELINE SERVICE
Hundreds of thousands of pipelines help bring oil and natural
gas to and from processing facilities. This article describes the
various types of valves that control that flow.
BY GREG JOHNSON
FEATURES
ALSO ON THE WEB:
The State of U.S. Refining
Ball Valve Coatings
Lean Series:
Leading a Spirited Organization
New articles posted and news items updated
regularlyvisit ValveMagazine.com often!
Editors Picks
Large bore
isolation valve
Flame-free press
system
Push-through
slurry valve
Two-way-tight,
single-seat valve
Automated
flushing system
Stainless-steel
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and more
54
54
PRODUCTS
Valve
M A G A Z I N E
EDITORIAL REVIEW BOARD
Richard D. Oaks
AUMA ACTUATORS, INC.
Mike Hendrick
CONVAL, INC.
Doug Clendenin
CRANE FLOW SOLUTIONS
John Wells
EMERSON PROCESS
MANAGEMENT
Ed Holtgraver
QTRCO, INC.
Christopher Warnett
ROTORK CONTROLS, INC.
VALVE MAGAZINE (ISSN No. 1057-
2813) is the official magazine of the
Valve Manufacturers Association of
America (VMA) and is published
quarterly by VMA, located at
1050 17th Street NW, Suite 280,
Washington, DC 20036-5521;
202.331.8105; Fax: 202.296.0378.
Advertising queries: 540.374.9100.
Periodicals postage paid at Washington,
D.C., and at additional mailing offices.
POSTMASTER: Send address changes
to VALVE MAGAZINE, P.O. Box 1673
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Subscriptions are free to qualified
readers in the United States and Canada;
$40 per year to unqualified readers in the
United States and Canada; $60 per year
for all subscribers outside the United
States and Canada. Statements of fact
and opinion made are the responsibility
of the authors alone and do not necessar-
ily imply endorsement or agreement on
the part of the officers or membership
of VMA. Materials may not be
reproduced in any form without written
permission of VMA.
Copyright 2011. All rights reserved.
A
s we went into VMAs 30th Annual
Market Outlook Workshop, which was
held in Boston, our presenters were faced with
a particularly large challenge. The stock
market was seeing huge swings, and several
speakers offered a glimpse of how the situa-
tion had changed in just the few days leading
up to the August workshop.
However, overall, the attitude was opti-
mistic as our experts shared with audience
members news about the process control
industries. The economic recovery is well
underway and most presenters pointed out
that manufacturing and industry is at the
forefront of that recovery. They indicated that
the near-term future was more positive than
the last five years, but issued caution because
of the uncertainty.
The figures most speakers gave showed
that 2011 was a good year and 2012 will
probably be even better. For the long-term,
end-user experts gave those in attendance
hope for the future of the valve industry.
Meanwhile, a record number of people
showed up to listen to those comments. We had
70 VMA members there, as well as 45 addi-
tional attendees from the Hydraulic Institute,
the trade association representing pump manu-
facturers and our partner at the workshop the
last seven years. Evaluations for this particular
workshop were very favorable both in terms of
value of the presentations as well as the meet-
ing facility and the staff. Speakers included
such long-time friends of the industry as John
Spears, Spears and Associates, a company that
has shared its knowledge of the oil & gas indus-
try for all 30 years of the workshop beginning
with Johns father Bob, who spoke in 1982.
Some other long-timers, such as water/waste-
water expert Tom Decker and U.S. economic
expert Alan Beaulieu, also were on hand to
share their expertise.
The audience seemed very interested in a
few new topics on the agenda this year includ-
ing valves and pumps in India (see related
story, as well as this issues Conversation
with), and a special presentation on renew-
ables. For an in-depth look at what was said
this year, turn to page 14 to read an overview
of the presentations, written by Genilee Par-
ente, managing editor, Valve Magazine.
In addition to listening to 12 excellent
presentations, I also heard what attendees
were saying about their business experience
over the past half-year, which was mostly pos-
itive. While no one said they were building a
new manufacturing facility, many attendees
were adding personnel to their production
staffs.
Alan Beaulieu, whose advice our industry
has come to highly value, told us there were
seven items we should watch closely in the
near future:
Money Supply
Corporate Bonds Rate-of-Change
U.S. Leading Indicator
Purchasing Managers Index
Retail Sales
Employment
Nondefense Capital Goods New Orders
He went on to say there would be a slower
rate of recovery in 2011 than originally fore-
cast, followed by ongoing recovery in 2012.
Next year VMA will once again evaluate
how the economy and industry is doing at our
31st Market Outlook Workshop, scheduled
for Aug. 9-10, 2012 in Chicago. VM
P E R S P E C T I V E S
www.vma.org
www.ValveMagazine.com
Bill Sandler
President
Valve Manufacturers Association of America
A Brighter
2012

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6
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Valve M A G A Z I N E
ACQUISITIONS
Rotork Acquires K-Tork International Inc.
Rotork Plc has purchased the share capital of fellow VMA
member K-Tork International Inc. Based in Dallas, K-Tork
manufactures pneumatic vane actuators and damper drive sys-
tems, serving a wide range of industries and utilities. K-Tork
actuators are designed for precise control of quarter-turn
valves and dampers. These products will be used to comple-
ment Rotorks existing actuation portfolio and provide an addi-
tional product offering for the Rotork Fluid Power division.
Forum Energy Technologies Acquires SVP Products
Forum Energy Technologies, Inc. (formerly Global Flow
Technologies) has acquired SVP Products Inc., a provider of
high-pressure flow control equipment and products used in
hydraulic fracturing and flow back of oil and gas wells. The
company sells Forums Wood Flowline and Phoinix product
lines, including swivels, plug valves, relief valves, chokes, pup
joints and manifold trailers from three facilities in North, East
and West Texas. SVP also performs critical repair and recer-
tification services of these products from its stores as well as
from its fleet of mobile units.
Automation Technology, Inc. Acquires Gevalco
Automation Technology, Inc. (ATI) has acquired Gevalco,
which specializes in pipeline valve automation. Gevalco has
been in business for 16 years and offers unique valve automa-
tion solutions and a focus on ensuring pipeline safety. The
company markets and manufactures valve actuators (severe
service), line-break control systems, hydraulic power units,
station bypass and emergency shutdown systems.
Curtiss-Wright Agrees to Sell
Valve Distribution Business
Curtiss-Wright has completed an asset purchase and sale
agreement to divest the legacy distribution business of its Valve
Systems and Controls (VSC) operation to McJunkin Red Man
Corporation, a global distributor of pipes, valves, fittings and
related products to the energy and industrial markets.
Although the rights to the name Valve Systems and Con-
trols is included in the sale, Curtiss-Wright Flow Control
retains all rights in its Total Automation Solutions and
DeltaValve business segments, and continues to provide
turnkey valve, automation and control solutions for the oil and
gas production, refining, petrochemical and power markets.
Crane Co. Purchases W.T. Armatur GmbH & Co.
Crane Co. has purchased all the equity interests in W.T.
Armatur GmbH & Co. KG (WTA). WTA is primarily a manu-
facturer of bellows sealed globe valves, as well as certain types
of specialty valves, for chemical, fertilizer and thermal oil
applications. Located in Maxdorf, Germany, WTA employs 95
people. WTAs 2010 sales of about $21 million were primarily
to customers in Germany and surrounding countries.
Emerson Process Management
Acquires Net Safety Monitoring
Emerson Process Management has acquired Net Safety Moni-
toring, Inc. For nearly two decades, this Calgary-based com-
pany has developed products engineered for continuous per-
formance in extreme conditions, particularly for the oil and
gas industry. Net Safety and its global sales and support
offices in Calgary, Houston, Abu Dhabi, Beijing and Singapore
will continue operating as a separate business within Emerson
Process Management.
ITT Signs Corporate Procurement
Agreement with Saudi Aramco
Saudi Arabian Oil Company (Saudi Aramco) and ITT Corpo-
ration have signed a comprehensive seven-year strategic part-
nership agreement for ITT to provide products and services to
the worlds largest oil producer for oil, gas and petrochemical
projects in Saudi Arabia and internationally.
Curtiss-Wright Flow Control and
CCI Thermal Technologies Sign Agreement
Enertech, a business unit of Curtiss-Wright Flow Control
Company, and CCI Thermal Technologies, Inc. have signed an
agreement to work together in providing heating and filtration
solutions and products to the nuclear industry worldwide.
Under the terms of the agreement, Enertech will focus its
efforts on sales and marketing for CCI Thermal Technologies
Caloritech Engineered Electric Heat and 3L Filters Engi-
neered Filtration Systems used in safety-related and non-
safety-related applications for nuclear power plants and other
facilities performing nuclear activities.
Weir Acquires South Korean Valves Business
The Weir Group PLC has agreed to acquire a majority interest
in the South Korean valves business formerly operated by
HIM Tech Co. Ltd. Weir will purchase 60% of a new Korean
company, Weir International, into which the HIM Techs
valves business has been transferred.
Located in Ansan, near Seoul, the business designs and
manufactures control and choke valves for severe service
power generation and oil & gas applications. Its products are
supplied to both domestic customers and major South Korean
engineering contractors for international projects. In 2010,
HIM Techs valve business recorded sales of $10.5 million.
IN
D U S T R Y C A P S U L E S
F a l l 2 0 1 1
|
7
Lone Star Products Group Acquires
Energy Hardware Holdings LLC
Lone Star Products Group expanded its global footprint via a
merger with Energy Hardware Holdings, LLC (EH). Headquar-
tered in Wolverhampton, UK, the Lone Star Group is a global
provider of customized, high-performance fasteners, gaskets
and flow control components. EH currently operates two distri-
bution facilities, the companys main distribution center and
headquarters in Greer, SC, and another distribution center in
Pensacola, FL. Additionally, EH maintains stocking locations
in California, France and Hungary.
CONTRACTS & AGREEMENTS
Flowserve Announces Certification to
Supply Control Valves to Saudi Aramco
Flowserve Corporations manufacturing plant in Dammam,
Saudi Arabia, which is operated by Flowserve Abahsain Flow
Control Company Ltd. (FLS/ABA), has been certified by Saudi
Aramco for supply of control valves. FLS/ABA is a joint ven-
ture of Flowserve and S&A Abahsain Co. Ltd. The certification
by Saudi Aramco allows valves produced by FLS/ABA at the
Dammam plant to be sold to Saudi Aramco.
Shell Signs Agreements with Tyco, Emerson
Shell has selected Tyco International Ltd.s flow control unit
to provide butterfly valves globally. The five-year Enterprise
Framework Agreement covers more than 2,500 of Tycos
Vanessa, Winn, NeoTecha and Sapag brand highly engineered
butterfly valves for use in projects, maintenance repair opera-
tions and turnaround applications.
Shell and Emerson Process Management have also signed a
five-year enterprise framework agreement that makes Emerson
the single-source supplier of on/off valve actuators to Shell and
its affiliates.
Cameron and Petrobras Renew
Subsea Aftermarket Service Agreement
Cameron has renewed an agreement with Petrobras for the sup-
ply of aftermarket services and support for developments in off-
shore Brazil. This agreement is a continuation to the CAM-
SERV aftermarket services contract previously signed in 2007
and is expected to generate more than $150 million in revenue
to Cameron over the next three years.
Cameron will manage the agreement from its service center
in Macae. The facility will support Petrobras operations with
inspection, maintenance, repair and remanufacturing, storage
and offshore installation services.
Emerson Supplying Control Valves for
South Carolina Nuclear Power Plant
Westinghouse Electric Company has awarded Emerson Process
Management more than $8 million in purchase orders for
critical control valves to be used in two AP1000 pressurized
water reactors at SCANA Corporations Virgil C. Summer
Nuclear Generating Station in Jenkinsville, SC. With site
preparation already underway, construction is scheduled to
begin late this year or early next year. The two new reactors are
scheduled to begin commercial operation in 2016 and 2019.
Metso Supplying One
of the Worlds Largest
Biomass Boilers
Metso will supply a 100 MWe
biomass boiler island and plant
automation system to the
Gainesville Renewable Energy
Center (GREC) in Gainesville, FL.
Metsos delivery represents more
than 25% of the nearly $500 mil-
lion in construction financing
GREC has successfully raised. The
new power plant installation will
supply Gainesville Regional Utilities with a firm source of
renewable electric power under the terms of a 30-year power
purchase agreement.
Mueller Co. Signs Distribution Agreement
with Advanced Valve Technologies
Mueller Co. has signed an exclusive distribution agreement
with Elk Grove Village, IL-based Advanced Valve Technologies
(AVT) for its EZ2 Insertion Valve System, the company
announced. The agreement makes Mueller Co. the master dis-
tributor in the U.S. and Canada for AVTs EZ2 Valve System.
ValvTechnologies Signs Agreement with KISC
In July ValvTechnologies signed a purchase order with KISC for
valves to be used in Chinas Yunnan Province. The valves pur-
chased will be used in slurry lines in KISCs mining operations.
In addition, the two companies signed a contract of mutual
agreement where ValvTechnologies agreed to purchase an intel-
ligent software system to monitor the valves put in place.
KISC is an enterprise group engaged in a variety of endeav-
ors, including iron and steel metallurgy, mechanical manufac-
ture, project engineering, electronic information technology
and environmental protection.
Rotork Tapped for Wastewater Project in Qatar
Rotork valve actuators will assist the operation of the largest
and most advanced wastewater treatment, water reuse and
sludge treatment plant in the Middle East. Described as a land-
mark project, the Doha North Sewage Treatment Works in
Qatar has a peak wastewater treatment design capacity of
439,000 cubic meters per day. Advanced membrane and ultra-
violet treatment technologies are being used to reclaim high-
quality water for non-potable purposes, thereby freeing-up
drinking water supplies for the community.
Valve
M A G A Z I N E
STAFF
PUBLI SHER
William S. Sandler
ASSOCI ATE PUBLI SHER/
EDI TOR- I N- CHI EF
Judy Tibbs
MANAGI NG EDI TOR
Genilee Parente
ASSI STANT EDI TOR
Chris Guy
CONTRI BUTI NG EDI TORS
Greg Johnson
Peter Cleaveland
Gary Grauerholz
ART DI RECTOR/
PRODUCTI ON MANAGER
Michelle Wandres
ADVERTI SI NG DI RECTOR
Sue Partyke
How to Contact
VALVE MAGAZINE
EDI TORI AL OFFI CES
7000 Radford Drive
Fredericksburg, VA 22407
phone: 540.785.8901
fax: 540.785.8903
email: jtibbs@vma.org
website:
www.ValveMagazine.com
ADVERTI SI NG SALES
Sue Partyke
145 Harrell Road
Suite 119
Fredericksburg, VA 22405
phone: 540.374.9100
fax: 540.374.9265
email: spartyke@vma.org
CI RCULATI ON/ SUBSCRI PTI ONS
phone: 570.567.1193
fax: 570.320.2079
email:
valve@PublishersServiceAssociates.com
NEW PRODUCTS, MEDI A &
I NDUSTRY NEWS
Chris Guy
phone: 540.785.8901
fax: 540.785.8903
email: cguy@vma.org
ARTI CLE SUBMI SSI ONS
VALVE MAGAZINE
welcomes articles, proposals,
manuscripts, photographs, and
ideas from our readers. For a
copy of the magazines Authors
Guidelines, contact Judy Tibbs,
editor-in-chief, at jtibbs@vma.org
or call 540.785.8901.
I N D U S T R Y C A P S U L E S
8
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Tyco Joins Action Against Hunger to Launch Clean Water Access Initiative
In a new private-nonprofit venture, Tyco International and Action Against Hunger | ACF Inter-
national have launched the Clean Water Access Initiative, a global partnership to bring safe
drinking water to some of the most vulnerable communities around the world. Dedicating more
than $2 million over the next three years, and drawing on the extensive product line, global
workforce and technical expertise of Tycos flow control business, this initiative will improve
ACFs ability to deploy effective solutions for communities lacking access to clean water.
Sales in the chemical processing industry (CPI) should continue
to show steady but slow improvement in the coming months,
according to a recent survey.
The survey of CPI equipment suppliers and chemical manu-
facturers queried about 300 Chem Show exhibitors. Over 75%
of those respondents said they believe the industry is showing
signs of growth for 2011. In fact, 83% expect sales to be better
than 2010, while nearly 15% said sales would be about the
same as 2010. Only 2% expected sales to be less than 2010.
The predictions were supported by figures from the Mid-
Year 2011 Situation & Outlook, released by the American
Chemistry Council this past summer. According to that report,
capacity utilization will be 71.3% in 2011 (up from 69.6% in 2010) and will increase to
75.3% in 2012. Other findings were:
American chemistry output is anticipated to rise 4.1% in 2011 and 3.5% in 2012.
Chemistry pharmaceuticals output should rise 3% in 2011 and 4% in 2012.
Production of basic chemicals should grow 4.8% in 2011 and 3.2% in 2012.
Capital spending in the business of chemistry will reach $30 billion in 2011.
Long-term U.S. chemistry growth will average 2.9% annually, exceeding the U.S.
economy.
Strong global industry capital spending gains are expected for several years.
U.S. BUSINESS OF CHEMISTRY OUTLOOK
(% change in volume, unless noted otherwise)
Average
2010 2011 2012 2013 2014 2015 2016 2017-21
Capacity 3.7 0.0 0.8 1.8 2.5 2.8 3.0 2.8
Capacity Utilization (%) 69.6% 71.3% 73.2% 73.9% 74.0% 74.0% 73.9% 74.1%
Total Output 3.5 4.1 3.5 2.8 2.6 2.8 2.8 2.9
Pharmaceuticals 1.0 3.0 4.0 4.0 4.0 4.1 4.2 4.2
Total, excluding Pharmaceuticals 6.1 4.8 3.1 2.0 1.7 1.8 1.8 1.9
Consumer Products -0.1 4.6 2.5 2.0 2.0 2.1 2.1 2.2
Agricultural Chemicals 4.0 5.3 2.3 1.0 1.0 1.2 1.3 1.3
Specialties 4.6 3.5 4.0 2.9 2.7 3.0 2.8 2.6
Coatings 9.7 -0.9 3.3 2.3 2.2 2.1 2.2 2.3
Other Specialties 2.6 5.4 4.2 3.1 2.9 3.4 3.1 2.7
Basic Chemicals 7.5 4.8 3.2 1.8 1.1 1.3 1.3 1.5
Inorganics 9.2 3.2 3.0 1.4 0.5 0.6 0.8 0.8
Bulk Petrochemicals
& Organics 7.3 5.6 3.1 1.9 1.4 1.5 1.6 1.8
Plastic Resins 5.4 4.7 3.6 2.1 1.4 1.5 1.3 1.8
Synthetic Rubber 8.2 5.7 3.2 1.5 1.1 1.3 1.1 1.5
Man-Made Fibers 12.4 4.1 1.3 -0.2 -0.8 -1.1 -0.6 -1.2
Source: American Chemistry Council
MARKET FOCUS
Chemical Processing Industry Faring Well
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10
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VMA Membership Continues to Grow in 2011
Since our last new member update in the summer issue of Valve Magazine, three more companies
have been added to the VMA roster, bringing the total for new members this year to 11.
Hemiwedge Valve, a division of Chromatic Industries, Inc., is located in Conroe, TX. The
company makes cartridge valves for the refining, mining, power, pipeline and petrochemical
industries. Learn about the company at www.hemiwedge.com.
Victaulic, based in Easton, PA, specializes in grooved and plain-end mechanical pipe joining
systems. For additional information, go to www.victaulic.com.
A.W. Chesterton Company of Groveland, MA is VMAs newest associate member. The
company specializes in valve and pump packing, mechanical seals, polymer seals, epoxy coatings
and maintenance lubrications. Find out more at www.chesterton.com.
Plans Underway for Online Basics Training Tool
By spring of 2012, there will be a new addition to the
Valve Ed familyan online, self-conducted training
program. While VMAs highly successful Valves &
Actuators 101 programs will continue to be held at a
rate of two per year, many individuals in need of training
arent able to travel to an out-of-town location for
budgetary reasons, or dont have the time to be out of
the office or plant for 2 days.
Weve known all along that to reach the maximum
number of people, we would need to provide alternate methods
of delivering our training program, said Greg Johnson,
president of United Valve and chairman of VMAs Education & Training program.
Now that our Valves & Actuators 101 course content has been fine-tuned, the time has come
for us to take the next step.
Judy Tibbs, VMA director of education, explains how the online program will work: The
course will be divided into seven different modules, similar to the seven lessons that make up the
current course. Those who wish to sign up for the course will first pay a fee in The VMA Store,
then be given a code that allows them to enter a special website. Next, an audio narrative will
guide students through each slide in the lesson. At the end of each lesson, participants will take
a short quiz; once the questions have been answered correctly, access will be granted to the next
lesson, until all seven lessons have been completed.
Once the student has successfully completed the program, a certificate of completion and
continuing education units will be awarded by the Valve Manufacturers Association.
The online course is expected to launch in the second quarter of 2012.
Meanwhile, VMA will continue holding the Valve Basics Seminar & Exhibits, which includes
the Valves & Actuators 101 course, valve petting zoo and a tabletop exhibition. The 2012
events will take place in Houston, March 6-7, at the Hilton Houston NASA Clear Lake, and
Oct. 10-11 in the Denver area.
VMA also offers an onsite training programValve Basics in a Boxwhich supplies all the
materials needed for someone knowledgeable in the valve industry to use for training a group of
individuals at a companys plant or facility. A slimmed-down version of this program, Valve
Basics in a Manualdesigned for an individual that wishes to independently review and learn
the course contentwill be offered by early 2012.
We asked Greg Johnson what else VMA has in store for its Valve Ed program: Were
looking at adding some 201-level short courses. Right now the plan is to offer an optional
seminar following the one-and-a-half day 101 course.
All VMA products can be purchased in The VMA Store on VMA.org. For additional
information, contact Judy Tibbs at jtibbs@vma.org.
OCTOBER
26-27
Valve Basics Seminar
& Exhibition
Rosemont (Chicago), IL
www.vma.org
NOVEMBER
1-3
The Chem Show
New York
www.chemshow.com
DECEMBER
13-15
POWER-GEN
International
Las Vegas
www.power-gen.com
JANUARY
16-17
Valve Industry
Leadership Forum*
Sarasota, FL
www.vma.org
23-25
AHR (Air Conditioning,
Heating, Refrigeration)
Exposition
Chicago
www.ahrexpo.com
MARCH
6-7
VMA Valve Basics
Seminar & Exhibition
Houston
www.vma.org
8-9
VMA Technical Seminar
& Exhibition
Houston
www.vma.org
APRIL
1820
VMA Manufacturers
Workshop & Tour*
Houston
www.vma.org
26-27
VMA Finance Leaders
Seminar*
Arlington, VA
www.vma.org
*These meetings are open only to
VMA/VRC members. For more
information, go to VMA.org >
Events.
CALENDAR
2011-2012
VMA NEWS
ASSET
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VM_FALL10_VM_FALL10.qxd 10/7/10 12:00 PM Page C3
12
|
EVENTS
I N D U S T R Y C A P S U L E S
More than 19,000 people involved in power generation from
around the world will gather at the Las Vegas Convention
Center Dec. 13-15 for the 23rd Power-Gen International
2011. Those people come from every sector of the industry
from engineering to operations to consultants and top level
decision makers within power companies, public utilities, sup-
pliers and government entities. They also come from all types
of energy industries including coal, nuclear, oil, natural gas,
wind, hydro, biofuels and solar.
Keynote speakers this year are David M. Walsh, senior vice
president of Service & Manufacturing for Mitsubishi Power
Systems America as well as Donald B. Karner, president and
CEO of ECOtality North America, a clean technology compa-
ny. In addition, almost 40 educational and informational
sessions are held on topics such as industry trends in power
generation, environmental issues, newer kinds of energy such
as waste reclamation, renewables, fossil fuels, and perform-
ance of plants and other power sectors. This years education-
al program will also include an extensive mega session on the
state of the economy and how the various energy sectors will
be affected.
In addition, during three days of exhibits, over 1,200 com-
panies will feature products and services that power profes-
sionals need in their lines of business. Among those exhibitors
are numerous VMA member companies as well as Valve Mag-
azine, VMA and the Valve Repair Council, all located at booth
#1362. Be sure to visit the VMA exhibit and pick up a free
copy of the North American Catalog of Valves and the latest
issue of Valve Magazine.
The Power-Gen show is held in conjunction with two
concurrent shows: Nuclear Power, which has its own section of
the exhibit floor and the newest co-located event, the Financial
Forum. The financial forum will provide corporate level
project developers and financiers an exclusive venue to learn,
network and do business.
For information go to www.power-gen.com.
The 2011 Chem Show, which is Nov. 1-3 at the
Jacob K. Javits Convention Center, New York
City, is expected to attract more than 5,000
chemical industry processing professionals
from around the world who will come together
to assess how their industry is faring in the cur-
rent economy, as well as find out about the lat-
est in technology and process improvements.
According to an exhibitor survey done
before the show, buying power should be in full
might63% of respondents said they will fea-
ture new products this yearalmost half of
those products will have never been shown. One
area where those products will be featured is
the Process Control & Automation Center at
the show, which highlights a wide range of
innovations in process control systems, wireless monitoring
devices, data collection, instrumentation, sensors, trans -
mitters and much more.
The 54th biennial Chem Show is the leading event for the
chemical processing industry in North America covering criti-
cal industry topics with concentration in key areas of process
control and automation solutions, optimizing process efficien-
cy, water/wastewater treatment, emerging tech-
nologies, saving energy and sustainability.
The American Institute of Chemical Engineers
offers a comprehensive, solution-focused educa-
tion conference program during the show broken
down into three areas: nanotechnology; engineer-
ing technologies for plants, products and opera-
tions; and energy, safety and consulting issues.
Included in the conference program is a
VMA-sponsored sessionAn Introduction to
Valves, Actuators and Controlswhich is a con-
densed version of the associations popular Valve
& Actuators 101 seminar. Readers are invited to
register for the session, slated for Tues., Nov. 1,
from 1:00 to 4:00 p.m. Registration information
can be found at www.chemshow.com. In addition,
Valve Magazine, VMA and the Valve Repair Council will also
be hosting a booth at The Chem Show (#544), distributing
complimentary copies of the North American Catalog of
Valves as well as magazines and information about new
educational resources.
For information on the Chem Show, go to
www.chemshow.com.
Power-Gen Now in its 23rd Year
The Chem Show Highlights both Innovation and Established Processes
High pressure. Extreme temperatures. Volatile products. Its all part of the job in
hydrocarbon processing. But so is the goal of maximizing safety integrity. We make
the process more secure with our innovative valves and controls, which is why the
industry relies on us to keep their workers safe and their plants running smoothly.
/ea|n mo|e aoo0t o0| o|ant oe|fo|mance so|0t|ons at www.cwfc.com
Eng|nee||ng t|ansfo|mat|on.
R|sk has
a|ways been
part of
th|s job.
A part we can do without.
VM_SPR11_VM_FALL10.qxd 4/7/11 9:25 AM Page 9
A
ttendees at this years VMA Mar-
ket Outlook walked into the meet-
ing room with a bit of shell shock. The
stock market fluctuated wildly in the
days leading up to the Aug. 11-12
event in Boston following weeks of
tough U.S. federal budget negotiations
and the downgrading of the U.S. credit
rating for the first time in history. Sara
Johnson, senior research director of
IHS Global Insight, called the events
headwinds blowing against what had
been expected. She said the year 2011
had been filled with such unusual
occurrences, including the Japanese
earthquake/tsunami earlier that year as
well as other natural disasters and
political upheavals.
But attendees were soon to learn that
outlook speakers, while they admitted
some figures might need to be adjusted
for the remainder of 2011, felt their
overall prediction was on trackthe
valve and actuator industry will see a
brighter 2012.
I hope as you leave here today, you
leave uncertainty behind and realize
things are not as bad as you may have
thought. There is still force in our sails
it just might be time to adjust those
sails to the prevailing winds, Alan
Beaulieu, president, Institute for Trend
Research,
emphasized.
MARKET OUTLOOK 2012:
THE WINDS
OF CHANGE
THE DOMESTIC ECONOMY:
A BRIGHTER YEAR TO COME
When economist Alan Beaulieu of the Institute for Trend
Research stood before the Market Outlook workshop audience
this year, he was facing a room of people afraid of what he
might say. Last year, Beaulieu dropped a bomb when he pre-
dicted a depression 20 years down the road, and that predic-
tion did not change this year. However, as far as the short-
term future, Beaulieu was this years voice of reassurance.
This country has no institutional memory. Weve
already forgotten the early 1980s, which was a much
worse time, Beaulieu pointed out. This feeling of
doom and gloom has really been overplayed.
However, the main point he said he wanted to make
was this: The next 20 years are going to be
vastly different than the last 20 years.
In the immediate future, stock market
volatility will remain, and it may mean
some of the forecasts that experts have been
laying down as the nation recovers from the
Great Recession may not be as rosy as
originally predicted.
But the recovery will continue through
2012 and 2013 before we hit the next dip. And
unless youre into housing, there will be significant
opportunities, Beaulieu said.
In fact, Beaulieu said that during 2012, there will be a mild
movement upwards in stocks overall, which means it will be a good
year for investing. He also said that because the real
estate market is still suffering, investing in that area
could be beneficial.
CONTI NUED ON PAGE 16
MARKET OUTLOOK 2012:
THE WINDS
OF CHANGE
Its a different world: There wasnt much talk
this year about looking to the past to respond to
the future. Thats because almost every presen-
ter pointed out that the world and this nation are
in a unique economic situation. Most said to
expect the rocky stock market in the U.S. to
remain volatile and that while the nation is in
recovery mode, its going to be a long steady
climb back to the prosperity we experienced just
before the Great Recession.
Shining stars burning brightly: India was
mentioned by more speakers this year than at
any previous workshop. The country began a
climb toward prosperity in the 1990s when
economic reforms went into effect. It did not
suffer the consequences of some other nations
during the recent economic woes so it is one of
todays shining stars. Brazil continues to prosper
and was mentioned by many
speakers as a good place to do
business. China is still a tough
contender for business, but it
has experienced high inflation
rates and other challenges
that may mean some busi-
ness returning to U.S. soil.
Renewables are catching hold:This is the first
workshop where one session was devoted to
renewable energy sources, but it wasnt just that
speaker who explained why. From international
reports on global warming to new technologies that
make renewables more cost effective to unfavor-
able attitudes toward coal, speakers gave reasons
why wind, solar, biofuels, biomass, hydropower and
other new sources of energy are gaining ground.
Shale drilling rocks: Any of the speakers who
addressed energy, petroleum or related products
mentioned the changes in this country that are
occurring because of shale drilling both here and
in Canada. Gas prices remain low; drilling has
increased; more drilling is
occurring on-shore;
new technologies are
increasing outputs; new
shale sources are being
discovered. All of
these shale drilling
developments mean
less reliance by North
America on foreign
sources of fuel.
COMMON THEMES
Although Beaulieu focuses on the
domestic outlook, he brought up several
points about whats happening globally
because of the effects those develop-
ments will have on this country. For
example, he said that the downgrading
of U.S. credit rating means little in the
international picture.
With all the uncertainty going on in
Europe and other places, the bond mar-
ket still favors the U.S. Its a safe haven
for investors, and a downgrade will not
bring skyrocketing interest rates or a fall
in the U.S. dollar as newscasters pre-
dicted, he said.
He also brought up whats happening
in China, where inflation is significant.
We cant ignore whats going on [in
that country], because we will eventually
feel the pain. Inflation will come to the
U.S. in the form of higher prices for
many consumer goods, Beaulieu said.
Still, China and many other areas of
world are currently losing some of the
advantages that made them so appealing
a place to do business at the same time
their economies are in need of additional
goods.
That should translate into business
for you, including more export busi-
ness, he said.
As far as whats happening on this
shore, Beaulieu said to look at:
Employment. Instead of looking at
the unemployment rate (which was 9.1%
at the time of the workshop) corpora-
tions need to focus on how many jobs are
created in the private sector. At outlook
time, that number was about 157,000
jobs per month, and anything over
100,000 is a favorable figure, he said.
When jobs are created (as opposed to
lost), that means houses are paid for,
kids are going to school, people are buy-
ing.
Lending. Another good piece of news
in this country is that banks are lending,
Beaulieu said. Delinquencies are down,
the money supply is expanding. Thats
economic activity, not a double dip.
Interest rates. Along with the infla-
tion rate, interest rates will begin to
move up and will continue to do so for the
next 20 to 25 years, Beaulieu warned.
Most people in business today dont have
much experience with this pressure; how-
ever, we are returning to the 1970s, so
look to what happened during that time
as an example of what to do.
FORECAST: The rate of recovery will
slow in 2011, but continue to climb in
2012 and then flatten out in 2013,
when the next recession will begin.
The years 2015 to 2017, however, will
create new opportunities. Beaulieu
said his prediction of a depression in
the 2030s is still on target, but that a
lot will depend on whether Congress
is able to do anything in the next year
about the U.S. budget woes. 2012
could be a very interesting year to be
alive, he concluded.
WALL STREET:
A NOTE OF CAUTION
Although Michael Halloran, vice presi-
dent of Robert W. Baird and Company,
agreed with other speakers that the
market has certainly thrown us for a
loop, he said caution, not panic is in
order.
I think its important to start with
the fundamental tenet that industrial
companies are not seeing weak trends at
all; there are markets that are weak and
there is deceleration in growth rates, but
demand is pretty healthy when you look
at the overall industrial picture, he told
attendees.
The industrial economy is entering a
mid-cycle slowdown after seeing growth
rates peak in 2010growth in the U.S.
turned positive in March of 2010 and
peaked in December of that year. Since
then, trends have generally moderated.
Globally, trends have been on a similar
trajectory and currently remain at
healthy levels, Halloran said.
For example, Global Insights fore-
casts favorable trends in global fixed
investment (GFI) growth, which turned
positive in the second quarter of 2010
and averaged 5% for the rest of that
year. Although those trends were slightly
weaker in the first quarter of 2011, the
company still is projecting healthy
growth for the remainder of the year and
into 2012, Halloran said.
However, he also cautioned that
threats of recession cast a long shadow
on the capex opportunity for project
work and expansionary capital
deployment.
One trend that remained a positive
development despite the markets
volatility was that lending standards are
relaxing. Lending standards are pretty
straightforward. If things are loose and
credit is available, its more conducive to
capital spending, Halloran explained.
Currently, access to capital is readily
available, but the question in an uncer-
tain market is do people want to take
advantage?
The indicator that Halloran says
Baird and other investment firms look at
most closely in regards to how invest-
ment should fare is the Purchasing Man-
agers Indexwhich is positive above 50.
16
|
2 0 1 2 M A R K E T O U T L O O K
Corporate Profits - 1st Quarter (Billions of $)
Source: U.S. Bureau of Economic Analysis
Financial
Manufacturing
Retail trade
Information
Wholesale trade
Utilities
Transportation
and warehousing
2011 (1Q SAAR)
2010
2009
$378.4
$362.7
$141.6
$280.6
$250.4
$141.0
$124.0
$129.1
$97.7
$123.3
$112.9
$69.6
$73.5
$91.5
$103.9
$31.9
$41.5
$37.7
$37.3
$39.4
$26.9
$0 $50 $100 $150 $200 $250 $300 $350 $400
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The index rose above that point in
August of 2009 and has remained above
it since then. It did very well in the
beginning of 2011 but was hovering
around 50 at the time of the workshop
so things are still growing, but more
moderately.
As far as end-user industries:
Oil & gas demand was strong at the
time of the workshop, showing no signs
of deceleration. Globally, rigs were up
over 50% from where they hit bottom in
2009, and in North America, rigs were
up more the 100%. Halloran said high
oil prices are contributing to the sus-
tained drilling trend, as oil companies
look to take advantage.
Horizontal rig applications have
been the driver in recent years in the
upstream market, which is good for
equipment suppliers because this type of
drilling leads into a lot of burn and
replacement, Halloran said.
An important overall global trend in
upstream oil & gas markets is that
capital spending should grow at rates
of 5% to 7% (or more) because infra-
structure investment in emerging
regions has yet to catch the pace of
demand, Halloran said.
On the downstream side of the busi-
ness, he noted that Global Insights said
global capex spending increased 7%
year over year in 2010, which indicates
the potential for favorable growth rates
long term on the refinery side. Most of
that growth, however, is in emerging
markets. In North America, most new
additions are for Canadian refinery proj-
ects, though some modest growth in all
areas will occur in maintenance spend-
ing going forward.
Halloran said that trends in the
chemical market overall are healthy and
have been since late last year. In the
U.S., plant capacity utilization rose in
2010, but remained well below peak lev-
els at about 76% for the year. The over-
all trend in the chemical industry contin-
ues to be that chemical production is
moving away from North America and
Western Europe to the emerging mar-
kets and the Middle East.
In power, Halloran said demand in
the U.S. and some other developed
regions remains sluggish, but quoting
activity appears to be picking up in
places (especially emerging nations)
because of the need for infrastructure
investments.
The water/wastewater market is
growing at a rate of 6% to 8%, driven by
population growth, rising living stan-
dards, industrialization and the need for
maintenance. Halloran said that in gen-
eral, the market is weak for capex
spending, though the stimulus monies
have helped. The operating expenditure
side, however, is seeing some growth
right now.
FORECAST: Global Insights believes
global oil & gas downstream capital
expenditures should increase 10% in
2011, 6% in 2012 and 7% in 2013.
Further, Global Insights believes glob-
al capital expenditures for chemicals
should grow 13% in 2011 and 9% in
2012, but that growth will be driven
by China and Latin/Central America.
Estimates are for world energy con-
sumption to grow 49% by 2035 (over
2007) driven primarily by developing
regions. Renewable energy use will
grow 3% per year to take a 23% share
of the energy market by 2035.
18
|
tions, as well as end users. The most sig-
nificant differences in testing procedure
documents are allowable leakage rates.
PIPELINE VALVES
Pipeline safety has come to the forefront
lately because of catastrophic pipeline
failures. These failures have occurred pri-
marily on older pipelines because quality
requirements for new pipeline construc-
tion are very stringent. Valves for
pipeline service are also scrutinized very
closely. While all pipeline valves are
hydrostatically tested at the factory, usu-
ally in accordance with API 6D, addi-
tional tests are almost always performed.
The most common extreme test for
pipeline valves is a long duration shell
test, which is carefully monitored by a
recording device tracking the pressure
and the temperature of the valve as it is
tested.
During these enhanced duration shell
integrity tests, the pressure on the valve
must be maintained, or the pressure
drop must coincide with a proportional
drop in temperature to avoid valve fail-
ure. It is not uncommon for test dura-
tions to run several hours long.
FUGITIVE EMISSIONS
TESTING
The desire to keep our nations air clean
is manifested in the valve industry
through the Clean Air Act and various
state and local regulations. For manu-
facturers to meet todays low emissions
requirements, valves must be tested to
determine their ability to contain these
fugitive emissions (FE). FE testing is
now a requirement by most refiners and
chemical companies that must contain
hazardous fluids as part of their every-
day processes.
FE testing requires the valve be pres-
sured up with an easily measurable gas
such as methane or helium, and then
checking the body and seals, particular-
ly the packing, for leakage. An alterna-
tive method is to create a vacuum drawn
on the valve through a closed piping sys-
tem and introducing a tracer gas into
the areas of the valve exterior suscepti-
ble to FE leakage.
Two distinct schools of thought exist
on what gas should be used to FE test a
valveschools separated by the
Atlantic Ocean. In Europe, it is deemed
unsafe to test with methane, so all test-
ing must be performed with helium; in
the U.S., the preferred test media is
methane, which more closely resembles
the molecular structure of the volatile
organic compounds (VOCs) that both
industry and government are working
hard to control.
The procedures for FE testing gener-
ally require the test valve be mounted in
a device that can firmly hold both the
valve and its actuation mechanism. The
valve is then cycled from dozens to hun-
dreds of times while pressured up with
methane or helium. As an added service
S u m m e r 2 0 1 1
|
25
Table 1. Cryogenic Testing Standards
Document Organization Notes
BS 6364 British Standards Organization Still the most popular
MSS SP-134 MSS (USA) Published in 2008
ISO XXXX ISO (International) Still under development
A valve is prepared to undergo fugitive
emissions tests.
VM_SUM11_VM_SUM11.qxd 7/7/11 4:49 PM Page 25
2 0 1 2 M A R K E T O U T L O O K
-20%
-15%
-10%
-5%
0%
5%
10%
15%
20%
1
9
6
9
1
9
7
1
1
9
7
3
1
9
7
5
1
9
7
7
1
9
7
9
1
9
8
1
1
9
8
3
1
9
8
5
1
9
8
7
1
9
8
9
1
9
9
1
1
9
9
3
1
9
9
5
1
9
9
7
1
9
9
9
2
0
0
1
2
0
0
3
2
0
0
5
2
0
0
7
2
0
0
9
Recession U.S. Industrial Production
U.S. Industrial Production (3MMA YOY % Change)
Source: Federal Reserve
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THE GLOBAL PICTURE:
FIGHTING BLACK SWANS
Despite significant headwinds that arose
last year, the global economic expansion
will continue on course in 2011 and
2012, according to Sara Johnson, senior
research director of IHS Global Insight.
Certainly we will be at a more mod-
est pace [than some economic recoveries
have been], but that is to be expected in
the aftermath of such a severe economic
challenge, Johnson said. Households
are still cautious and trying to rebuild
their retirement assets while govern-
ments that provided massive stimulus
are having to wind down that support.
Were projecting world GDP [gross
domestic product] will slow from 4.1%
last year to 3.1% this year, she said.
However, part of that slowdown is a
direct result of what Johnson called black
swans: a number of events that had low
probability but high impact, she said.
For example, because Japan makes up
8% of the worlds economy, 40% of the
global deceleration can be tied to after -
effects of Japans earthquake and tsuna-
mi. Also, geopolitical instabilities are
affecting areas of North Africa and the
Middle East, causing events such as a
major disruption in Libyan oil production
(and a drop of 40% to 50% in that coun-
trys GDP), she added.
And in many areas of the world,
including the U.S., developed countries
are discovering that the recessions
effects were deeper than originally
thought.
So instead of having this cycle [of
past recessionary periods] where house-
holds spend more and employment rises,
we are in a more stagnant position with
a loop of weak hiring and weak spend-
ing, she pointed out.
Confidence in policymakers has not
helped, she saidnot just in Washing-
ton, DC, but also in most parts of Europe
after the spread of the sovereign debt
crises to Spain, Italy and even France.
European policymakers seemed to
be a couple of steps behind the market,
Johnson observed.
She said the major driving force in
the global economy now is the emerging
markets, and this two-speed world
20
|
2 0 1 2 M A R K E T O U T L O O K
or how it is determined might be
described in the following simplified
sequence:
A decision is made that a process
plant needs to comply with the
international standards for
process safety systems, usually
IEC 61511.
The plant forms a HAZOP (Haz-
ard and Operability Study) team.
Essentially the HAZOP procedure
involves taking a full description
of a process and systematically
questioning every part of it to
establish how deviations from the
design intent could arise. Once
identified, an assessment is made
whether such deviations and their
consequences can have a negative
impact upon the safe and efficient
operation of the plant. If consid-
ered necessary, action is then
taken to remedy the situation. In a
sense, this is based upon Murphys
law: Anything that can go wrong,
WILL go wrong. What the
HAZOP team attempts to deter-
mine is: What will go wrong? The
team might be comprised of
process design engineers, opera-
tions personnel, maintenance and
instrumentation engineers, etc.
As part of the HAZOP, all instru-
ment safeguards, i.e., SIS, are
identified and validated for their
primary capability to prevent an
incident from occurring or to miti-
gate the consequences of an acci-
dent. SIL classification of an SIS
is the next step after the HAZOP
to ensure that the SIS provides
sufficient risk reduction.
Essentially, the HAZOP team
identifies which systems will cre-
ate the highest level of risk if the
SIF fails and then determines the
impact of the failure, i.e., the con-
sequence of failure.
Consequences of failure might
include escalating examples, but
the possibilities are endless. In
other words, the list might
address: If the system fails:
The plant will lose $15,000 per
day.
The plant will lose $1 million
per day.
The plant will become dam-
aged and will shut down for
three weeks.
A high degree of probability
exists for injury or loss of life
to company personnel in the
immediate area.
A high degree of probability
exists for explosion and loss of
life to non-company personnel
outside the parameter of the
facility.
Ultimately, it is up to the plant owner
and operator to determine what level of
risk is acceptable based on their own
criteria (best practice, company philoso-
phy, insurance rates and requirements,
budgets, etc). Therefore, risk tolerance
is subjective and site-specific.
Once the level of risk tolerance is
established, SIL levels may be estab-
lished for specific SIF within an SIS.
THE ROLE OF PROBABILITY
Before discovering how the numerical
value of SIL is derived, a better under-
standing of PFD is needed.
32
|
S I L M A D E S I M P L E

U.S. ALLOYS, INC
Since 1976, Round Bar Supplier for Valve & Fitting Manufacturers
of
Petrochemical / Power Generation / Nuclear / Aerospace
Round Bar Stock
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Phone (713) 644-1983 Fax (713) 644-9889 www.usalloys.cc
Figure 2. PFD
AVG
and Valve Life Cycle
Graphs reprinted by permission from ANSI/ISA-TR96.05.01-2008.
ISA 2008
PFD
AVG
See Detail
Time
End of Life
1
0.1
0.01
0.001
0
Copyright 2011 IHS Global Insight. All Rights Reserved.
-9
-6
-3
0
3
6
9
1974 1979 1984 1989 1994 1999 2004 2009 2014
Real GDP Industrial Production (
P
e
r
c
e
n
t

c
h
a
n
g
e
)
-4
-2
0
2
4
6
8
10
1990 1993 1996 1999 2002 2005 2008 2011 2014
Advanced Countries Emerging Markets
(
R
e
a
l

G
D
P
,

p
e
r
c
e
n
t

c
h
a
n
g
e
)
Continued Recovery of the World Economy
Emerging Markets Will Lead the Global Expansion
Source: IHS Global Insight

economy will persist well into the future.
Advanced countries will experience slow
to moderate growth, high fiscal deficits,
lower inflation than emerging nations
and currency depreciation while emerg-
ing markets will see rapid growth, mod-
erate to high inflation, rising interest
rates and currency appreciation.
More specifically, Johnson said:
Asia will see the fastest growth rate at
an average of 7% over the next few
years. China will see a deceleration of
exports, but a growth in industrial pro-
duction, giving the country a soft land-
ing. Indonesia will see very strong per-
formance with strong growth prospects.
Japan is bouncing back rapidly, held
back by the shortage of electric power
because its operating at about 20% less
nuclear capacity than a year ago and by
the need for financing for reconstruction.
India is supported by a rising middle
class and the easy availability of credit.
However, interest rates are rising, slow-
ing investment growth.
In South America, Johnson said there
are two sets of countries: those that are
able to attract foreign investment such as
Brazil, Chile, Peru and Columbia and
those that suffer from resource national-
ism such as Venezuela, Bolivia and
Ecuador. Brazil faces a particularly chal-
lenging inflation picture, and the environ-
ment changes day to day. But fiscal poli-
cy in that country is tightening and the
administration is focusing on social pro-
grams and infrastructure challenges.
In the Eurozone, confidence is fragile
right now, not just from consumers, but
also in the industrial and services sectors.
Western Europe in general faces persist-
ent unemployment, meager wage gains
and higher inflation, which will restrain
consumer and housing markets. Germany
and Sweden will be the pacesetters with
growth led by exports. In emerging
Europe, the Commonwealth of Independ-
ent States is currently benefiting from
high oil and metal prices, Johnson said.
However, the region is unlikely to recap-
ture the 5% to 7% growth rates experi-
enced before the recession.
FORECAST: Asia will lead global
growth, while Latin America and
Africa will improve upon historical
performances. Emerging markets will
run about 6% to 7% growth while
developed markets will run at about
2% to 3% growth in GDP in the next
few years.
WATER/WASTEWATER:
ITS A BLUE AND GRAY
MARKET
The water/wastewater market is no
longer a black and white marketit
might better be described as blue and
gray, Thomas Decker, PE, BCEE, vice
president and mid-Atlantic area manag-
er for Brown and Caldwell, Alexandria,
VA, told attendees. Decker chose those
colors not because of their similarity to
water/wastewater, but because his pres-
entation carried a Civil War theme in
commemoration of the 150th anniver-
sary of that conflict.
There are a lot of opposing forces
22
|
2 0 1 2 M A R K E T O U T L O O K
working in opposite directions in the
water business right now, he explained.
For example, in the year 2010, the
market was up slightly: about 4% growth
over 2009. However, it was an interest-
ing year to look at the statistics I typically
trackthe market was all over the place
with really high highs and low lows, he
said. But it also faced a number of con-
flicting pressures and situations.
On a positive note, there was the
American Recovery and Reinvestment
Act, which pumped money for con-
struction that boosted the marketplace,
he said.
There was also the pressure of con-
tinued and increased enforcement
actions especially for wet weather,
combined sewer overflow and sanitary
overflow programs, and also some
enforcement on nutrients as well as
good old secondary wastewater treat-
ment issues, Decker said.
Another positive was the fact that
money was available not just from the
federal stimulus, but from attractive
interest rates and increased utility
revenues.
What happened in 2010 as a result of
these and other factors actually defied
historical trends, Decker pointed out. In
past recessions, the water/wastewater
market lagged behind the general econo-
my, starting to dip or fall as the rest of
the economy began to recover.
But we actually saw an increase in
the market during the last 18 months,
Decker said.
To understand how the industry got to
this point, Decker took the audience
through an introspection, and said:
The market is huge and the U.S. has
a large chunk of it. Internationally,
water/wastewater is a $500-billion
business. Of that amount, the U.S.
holds about $107 billion.
The market has seen significant
regional swings, which will continue.
An interesting development during
this recession is that the northeast
F a l l 2 0 1 1
|
23
S u m m e r 2 0 1 1
|
31
Industry responded to this question
with accepted industry standards (essen-
tially self-governing practices) such as
ISA-S84.01 and IEC 61508/61511 to
measure the acceptable level of perform-
ance of these systems. Adherence to the
standards became a best practice. Note
that the standards are not prescriptive
they are performance oriented. They say
what level needs to be achieved, not how
to reach those levels. Ultimately, it is up
to the end user to make the decision of
how thats to be done.
An SIS is designed to prevent or
reduce hazardous events by taking a
process to a safe state when predeter-
mined conditions are violated. An SIS
can typically be an emergency shutdown
system (ESD), a safety interlock system
or a safety shutdown system. Each SIS
will have one or more Safety Instru-
mented Functions (SIF). Such a func-
tion might be something like:
When the tank pressure gets too
high, a safety valve opens.
When the solution in the tank gets
too hot, the inlet steam valve closes.
Of course, each SIF loop will be a
combination of logic solvers, sensors,
solenoids and final control elements,
such as an automated valve. Every SIF
within an SIS will have an SIL level.
These levels may be the same or they
may differ, depending on the process. A
common misconception is that an entire
system must have the same SIL level for
each safety function.
An SIL is essentially a measure of the
system performance in terms of Proba-
bility of Failure on Demand (PFD). If the
goal is to reduce risk, we need to under-
stand what that risk is. The simplified
equation for risk is:
Risk = Probability X Consequence
We can think of probability in terms
of hazard frequency (how often will a
process exceed normal conditions and
need to be brought to a safe state?); and
consequences in terms of hazard conse-
quences (what happens to the plant,
employees, environment and community
if the process upset is not brought to a
safe state?).
Where the SIL number comes from
Figure 1. Safety Integrity Levels
Safety Integrity Level Risk Reduction Factor Probability of Failure on Demand
SIL 4 100,000 to 10,000 10
-5
to 10
-4
SIL 3 10,000 to 1,000 10
-4
to 10
-3
SIL 2 1,000 to 100 10
-3
to 10
-2
SIL 1 100 to 10 10
-2
to 10
-1
G
r
o
w
t
h
Time

What Happened
What Usually
Happens
~ 18 months
June 2009
January 2011
Economy/GDP
Water/Wastewater
A Lag Line that Defied History
Source: Brown and Caldwell
quadrant of the U.S. is seeing the
most activity while the traditionally
bulletproof areas of the southwest
and Florida are experiencing drop-
offs in business.
Although engineering firms report
a drop-off in design activity, the
industry is still attracting many
bidders for projects. However, the
pencils are getting sharper on con-
struction projects and fewer new-
bies are entering the business
(firms who got into the business
without a lot of experience when the
market was so hot).
Notices to proceed with utility
projects are slow as molasses
right now, though Decker is not
seeing outright cancellations of
existing projects as much as owners
backing off of projects they had
announced.
A newer macrodriver in the
water/wastewater business is climate
change. He cited a recent National
Resources Defense Council study that
examined the effects global warming are
having in this country. Some traditional-
ly wet areas in the U.S. are getting drier
and some traditionally arid areas are
getting wetter, which is going to affect
water supply and demand in the future,
Decker pointed out.
Another macrodriver is the balance
between population growth and conser-
vation. Decker said that, in this country,
conservation efforts, such as low-flow
showerheads, smarter water use, reuse
of water for landscaping and other prac-
tices have been successful. He cited fig-
ures that show in 1980, this nation used
440 billion gallons of water per day
more than 30 years later, that number
was 410 billion, which is pretty incredi-
ble considering the population growth.
For 2011, Decker says the battles
between forces will continue but that
we havent hit a stone wall the
market will continue to grow as it
balances the pressures.
FORECAST: The market will be flat to
slightly up at the end of 2011 over
2010 and will do better in 2012.
POWER: LONG TERM
FAVORABLE; SHORT
TERM COMPLICATED
Because the power industry is driven by
demand, and because the pressures and
influences on that demand are so wide
and varied today, policy in the industry
is changing almost daily, said Mark
Zeiger, principal vice president and man-
ager of procurement for Bechtel Power
Corporation.
For example, in the UK, the country
has decided to place emphasis on clean
air so its shutting down a lot of its coal
facilities, and in Germany, the country
has looked at what happened following
Japans earthquake/tsunami and is con-
sidering shutting down its nuclear plants
again, Zeiger said.
Overall, however, the power industry
faces a favorable long-term outlook
because demand throughout the world
will grow. In developing countries, for
example, consumption is only limited
to the extent you can get power to the
people, so your potential is endless, he
said. And in certain other areas, the sit-
uation is rosy for other reasons. For
example, Australias demand is growing
because the mining business is robust
and takes a lot of power, Zeiger said.
And in Brazil, the economy itself is very
strong, which means development, and
that translates into power demand from
both manufacturing and consumer
needs.
Then, theres China, which dwarfs
other global markets with its potential.
Zeiger pointed to figures from Global -
Data that show China will add over 350
gigawatts (GW) of power in the next
four years.
About 200 of those GWs will be
coming from coal-fired plants, Zeiger
said, but China has a robust nuclear pro-
gram, as well. The country also is mov-
ing heavily into renewablesGlobal -
Datas figures show that wind capacity
will grow to 77 GW, and hydro will grow
to 50 GW by 2015.
Globally, coal is still the leading
source of capacity additionsit will con-
stitute a third of the worlds market for
additions, but most of the growth will be
in China. Gas will be the next greatest
24
|
or mitigate the hazardous condition
resulting from pressure vessel over -
pressure. The SIS will have an SIF
which might include a pressure trans-
mitter which can sense when an intol-
erable level of pressure has been
reached, a logic solver to control the
system logic, and a solenoid valve
which might vent the contents of the
vessel into a safe location (flare stack,
environment, storage tank, etc.), thus
bringing the pressure vessel to a safe
state.
If the risk reduction factor required
from the Process Hazard Analysis is a
factor of 100 then an SIL 2 level of SIF
performance would be specified. Cal-
cula tions for the components of the
entire SIF loop will be done to verify
that the PFD of the safety function is
10, meaning that the SIF is SIL 2 or
reduces the risk of the hazard by a
factor of 100. This one SIF may consti-
tute the entire SIS, or the SIS may be
composed of multiple SIFs that are
implemented for several other unac-
ceptable process risks in the facility.
Now we see from the chart in Table
1, and the example, above, the SIL
numerical values relate directly to the
minimum risk reduction factor. For
example: SIL 1 = 10, SIL 2 = 100,
etc. This is helpful in allowing us to get
a feel for what SIL is.
SIL AND THE VALVE
INDUSTRY
Since this article is primarily for those
who are not instrumentation engineers,
it is helpful to also know how SIL
applies to the valve and actuator
industries.
A HAZOP team will look closely at
automated valve systems that need to
perform an action to return the process
to a safe state when design or operat-
ing parameters have been exceeded.
To keep the discussion simple, we will
use the term ESD, assuming we are
concerned with an emergency shut-
down valve.
The HAZOP team will want to
know: What is the likelihood of my
valve working when I need it to work?
They will perform a risk analysis and
assign an SIL level to that ESD sys-
tem. The SIL will cover the entire ESD
systemfrom initial process sensor to
the valve itself, and everything in
between. It is important to note that
SIL covers systems comprised of indi-
vidual products. Products are not SIL
rated. There is no such thing, for
example, as an SIL 3 actuator, an SIL
3 digital valve controller or an SIL 3
solenoid valve. There are only products
that are reliable to the degree they are
suitable for an SIL 3 environment.
So, as industrial fluid control repre-
sentatives, it would be inappropriate to
say of a product: This is SIL 2. The
correct nomenclature would be: This is
suitable for an SIL 2 environment.
Likewise, as a consultant or end user, it
is inappropriate to ask a vendor: What
is the SIL rating of your product? It
would be more appropriate to ask for
specific failure rates.
In determining whether a product is
suitable for use in a given SIL environ-
ment, the important factors are failure
rates such as PFD.
PFD average (PFD
AVG
) is relevant to
the valve industry and users of valves.
As the graphs in Figures 2 and 3 indi-
cate, the probability of operational
failure for a valve escalates soon after
every full cycle test. It has been
demonstrated that partial stroke test-
ing (PST) of the valve (when full stroke
testing is not practical) significantly
lowers the PFD
AVG
.To say it another
way, partial stroking increases the
probability that the system and valve
will work when it needs to work
(Figure 3).
Based on the need to increase relia-
bility and the desire by end users to
comply with new safety standards, a
PST industry has emerged. It has
spawned a plethora of increasingly
sophisticated products and systems
promising to make the SIS more reli-
able. The end result has been confusion
not only for vendors, but for consult-
ants and end users as well.
A good way to think about this
36
|
2 0 1 2 M A R K E T O U T L O O K
source of capacity additions in the imme-
diate future because its the best and
fastest source of replacement power in
areas where coal or nuclear is losing
ground, but renewables are gaining
ground in many areas of the world,
Zeiger said.
In the U.S., coal will not be playing
much of a role going forward whereas
gas is entering the picture very rapidly,
Zeiger pointed out.
Right now, there are only a couple
dozen new [gas-fired] plants in develop-
ment, but that can change quickly
because plants have a very short devel-
opment cycle, he said. However, wind
seems to be where developers are placing
their bets with a fair amount of solar on
its way. But solar takes a lot of foot-
print, he said. A lot of the drive in the
U.S. for renewables, however, is driven
by incentives, and with the economic sit-
uation putting constraints on budgets
we dont know where those incentives
will be going forward, Zeiger said.
The next largest market, after China
and the U.S., is India. That country will
also have a very high amount of coal
activity, some nuclear and some com-
bined cycle, but its also got a source for
power that many other countries havent
tapped to the extent India has:
hydropower. Figures from Global Insight
show that capacity additions in hydro in
that country almost match additions in
coal and this could be understated if
funding [for development] can be accel-
erated, Zeiger said.
As far as the markets for valves in the
power industry, the largest installation
in valves on a global basis will be in China
and India in coal. In the U.S. the great-
est potential for power business currently
is wind and combined cycle plants.
As far as nuclear, the industry has
stalled for new plant generation con-
struction. But at the same time events
from Japan may cause modification
work to be done to include lessons
learned and retrofits, Zeiger said.
F a l l 2 0 1 1
|
25
Coal
39%
Gas
14%
Oil
3%
Nuclear
7%
Wind
16%
Solar PV
2%
Solar Thermal
0%
Geothermal
1%
Biomass
1%
Biogas
0%
Hydro
17%
Coal 200
Gas 3
Nuclear 35
Wind 77
Solar PV 6
Solar Thermal 1
Biomass 1
Hydro 50
Total World New Capacity Additions by
Technology Share (2011-2015, excluding China)
Chinas Capacity Additions by 2015
S u m m e r 2 0 1 1
|
39
However, both types are capable of
continuous movement. They both have a
variety of failure modesthrough the use
of simple springs or stored energy devices
such as accumulators and volume tanks.
However, pneumatics is more akin to
conventional hydraulic technology
regarding the power source. Just as a
conventional hydraulic uses a continuous-
ly running unidirectional motor and
pump to maintain pressure, the pneumat-
ic has stored energy (supply pressure)
from a central air compressor. Both
approaches consume much more power
than either the electromechanical or the
discrete electrohydraulic technologies.
The real chink in the armor of the
pneumatic dynasty is positioning per-
formance: pneumatics (air) is a com-
pressible substance that will limit the
positioning performance of the actuator.
Boyles Law in physics simply states
that P1 x V1 = P2 x V2. There is no
getting around that reality; but think
what that means in relation to static
and dynamic forces on actuator stems.
AN ALTERNATIVE
Effectively, whats taken place gradual-
ly over the last 20 years is emergence of
a viable alternative to both electro-
mechanical and pneumatic actuation.
By modernizing the solid, but obsolete
hydraulic-based actuation technology,
with performance more in line with
market needs, new application opportu-
nities have opened up for use of discrete
electrohydraulics. Some interesting
applications include: steam temperature
control or spray valves, boiler feedwater
control valves, power plant damper con-
trols, mining separator level control
valves, water treatment plant filter level
control valves, and more.
Such applications have historically
been pneumatically or electromechani-
cally actuated. The advantages of elec-
trohydraulic actuators were outweighed
by the capital and maintenance expense
of older hydraulic actuator technology.
With advances in electrohydraulic tech-
nology, there are now applications that
can benefit economically from electro-
hydraulic through process efficiency
improvements.
The conventional hydraulically oper-
ated valve (HOV) and electrohydraulic
actuator (EHA or EHV) applications
are also being fit with newer discrete
hydraulic actuators. These applications
historically were specified HOV, EHA or
EHV for one of three reasons:
1) The control requirement was
known to exceed the capability of
compressible pneumatics (i.e.
steam turbines).
2) The torque was too large for pneu-
matic or electromechanical actua-
tor.
3) Compressed air was not available.
Today, these applications are being
retrofit with todays discrete high per-
formance electrohydraulic actuators to
gain the benefits mentioned above.
The level of requirements for actuator
sophistication do vary greatly across
applications. Some specification break-
points to consider when evaluating elec-
trohydraulic actuator technology versus
other technology are: valve operation
(on/off, modulating, fail-position); com-
munications requirements (feedback, bus
networks); power consumption/availabili-
ty; and the critical nature of the location
and application.
This last consideration can be con-
strued many ways, but a general way to
put it is: How critical is the availability of
a valve to the process? Is it acceptable to
take this valve out of service annually? Is
the location an environment that is easily
accessed, inhospitable or hazardous?
The answers to these questions are vital
to the type of electrohydraulic actuator
technology selected. The answers can
also influence which overall technology to
selectwhether it is pneumatic, electro-
mechanical or electrohydraulic. VM
KEVIN HYNES is president and CEO of KOSO Amer-
ica (www.koso.com). Reach him at khynes
@rexa.com.
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FORECAST: Although capital expen-
diture spending has suffered from the
economic uncertainties and policy
issues, significant growth for power
on a global basis is ahead. Projects
worldwide will continue to provide
greater challenges in scope and size.
In the end, quality of product will be
the differentiator for suppliers to the
power industry.
PETROCHEMICALS:
NORTH AMERICA BACK
AT BAT
Unlike some of the end-user industries
covered at this years workshop that take
a longer time to recover from a reces-
sion, the news from petrochemicals was
mostly already bright.
In fact, speaker Mark Eramo, exec-
utive vice president, CMAI, says that
North America is back in the game,
while Asia is presenting new demand
opportunities and seeing tremendous
growth, and South America continues
to pick up speed.
Thats partly because the industry is
tied so closely to what people buy, as
opposed to how cheaply raw materials
can be taken out of the ground.
At the end of the day, this business
isnt about pipelines. Its about efficient
delivery and demand for durable and
nondurable goods, Eramo said.
In North America, investments in
the conversion industry started to shut
down over the last decade, but recently
were getting back into this business
because were at a lower cost basis,
Eramo said. This wont occur immedi-
ately, but people are making
announcements, and building should
begin sometime in the next five years.
During 2011, for example, Eramo said
more than 5.0 million metric tons of
new capacity for ethylene investment in
North America were announced for
start-up by 2020.
Eramo said he expects to see a full
recovery in the petrochemical market by
2012 or 2013. What drove down
margins in 2008 and 2009 was surplus
capacity, but weve chewed through a
lot of that, he said, and demand is
actually outpacing capacity in some
areas of the world.
For example, demand in China and
India is booming. Asias cumulative
demand for basic chemicals and plastics
grew at about 8% per year over the last
decade. It suffered a small retraction
during the recession, but its now back at
about 7% cumulative growth each year
going forward, which means the area
cannot build fast enough to keep up
with demand so it needs imports,
Eramo pointed out.
In North America, on the other hand,
some manufacturing moved offshore,
which means this region has lost some of
its export capability to competitors.
The good news is that there has been
a steady level of demand growth in North
America, which means some of the
26
|
S u m m e r 2 0 1 1
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43
ANOTHER MIND
Why do I advise this? Beyond the social
bonds you establish, with each and every
connection, you are adding another
human brain to the equation (as one
source puts it):
containing about 10 billion nerve
cells, or neurons. On average, each
neuron is connected to other neurons
through about 10,000 synapses The
brains network of neurons forms a
massively parallel information pro-
cessing system. This contrasts with
conventional computers, in which a
single processor executes a single
series of instructions.
i
Imagine if youve built your social
network into the hundredsthats a
massively parallel information-process-
ing power with the potential to help in
your problem-solving quest.
One way to expand that network is to
join Groups if you use LinkedIn, in
your areas of expertise or use the
Answers area to ask questions. You
also might try answering others ques-
tions and building expertise credibility
when your answer is selected as a good
or best answer. If you do a search on the
word valve in the LinkedIn Groups
area of the site, youll find 10 pages of
groups, including Valve World Group,
Valve Network, Valve Solution and
Valve User Forum, to name just a few.
Increasingly, Facebook fan pages are
being used by businesses and leading
brands. Similar to LinkedIn Groups,
these fan pages provide a wall on which
to ask and answer questions. You may
want to search and connect with the
company or brands that you use when
you encounter the need for answers. I
did a Facebook page search on valve,
for example, and again had pages and
pages of search results.
If you use Twitter, try posing ques-
tions to those who choose to follow you.
Youll grow your list of followers as you
share interesting things about yourself
and/or your expertise. Or if Twitter is
not for you, try using some of the well-
established email lists from the Interna-
tional Society of Automation and Con-
trol.com.
My recommended problem-solving
path is to start with the search engines.
Next, tap your close circle of colleagues.
Then, try your social network.
And as you take these steps, always
look for ways to build this social network
by offering your expertise through some
of the ways Ive highlighted. Your efforts
will be rewarded exponentially. VM
JIM CAHILL leads Emerson Process Manage-
ments social media efforts and writes the
Emerson Process Experts blog:
www.EmersonProcessXperts.com.
2 0 1 2 M A R K E T O U T L O O K
Leading the Industry. Yesterday, Today, and Tomorrow.
NE W PRODUCT S COMI NG I N 2011
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capacity may be repatriated here. Mean-
while, this area has other advantages.
What it now costs to make goods in
North America, for example, supports
growth in the sector, especially for prod-
ucts based on natural gas liquids. As with
many developments in the oil- and gas-
related field today, shale gas is having a
significant impact on the situation, giving
North American producers an advantage
over other regions, Eramo concluded.
FORECAST: Global ethylene capacity
will grow to 165 million metric (MM)
tons by 2015. Of that amount, Asian
capacity will grow to 54 MM. After
falling from 2008 to 2010, North
American capacity will grow over the
next few years to more than 32 MM.
North American exports based on
light feeds will continue to accelerate
and new investment in the petro-
chemicals-to-derivatives part of the
chain will total in the multi-billions of
dollars going forward.
OIL & GAS: STRENGTH
ESPECIALLY FOR
EMERGING MARKETS
Barring a double-dip financial crisis, the
petroleum industry should remain strong
for the next several years, according to
John Spears, president of Spears and
Associates. Over the long term, industri-
alized countries will see little growth in
their own oil markets, but globally, that
will be balanced by emerging markets.
Global oil demand can grow at
about $100 per barrel, Spears said,
and while some areas of the world are
running higher than that, the U.S. has
stayed about that level because of its
supply, while the emerging nations have
evened things out globally as far as
demand.
The world consumes about 90 million
barrels of oil per day and about half of
that is consumed in the industrialized
world, Spears explained. And while the
countries in the other half of the world
have only about a fifth of the consump-
tion per capita, they have five times as
many people.
Clearly as emerging countries con-
tinue to industrialize and urbanize, they
can support increased consumption of
petroleum products, he said.
One of the more immediate trends
affecting the industry is that, because of
volatility and high costs in the energy
world, prices will increasingly reflect
the production end of the business
instead of consumer use, Spears said.
In the U.S., oil production from con-
ventional sources such as Alaska and off-
shore is on the decline; however, that has
been more than offset by increases from
unconventional sources, such as the ris-
ing output from the Williston Basin in
North Dakota, Spears pointed out.
28
|
2 0 1 2 M A R K E T O U T L O O K
0%
20%
40%
60%
80%
100%
120%
0
2
4
6
8
10
12
14
16
18
20
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
G
a
s

a
s

%

o
f

C
r
u
d
e

$

/

M
M

B
t
u
Crude (WTI) Natural Gas Gas as % of Crude
North America Energy Dynamics
U.S. Drilling Activity by Rig Type
Source: Purvin & Gertz
Sources: BHI, Spears
1600
1400
1200
1000
800
600
400
0
2009 2010 2011 2012
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
Horizontal
Directional
Vertical
United Valves engineering testing department is
equipped and staffed to provide a host of extreme
valve inspections & evaluations. Several cryogenic
testing tanks and advanced tank control systems
allow us to easily test any
valve at cryogenic
temperatures from 0
degrees F, down to -320
degrees F as well as all
intermediate temperatures.
On the other side of the
temperature spectrum,
our fire testing facility is
equipped to provide high-
temperature fire testing in
accordance with ISO, API
or customer specifications.
Fugitive emissions
(FE) testing is supported
by several specially-
designed and built testing
fixtures. The actual testing
is controlled by custom
software and human-machine-interface (HMI)
technology. FE testing can be performed with either
Methane or Helium.
The qualification of valves for refinery service per
API RP591 is another service of the engineering
testing group. All types of valves are evaluated with
results compared to original design specifications as
well as RP591 testing and inspection criteria.
Fire
&
Ice
Searing flame to liquid nitrogen -
We can test in it!
Cryogenic testing at
all temperatures from
zero to -320
o
F
Fire testing to API
and ISO standards
Fugitive emissions
testing to API and
ISO standards
Gasket & packing
evaluation
Valve qualification
per API 591
Valve failure analysis
Valve type testing
Burst testing to
40,000 psi
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Meanwhile, the numbers for natural
gas liquids will grow pretty dramatical-
ly because of drilling in liquid-rich gas
reserves such as the Marcellus and
Eagle Ford shales, Spears said. Over the
next five to six years, about 25% to 30%
of natural gas will come from onshore
shale sources and by 2035, almost half
the production of gas in the U.S. will
come from shale sources.
This emerging market is also
spreading to a number of other
countries around the world. Spears
pointed to a recent Energy Information
Agency report that showed 33 countries
around the world have enough
recoverable shale gas reserves to
increase the worlds supply by 40% to
22,600 trillion cubic feet.
New horizontal drilling methods will
compound the importance of these shale
supplies, changing the economics of
drilling tremendously, Spears said. The
combination of hydraulic fracturing and
directional drilling, a combination that
began to be used for gas in 2004 and
for oil in 2009, means that each well
can produce much more and the returns
on investment for operators have gone
way up. For example, the Bakken field
is currently producing about a 70%
return compared to only about 5% for
open water shelf drilling.
Costs for drilling, however, will also
rise, and Spears said that means
activity may shift to some of the higher
profitability areas.
FORECAST: U.S. natural gas demand
will reach 25.6 trillion cubic feet in
2016, with the lower 48 onshore pro-
duction of shale gas growing at an
average annual rate of 14%. U.S.
drilling activity will be up about 22%
from last year and about 17% in 2012
with horizontal drilling activity up
more than 25% in the coming year.
Well costs are expected to rise about
4% per quarter through the end of
next year. Canadian rig count will
increase 17% in 2011 and 15% in
2012. International activity is expected
to increase 7% in 2011 and 8% in
2012 with South America and the Mid-
dle East the fastest-growing regions.
RENEWABLES: NEW
OPPORTUNITIES FOR
VALVE MANUFACTURERS
Despite the fact the advancement of
renewable energy depends so heavily on
government policies, many of which are
in a state of flux, the industry has seen
continuous growth around the world,
according to Rakesh Radhakrishnan,
associate director for Navigant Consult-
ing, Inc.
The market share of energy that
renewables provided stood at about 12%
worldwide in 2009, according to the
International Energy Agency (IEA) and
about 6.2% in the U.S., but Radhakrish-
nan explained to outlook attendees why
all that is about to change.
Over the next decade, I feel it
[renewable energy] will evolve into a
clean energy standardthere are going
to be a variety of technology systems
adopted depending on regional priori-
ties, he said.
In the U.S.s immediate future, the
year 2012 will see annual renewable
installations leap to almost 13,000
megawatts (MW) from just over 6,000
MW in 2010. What happens after that
point, however, is largely dependent on
whether the production tax credit due to
expire for wind that year is renewed, the
production tax credit for biomass
expires as planned in 2014 and the
investment tax credit for solar expires as
planned in 2016.
Still, even with those expirations,
renewable energy annual investments in
the U.S. will range between $15 billion
and $25 billion per year and biofuels
make up another $25 billion to $35 bil-
lion per year going forward to 2020
(according to IEA). That opens up a lot
of opportunity for suppliers to these
industries, Radhakrishnan pointed out.
Specifically, he said:
Around the world, hydropower is the
largest source of growth and opportu-
nity, especially in developing coun-
tries such as India and China where
the industry is well established. Its
also one of the cheapest sources of
power available, producing electricity
at about 2 cents per kilowatt hour
compared to 9.5 cents for nuclear,
7.5 cents for coal and 6 cents for nat-
ural gas. In the U.S., growth will
depend on policy, but a bill has been
introduced in Congress that would
support development of smaller
hydroelectrical plants. These micro-
plants are compelling because they
dont need the extensive permitting
and approval process that large dams
go through in the U.S.
Seventy to 110 GW of biomass power
will be added in the world by 2030
(according to IEA), though biomass
will be competing with the biofuels
sector for resources. In the U.S., facil-
ities are being built to make pellets
30
|
2 0 1 2 M A R K E T O U T L O O K
Source: Energy Information Administration
Gas Demand and Supply
30
25
20
15
10
5
0
1990 2000 2009 2015 2025 2035
History
Shale gas
Tight gas
Lower 48 onshore conventional
Lower 48 offshore
Coalbed methane
Alaska
2009 Projections
Farris Engineerings global FAST Center network adds value to every Farris valve.
Our FAST Centers offer total valve replacement, service and repair any hour, any
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working in ASME and VR certifed valve testing facilities. At Farris, our work is
never done. Once we sell you a valve, our FAST Team is there to keep your valves
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Real value behind
every valve
Thats the FAST Center guarantee
To locate your local FAST Center: http://farris.cwfc.com or 1-877-FARRIS1

VM_SPR11_VM_FALL10.qxd 4/7/11 9:25 AM Page 11
that will be exported to Europe where
the biomass market is expansive.
Feedstock will be the greatest chal-
lenge in the industry, though new tech-
nologies to use new sources are
emerging such as animal digestive
gas, cow waste and other sources.
The geothermal market going for-
ward will depend on how quickly
new systems can be developed.
About four years ago, systems were
launched that could use low temper-
ature heat such as wastewater from
oil and gas drilling, which invigorat-
ed interest in geothermals. But
although many projects were
announced, few made it to maturity.
Meanwhile, enhanced geothermal
systems that harness energy from
deep below the earths surface are
also under development, and how
fast the industry grows will depend
on how quickly those systems, which
share some of the same challenges
as the shale gas drilling and frack-
ing industry, can be put in place.
The biofuel industry will see signifi-
cant growth going forward as oil
prices rise. Between 2009 and 2035,
worldwide consumption will grow by
2.4 million barrels per day as a con-
servative estimate (by IEA). New
generations of biofuels are currently
being developed from cellulose and
algae, and as a result, more specialty
chemical production will be added,
which means more capital expendi-
tures (capex) spending in this area.
FORECAST: Navigant estimates
(based on IEA figures) that capex in
hydropower will offer $970 million
to $1.4 billion in opportunities for
valve sales by 2030. Capex for bio-
mass will offer $3.1 billion to $4.9
billion in valve sales opportunities
while capex opportunities for geo-
thermal would be $600 million to
$900 million; solar will offer $1.1
billion to $2.1 billion; and biofuels
will offer $9 million to $1.2 billion.
INDIA: A LUCRATIVE
MARKET FOR VALVES
India has a very strong demand for flow
control equipment and is about a $2 bil-
lion market for valves, according to
Ravi Krishnan, principal consultant at
Krishnan & Associates. The country is
one of the few in the world that did not
suffer much loss from the Great Reces-
sion, and it is poised for major growth in
many of the sectors where valves are
used, he said.
The reason it was not affected as
much by economic woes was because
India is not a high credit market. We
had a small bubble burst, but the country
has a low dependence on imports, a
closely regulated banking system and an
economy that has seen resilient year-to-
year growth, he said. In fact, Indias
economy is projected to grow 8.75% this
year. The gross domestic product, which
is growing at one of the highest rates in
the world (about 7.5% to 8% per year
for the last 6 to 7 years), just crossed the
$1.4 trillion line, which is pretty aston-
ishing growth compared to the $410
billion it was just 10 years ago, Krishnan
pointed out.
The huge population growth means
the country has a large pool of both
skilled and unskilled workers, and while
many of them require training, the coun-
try ranks second only to China in the
number of engineers, he said. At the
same time, the manufacturing sector in
India is growing rapidly, held back only
by infrastructure challenges, govern-
ment red tape and the need for tech -
nology expertise.
In terms of individual sectors:
The current power generation capaci-
ty is at 167 GWs, putting it about sixth
in the world in generated power. About
64% of that is from fossil fuels (53% is
coal, 10% from natural gas and 1% from
oils), 33% from renewables and
hydropower, and 3% from nuclear. Coal
is highly abundant in the country with
proven reserves estimated at 200 years.
Privatization of the coal mining sector
will only accelerate the process of getting
the coal out of the ground.
In the oil & gas market, deregulation
of the upstream market means that
32
|
2 0 1 2 M A R K E T O U T L O O K
2.80%
6% 6%
7%
8%
6.80%
8.50%
9%
0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
10%
1971-79 1980-89 1990-99 2003-06 2007-2008 2009-10 2010-11E 2010-20E
Actual & Projected GDP Growth: India
Source: Goldman Sachs
Notes: Forecasts assume 1) no renewal of existing federal tax credits after their current expiration dates,
and 2) no new federal stimulus program is created.
Source: Navigant Consulting, Inc., February 2011
U.S. Annual RE Capacity Additions 2010-2020
A
n
n
u
a
l

I
n
s
t
a
l
l
a
t
i
o
n
s

(
M
W
)
14,000
12,000
10,000
8,000
6,000
4,000
2,000
0
Ocean
Offshore Wind
Geothermal
STE
Biomass
Hydro
Solar PV
Onshore Wind
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Expiration of PTC
in 2012 for wind
Expiration of PTC on
1/1/14 for biomass
Expiration of ITC in
2016 for solar
private players are expanding into the
market, and equipment opportunities
for exploration, production and modern-
ization stand at about $6 billion. In the
midstream market, the infrastructure is
growing at a rapid rate with pipeline
projects under development that will
add 6,400 miles for natural gas, 5,200
for cooking gas and 5,125 for crude
products. And in the downstream area,
refining capacity is undergoing an
expansion from 150 metric tons per
annum (MTPA) to 250 MTPA by 2015.
Geographically, the country is better
positioned for downstream production
than China because facilities are closer
to crude oil producers.
Petrochemicals is one of the fastest
growing sectors of the Indian economy,
mirroring the rates of the GDP, Krishnan
said, with a 15% growth in the polyester
industry alone in 2010. The industry has
also been helped along recently by gov-
ernment initiatives designed to promote
investment in this area.
Government incentives play a role in
encouraging private investment in
water/wastewater in India, Krishnan
said. That market is driven by the rapidly
expanding infrastructure for the country
as well as diminishing water quality, and
more recently, public awareness of the
need for clean water and sewage treat-
ment.
In all of these market sectors, there
is a strong demand for flow control, fluid
isolation and pressure relief, thus a con-
tinual need for valves, he said.
In recent years, Indias manufacturing
sector is also seeking partners and suppli-
ers that are experienced. Traditionally,
the market has been very price sensitive
with low bidders at an advantage and
western technology at a disadvantage.
However, the countrys industry is now
looking at life cycle costs of equipment
more broadly as some purchases have
brought serious problems (such as boiler
failures in the power industry).
A lot of industries that procured low-
cost equipment are now seeing that was-
nt necessarily the best decision, Krish-
nan says, so differentiated tech nology is
beginning to command premium pricing.
FORECAST: Long-term growth rates
are projected at 9% for the Indian
economy supported by strong domes-
tic consumption and strong growth in
the services sector. Nearly 100,000
MW of new commissioning in the
power industry will occur by 2017.
Power capacity will grow from 167
GW in 2010 to 400 GW over the next
decade. Petroleum refining will grow
from 153 tons per year installed
capacity to 302 tons per year by 2017.
The water/wastewater market will
grow at a rate of about 15% annually.
Consequently, the valve industry will
realize annual growth rates of 12% to
14% going forward. VM
GENILEE PARENTE is managing editor of Valve
Magazine. Reach her at gparente@vma.org.
F a l l 2 0 1 1
|
33
have multiple areas designated within
each plant with different approval
requirements depending on the media
that could or would be present in those
areas of the plant. These decisions have
to be made when the plant is designed,
and they are reviewed by the appropri-
ate safety officials and insurance com-
panies. However, hazardous environ-
ment considerations are an area of
major expense for end users and for
solenoid manufacturers. The initial cost
to get approvals is just the beginning of
that cost. Next come regular plant
inspections, file fees and paperwork
change charges.
VOLTAGE
Voltage is a simple, but still vital part of
the specification process. It merely is the
voltage of the system to which the valve
is wired. Most coils are designed per UL
requirements to operate at +10% to -
15% of the rated voltage because of nor-
mal voltage fluctuations in the line or
from the source. However, care is needed
with voltage range tolerances, because
all coils are not designed this way. The
information needed to determine coil
design is in the valve manufacturers
installation and maintenance sheets or
catalog information. When specifying
voltage do not assume that the manufac-
turer knows whether voltage require-
ments are AC or DC. When specifying
DC voltage, the letters DC should be
written out after the voltage value: as in
24/DC. When specifying AC voltage, the
frequency should be included (For exam-
ple: 120/60 or 230/50).
EXTRAS
The extras category in specification
points can mean just about anything. For
example, if something like extra-long
lead wires, manual operator, mounting
bracket, manual reset, functional safety
data, certificates of compliance, low
power or bus system compatibility is
added, it can be mentioned under
extras. Many extra features are possi-
ble, but not always available on every
solenoid valve. Those specifying solenoid
valves need to use this category to list
whats not listed in the other categories.
Many areas must be considered
when selecting solenoid valves. A cata-
log cannot answer all the questions
because there are many optional fea-
tures that may not be included. To be
sure the right valve is selected, list spe-
cific considerations along with quanti-
ties and needed lead times. What is not
optional needs to be outlined. If some
flexibility in the specification exists,
options can be recommended, which is
especially helpful when lead times are
crucial. A good technical support rep-
resentative can not only find a valve
that meets specification needs, but be
able to find one that can be delivered in
desired time frames. VM
BILL REESON is a technical support manager at
Emerson Industrial Automation, ASCO Numatics
(www.ASCONumatics.com). Reach him at
Bill.Reeson@Emerson.com.
22
|
S O L E N O I D V A L V E S
A solenoid valve manifold is used for fluid
power and process valve automation
applications. One manifold can contain
several 3- and 4-way solenoid valves together.
34
|
C
urrently, 104 nuclear power-
plant reactors are working in the
United States, and all of them have
operating environments that are
extremely challenging. Of those 104
plants, 35 are classified as boiling
and 69 as pressurized water reactors.
While the design details vary from
plant to plant, each nuclear facility
has thousands of valve actuators used
in various processes and applications.
The newest-generation nuclear plant
has more than 13,000 valves.
Its clear, then, that valve actua-
tors play vital roles in maintaining
process safety, efficiency and produc-
tivity in a wide range of situations.
This article contains a brief
description of some of the special cir-
cumstances encountered in challeng-
ing nuclear environments and the dif-
ferent styles of actuators used to meet
demanding operational and safety
requirements.
STRICT GUIDELINES AND
REQUIREMENTS
All equipment used in nuclear plants
built in the United States is certified
under stringent guidelines mandated
by the Nuclear Regulatory Commis-
sion (NRC). Verification of reactors
or equipment to standards from other
countries is not acceptable for the
104 working reactors in the U.S.
To understand basic requirements
the nuclear power industry faces in
this nation, a review of the similari-
ties and differences between nuclear
power and fossil power is helpful.
In a fossil power plant, coal might
be crushed and mixed with air to boil
ACTUATION IN
THE THOUSANDS OF ACTUATORS USED
IN A NUCLEAR PLANT FACE SOME
PRETTY TOUGH CONDITIONS AS WELL
AS RIGOROUS TESTING.
BY PETE KUNDIN
The actuator pictured right operates a main
steam isolation valve for General Electrics
boiling water reactors. It is a pneumatic
cylinder in tandem with a hydraulic speed
control system. While the hydraulics are self
contained, there is a small piston
accumulator that accounts for thermal
expansion of fluid in the plant.
F a l l 2 0 1 1
|
35
water, which produces steam to drive a
turbine. With nuclear reactions, the
process is different, but the operational
objective is essentially the sameto
heat water to produce steam to drive a
turbine. With a coal steam generator,
the activity of burning the pulverized
coal and producing steam is contained
within what is termed the boiler
island. Because of the strong similarity
to what happens in the coal plant, many
engineers and technicians in a nuclear
plant refer to the area where steam gen-
eration occurs as the nuclear island.
Within the nuclear reactor, equip-
ment must meet rigorous standards.
Since radiation is very high, the stan-
dards require all equipment materials
used in this phase of the process to with-
stand high levels of radiation for the life
of the plant. Therefore, materials such
as iron or steel are required rather than
aluminum. Also, temperatures in this
portion of the plant are elevated, which
will affect seal materials. The combina-
tion of severe environmental conditions
determines the various coatings and
paints allowed for use in this area,
which is known as inside contain-
ment.
To be suitable for service in a nuclear
reactor, an actuator must go through
specific testing by outside testing agen-
cies. The test reports produced must
then be reviewed not only by the actua-
tor suppliers, but by consulting engi-
neers and the utilities themselves. Many
documents also are reviewed by the
NRC.
The tests for actuators used inside
containment apply to all styles. The
plants use electric motor operators as
well as pneumatic cylinder actuators and
hydraulic cylinder actuators. All of these
actuators must be tested to ensure they
can withstand the environment for their
expected lives. Also, in addition to envi-
ronmental concerns, the actuators must
be able to operate during extreme acci-
dent conditions such as an earthquake.
THE TESTING PROCESS
Testing for a motor operator is
described in a standard written by the
Institute of Electrical and Electronic
Engineers (IEEE)IEEE-382. This
standard describes the testing required
to produce a motor operator for use in a
U.S. nuclear reactor. An additional key
standard used is IEEE-344, which
describes standards for seismic testing.
The certification process puts the
actuator through a simulated life test
where it is aged seismically, environ-
mentally and mechanically. In other
words, the actuator is exposed to the
normal radiation and temperatures it
would experience in over 40 years of
operating in a nuclear plant, and it is
stroked as many times as expected over
that time period. When it is shown to be
at the end of its expected life, it is then
put through the most rigorous test of all,
which is known as the loss of coolant
accident (LOCA) test.
The LOCA test simulates a Design
Basis Event (DBE), such as an earth-
quake, in which the severity would vary
depending on where the plant was
located. During the test, the actuator is
exposed multiple times to extreme
temperature variations up to 500 F
(260 C). It also might be sprayed with
various caustic materials and/or be
required to stroke to ensure it can
operate under those conditions. The
bottom line is that very few safety-
related actuators have the integrity to
pass this sort of testing, but whether
the safety-related actuator is pneumat-
ic or electric, it has to be able to sur-
vive the stipulated LOCA test require-
ments to serve inside containment.
Another issue regarding nuclear
actuators concerns the designation of
active with regards to safety systems.
When a situation occurs in which a safe-
ty system needs to be invoked, such as
ensuring coolant water is available for
the reactor, actuators required to oper-
ate to deliver that water are part of the
safety system. These actuators are then
classified as active as they may be
required to operate during or after a
DBE. Thus, even when equipment is not
within the inside containment area
itself, if it is considered active, it must
go through stringent testing to ensure
reliability.
The seismic and environmental tests
can take 12 to 18 months to complete.
Once the actuator is qualified to work
within this environment, another impor-
tant step is taken.
Although actuators are used on
dampers in heating, ventilation and air
conditioning systems, many actuators
are operating valves inside the contain-
ment building. The valves have their
own standards because they are pres-
sure containment devices. To operate in
those areas, the valves must carry what
is known as the N stamp, and the
tests of valves associated with the N
stamp are demanding and arduous.
Sometimes, the N stamp testing
terminology causes confusion as far as
how it relates to actuators. Actuators by
themselves have no N stamp. Instead,
they have a pedigree based on various
testing results over many years. Review-
ing and evaluating the numerous test
reports is how a determination is made
as far as whether or not an actuator can
ACTUATION IN
With O-ring sealed covers in place on this
electric actuator, the motor, limit and torque
switches, as well as other electrical
components, are housed within a pressure-
tight enclosure. This keeps out dirt and
moisture and prevents breathing from
expansion and contraction of the internal air
caused by temperature changes.
This cutaway illustration shows the internal
components of a typical electric actuator.
be used for an application.
When a qualified actuator with the
appropriate pedigree is mated to an
N stamp valve, the integral unit must
pass one more important test. This test
is to assure the N stamp valve com-
bined with the approved attached actua-
tor has sufficient integrity to withstand
difficult seismic requirements. The test
is governed by another standard known
as QME-1. Although it is essentially a
valve test, the actuator is an important
component so it is part of the testing.
WHEN AND WHERE
EQUIPMENT CAN BE USED
As explained, only the most rugged
actuators manufactured today are suit-
able for use inside a nuclear reactor.
When equipment is not part of the safe-
ty system and it is outside of the reactor,
standard industrial equipment can be
used that takes advantage of some of
todays newer technologies.
An example is smart actuators. The
modern electric actuator used in many
process plants today consists of an inte-
gral motor control center with a digital
control module. That configuration
allows remote monitoring of valve and
actuator data useful for maintenance
and diagnostics. Unfortunately, the tech-
nology of today does not allow these
sophisticated electronics to reside within
an actuator or to pass the environmental
and seismic testing required for inside
the reactor. Actuators with advanced
technology can only be used in applica-
tions that do not require active testing.
ENHANCEMENTS UNDER
STRINGENT TESTING
Because motor operators are very sim-
ple with just a motor, gear set, and limit
and torque switches within robust cast
iron and steel housing, some advanced
options are available that can assist the
nuclear industry in certain applications.
For example, several major actuator
manufacturers offer a thrust monitoring
component so the nuclear plant can
monitor valve thrust requirements and
actuator thrust outputs. While that
capability is a standard item with a
smart actuator, its not as simple with
the nuclear actuator. The typical way
this capability is achieved in a nuclear
actuator is by measuring the deflection
of the motor shaft via the spring pack
on the end of the motor.
Another example of a nuclear option
becoming very popular is the torque
limiter. When sizing an actuator for a
valve in a nuclear application, the crite-
ria are different than for most other
applications. The valve factors used to
calculate the thrust required are very
high so sufficient safety margins are
ensured. The safety margins are set by
the industry and monitored very closely.
Another factor that comes into play is
power voltage. The actuators must be
sized to work on reduced voltages that
might be available during accident condi-
tions. When a motor is running on
reduced voltage, it produces reduced
torque. The combination of these chal-
lenges means an actuator might be much
larger for a valve than normally used.
Motor operators are also very power-
ful and have a reserve torque and thrust
capability. The industry calls them stall
torques, and they can more than double
the rated output torque of an actuator.
Because of the demands, the associated
valve must have a stronger superstruc-
ture as well as a larger stem than what
might be expected. The larger stem then
might require a larger thrust, and the
exact balance becomes a challenge for
specifying engineers.
The torque limiter is a brake that will
reduce the force put on the valve during
abnormal operation so that the valve
does not need as large a structure to
hold the actuator. Another option used
for high-speed valve applications is
thrust compensators, which are essen-
tially disc spring packs that allow for a
gradual loading of the actuator as the
valve seats.
PNEUMATIC PISTON/
HYDRAULIC/DIAPHRAGM/
MANUAL
Various nuclear plant applications use
pneumatic piston operators. In many
36
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A C T U A T I O N I N N U C L E A R P O W E R P L A N T S
This self-contained, linear hydraulic actuator is
designed for a nuclear plants main steam
isolation valve or main feedwater isolation
valve. It uses an electric motor to turn the
hydraulic pump, which generates the fluid
power pressure and flow to extend and retract
the main hydraulic cylinder. It is coupled to the
isolation valve to safely shut down the plant.
Much testing and precise quality control goes into manufacturing nuclear actuators. Here, a
highly trained quality control inspector is performing a quality test on two control packages for
a nuclear pneumatic linear actuator.
F a l l 2 0 1 1
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37
cases, spring-return actuators are used
when the valve must fail to a position on
loss of air supply. In other cases, nitro-
gen-charged accumulators can power
the cylinders to achieve the desired fail-
ure position. Often, these actuators are
used in critical applications, such as to
operate main steam isolation valves.
Typically, such pneumatic spring-return
actuators will have very fast operating
times with many redundant sets of con-
trols to ensure operation during a plant
shutdown.
Pneumatic spring-return actuators
can be constructed of ductile iron, cast
iron or steel and have to pass the same
difficult tests as their electric counter-
parts. Because the controls for pneu-
matic actuators tend to be bolted onto
the cylinder and gearbox housings, these
controls usually require their own IEEE
testing. Once the controls are mounted
to the cylinders, they are tested as a
dedicated package.
The cylinders themselves can also be
hydraulically powered. Because of the
compressibility of air, hydraulics can
provide more precise control than pneu-
matics. However, hydraulics can add
cost and complexity to a system. Also,
hydraulic equipment could require more
maintenance during its life because of
the nature of the sealing surfaces with
cylinders.
To best meet the needs of nuclear
customers, many manufacturers of
hydraulic actuation equipment offer
maintenance programs to assist utilities
in keeping equipment up to date and in
line with current qualifications and
standards, which is an important goal of
every well-run nuclear facility.
Nuclear plants also have a need for
traditional quarter-turn cylinder actua-
tors to operate the growing population
of quarter-turn valves in their facilities.
For example, rubber-seated butterfly
valves for water service are used exten-
sively as well as the more industrial-
service butterfly valves. In the past,
electric actuators were often employed,
but today, with the addition of more
high-pressure severe service quarter-
turn valves in the market, many of these
valves are provided with spring-return,
quarter-turn cylinders and are mainly
pneumatic.
Inside the containment, there is still
a large population of diaphragm-operat-
ed control valves. The actuators tend to
be an integral part of the valve in this
case. While pneumatic actuators are the
norm for this application in nuclear
plants, many industrial process plants
are starting to look at the use of electric
actuators to operate various control
valves. Also, interest is growing among
new plant designers for electric solu-
tions for modulating service particularly
where instrument air is difficult to pro-
vide or maintain.
Finally, no nuclear plant would be
complete without a large number of
manual gear operators. If these opera-
tors are in critical areas, they also need
to be seismically tested and qualified.
This can be difficult since the gears can
be quite large, which makes finding
shaker tables for seismic testing big
enough to handle those gears a
challenge. Bevel, spur and worm gears
also are all used in various nuclear
applications.
SUMMARY
Because of the hundreds of different
valve-actuator applications in a
nuclear facility, its essential that
those involved in specifying and main-
taining such equipment work closely
with reputable actuator manufacturers
to determine the best solution for each
situation.
Safety, efficiency, meeting the appro-
priate standards and longevity are all
crucial issues that need to be considered
for each and every valve actuator
installed in a nuclear plant. VM
PETE KUNDIN is general manager of the Eastern
USA business unit, Rotork, Rochester, NY.
(www.rotork.com). Reach Kundin at
pete.kundin@rotork.com.
A C T U A T I O N I N N U C L E A R P O W E R P L A N T S
Environmental qualification parameters.
38
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VIBRATION ANALYSIS PINPOINTS
VALVE NOISE SOURCE
A REFINERY THAT SHARED A PROPERTY LINE WITH LOCAL
RESIDENTS LOCATED AND CORRECTED A WHINING SOUND
THAT THREATENED THE PEACE OF THE COMMUNITY.
BY DANIEL EILERS
T
he beaches and vast expanse of the
southern California coast serve as
a drawing card both for recreation and
residency. Yet while the sound of the
ocean can prove refreshing and sooth-
ing, excessive noise from businesses,
traffic, construction and industrial
operations can disrupt and impact the
quality of a community.
Such is the case today with a heavily
populated, coastal California town that
constantly strives to reduce noise and its
impact within its urban environment.
The city has a noise ordinance that
establishes exterior noise standards by
land use. The ordinance regulates a
variety of noise generators, with a focus
on commercial and heavy industrial
operations.
One of the operations that is a source
of problems is a major in-town refin-
ery. However, the refinery constantly
works to reduce its disturbances. In a
recent case, they pinpointed and
removed a noisy valve.
THE REFINERY
When founded over 90 years ago, the
refinery was distant from heavily popu-
lated areas. Today, however, the refinery
complex is tightly surrounded by areas
consisting of industrial, commercially-
zoned, recreational and residential
properties.
Land use to the north of the refinery
is primarily residential mixed with some
commercial and light industrial zoning.
Heavy industrial operations with a small
parcel of commercial and multiple-fam-
ily residences dominate the west side of
the refinery, while to the east is a golf
course along with light commercial and
heavy industrial zones. The noise prob-
lem was most prevalent, however, at the
southern length of the refinery, which
borders single-family residences, sepa-
rated from refining processes only by
the width of a four-lane avenue.
The oil refinery is configured to pro-
duce large volumes of high-value, clean-
er-burning gasoline and diesel fuels
designed to meet the air quality stan-
dards of the California market. It has a
capacity of over 300,000 barrels per day,
but operates around the clock so the pro-
cessing units contribute ambient noise to
the surrounding neighborhoods. This
noise is particularly troubling to residents
who live on that southern border.
THE REFINING PROCESS
IN A NUTSHELL
To understand the source of the noise, it
is helpful to review the refining process
itself. This particular refinery receives
crude oil both from a marine terminal
and by conventional pipeline. The oil is
heated and processed in the crude unit
for primary distillation and separation
into various components. It is processed
first in the crude distillation tower
where the oil is fractionated into the
following streams:
Liquid and non-liquid petroleum
gas products, such as fuel gas,
propane and butane.
Light liquid products (naphtha),
which are further upgraded in the
naphtha hydrotreater and plat-
former for subsequent blending
into gasoline.
Middle distillates (kerosene and
diesel), which are produced from
the middle of the distillation
tower. The kerosene goes to either
jet fuel blending, the distillate
hydrotreater for ultra-low sulphur
diesel (ULSD) production or No.
6 fuel blending. The diesel goes to
the distillate hydrotreater for
ULSD production.
The material remaining in the
bottom of the crude distillation
tower (the material is called
atmospheric tower bottoms or
ATB) is sent to the vacuum tower
for further separation.
F a l l 2 0 1 1
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39
VALVE NOISE
BROADBAND VS. TONAL
In general, valves in refineries pro-
duce two types of noises. They are:
BroadbandTypically, noise gen-
erated by valves and piping com-
ponents is broadband. That means
human ears can hear the noise, but
it is difficult to distinguish between
sources.
TonalValves can also generate
tones, but these situations are
rare. Tones drive the overall sound
pressure level, and therefore the
human ear perceives them as
being louder than the same overall
level from a broadband source.
Tones are typically generated
by a resonance, which can be
either mechanical or acoustical in
nature.
Typical mounting of accelerometer to valve stem. Magnetic mounting of an accelerometer to a pipe wall.
The vacuum tower operates at less
than atmospheric pressure and fraction-
ates the ATB further. Vacuum gas-oil
(VGO) recovered from the vacuum
tower is then routed to the ISOMAX
unit to be upgraded primarily into naph-
tha, kerosene and ultra-low sulphur
diesel. The residual vacuum tower bot-
toms (VTB) stream is routed to the vis-
breaker.
THE OFFENDING UNIT
The ISOMAX unit (a unit that runs a
patented and licensed hydrocracking
process) uses high heat and pressure to
upgrade the VGO through catalytic
hydrogenation. This process removes
contaminants and produces naphtha for
gasoline blending and platformer feed,
ULSD and jet fuel. The ISOMAX frac-
tionation bottoms (frac bottoms) are
sold as a valuable lubricant feedstock.
For many years, very loud harmonic
noises (over 113 dBA, refer to Figure 1)
were generated somewhere in the ISO-
MAX process unit near the hydrogen
compressors and hydrogen quench con-
trol valves. Although the refinery hired
an outside consulting firm to determine
the exact source of the process unit
noise, a problem that had increased over
several years, the tests by the consultant
were inconclusive.
The problem was exacerbated recent-
ly, when the ISOMAX unit began to gen-
erate noise that propagated beyond the
refinery property line. In fact, the refin-
ery received complaints from nearby
residents about a continued, high-
pitched whine.
Refinery engineers were uncertain
how to resolve the issue since previous
studies were inconclusive. Suspecting
that control valves could be the poten-
tial noise source, they contacted the
local business partner of their major
valve supplier. Subsequent discussions
led to consultation with the valve manu-
facturers severe service group, which
recommended using vibration-analysis-
based, noise measurement equipment
and processes.
PINPOINTING THE SOURCE
Since the exact noise source could not
be identified using acoustic sound pres-
sure level measurement techniques,
which was the process used earlier by
the consulting firm, the efforts to meas-
ure vibrations began with a survey of
the quench valve area to determine
where to begin testing.
Accelerometers were used to allow
testers to isolate a specific component
for analysis, which leads to a systematic
evaluation and subsequent elimination
of suspect piping and valves.
To determine whether the noise source
in this case was upstream of the valves
with noise then propagating through the
system, the accelerometers were mount-
ed upstream and downstream of the
motor-operated valves that feed the
quench valves. Following measurements
taken at these locations, the sensors then
were placed immediately upstream and
downstream of each quench valve, as well
as mounted on the stem of each valve.
The highest piping vibration levels
were found next to the quench valves,
with the highest overall reading being
taken on the valve stems. This finding
indicated that the source or cause of
the noise was most likely the valve trim
components.
Stroking the quench valves was
shown to impact the tone of the noise.
Depending upon the travel, the tones
would disappear, increase or change
frequency.
The quench valves were 25-year-old
units that used post guiding of the
valve plug. In such valves, if the toler-
ance between the plug and valve body
is too large, the plug/stem assembly
can vibrate. If the assembly is excited
at the resonance of the plug/stem com-
ponent, the vibrations can cause tones.
NEW VALVES
SOLVE THE PROBLEM
Working together, refinery engineers
and engineers from the local valve
sales office identified a valve configu-
ration that could meet the required
performance level and eliminate noise
concerns.
A cage-guided valve design for high-
pressure control requirements was
chosen for its more stable operating
capability. Also, a digital valve con-
troller was added to each valve to allow
optimizing control of the reactor tem-
perature as well as to gain the ability to
perform online valve diagnostics. All
eight quench valves that were in the
ISOMAX unit were replaced with this
new valve configuration. The problems
with noise were also helped out when the
refinery installed a noise monitoring
and early warning system to assist in
identifying and subsequently controlling
unwanted sound.
The result is that the refinery and the
nearby community live much more com-
fortably side by side. VM
DANIEL EILERS is a research engineer at Emerson
Process Management, Fisher Division. He is
responsible for noise and vibration testing, noise
prediction development, and computational fluid
dynamic simulations of flow-through control valves.
Reach him at daniel.eilers@emerson.com.
40
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V I B R A T I O N A N A L Y S I S
Figure 1. Noise/Land Use Compatibility
Noise Level Noise Environment
Below 55 dB Relatively quiet suburban or urban area
55 65 dB Somewhat noisy urban area, but not directly adjacent to high-
volume traffic
65 75 dB Very noisy urban areas, near arterials, freeways or airports
75+ dB Extremely noisy urban area with potential hearing
damage with constant exposure
Accelerometers were mounted upstream and
downstream of each quench valve as well as
on the valve stem.
42
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A
ccording to Hart Data and Map-
ping Services, the United States
has over 700,000 miles of crude oil
and natural gas pipelinesabout
100,000 miles of crude onshore
pipelines and over 600,000 miles of
onshore gas pipelines. This number
stands to greatly increase as drilling
in the various shale plays across the
continent occurs. These seemingly
endless strings of pipe have one thing
in common: They all contain large
numbers of valves optimized for
pipeline operating conditions.
WHATS IN A PIPELINE?
Both quarter-turn and multi-turn
block valves as well as check valves
are used in pipeline service. Those
built for gas or crude oil pipeline
service are designed and tested in
accordance with the American Petro-
leum Institute (API) specification 6D
Pipeline Valves. The document,
which is also published by the Inter-
national Organization for Standardi-
zation as ISO 14313, includes
requirements for gate, ball, check
and plug type valves. Prior to the
mid-1950s, the choice of valve for
use in pipeline blocking applications
was easygate valves were used
because the pipeline ball valve had
not been invented yet. Some plug
valves also were used back then, but
the majority of the designs for these
valves were reduced-port type that
were not piggable.
The term piggable has nothing
to do with breakfast meat choices.
Rather, it means being pig-capa-
blein other words, the devices
designed to clean or inspect the interi-
or of the pipeline (the pigs) also
may be passed through the bore of the
valve without catching on a reduced
bore or other interior projection in the
valve. A requirement in API 6D gate
PIPELINE VALVES
ALWAYS READY
This nation is crisscrossed by hundreds of
thousands of miles of crucial pipelines that
transport vital feedstock from sources to the
places where its transformed into fuel and
products. For the valve industry, that translates
into millions of dollars of business.
BY GREG JOHNSON
W
H
E
R
E
V
A
L
V
E
S
A
R
E
U
S
E
D
valves is that their inside bore dimen-
sions are precisely specified to allow this
passage of pigs.
With the advent of quality pipeline
ball valves over the past few decades,
sales of pipeline gate valves have fallen.
Meanwhile, pipeline ball valves, which
are trunnion style, are now making
inroads in all types of pipeline service,
particularly in natural gas. Still, hold-
outs exist.
Some companies are staunchly
entrenched in the gate valve, according
to David Fehrenkamp, a senior sales engi-
neer with Cameron. He also adds that in
many natural gas pipeline operations,
quarter-turn has taken over 100%.
So why do many pipeline owners
favor the gate valve for pipeline service?
Product pipelines that carry fluids such
as gasoline, distillates, diesel fuel and
other finished petroleum products are a
popular place for the rough and ready
gate valve. We use slab gate valves for
most of our main line valves, but we do
use expanding gate valves on our prod-
uct line from Texas City to Pasadena,
says Billy Daigle, maintenance services
specialist for Marathon Pipe Line LLC
(MPL). We use expanding gate valves
for station isolation valves and pig
launchers. Pig launcher and receiver
service is harder on valves because of
the debris from the pigging operation,
so we choose expanding gates because
of their toughness, he adds.
The quarter-turn vs. gate valve debate
gets hotter when cost becomes the prime
factor for selection. The quarter-turn
trunnion pipeline ball valve is much
cheaper to make than the jumbo-sized
gate valves, with their large and expen-
sive body castings. Another factor that
tips the pendulum toward quarter-turn
pipeline valves is the availability and
delivery of quarter-turn products.
Because drilling in the shale plays across
the country is exploding in terms of how
fast its occurring, Fehrenkamp says the
requests from customers for delivery
time is rush, rush, rush, I need it now!
A domestically produced trunnion
pipeline ball valve can be built in roughly
four weeks, which is about the time
needed to get a good gate valve casting
under the luckiest of circumstances. An
additional four to six weeks might then
be required to complete the gate valve
machining, assembly and testing.
Some explanation is in order when
speaking of pipeline gate valves. Gate
valves used in this service are different
from the wedge-type gate valves com-
mon in the downstream petrochemical
and refining industries. The pipeline
gates come in two basic types: slab and
expanding wedge. The slab type utilizes
a large slab that floats slightly in the
valve body and seals downstream with
the aid of upstream pressure. Spring-
loaded seats are often employed to
increase the sealing efficiency. The
expanding gate, on the other hand, uses
a split-disc design and separator mecha-
nism that tightly expands the gate both
upstream and downstream as the valve
is closed. This type then reverses the
process upon opening. The tighter clos-
ing design enables the valve to seat
more effectively at lower pressures.
A QUESTION OF INTEGRITY
Valve integrity along with pipeline
integrity is of prime importance to the
pipeline owner as well as those who live
and work close to the line. A complex
formula for risk assessment is used to
guide pipeline operators with inspection
programs. The assessment criteria
include the product, age of the pipeline,
and proximity to population centers,
local housing and occupied structures.
The pipeline itself must be inspected at
specified intervals. This line inspection
is usually performed by smart pigs,
complex devices that roll through the
line to perform radiography, remote
visual, ultrasonic evaluation and other
inspections.
Valves, on the other hand, need their
own inspection programs. The U.S.
Department of Transportation has devel-
oped natural gas pipeline valve inspec-
tion criteria detailed in CFR Title 49,
part 192, The Transportation of Natu-
ral and Other Gas by Pipeline: Minimum
Federal Safety Standards. Paragraph
192.745 of that title states, Each
transmission line valve that might be
required during any emergency must be
inspected and partially operated at
intervals not exceeding 15 months, but
at least once each calendar year. Simi-
lar requirements are published for crude
oil and hazardous liquid pipelines in
CFR Title 49, part 195, Transporta-
tion of Hazardous Liquids by Pipeline,
paragraph 195.420.
Proper valve maintenance is always
UPSTREAM, DOWNSTREAM, MIDSTREAM:
WHATS THE DIFFERENCE?
Those three terms are used all the time in the oil and gas industry, and although
the definitions sometimes overlap, they denote specific areas on the oilfield to
refinery trail:
Upstream: Starts at the bottom of the hole in the ground and covers most every-
thing on the wellhead up to the choke. The choke is a specialized globe valve that
is mounted on wellheads and is used to regulate the output of the well.
Midstream: Starts at the output of the choke and continues through all the sur-
face processing equipment and through the pipeline to the fence at the refinery.
In decades past, the term midstream was not in vogue, and everything was
either upstream or downstream. Now, midstream is used extensively.
Downstream: Generally speaking, everything inside the fence of the refinery.
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43
PIPELINE VALVES
ALWAYS READY
Ball, check and manifold valves are commonly
used in pipeline service.
vital, and pipeline valves are no excep-
tion. Since most pipeline valves have a
seat sealant injection feature to facili-
tate tight closure, the sealant must be
properly introduced into the seat seal
area. New valves typically require more
sealant top-off than those that have
been in operation for a year or two.
All pipeline operators have preven-
tive maintenance (PM) and repair pro-
grams to ensure the life and functionali-
ty of their valves. Most
companies will use a com-
bination of in-situ repair
along with shop refurbish-
ments for tough repair cases. We
spend over 25% of our time in valve
shops to get the valves just like we want
them, says MPLs Daigle.
Because of the importance of proper
pipeline valve repair, a specification that
describes the repair procedure is in
place: API 6DR, Repair and Remanu-
facture of Pipeline Valves.
HOW PIPELINES WORK
Understanding how pipelines operate
provides a better understanding of how
valves are used in pipeline service.
Major pipelines receive input from
either smaller gathering lines, tank
farms or, in the case of finished prod-
ucts, refineries and petrochemical
plants. Because of friction losses,
the arriving pressure of the
fluid is much too low to pro-
vide enough energy to
send the product very far
through the line. Most
transmission pipelines in
the United States operate
at maximum pressures of
less than 1440 psi. Com-
mon maximum target pres-
sures range from 700-725 psi and
1300-1400 psi, which equates to ANSI
classes 300 and 600 respectively. These
maximum pressures would only be
found immediately downstream of
pumps or compressors.
Because of the pressure drop in the
line, booster pumping stations at inter-
vals along the line are needed. In the
case of a liquid such as crude oil, a min-
imum pressure of about 25-50 psi is
needed for the suction side of the boost-
er pumps to operate. Each booster
pumping station is equipped with mani-
folds containing many valve types,
including gate, ball, check, and in areas
where pigging is not required, reduced
port, lubricated plug valves. Additional-
ly, control valves often are used to regu-
late flow from the stations.
The most common pressure class for
pipeline transmission lines is class 600,
which has a working pressure of 1440
psi. The valve ratings are in accordance
with The American Society of Mechani-
cal Engineers (ASME) standard
B16.34 and API 6D.
Although a number of valves are in
operation at each pumping station (for
liquids) or compressor station (for gas
transmission), the critical valves in a
pipeline are spaced along its route. They
serve as blocking or isolation valves to
segregate pipeline sections for required
maintenance or to help in cases of an
44
|
P I P E L I N E V A L V E S
Above: Pig launchers are hard on valves because of the debris from the pigging
operation. Right: Valves play a critical role in keeping the nations pipelines safe.
Pipelines use a variety of
valves to control fluids both
above and below the ground.
accident. The minimum required spac-
ing of these valves is prescribed in
ASME B31.4, Gas Transmission &
Distribution Piping Systems and
ASME B31.8, Pipeline Transportation
Systems for Liquid Hydrocarbons &
Other Liquids.
Several factors influence valve spac-
ing, including: 1) the amount of poten-
tial fluid leakage, 2) the impact of a
release, 3) future development in the
pipeline area, and 4) the time required
to blow down (empty) an isolated sec-
tion. Other criteria include how close the
line is to occupied buildings and houses.
According to B31.4, the distance
between block valves could be as little
as four miles apart for a gas pipeline.
Liquid pipelines have their own crite-
ria for valve placement. They are
placed: 1) at the suction end and dis-
charge ends of a pump station, 2) on
each line entering or leaving a storage
tank area, 3) on each mainline at loca-
tions along the pipeline that will limit
damage or pollution from accidental
hazardous liquid discharge, 4) on each
lateral take-off from the trunk line, 5)
on each side of a water crossing that is
more than a 100 feet wide, and 6) on
each side of a reservoir holding water
for human consumption.
Additionally, check valves may be
installed on grades and the downstream
side of rivers and streams for more pro-
tection from backflow conditions in case
of a line breach.
Many block valve installations are
outfitted with automatic shutdown con-
trols. These controls are set to close the
valve if pressure or flow rates change,
indicating a possible breach in the line.
By having these valves spaced through-
out the line, the amount of potential
fluid leakage that might occur during a
line break is limited. Additionally, many
pipeline valves are designated as emer-
gency shutdown valves (ESD), which are
remotely operated from the pipeline
control center.
These block valve location require-
ments account for the numerous small,
fenced-in valve installations visible
when driving around areas with many
pipelinesnumerous pipeline block
valves are located above the ground for
easy maintenance. However, some are
buried, with only the operating mecha-
nism and auxiliary lubrication and bleed
lines showing. These installation areas
used to be the exclusive domain of gate
valves. However, today welded body
trunnion-mounted ball valves are very
popular, especially for clean natural gas
transmission lines. The unique welded
body construction eliminates the poten-
tial body-bonnet leak path, while the
only remaining leak path is up through
the packing area.
Though fugitive emissions (FE) leak-
age has been a focal point in the refining
industry for over 20 years, the upstream
and midstream markets have been fairly
immune from FE scrutiny. However,
that situation is changing. According to
MPLs Daigle, LDAR [leak detection
and repair] for pipelines is becoming
popular and required, especially since
packing leaks are the most common
leaks we deal with.
One place where emissions of any
type are unacceptable to almost every-
one is in undersea pipelines. Because
they are surrounded by water and
vibrant marine life, undersea pipelines
certainly have their own set of chal-
lenges. However, there are other key dif-
ferences from on-land pipelines that
affect design, including the design of the
valves attached to the pipelines.
For example, undersea pipelines that
connect wellheads to gathering points
often operate at much higher pressures
than their onshore counterparts. It is
not uncommon for these lines to see
10,000 psi. Valves designed for this
submerged service are critical, purpose-
built flow control devices that absolutely
must work properly when called upon to
operate. Because of the unique undersea
environment, standard API 6D require-
ments are not deemed tough enough, so
a special underwater valve specification
was written to cover these products:
API 6DSS Specification for Subsea
Pipeline Valves.
TESTING
Although interior pressures are also
quite high in subsea pipelines, it is
sometimes the outside pressure from the
extreme depths that introduces the most
stress on valves and piping. As a result,
pipeline valves designed for installation
at great depths are often tested in a
hyperbaric chamber, where extreme
pressure is exerted on the outside of the
valve, while the inside is sealed against
the external pressure.
All pipeline valves receive seat and
shell tests per API 6D or 6DSS, not
unlike their downstream counterparts,
which are usually tested in accordance
with API 598, Valve Inspection &
Testing. One difference between the
two testing documents is that, with API
6D pipeline valves, the holding times for
the tests are much longer. For example,
a 24-inch valve shell tested per API 598
requires a five-minute duration, while
the same size valve tested per API 6D
requires a 30-minute duration. These
longer holding times for pipeline valve
tests are often extended into hours by
the supplementary test requirements of
many pipeline owners.
While pipelines and pipeline valves
lie mostly invisible beneath six feet of
earth or under 600 feet of ocean, they
are nonetheless highly visible when
an accident occurs. As a result, pipeline
valves are closely scrutinized members
of the valve family. They are built to
tougher standards and must work every
time because they must protect lives and
property that lie near their installations.
Pipeline valves could borrow the Latin
motto of the United States Coast Guard,
which is Semper Paratus, which
means: always ready.VM
GREG JOHNSON is a contributing editor to Valve
Magazine and president of United Valve
(www.unitedvalve.com), Houston. Reach him at
greg1950@unitedvalve.com.
F a l l 2 0 1 1
|
45
Slab gate valves
are used along
the pipeline
systems.
46
|
Q: My customer has rejected
my welding procedure
specification (WPS) and has
asked me to address items
that are not required by
ASME Section IX. Is this
reasonable?
A: Yes, this is a reasonable request. In
many cases, it is a good idea to address
items not covered by Section IX
1
.
Many people view any given ASME
code section as a handbook, and
assume that if they follow everything in
that code section, they have met all
necessary requirements. However, each
ASME code section has verbiage in the
foreword warning the user that merely
following the rules in that particular
section will not ensure an adequate
design. Such wording is phrased in
ways like: The user of the Code should
refer to other pertinent codes, stan-
dards, laws, regulations or other rele-
vant documents, and it is not intend-
ed that this Section be used as a design
handbook; rather, engineering judg-
ment must be employed in the selection
of those sets of Code rules suitable to
any specific service or need.
For example, Section IX does not
impose enough controls to ensure reli-
able weld joints because it does not
address the proper choice of filler
materials. Section IX would allow
welding nickel alloys or copper alloys
together using carbon steel filler, pro-
vided the qualification specimen passed
the appropriate mechanical tests.
Many variables are not required to be
addressed in a Section IX WPS. But in
many of these cases, a WPS that does
not address those variables may not
produce consistently reliable weld
joints or provide adequate guidance to
the welder, both of which should be the
primary purpose of the WPS.
The following are examples of fac-
tors Section IX does not require, but
that should be considered for inclusion
in a WPS:
1. There are supplementary essential
variables not required to be
addressed for a WPS to be used on
materials that are not impact-
tested. One such essential variable is
heat input, which is calculated
based on current, voltage and travel
speed. If heat input does not need to
be addressed, Section IX does not
require including voltage or travel
speed values. Some of the software
packages for creating WPS docu-
ments will even omit this informa-
tion automatically. On the other
hand, if no voltage or travel speed
values are specified, it is possible to
follow the WPS and still produce
unacceptable welds. Therefore, even
though not required by Section IX,
it is beneficial to include reasonable
voltage and travel speed values on
the WPSeven for materials that
are not impact-tested.
2. For a WPS that involves carbon and
alloy steels postweld heat-treated
(PWHT) below the lower transfor-
mation temperature (LTT), Section
IX only requires the WPS to indicate
the PWHT must be below the LTT.
Most WPSs for non-impact-test-
ed carbon steels and alloy steels will
actually state a PWHT temperature,
but many omit the tolerance on this
temperature and any soak time
requirements.
To ensure that proper strength,
ductility and hardness requirements
are met, a PWHT temperature
range should be stated on the WPS.
That temperature range should be
M A T E R I A L S Q & A BY DON BUSH
Its easier to express probability in
terms of failure, rather than in terms of
proper performance. As published in the
aforementioned standards and some
product brochures, four levels of SIL
are listed, enumerated 1-4the higher
the SIL level, the higher the associated
safety level, and the lower probability
that a system will fail to perform prop-
erly (Figure 1).
These various SIL levels might be
correlated to the above mentioned
examples of consequences of failure.
For purposes of this article, it is
appropriate to think of SIL as the
degree of likelihood that our system will
work when we want it to. (Generally,
SIL 4 is beyond the scope of what we
see in the process industries.) Again, we
might want to think of a function as
an emergency shutdown valve system,
typically consisting of a sensor of some
type (pressure, level, temperature) and a
logic controller that will send a signal to
an automated valve. The automated
valve package might consist of an
actuator (pneumatic, electric, hydraulic,
etc.), solenoid valves, quick exhaust
valves and the final control element, the
valve. The system may consist of
many functions; it might have five emer-
gency shutdown valves protecting a
pressure vessel cooking a process. Or, it
might have only one function (the SIF)
making the entire SIS.
To summarize, the HAZOP team will
determine SIL levels based on deter-
mined PFD. Michael Young of General
Monitors has summed this issue up nice-
ly in his paper, SIL 101: How Safe Do I
Need to Be?
A simple example will help illus-
trate the concepts of SIS, SIF, and SIL.
Consider the installation of a pressure
vessel containing flammable liquid. It
is maintained at a design operating
pressure by the Basic Process Control
System (BPCS). If the process control
system fails, the vessel will be sub-
jected to an over-pressure condition
that could result in a vessel failure,
release of the flammable contents
and even fire or explosion. If the risk
in this scenario is deemed to be
intolerable by the facility owner,
an SIS will be implemented to
further reduce this risk situation to
a tolerable risk level.
The SIS system will be independent
from the BPCS and will act to prevent
34
|
Figure 3. PFD
AVG
is decreased due to PST combined with full cycle testing
Graphs reprinted by permission from ANSI/ISA-TR96.05.01-2008. ISA 2008
PFD
AVG
Detail
Time
Partial Test
Full Test
Partial Test
Full Test
0.1
0.01
0.001
YELLOW JACKET WEATHER
CAPS EXTEND THE LIFE OF
YOUR PRESSURE RELIEF VALVES
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F a l l 2 0 1 1
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47
based upon the PWHT temperature
used on the qualification coupon,
taking into consideration the effects
of higher and lower temperature on
the strength, ductility, hardness and
toughness of the material. In addi-
tion, as a function of base metal
thickness, guidance should be pro-
vided regarding the soak time, as
well as providing absolute minimum
and maximum allowable soak times.
Again, strength, ductility, hardness
and toughness of the material
should be taken into account.
3. Section IX does not prohibit com-
bining procedures that have been
qualified in different ways, such as
procedures qualified with and with-
out PWHT, or procedures qualified
with and without controls required
for impact-tested materials. In fact,
creating one WPS that covers non-
impact-tested material (such as
WCC) and impact-tested material
(such as LCC), with and without
PWHT is both possible and allowed.
These procedures are handy when it
is necessary to get a customer
review. However, the combined pro-
cedures tend to be difficult for
welders to follow because they usu-
ally contain a number of notes and
tables, and for any given job it can
be hard to determine what informa-
tion actually applies.
Although the combined approach
is allowed, and although the com-
bined document might be convenient
from a creation and maintenance
standpoint, it is actually better to
create four separate WPS docu-
ments (non-impact without PWHT,
non-impact with PWHT, impact
without PWHT and impact with
PWHT), because each WPS will
then convey much more clearly the
specific requirements for the perti-
nent situation.
In summary, although Section IX
imposes an abundance of rules for
qualifying and writing WPSs, there are
many instances where additional con-
trols and information need to be con-
veyed to ensure results that meet the
intended requirements of the weld.
Therefore, if your customer makes a
comment on your welding procedure,
view it as a possible learning experi-
ence. In the end, your WPSs will be
better for it. VM
Reference:
1
ASME Boiler and Pressure Vessel Code, Section
IX, Qualification Standard for Welding and
Brazing Procedures, Welders, Brazers, and
Welding and Brazing Operators, American
Society of Mechanical Engineers, New York, NY,
USA.
DON BUSH is a principal materials engineer at
Emerson Process Management-Fisher Valve
Division (www.emersonprocess.com). Reach
him at Don.Bush@Emerson.com.
SPEC IT AND
FORGET IT.
Check-All Valve is your
one-stop supplier for the
check valves you need in the
materials you require. Better
yet, every valve includes the
experience, engineering, and
application know-how you need
for "spec-it-and-forget-it reliability.
After all, you have better things to
do, and check valves are all we do.
Call us at 515-224-2301 or
e-mail us at sales@checkall.com.
www.checkall.com
Since 1958
West Des Moines, Iowa, USA
I
n earlier columns, I highlighted the
value of online communities and their
ability to connect people with similar
expertise. The successful communities
typically grow into the thousands and
have many people actively participating
by asking questions, providing answers
and linking to interesting information
available on the Web.
LinkedIn is a vibrant place for many
of the professional groups, including
those that deal with automation, which
is one of the discussion areas that is a
good source for Emerson Process
Experts blog posts.
A quick check to see how many
valve-related LinkedIn groups were
active revealed a long list. At the time
this article was written, the top five
were Valve World Group with 3,052
members, Valve Network with 2,615
members, Valve Sales with 1,262 mem-
bers, Valve Solutions with 995 mem-
bers, and Valve Actuation Group with
759 members (see listings for these at
the end of this column).
Together, thats a lot of people shar-
ing what they know on the subject of
valves. A good way to see how useful the
individual sites are is to look at a sam-
pling of some of the discussions current-
ly taking place.
The Valve World Group community
is described as, ...a platform for valve
professionals in the global process
industries to exchange knowledge and
offer networking opportunities. Its dis-
cussions range from asking for sugges-
tions for suppliers for specified valves,
to suppliers sharing their recent white
papers, to people new to the industry
asking how to gain experience in the
valve industry. The Valve Manufactur-
ers Association and VMA.org website
were highlighted by many respondents
as an excellent resource for people new
to process automation.
The rest of these groups require
membership to see whats available in
the discussion threads. LinkedIn allows
group owners the choice whether to
have open groups or not. If open, any-
one can view information about the
group, but not participate unless he or
she is a member. If the goal of these
groups is to be broad based and easily
findable through search queries, admin-
istrators are well served to open up
their groups.
Each of the five groups mentioned
above has a description that may help in
deciding if they are valuable. For exam-
ple, Valve Network is described as, ...a
global networking platform for market-
ing, sales, development, design and
manufacturing professionals dealing
with valves and control valves.
Valve Sales describes its purpose as,
...for sales professionals within the
valve industry, to network and job
search. The Valve Solutions group
shares its mission as, ...to offer a plat-
form where piping & design engineers,
flow professionals, process & operations
personnel from various upstream &
downstream manufacturing plants can
interact with each other and seek flow
solutions to various process applica-
tions. Finally, the Valve Actuation
Group, ...is for actuator, valve, control
valve, instrumentation and automation
experts in the global process industries.
Through the group, members can devel-
op their professional networks, transfer
knowledge and share experiences.
In just this small sampling of
LinkedIn groups, you can see the focused
communities for valve manufacturers,
valve sales professionals, and project and
plant engineers. If you are in one of these
groups, it may be worth a look to join the
communityit costs nothing except your
time. You can configure your group set-
VMA AND VALVE MAGAZINE ON THE WEB
As columnist Jim Cahill has noted, many in the industry are aware that the Valve
Manufacturers Association has a websitewww.VMA.orgthat contains much
useful information and resources. The same can be said of Valve Magazines web-
site, www.ValveMagazine.com, in which we post Web-exclusive articles, new
products, frequent news updates about valve manufacturing, end-user news and
more.
Wed also like to remind readers that we have been posting digital editions of
the magazine online since 2008 (www.ValveMagazine-digital.com). This can be a
great way to find articles that include information you are seeking, using a key-
word search.
Finally, we have plans to start our own group in LinkedIn, which will be active
by the end of the year. Our focus will be on connecting U.S. and Canadian valve,
actuator and control manufacturers with those who specify, purchase, maintain,
operate, distribute and use these products.
48
|
Online Valve Communities
Something for Everyone
BY JIM CAHILL
tings to get a daily or weekly summary of
the discussions sent to your work or per-
sonal email. I find these email summaries
helpful so that I can view whats being
said on my own time and to get a quick
sense for the conversations occurring in
the community.
There is also no cost to start one of
these communities, so if you have an
area of specialization, you can easily
become administrator for your own
group. And the fact they can be open or
closed to different degrees can be help-
ful in targeting the discussion. For
example, if the knowledge you want to
share is strictly for people inside your
company, it makes sense to start this
community inside your own firewall.
Many enterprise software products also
are adding their own capabilities for
forums, status updates and other social
forms of communication. In addition,
open source software such as Wordpress
and the BuddyPress provide a way to
quickly enable knowledge-sharing sites
inside your own firewall.
These online communities continue to
grow in popularity because they are eas-
ily discovered through search engines. If
youre searching and land upon a thread
that helps solve a problem, its possible
you will end up joining the community
to help you solve future problems.
Email most likely will remain a domi-
nant form of business communication for
the foreseeable future. But, as these
online communities spring to life and add
capabilities, their appeal will grow.
Email is limited by who is already in your
address book, and how easy it is to find
information by digging through your
archives. Online communities connect
people with common knowledge and
interests together from across the world.
By and large, if the community is open,
the content is fully indexed in the search
engines and waiting to be discovered.
I hope youll give one of the men-
tioned valve communities a try to see
whether or not it adds value. If it does, I
encourage you to seek more value by
getting your fellow experts to join. VM
JIM CAHILL leads Emerson Process Manage-
ments social media efforts and writes the
Emerson Process Experts blog:
www.EmersonProcessXperts.com.
LINKS
Valve World Group:
www.linkedin.com/groups?home=&
gid=2067722
Valve Network:
gid=1890432
Valve Sales:
gid=2105714
Valve Solutions:
gid=2436680
Valve Actuation Group:
gid=134832
F a l l 2 0 1 1
|
49
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51
I
nformation about the performance of
a facilitys valves has never been more
readily availableor more important.
Digital positioners and distributed con-
trols can provide valuable data about the
operation of the overall system. At the
same time, the growing complexity of
todays facilities, increasingly stringent
regulatory and reporting requirements,
and growing pressure to improve plant
performance have combined to make
that valve data more vital than ever.
But how can an operations or main-
tenance manager get the best informa-
tion? To be useful, the data must be
readily available and presented in a
user-friendly manner. Asset manage-
ment systems can fulfill this need by
providing easy access to a database con-
taining details of the history and health
of every valve in a plant.
WHAT IS AN ASSET
MANAGEMENT SYSTEM?
An asset management system is the
valve equivalent of the electronic med-
ical recordkeeping systems used by hos-
pitals and clinics. For medical applica-
tions, the patients electronic record con-
tains such information as test results,
prescription history, diagnostic images
and notes on previous appointments. The
physician can access this data with just a
few clicks of a mouse, no matter the
time of day or night or whether he or she
is in the office the patient typically visits,
or at a sister facility. Having this com-
plete record helps the physician identify
any changes in the patients health over
time, make accurate diagnoses, alert
when routine tests and procedures
should be completed and properly bill
the insurance provider.
Similarly, an asset management sys-
tem for valves stores performance data,
maintenance records, test results, pip-
ing and wiring diagrams, photos and
other vital and diagnostic records in a
simple and logical manner. The infor-
mation can then be easily retrieved for
use in tasks such as performance analy-
sis, outage and maintenance planning,
inventory management, validation
reporting to inspectors and loop analy-
sis. An asset management system also
can help plant personnel see trends in
valve performance over time, diagnose
performance problems, determine
whether a valve should be repaired or
replaced, streamline plant turnarounds
and other maintenance activities, and
more easily meet documentation and
reporting requirements.
Various types of asset management
tools are in use today, ranging from
spreadsheets and other user-designed
tools to sophisticated Web-based pro-
grams. The following are key factors to
consider when evaluating the options
and choosing the right solution.
RANGE OF CAPABILITIES
A key objective of implementing an
asset management system is to simplify
and streamline processes. To aid in this
goal, plant personnel can choose a sin-
gle tool that will meet all of the plants
needs, rather than juggling multiple
tools to accomplish different tasks.
This single tool should be able to
capture data about all types of valves in
a plantcontrol, pressure relief, line,
gate, motor-assisted, etc. It also should
record information about a valve and all
of its accessories, not just an individual
component, such as a positioner.
SUPPLIER SUPPORT
It also is important to have confidence
that the systems developer will stand
behind the product and provide ongoing
support and service, including adding
new features and modules. The college
student next door who is home for the
summer may be a software development
whiz; but he or she is not likely to be
available come fall, let alone years down
the road, to field technical questions and
ensure a tool meets evolving needs. A
wiser move would be to choose a strong
provider committed to its product.
MAINTENANCE & REPAIR
BY GARY OSTROWSKI
Asset Management: A Plant Managers Best Friend
Asset management tools can allow
users to upload or view a wide variety
of images associated with a valve,
including parts photos and other
documents related to a recent repair.
The user can then browse the image
list, edit images or add comments.
BASICS
52
|
DATA INPUT
Because asset management is about the
quality of data, the old adage garbage
in, garbage out holds true. Data input
and maintenance must be regular and
accurate if a tool is to provide expected
benefits. Some plant operators prefer to
handle these tasks in-house. Those who
do not have on-staff resources to
accomplish these tasks faithfully, how-
ever, should consider other options.
Some valve service providers offer man-
aging their customers asset manage-
ment systems as a value-added benefit
at no additional cost. The end user still
owns the data and links to that informa-
tion, but the service provider handles
the data entry and system maintenance.
KEY FEATURES
Information is only valuable if it is
accessible when needed. In todays 24/7
business world, that can be any time of
the day or night, any day of the year.
Web-based asset management tools
provide around-the-clock access 365
days a yeareven when the plant man-
ager has questions about the plans for
an upcoming turnaround at midnight on
a Saturday.
Something else a good asset
management program has is tight
security, and in todays world of cyber-
crimes, thats even more critical. Key
features to ask for when considering an
asset management system include
strong firewalls against outside intru-
sion, robust password protection within
the system and the ability to restrict
access so that individuals within a
facility only have access to the data
that pertains directly to their areas of
responsibility.
Another key ingredient is provision
of reports that are useful and key in
planning future action as well as review-
ing past events.
Reports are an essential piece of any
good asset management tool. Personnel
should have the flexibility to customize
reports and make the process of manag-
ing assets and providing these reports
quick and easywhether the user needs
MAINTENANCE & REPAIR
Tablet computers can allow a member of the
maintenance team to access the asset
management tool as he or she walks through
the plant.
The Manufacturers Standardization Society (MSS) has created and
maintains a number of quality assurance standards for the PVF industry
QualityStandards...
TheManufacturers StandardizationSociety
of theValve&Fitting Industry
For further information on
MSS membership or MSS
standards, contact Bob ONeill,
MSS executive director at
703/281-6613, or on the web
at www.mss-hq.com. MSS is
anANSI accredited standards
developer.
SP-53 Magnetic Particle
examination of Steel Castings
and Forgings
SP-54 Radiographic
Examination of Steel Castings
SP-55Visual Evaluation of
Surface Irregularities of Steel
Castings
SP-93 Liquid Penetrant
Examination of Steel Castings
and Forgings
SP-94 Ultrasonic
Examination of Ferritic and
Martensitic Steel Castings
SP-112Visual andTactile
Method for Evaluation of Cast
Surface Finishes -
SP-137 Quality Standard
for Positive Material
Identification
Fall_2011 Ad_FA 9/29/11 7:29 AM Page 1
F a l l 2 0 1 1
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53
to create pie charts showing the plants
valves by brand, to generate a list of
valves due for repair during an upcoming
turnaround (and hopefully a calendar to
assist in that process) or to identify all of
the pressure relief valves for which test
certificates must be submitted to the
local or state boiler and pressure vessel
inspectors the following month.
OUTAGE PLANNING
Asset management tools can be a huge
help in planning outages, especially in
light of the fact that delays can cost
thousands or even millions of dollars per
day in lost production. Such tools have
the potential to save both time and
money. Key features that can be includ-
ed in an asset management tool are:
The ability to plan spare parts
across an entire loop so that parts
can be ordered in advance of an
outage and surprises that might
occur during that outage can be
prevented.
The ability to see comments noted
during a previous outage that
may be pertinent to an upcoming
outage.
The ability to track the progress
made in completing a turnaround
and comparing the actual comple-
tion timeline to the planned time-
line. This allows maintenance per-
sonnel to easily provide updates to
plant management.
IMAGE DEVELOPMENT AND
STORAGE
The saying that a picture is worth a
thousand words certainly applies to
management of valve assets. Good man-
agement tools allow users to quickly and
easily record and view a wide variety of
images of those valves and their environ-
ment from before and after parts
photos and other documents related to a
recent repair, to reports from the in-situ
testing of a safety valve and the piping
and instrumentation diagram of the loop
associated with a valve. There is, after
all, no better sign of preparedness than
being able to answer an inspectors
question immediately by calling up the
required materials on a computer with
just a few clicks of a mouse.
We live in a digital world in which
information has become our king.
An asset management tool can be the
best friend a plant and maintenance
manager has by helping to navigate
the waters of this digital world while
providing quick access to essential
information. VM
GARY OSTROWSKI is director of product
management aftermarket with GE Energy
(www.ge-energy.com). Reach him at
gary.ostrowski@ge.com or 508.941.5407.
The OEM Approach To Repair
The Valve Repair Council (VRC) is the most reliable OEM parts supply and repair
network in the industry. From critical upgrades, full life-cycle engineering support
and strict documented quality procedures, our members offer unequaled safety and
efciency in OEM rebuild and supply, backed with the full support of the manufacturer.
With VRC, youre guaranteed trust, reliability and quality with all your repairs.
VRC Members
When it comes to your valves and actuators RELAX you can TRUST a VRC repair.
1050 17th Street, N.W. Suite 280, Washington, DC 20036
Phone: 202.331.0104 | Fax: 202.296.0378 | http://www.vma.org/?ValveRepairCouncil
VRC_AdV2.indd 1 7/27/2010 9:22:57 AM
Dowco Valve Company
Allied Valve
AVP Valve, Inc.
Bay Valve Service, Inc.
Cameron
CCI Houston (Repair Center)
CFM/VR-TESCO LLC
Chalmers & Kubeck North
Cleveland Valve & Gauge/
Renew Valve & Machine Co.
CRANE Energy Flow Solutions
CWFC Farris Engineering
Dayton Precision Services
DMC Carter Chambers
Dowco Valve Company
Dresser, Inc. - Consolidated
Dresser, Inc. - Direct
Dresser, Inc. - Masoneilan
ECI/ICE Valve and Instrument Services
Emerson Process Management -
Fisher
Flotech, Inc.
Flowserve Corporation
Formosa Plastics USA
Furmanite
Gulf Coast Modification, LP
Gulf Coast Valve, Inc.
J&S Machine and Valve, Inc.
Kirksey Machine
Metso Automation
Midwest Valve Services, Inc.
The Wm. Powell Company
Precision Pump & Valve Service
Quality Valve
Southeast Valve Inc.
Southern Valve Service, Inc.
Thorco, Inc.
Tyco Valves and Controls
United Valve
Valve Reconditioning Service Co.
Wal-Tech Inc.
54
|
Editors Picks
ENERTECH, a business
unit of Curtiss Wright
Flow Control Company,
has developed an extend-
ed mission model to sup-
port nuclear plant cool
down during station black
conditions. Conventional
electrohydraulic, gas
spring actuators are lim-
ited to one directionfail
safe positioning of isola-
tion valves. Enertechs
advanced technology permits bi-directional, mid-position
cycling of throttling valves and dampers from stored ener-
gy for a 72-hour period or longer without dependency on
off-site power, emergency diesel generator power or air
supply. The space required to facilitate the stored energy
module is a fraction of that required by traditional air sup-
ply tanks and control panels used in early generation
nuclear plants.
ITT ENGINEERED VALVES introduces
the Fabri-Valve 33 PTA push-through
slurry valve, specifically designed to
withstand harsh slurry applications in
the mining industry. It incorporates pro-
prietary sleeve technology and a wide
body design, which increases the valves
life span in slurry applications.
The product has elastomeric seats
that have been engineered to provide the
highest degree of abrasion resistance and
chemicals compatibility. The valve seats
form a pressure boundary, allowing the
gate and actuation to be maintained
while under pressure, ultimately reducing
downtime.
METSO offers a new valve
design derived from their tra-
ditional V-port segment valve
series. The two-way-tight, sin-
gle-seat design is suitable for
numerous applications and is
available for R-series valves.
The optional two-way-tight
feature covers size ranges
from DN25 up to DN700 (1
up to 28) in all available
pressure classes.
The V-port segment valve series is designed to improve
process performance and reduce variability in control
applications. However, there are a lot of applications
where two-way-tight, on-off type performance is required.
The customer benefit of the new valve design is that it
offers the possibility of combining control and on/off per-
formance in a single valve assembly.
MUELLER CO., a
wholly owned sub-
sidiary of Mueller
Water Products, Inc.,
has expanded its prod-
uct line with the addi-
tion of the Hydro-
Guard brand of
automated flushing
systems. The system
uses modern technologies, including SCADA compatibility,
to monitor water quality in distribution piping and auto-
matically initiate flushing as necessary to maintain disin-
fectant residuals as required by the U.S. Environmental
Protection Agency. This system conserves water, reduces
chlorine consumption and improves customer satisfaction
by avoiding taste and odor, while requiring virtually no
supervision by utility personnel. On average, one Hydro-
Guard Automatic Flushing System can save as much as
180,000 gallons of water annually compared to traditional
hydrant flushing methods.
ASCO NUMATICS
has introduced the
8361 Series of stain-
less-steel pilot valves.
The series unique
design eliminates the
dormancy or sticking
problems that can
occur in control valves
installed in the pneu-
matic logic panels that
control monitoring
safety systems in off-
shore oil and gas production facilities. In addition, the
valve line was launched with online tools that permit rapid
product configuration and ordering.
The 8361 Series (-inch NPT, 3-way, 316L stainless
steel) valves are offered in manually operated, air-piloted
and solenoid-piloted versions. They can be configured as
breathing and non-breathing. The non-breathing version
isolates internal components from the atmosphere and is
Products
F a l l 2 0 1 1
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55
INDEX TO
ADVERTISERS
26 American Foundry
www.americanfoundry.com
1 ASCO
www.ascovalve.com/lowpower
41 AUMA Actuators
www.auma-usa.com
9 Badger Meter
www.badgermeter.com/valvefam27.aspx
53 Check-All Valve Mfg. Company
www.checkall.com
C4 Crane Energy Flow Control
www.craneflowsolutions.com
13 Curtiss-Wright Flow Control
Company
www.cwfc.com
5 Delta Centrifugal
www.deltacentrifugal.com
31 Farris Engineering
(a div. of Curtiss-Wright Flow Control)
http://farris.cwfc.com
C2 Flexitallic
www.flexitallic.com
23 Highland Foundry
www.highlandfoundry.com
25 Key Bellevilles
22 Kimray
www.kimray.com
52 Manufacturers Standardization
Society
www.mss-hq.com
19 Matrix Metals
17 Mazak Corporation
www.mazakusa.com
21, 27 The Wm. Powell Company
www.powellvalves.com
C3 Power Gen
www.power-gen.com
33 Reyco Valve
www.reycovalve.com
11 Rotork Controls
www.rotork.com
46 Scientific Linings & Coatings
www.weathercap.com
18 Solon Manufacturing Company
www.solonmfg.com
20 U.S. Alloys
www.usalloys.cc
29 United Valve
www.unitedvalve.com
24 UniTorq Actuators & Controls
www.senitec.com
53 Valve Repair Council
www.vma.org
2 Velan Valve
www.velan.com
internally vented, preventing contami-
nants such as salt and dust from enter-
ing the valve and corroding internal
components.
TYCO FLOW CONTROL has expand-
ed its Anderson Greenwood instrument
valve line to include the new M30
series primary isolation instru-
mentation root
valve. This large-
bore isolation valve
handles particularly
hostile environments and process-
es, including high temperatures
and pressures, while pro-
viding excellent seating
capabilities.
The M30 series includes single
block (M37), block and bleed (M38),
as well as double block and bleed
(M39) functions built into one compact
modular single valve body. This elimi-
nates the need for field assembly and
testing of conventional valve and fitting
stacks while reducing leak points.
These valves can be used in appli-
cations such as refineries, chemi-
cal plants, power
generating facilities
and at unconven-
tional petroleum
projects such as oil sand
production and high-pres-
sure natural gas shale-
field production.
FEATURED PRODUCTS
Specify
CamseaI
Zero Leakage Forged
BALL VALVES
for the worId's most
appIications.
ASME 900 through 4500, 1/2 thru 4 sizes,
for new construction and MRO. Brochure
available in hard copy or online.

SO Certified
PED Certified
World Headquarters
265 Field Road
P.O. Box 1049
Somers, CT 06071-1049
(860) 749-0761
Visit us today at ConvaI.com
A Great Addition to Your
Reference Library
Weve assembled 24 articles
from the pages of Valve Magazine
on the subject of ACTUATORS &
CONTROLS. Visit The VMA Store
at www.VMA.org to learn what
topics are included and how you
can order this collection!
Plusfor every 5 Actuators &
Controls compilations you
purchase, you will receive 1 free!
AT THE VMA STORE
Editors Picks
Editors Picks
56
|
GE recently
released the Con-
solidated 1900
Series Universal
Media Cryodisc
safety valve
option, one of the
products that were
part of GEs Feb-
ruary 2011 acqui-
sition of Dresser, Inc. Consolidated Valves patented Cryo-
disc technology, which deflects toward the nozzle to create
a seal tighter than other technologies when exposed to iso-
lated colder spots, helps reduce leakage of cryogenic fluids
and correct small leak paths. The technology helps cus-
tomers such as LNG processing facilities curb plant emis-
sions and cut maintenance costs when keeping liquids at
cryogenic temperatures.
The 1900 Series Universal Media Cryodisc safety valve
option uses a unique disc geometry that is specifically
geared toward the cryogenic application of leakage solu-
tions. It diminishes the amount of process fluid lost during
a valve leakage and ultimately reduces the potential need
for intervention by maintenance personnel.
FLOWSERVE announces the
availability of the Limitorque
QXM smart valve
actuator, which is
designed for rising
stem valve applica-
tions, including
choke valves and small
control valves in the upstream oil and
gas, water, fossil fuel and renewable
power markets.
This smart electronic valve actuator is available with
either 6.5 total turns or a maximum of 20 total drive
sleeve turns, which is especially important for small valves
that require limited travel and maximum control. In addi-
tion, the encoder employs system-on-chip technology,
which permits redundant, 12-bit resolution over 20 total
turns or an accuracy of less than two degrees of drive
sleeve rotation.
The QXM uses an innovative brushless direct current
voltage motor that is designed to meet most global voltage
requirements. This unique design helps eliminate sparks,
reduce mechanical and electrical noise, and dissipate heat
better than direct-current motors with brushes. The brush-
less motor is designed to last longer than conventional
motors and allows for more accurate positioning.
VICTAULIC offers Vic-Press, a
flame-free press system that
joins pipe in a matter of sec-
onds. Vic-Press, the
industrys first ANSI
Schedule 10S pipe-
sized press-to-con-
nect system
designed for
off-the-shelf
ASTM A-312
Schedule 10S stainless-steel
pipe, is an industrial-grade solu-
tion for quickly and reliably
joining small-diameter piping
systems. The system offers
increased strength, durability and improved flow charac-
teristics compared to light-wall tube systems as well as
safer, more efficient pipe assembly than welding, threading
and flanging. It meets or exceeds industry standards. Vic-
Press is used with standard Schedule 10S stainless-steel
pipe, which offers increased strength and durability and
eliminates the need to stock specialty pipe.
SPIRAX SARCO has released a new range of lift check
valves, LCV3 (Cast Iron), LCV4 (Carbon Steel), LCV6
(Stainless Steel) and LCV7 (SG Iron) suitable for most
industries. These check valves are designed for EN and
ASME standards, which can be used for a wide range of
applications. They use proven designs including a clamp-
in-place seat. The replaceable seat arrangement offers
quick and easy in-line maintenance, reducing plant down-
time.
The check valves help prevent reverse flow in pipelines
carrying most types of liquids, steam and gas. They protect
any item of equipment and prevent pressure surges associ-
ated with hydraulic forces such as water hammer. The
range is
fabricated
for horizon-
tal pipeline
installations
for arduous
applications
and pro-
vides higher
flow rates
compared
to existing
disc check
valves. VM
Products
Start building your reference library. Each
issue of Valve Magazine contains valuable
information that you can turn to again and
again. For the first time, VMA is offering this
special CD archive of indexed and searchable
issues for fast retrieval of information.
Ready to order today from The VMA
Store, located on www.VMA.org.
$149 per CD ($119 for VMA/VRC
members) + $3 shipping/handling
Valve
DIGITAL EDITION ARCHIVES
2000-2010
GET THE DIGITAL EDITION!
Go to ValveMagazine-digital.com
to view the entire magazine online,
with live links and searches
Also
BACK TO BASICS:
Solenoid Valves
Extreme Testing
Making SIL Simple
Hydraulic Actuators
And on ValveMagazine.com:
Canadian Oil Sands
TODAYS
PULP & PAPER
INDUSTRY
Wi nt er 2008
VOLUME 20, NO. 1
The Greening
of Process
Control
PLUS:
The Corn Rush is On!
Cold Facts about Cryogenic Valves
The Case for OEMCertified Repair
Advances in Mechanical Seals
PLUS: Five Years of Features
For information on joining the Valve Manufacturers Association, contact Bill Sandler at 202.331.8105 or wsandler@vma.org.
58
|
Allagash International
Portland,ME
www.allagashinternational.com
Allagash Valves & Controls
www.allagashvalve.com
Forbes Marshall
www.allagashinternational.com
Nor East Controls
www.noreastcontrols.com
American Cast Iron Pipe Co.
Birmingham, AL
www.acipco.com
American Valve, Inc.
Greensboro, NC
www.americanvalve.com
ASCO Valve, Inc. - Emerson
Industrial Automation
Florham Park, NJ
www.ascovalve.com
AUMA Actuators, Inc.
Canonsburg, PA
www.auma-usa.com
Automation Technology, Inc.
Houston
www.atiactuators.com
Babbitt Steam Specialty
Company
New Bedford, MA
www.babbittsteam.com
Harold Beck & Sons, Inc.
Newtown, PA
www.haroldbeck.com
Bernard Controls, Inc.
Houston
www.bernardcontrols.com
Cameron
Houston
www.c-a-m.com
Flow Control
Houston
Valves & Measurement
Houston
Check-All Valve Mfg. Co.
Des Moines, IA
www.checkall.com
Conval, Inc.
Somers, CT
www.conval.com
Cornerstone Valve
Houston
www.cornerstonevalve.com
Crane Co.
Stamford, CT
www.craneco.com/business/
crane_valves.cfm
Crane Energy Flow
Solutions
The Woodlands, TX
www.craneenergy.com
Crane ChemPharma
Flow Solutions
Cincinnati
www.xomox.com
www.resistoflex.com
www.saundersvalve.com
Curtiss-Wright Flow Control
Corporation
Falls Church, VA
www.cwfc.com
DeltaValve
South Jordan, UT
Enertech
Brea, CA
Farris Engineering
Brecksville, OH
Peerless Instrument Co.
East Farmingdale, NY
Tapco/Enpro
Houston
Target Rock
East Farmingdale, NY
DeZURIK
Sartell, MN
www.dezurik.com
APCO Willamette
Schaumburg, IL
www.apcovalves.com
DFT Inc.
Exton, PA
www.dft-valves.com
Eii Valve Company
Houston, TX
www.eiivalve.com
Emerson Process Management
Marshalltown, IA
EIM Company, Inc.
Missouri City, TX
www.eim-co.com
Fisher Controls
Marshalltown, IA
www.fisher.com
TopWorx
Louisville, KY
www.topworx.com
Valve Automation Division
St. Louis
www.emersonprocess.com/
valveautomation
Flowserve Corp.
Irving, TX
www.flowserve.com
Flowserve, Cookeville
Cookeville, TN
Flowserve, Springville
Springville, UT
Flowserve, Raleigh
Raleigh, NC
www.edwardvogt.com
Flowserve, Lynchburg
Lynchburg, VA
www.limitorque.com
Flowserve, Sulphur Springs
Sulphur Springs, TX
www.nordstromaudco.com
FluoroSeal Inc.
Montreal, Quebec, Canada
www.fluorosealvalves.com
Forum Energy Technologies -
Valve Solutions
Stafford, TX
www.f-e-t.com
GE Energy
Houston
www.ge-energy.com
Consolidated Safety Valves
and Safety Relief Valves
Masoneilan Control Valves
Regulation and Control
Groth Corporation
Houston
www.grothcorp.com
Hemiwedge Valve, Division of
Chromatic Industries, Inc.
Conroe, TX
www.hemiwedge.com
High Pressure Equipment
Company
Erie, PA
www.highpressure.com
Indelac Controls, Inc.
Florence, KY
www.indelac.com
ITT Engineered Valves
Lancaster, PA
www.engvalves.com
Kinetrol USA, Inc.
Plano, TX
www.kinetrolusa.com
Kingston Valves
Torrance, CA
www.kingstonvalves.com
Kitz Corporation of America
Stafford, TX
www.kitz.com
KOSO America, Inc.
West Bridgewater, MA
www.kosoamerica.com
Lined Valve Company, Inc.
Woodland, WA
www.knifegatevalves.com
Mastergear, Division of
Regal-Beloit Corporation
Clinton, WI
www.mastergearworldwide.com
McWane Valve and Hydrant
Group
Elmira, NY
www.mcwane.com
American RD Valve Co.
Anniston, AL
www.american-rd.com
Clow Valve
Oskaloosa, IA
www.clowvalve.com
Kennedy Valve
Elmira, NY
www.kennedyvalve.com
M&H Valve Co.
Anniston, AL
www.MH-valve.com
Metso Automation USA Inc.
Shrewsbury, MA
www.metsoautomation.com
Mikron Valve and
Manufacturer Inc.
Cranesville, PA
www.mikronvalve.com
Moog Flo-Tork, Inc.
Orrville, OH
www.flo-tork.com
Mueller Water Products
Atlanta
www.muellerwaterproducts.com
Anvil International
Portsmouth, NH
www.anvilintl.com
Henry Pratt Company
Aurora, IL
www.henrypratt.com
Milliken Valve Company
Bethlehem, PA
www.millikenvalve.com
Mueller Co.
Chattanooga, TN
www.muellerco.com/water
U.S. Pipe
Birmingham, AL
www.uspipe.com
PBM, Inc.
Irwin, PA
www.pbmvalve.com
Portland Valve
South Portland, ME
www.portlandvalve.com
Cincinnati
Process Development &
Control, Inc.
Coraopolis, PA
www.pdcvalve.com
QTRCO, Inc.
Tomball, TX
www.qtrco.com
Richards Industries-Valve
Group, Inc.
Cincinnati
www.jordanvalve.com
Roto Hammer Industries, Inc.
Tulsa, OK
www.rotohammerinc.com
Rotork Controls, Inc.
Rochester, NY
www.rotork.com
Flow-Quip, Inc.
Tulsa, OK
www.flowquip.com
K-TORK Actuators
+ Controls
Dallas
www.ktork.com
Rotork Controls
Canada Ltd.
Calgary, Alberta, Canada
Rotork Controls
Canada Ltd.
Mississauga, Ontario, Canada
Rotork Gears
Rochester, NY
Rotork Controls Providence
N. Kingstown, RI
www.rciactuators.com
VMA MEMBER
ROSTER
Go to www.vma.org for a complete list of VMA members
S u m m e r 2 0 1 1
|
59
Rotork Process Controls
Milwaukee, WI
www.jordancontrols.com
R.S.V.P. Actuators & Controls
Hempstead, TX
www.rsvpactuators.com
Samson Controls, Inc.
Baytown, TX
www.samsoncontrols.com
SMG Valves, a Unit of Southern
Mfg. Group, Inc.
Morrison, TN
www.smg-global.com
Spirax Sarco, Inc.
Blythewood, SC
www.spiraxsarco-usa.com
Spirax Sarco Canada Ltd.
Concord, Ontario, Canada
Townley Engineering &
Manufacturing Company, Inc.
Candler, FL
www.townley.net
Tyco Flow Control
Houston
www.tycovalves.com
UniTorq Actuators & Controls
Duluth, GA
www.unitorque.com
ValvTechnologies, Inc.
Houston
www.valv.com
Victaulic
Easton, PA
www.victaulic.com
Velan Valve Corporation
Montreal, Quebec, Canada
www.velan.com
Weir Valves & Controls-USA
Ipswich, MA
www.weirvalveusa.com
WEY Valve
Nettleton, MS
www.weyvalve.com
Associate Members
A.W. Chesterton
Groveland,MA
www.chesterton.com
All-Pro Fasteners, Inc.
Arlington, TX
www.all-profasteners.com
American Foundry Group
Bixby, OK
www.americanfoundry.com
Auge Industrial Fasteners
Houston
www.augeusa.com
BelleFlex Technologies, LLC
Freeport, PA
www.belleflex.com
Delta Centrifugal Corp.
Temple, TX
www.deltacentrifugal.com
Engineered Software, Inc.
Lacey, WA
www.eng-software.com
Enthone Inc.
West Haven, CT
www.enthone.com
The Flexitallic Group, Inc.
Houston
www.flexitallic.com
Garlock Sealing Technologies
Palmyra, NY
www.garlock.com
Grede Holdings LLC
Southfield, MI
www.grede.com
Harrison Steel Castings
Attica, IN
www.hscast.com
Highland Foundry Limited
Surrey, British Columbia, Canada
www.highlandfoundry.com
IMT Partnership
Ingersoll, Ontario, Canada
www.imtcorporation.com
John Crane Packing
Morton Grove, IL
www.johncrane.com
Key Bellevilles, Inc.
Leechburg, PA
Lone Star Fasteners
Spring, TX
www.lonestarfasteners.com
Matrix Metals LLC
Richmond, TX
NAMCO Controls
Elizabethtown, NC
www.namcocontrols.com
Quadrant EPP
Reading, PA
www.quadrantplastics.com
Scientific Linings & Coatings
San Antonio
www.weathercap.com
Solon Manufacturing Co.
Chardon, OH
www.solonmfg.com
VanAire, Inc.
Gladstone, MI
www.vanaireinc.com
Allied Valve
Chicago
www.alliedvalveinc.com
AVP Valve, Inc.
Lakeland, FL
www.avpvalve.com
Bay Valve Service, Inc.
Seattle
www.bay-valve.com
Cameron
Houston
www.c-a-m.com
CCI Houston (Repair Center)
Houston
www.ccivalve.com
CFM/VR-TESCO LLC
Elgin, IL
www.globalfield.net
Chalmers & Kubeck North
Westfield, MA
www.candknorth.com
Cleveland Valve & Gauge/ Renew
Valve & Machine Co.
Cleveland/Carleton, MI
www.clevelandvalve.com
www.renewvalve.com
CRANE Energy Flow Solutions
Houston
www.craneenergy.com
CWFC Farris Engineering
Brecksville, OH
www.cwfc.com
Dayton Precision Services
Dayton, OH
www.daytonprecisionservices.com
DMC Carter Chambers
Baton Rouge, LA
www.dmc-cc.com
Dowco Valve Company
Hastings, MN
www.dowcovalve.com
Dresser, Inc.
Addison, TX
www.dresser.com
Dresser Consolidated
Alexandria, LA
Dresser Direct
Deer Park, TX
Dresser Masoneilan
Avon, MA
ECI/ICE Valve and Instrument
Services
Monessen, PA
www.service-solution.com
Emerson Process Management -
Fisher
Marshalltown, IA
www.fisher.com
Flotech, Inc.
Jacksonville, FL
www.flotechinc.com
Flowserve Corporation
Houston
www.flowserve.com
Formosa Plastics USA
Point Comfort, TX
www.fpcusa.com
Furmanite
LaPorte, TX
www.furmanite.com
Gulf Coast Modification, LP
Houston
www.gulfcoastmod.com
Gulf Coast Valve, Inc.
Corpus Christi, TX
www.gulfcoastvalve.net
J&S Machine and Valve, Inc.
Nowata, OK
www.jsmachineandvalve.com
Kirksey Machine
Houston
www.kirkseymachine.com
Metso Automation
Shrewsbury, MA
www.metso.com
Midwest Valve Services, Inc.
Minooka, IL
www.mwvalve.com
Cincinnati
Precision Pump &
Valve Service
Charleston, WV
www.ppvs.com
Southeast Valve Inc.
Charlotte, NC
www.sevalve.com
Southern Valve Service, Inc.
Baton Rouge, LA
www.southernvalve.com
Thorco, Inc.
Tulsa, OK
www.thorcoinc.com
Tyco Valves and Controls
Stafford, TX
www.tycovalves.com
United Valve
South Houston
www.unitedvalve.com
Valve Reconditioning
Service Co.
Melvindale, MI
Wal-Tech Inc.
Mobile, AL
www.wal-tech.com
V RC A S S O C I A T E ME MBE R
Quality Valve
Mobile, AL
www.qualityvalves.com
For more information, contact
Marc Pasternak at 202.331.0104
(mpasternak@vma.org).
For information on joining the Valve Manufacturers Association, contact Bill Sandler at 202.331.8105 or wsandler@vma.org.
MEMBERS OF THE VALVE REPAI R COUNCI L An affiliate of the Valve Manufacturers Association of America
C O N V E R S A T I O N W I T H
A
lthough this years Market Outlook had its share of gloomy
news regarding international economic woes, a bright spot
in many of the speakers comments was India. That country,
which did not have nearly the magnitude of problems during the
Great Recession as the rest of the world, has seen consistently
large year-over-year gains in the last decade and a half as it has
learned to deal with the major economic reforms that began in
the early 1990s.
The country now has one of the highest Gross Domestic
Product (GDP) growth rates on the globe (about 7.5% to 8% at
the time of the market outlook), with a strong demand for flow
control and a current market of about $2 billion in valves,
according to outlook speaker Ravi Krishnan, president of Krish-
nan and Associates.
Krishnans company is a technical and energy consulting
firm located in the U.S. that specializes in helping countries
here with their dealings in major Indian industries such as
power and infrastructure. Krishnan himself was born in India,
though he has made his home here in the U.S. for the last 20
years.
According to Krishnan, the growth that has occurred in his
native country has not been without its challenges.
For example, India still deals with infrastructure prob-
lems, Krishnan explained. There are many regions that are
very well developed with manufacturing activities running
smoothly. But there are other parts of the country with short-
ages of labor, power supplies and other essential commodities
needed for a successful business operation, he adds. Finding
skilled labor or contractors skilled in western standards to exe-
cute a job can also be a challenge, as can finding the right
equipment, he said.
Still, in the six years since starting his consulting business,
he says an enormous change has occurred in the business world
and that change permeates the Indian culture.
The Indian entrepreneur of today is lot different than the
businessman of the 1990s. Todays companies have access to
capital, knowledge of the technology, access to resources, and
they have learned to do business in a global environment,
Krishnan says.
That is a critical development for anyone who wants to do
business there because to be successful as an outsider requires
forming good partnerships and cooperative arrangements with
people and companies on the inside, he points out.
OTHER CHALLENGES
One of the reasons good partnerships are so critical is price sen-
sitivity within Indias borders, Krishnan says. The government
and industry in general have a high focus on low capital costs,
even if it means moderately higher life-cycle costs, Krishnan
explains. Competition for technology is tough in India so sup-
pliers to the Indian industry may have to either set up opera-
tions in low-cost regions of the world such as Viet Nam or
China or try to manufacture the products or most of the compo-
nents of the products in India itself, he said.
However, it does not mean
quality isnt important or is not
receiving increased attention as
the country learns the hard les-
sons that come from buying
cheaper products and finding
out how unsafe they can be or
how expensive short life cycles
can be.
Today, you can go into that
country at higher prices if you have a premium product, but it
has to have demonstrable value, he said. In the case of valves,
that translates into efficiency or performance improvements
over standard commodity valves.
But this value also needs strong intellectual property (IP)
protection.
Products that come into India that dont have a strong IP
position could easily be reverse engineered, he said. At the
same time, Krishnan pointed out that the country has come a
long way in this area. There has been a lot of progress in rela-
tion to IP issues in Indias court system, though damages
awarded there might not be as high as in western markets,
Krishnan says. The country has aligned itself with the World
Intellectual Property Organization and has patent offices in its
major cities with a system design to protect both domestic and
foreign technologyall of which are positive trends towards
enforcement of stronger IP situations, he said.
Finally, a requirement for success in India is learning to rec-
ognize cultural issues with respect to the working environment.
For example, in a small village, if there is a safety or envi-
ronmental incident at a plant site, its likely to start a riot if a
person is hurtthese issues could delay project schedules and
construction activity, Krishnan says. The country feels strong-
ly about its communities, local customs and labor relations.
For all of these reasons, its a good idea to enter the country
through a joint venture, a licensing arrangement, an agency rela-
tionship or some other form of collaborative partnership with
parties that know how to deal with local manufacturing issues,
personnel issues, sales and marketing issues, plant siting or con-
struction or project management issues, he concludes. VM
GENILEE PARENTE is managing editor of Valve Magazine. Reach her at
gparente@vma.org.
Ravi Krishnan on
Doing Business in India
You can go into
[India] at higher
prices if you have a
premium product,
but it has to have
demonstrable
value.
60
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The NEW Technical Paper TP-410 is a technical resource for engineers, designers and
engineering students that explains the flow of fluid through valves, pipe and fittings to
aid in the appropriate selection of equipment for piping systems.
The 2009 edition marks the introduction of a companion website containing a suite of
web-based tools that solve equations found within the paper.
Expect more from us.
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