Valve Magazine Spring 2008

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Spring 2008
V O LU M E 2 0 , N O. 2
Who
Makes
What?
PLUS:
Howand Why
to Build an AML
BACK TO BASICS:
40 Product Types, Control Systems
Pipeline
75 Manufacturers Actuation
A Special Excerpt from the Special Needs,
North American Valve Catalog Special Designs
Automated Valve
Packages
VM_SPR08.qxd:VM_FALL06.qxd5 4/7/08 10:01 PM Page C2
WED LIKE TO GIVE YOU A HAND.

The upper one.
Introducing the total static sealing solution.
Thermiculite
Innovative. Versatile. Complete.
To receive your free Thermiculite information package,

visit www.thermiculite.com or call
US 281.604.2400
UK 44.1274.851.273
CIRCLE READER RESPONSE #26
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FEATURES
Spring 2008
Valve
V O LU M E 2 0 , N O. 2
BACK TO BASICS: M A G A Z I N E
CONTROL SYSTEMS
The author first wrote about control valves in a Back to C O L U M N S
12
Basics article last summer. Now he expands on that topic by
discussing other elements of the cruising control system. Perspectives 3
BY JIM CASEY
An Industry Priority: Education and
Training
SPECIALIZED DESIGNS FOR

BY BILL SANDLER
PIPELINE VALVE ACTUATION Beyond Valves 54

The expansion of oil and gas production into increasingly Putting the P in PVF
22
remote and inhospitable areas challenges actuator BY GREG JOHNSON
manufacturers to produce rugged, reliable and often
specialized products. Maintenance & Repair 56
BY MARK CLARK PSV Inspections
BY BART COLLINS
BUILDING AN Materials Q&A 60

ACCEPTABLE Evaluating Portable Hardness Testers
MANUFACTURERS LIST
34
BY DON BUSH
Whats involved in developing an Acceptable

Manufacturers List (AML)? And why is having an AML The Last Page 68
so critical when sourcing valves from China? Alternative Energies a Big Draw at
BY PATRICK A. TOENSMEIER VMA Seminar
BY JUDY TIBBS
AUTOMATED
D E P A R T M E N T S
VALVE PACKAGES
Advanced controllers have revolutionized automated valve Industry Capsules 4
40
packages by offering greater intelligence and diagnostic
data than conventional methods. VMA Calendar 5
BY JACK DIFRANCO
Index to Advertisers 68
SPECIAL VALVE CATALOG PREVIEW:

COVER PHOTOGRAPHY BY GREG JOHNSON
WHO MAKES WHAT?

NEW
PRODUCTS 62
The 8th edition of North American Valve Catalog is now
47
available, both in print and online. Included in this special
preview from the catalog is the VMA Member Product
Matrix, where you can find out who makes what from 75
companies that manufacture valves, actuators and controls.
FOCUS:
Offshore Oil
and Gas
Now you can subscribe to
CASE STUDY:
VALVE MAGAZINE online Double Block-
and-Bleed
Go to www.ValveMagazine.com Valves in an
and click on this banner Oil Refinery
Free to qualified individuals

in the U.S. and Canada.
A World Leading Valve

Product Range
Fossil & Nuclear Power

Oil & Gas
Refining &
Petrochemicals
Chemicals
Pulp & Paper
LNG &
Cryogenics
Marine
Mining
HVAC
Water &
Wastewater
low emissions
easy maintenance
long, reliable service
www.velan.com
VELAN INC. 7007 Cte de Liesse,

Montreal, QC, H4T 1G2, Canada
Tel: (514) 748-7743 Fax: (514) 748-8635
P E R S P E C T I V E S
Valve An Industry Priority:

MAGAZINE
www.ValveMagazine.com
Education and Training
E D I TO R I A L R E V I E W B OA R D
have been involved with the valve industry for more than 30 years and cant
Richard D. Oaks
AUMA ACTUATORS, INC.
I ever recall a time when there was a more pressing need for industry education
and training. The need exists at all levels of the industry, from new employees in
Laurence Stratton companies that produce valves, actuators and controls, to personnel in plants,
CCI
and students exploring careers in trade schools, colleges and universities. A
Mike Hendrick recent presentation by Dr. Edward Gordon at VMAs Leadership Forum was
CONVAL, INC.
titled 2010 Meltdown and dealt with the declining labor forceespecially in
John Wells the manufacturing sector of our economy. He shared what many communities are
EMERSON PROCESS
MANAGEMENT doing to entice high school students into the trades.
As an association, VMA has recognized its role in leading the way with
Ed Holtgraver
QTRCO, INC. education and training programs for our industry and has made expanding such
programs a priority for 2008 and beyond. In addition to the education programs
Christopher Warnett
ROTORK CONTROLS, INC. we have made available to our membership, we see a need to develop industry
education and training for the many newcomers to the industry who will be
Charlie Marcum
TOPWORX replacing the experienced personnel we are losing to retirementnot only new
hires at valve companies but groups such as end users, distributors and students.
Dan Velan
VELAN VALVE The VMA Board of Directors recently approved the formation of an
Education & Training Committee comprised of training professionals from eight
member companies. Serving as liaison to the committee will be VMA
VALVE MAGAZINE (ISSN No. 1057-
2813) is the official magazine of the communications consultant and Valve Magazine editor Judy Tibbs. By the time
Valve Manufacturers Association of you are reading this column the committee will have had its first official
America (VMA) and is published quar-
terly by VMA, located at 1050 17th meeting and begun work on the first product.
Street NW, Suite 280, Washington, DC In the past we have presented such well-received programs as the Valving
20036-5521; 202.331.8105; Fax:
202.296.0378. 101 slide show and the Valve Actuation Seminar. We will use these programs as
a starting point for our new initiative, working with the committee and other
Advertising queries: 540.374.9100.
Periodicals postage paid at Washington, members to update and expand editorial content. Were also in the process of
D.C., and at additional mailing offices. determining what formats will be of most use. Web-based training? PowerPoint
POSTMASTER: Send address changes presentations? Trainers going into plants? Basics seminars held at various
to VALVE MAGAZINE, P.O. Box 1673 locations? What do you think would best serve the industry? Please feel free to
Williamsport, PA 17703-1673.
contact me at wsandler@vma.org or Judy Tibbs at jtibbs@vma.org with your
Subscriptions are free to qualified read- thoughts and ideas, and well share your comments with the VMA Education &
ers in the United States and Canada;
$36 per year to unqualified readers in the Training Committee.
United States and Canada; $50 per year Well update you on the progress being made on this initiative in future issues
for all subscribers outside the United
States and Canada. Statements of fact of this magazine. VM
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 Bill Sandler
of VMA. Materials may not be repro-
duced in any form without written permis- President
sion of VMA. Valve Manufacturers Association of America
Copyright 2008. All rights reserved.
www.vma.org
Spring 2008 | 3
D U S T R Y C A P S U L E S
IN
A BUSY QUARTER FOR ROTORK CONTROLS cally and pneumatically actuated block valves on duties
Rotork Controls LLC has had a busy first-quarter in 2008 including ESD (Emergency Shutdown), BDV (Blow Down),
with two major acquisitions and a name change for its Jor- HIPPS (High Integrity Pressure Protection) and SSIV (Sub
dan Valve division. Sea Isolation).
In February, Rotork acquired Remote Controls Sweden The technology, which Rotork has sold through its Fluid
AB (RCS), a designer and manufacturer of valve actuators Systems Division for a number of years, has been proven
based in Falun, Sweden. beneficial to the partial closure testing of valves in locations
Peter France, Group Chief Operating Officer of Rotork, as disparate as Sakhalin Island and Saudi Arabia.
said, RCS will sit within Rotorks expanding Fluid Power Finally, the company has renamed Jordan Controls,
division and provide it with a range of additional comple- Rotork Process Controls (RPC). RPC will be an independent
mentary products, for both existing and new international group within the Controls division encompassing ex-Jordan
customers, which will be sold through Rotorks worldwide products as well as CVA.
network of sales offices. This new venture allows us to leverage the best from all
In addition, Rotork recently purchased from Drallim of our operations, said newly appointed Managing Director
Industries Limited its Drallim SVM (Smart Valve Monitor- Derek Olson. In transitioning from Jordan Controls to
ing) partial stroke valve testing product. The SVM system is Rotork Process Controls we will grow the company in a
used throughout the world to assist in the testing of hydrauli- world-wide setting.
MARKET FOCUS: Petroleum Refining

Planned Turnarounds to Jump in Coming Years
Although the number of planned unit maintenance constraints and declining profit margins, the industry had
shutdowns in the North American Petroleum Refining been seeing a downward trend in turnarounds. In fact,
Industry has been decreasing in recent years, thats notes Industrial Info, some maintenance projects were
expected to change with significant increases beyond being delayed or rescheduled because of labor shortages.
2008, according to research conducted by Industrial Info Most of the upcoming maintenance work at refineries
Resources (www.industrialinfo.com), based in Sugar will focus on: crude, vacuum distillation, sulfur recovery
Land, TX. At the end of 2006, the research firm was units, reformers, HF alkylation, SF alkylation, fluid
tracking 257 units that had plans to be taken offline for catalytic cracker units and delayed cokers. These projects
maintenance, repair and overhaul. But for 2008 and have construction kickoff dates ranging through the first
beyond, Industrial Info reports a total of 1,282 planned quarter of 2013.
turnarounds. Refineries
across the continent are
increasing refining
capacity and improving
unit efficiencies by
planning a large number
of unit additions,
expansions and upgrades.
During the past year,
Industrial Info has
reported 622 Petroleum
Refining projects with a
total investment value
(TIV) of about $64.6
billion.
What with labor
4 | Valve M A G A Z I N E
CALENDAR
2008
MAY
5-8
ZY-TECH BECOMES GLOBAL FLOW TECHNOLOGIES Offshore Technology Conference
Zy-Tech Global Industries has changed its company name to Global Flow Reliant Center, Houston
Technologies (GFT). In conjunction with the name change GFT is launching www.otcnet.org
a series of new product and service offerings that demonstrate the 20-23
companys growth from its oil and gas roots to todays position as a global NPRA Reliability & Maintenance
provider of industrial valve solutions. Conference & Exhibition
In addition to the name change, the DSI and PBV divisions are being Henry B. Gonzalez Convention Center,
separated from the legacy Zy-Tech business as individual operating San Antonio
www.npra.org
companies, while a Corporate Engineering and Sourcing Services group has
been established to deliver on Global Flow Technologies commitment to JUNE
continue to deliver unmatched reliability and operational performance for its 8-12
customers. ACE 08The Worlds Water Event
Weve been evolving and growing over the last few years, and its time Georgia World Congress Center, Atlanta
to update our corporate identity, said Steve Twellman, President and CEO www.awwa.org
of Global Flow Technologies. Many of our customers rely on our well-
AUGUST
known DSI and PBV brands, and we want them to realize we have greatly
expanded our engineering, delivery and support capabilities by acquiring two 14-15
fine companies ABZ Valves and Controls, and Quadrant Valve & VMA Market Outlook Workshop*
Renaissance Boston Waterfront, Boston
Actuator to complement our offerings. www.vma.org
For more information, visit GFTs website at www.globalflowtech.com.
OCTOBER
14-16
TYCO SELLS INFRASTRUCTURE SERVICES TO AECOM ISA Expo 2008
Tyco International Ltd. announced that it has entered into a definitive Reliant Center, Houston
agreement to sell substantially all of its Infrastructure Services business to www.isa.org
AECOM Technology Corporation for approximately $510 million. 18-22
Infrastructure Services, which operates under the name Earth Tech, Inc., WEFTEC.08
provides consulting engineering, construction management and operating McCormick Place, Chicago
www.weftec.org
services for the water, wastewater, environmental, transportation and
facilities markets. The business had revenue of $1.3 billion in 2007 and 23-26
employs 7,000 people around the world. VMA and VRC Annual Meetings*
Loews Ventana Canyon Resort, Tucson
www.vma.org
SPIRAX-SARCO ACQUIRES FLEXICON NOVEMBER

Spirax-Sarco Engineering plc has agreed to acquire the entire issued share 4-6
capital of Flexicon A/S, based in Denmark. The transaction includes full Valve World
ownership of Flexicons distribution company for the U.S., Flexicon America MECC Maastricht, The Netherlands
Inc. Completion, which will likely take place by the end of February, is www.valve-world.net
subject to routine closing conditions. The acquisition is expected to provide a
DECEMBER
benefit to the companys earnings per share from 2008.
2-4
Power-Gen 2008
Orlando
ENPRO OBTAINS SINFLEX SEALING TECHNOLOGIES www.powergen.com
EnPro Industries has acquired the assets of Sinflex Sealing Technologies,
a distributor and manufacturer of industrial sealing products, located in *These meetings are open only to
Shanghai, China. The operation will do business as Garlock Sealing VMA/VRC members. To receive additional
Technologies (Shanghai) Co. Ltd. and will be operated by Garlock Sealing information on VMA meetings, visit
Technologies, an EnPro Industries company. Sinflex has been Garlocks www.vma.org and click on the Events
principal distributor in China for more than 10 years and in recent years has link.
expanded its manufacturing operations.
Spring 2008 | 5
Valve IN D U S T R Y C A P S U L E S
MAGAZINE
CELEBRATIONS improvement in the art.
It must be worth its price, making it a
S TA F F TYCOS YARWAY TURNS 100 profitable investment for the user.
PUBLISHER
When the Simplex Engineering Company The margin between manufacturing cost
William S. Sandler later to become the Yarnall-Waring and selling price must be sufficient to per-
ASSOCIATE PUBLISHER/
Company and eventually Yarway mit vigorous advertising and sales repre-
EDITOR-IN-CHIEF Corporationwas established, the founders sentation and to render necessary assis-
Judy Tibbs were young men who, by Quaker tradition tance in the field to guarantee user
ASSISTANT EDITOR
and training, believed that a business should satisfaction.
Chris Guy do more than produce profits for the owners.
COPY EDITOR
According to Robert Yarnalls written To learn more about the origins of the
Genilee Parente account, the decision to start the Yarway Yarway brand, visit www.tycoflowcontrol-
valve business was made on a warm Sunday na.com and click on the News section.
afternoon in 1908 as he and Bernard
ART DIRECTOR/
PRODUCTION MANAGER
Michelle Wandres Waring, childhood friends, stopped to rest RICHARDS INDUSTRIES

ADVERTISING DIRECTOR
during a walk along Crum Creek in REACHES SAFETY MILESTONE
Sue Partyke Philadelphia, PA. At that time, Yarnall was Employees and management of Richards
working as an engineering assistant and Industries have achieved more than 2.5 mil-
Waring was a traveling salesman for other lion hours worked without a lost-time claim,
How to Contact
private-owned companies. where an employee is off work for more than
VALVE MAGAZINE
And the rest, as they say, is history. The seven days due to injury. The company
EDITORIAL OFFICES company flourished in the decades to follow employs 125 associates and utilizes many
7000 Radford Drive
Fredericksburg, VA 22407
and in 1987 Keystone International pur- safety practices supported by the Ohio
phone: 540.785.8901 chased Yarway Corporation. Then in 2001, Bureau of Workers Compensation.
fax: 540.785.8903 Tyco International purchased Keystone Inter- Richards formed a safety committee com-
email: jtibbs@vma.org
website:
national. Today, 100 years later, Tyco/Yarway prised of employees from several areas of the
www.ValveMagazine.com still adheres to Waring and Yarnalls early organization. The committees efforts have
discussions in which the two decided: helped to develop a safety culture across the
The product must be needed and perform organization by conducting regular depart-
ADVERTISING SALES
Sue Partyke
1101 Caroline Street better than anything else being offered. mental safety checks that ensure safety pro-
Suite 200 There must be an engineering reason cedures are being followed and eliminate
Fredericksburg, VA 22401
phone: 540.374.9100 for its superiority, representing a distinct potential hazards.
fax: 540.374.9265
email: suepartyke@cs.com
CIRCULATION/SUBSCRIPTIONS
phone: 570.567.1193 CAMERON RECEIVES SUBSEA

fax: 570.320.2079 SYSTEMS CONTRACT
email:
valve@PublishersServiceAssociates.com Cameron has been awarded a contract with an ini-
NEW PRODUCTS, MEDIA &
tial value of approximately $650 million to provide
INDUSTRY NEWS subsea systems for the initial phase of Totals Usan,
Chris Guy
phone: 540.785.8901
a 44-well subsea development project offshore
fax: 540.785.8903 Nigeria.
Under the contract, Cameron will provide sub-
sea systems engineering and project management,
ARTICLE SUBMISSIONS
VALVE MAGAZINE
welcomes articles, proposals, along with subsea Christmas trees, production and
manuscripts, photographs, and intervention control systems, manifolds, flowline connection systems, installation support and
ideas from our readers. For a
copy of the magazines Authors associated spares for Totals Nigerian subsidiary, Elf Petroleum Nigeria Limited. The agree-
Guidelines, contact Judy Tibbs, ment also includes provisions for additional revenues of approximately $2 million per well asso-
editor-in-chief, at jtibbs@vma.org ciated with installation and commissioning support over the life of the contract. Initial equip-
or call 540.785.8901.
ment delivery and installation is slated to begin in the first quarter of 2009, with additional
deliveries of subsea trees and associated equipment to continue through 2012.
Safe and Reliable

DCU Equipment
With a reputation for innovative technology,
DeltaValve offers a full line of safe and reliable
equipment for the delayed coking industry
worldwide.
- coke-drum bottom and top unheading devices

- isolation valves
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- auto-switch coke cutting tools
- drill stem guides/blow-out diverters
For more information about our safe and reliable

products for the DCU call 1-888-DeltaValve, or
visit our website at www.deltavalve.com

IN OFFSHORE, REFINING AND WATER EVENTS SLATED FOR SPRING
Its springand that means trade shows are popping up effective maintenance organization, productivity, equipment
around the country, offering education and exhibitions for reliability, health and safety, training, environmental control,
industries from offshore technology to petroleum refining to predictive/preventive maintenance, maintenance and
water/wastewater. And while the industries vary, they have engineering standards, inspection, procurement and
this in commonvalves, actuators and controls play critical innovative reliability technology. Visit www.npra.org to
roles in their success. register or for additional information.
OTC.08The Offshore Technology Conferencewill take ACE08, to be held at the Georgia World Conference Center in
place in Houston, May 5-7, at the Reliant Center. And if you Atlanta, GA, June 8-12, will host the worlds water communi-
havent already made your hotel reservations, good luck! ty. The future of safe water, cutting-edge research and best
Youll be joining nearly 70,000 worldwide E&P professionals practices, and a close-up look at the latest products and serv-
expected to attend the worlds premier event for the ices are all on the agenda.
development of offshore resources in the fields of drilling, The event, sponsored by the American Water Works Asso-
exploration, production and environmental protection. ciation, will feature an exposition with more than 500
More than 2,000 companies will be exhibiting at this exhibitors offering products and technologies from valves to
mega-event, including many VMA members, who will be dis- pipes, meters to hydrants, and much more. In addition, 90
playing valves, actuators, controls and related equipment. In educational sessions, comprised of more than 500 presenta-
addition, OTC will feature more than 300 presentations cover- tions, will be given by experts in the water industry, along with
ing the latest topics, technologies and innovations in todays 14 in-depth workshops. Find out more at www.awwa.org.
exploration and production industry. For more information on
OTC.08, visit www.otcnet.org.
Visit San Antonio, TX, May 20-23 to attend the 2008 NPRA
Reliability & Maintenance Conference and Exhibition at
the Henry B. Gonzalez Convention Center. Sponsored by the
National Petrochemical & Refiners Association, the three-day
program includes keynote addresses, technical and
management presentations, discussion groups, Q&A sessions,
and an exhibition of products and services.
Presentations will focus on improving reliability in the
refining and petrochemical industry, including topics such as
PEOPLE IN THE NEWS

BVAA the British Valve & Actuator Association has while, Bob Paul, who was District Manager for Distributed
named as its chairman Bill Whiteley, CEO of Rotork Controls. Valves Industrial Sales Northeast Territory, has moved to
Whiteley has served as a vice chairman for the past 15 years. Houston to assume the role of National Sales Manager, Dis-
He follows David Caines who was active in the BVAA for 30 tributed Valves-Industrial.
years, and had served as BVAA chairman for the past six years.
Rotork named Alex Busby Managing Director of
The Wm. Powell Company named David Brandy Rotork Fluid Systems, the specialist designer and manufac-
Cowart Executive Vice President. Cowart will continue to be turer of pneumatic, hydraulic and associated heavy-duty
accountable for Powells global sales and marketing growth, pipeline and process valve actuators within the Rotork
in addition to his new areas of responsibility. Group. As Managing Director of Rotork Fluid Systems, Alex
Cameron announced that Leon Brooks, who had been replaces Peter France who has been promoted to Managing
serving as Cameron Valves & Measurements National Sales Director of Rotork Controls and Rotork Group Chief Operat-
Manager for Distributed Valves-Industrial, has been ing Officer, and who will become Group Chief Executive Offi-
appointed Director of Sales for Distributed Valves. Mean- cer in May 2008.
Anderson Greenwood
Anderson Greenwood
Tyco Flow Control -
Instrumentation providing innovative solutions to
Biffi the most challenging applications
Cash Valve
Century Valve
Clarkson
Crosby
Dewrance
Fasani
FCT
Gulf Valve
Hancock
Hindle
Hovap
Intervalve
Keystone Finding answers to your flow control Our products are used widely
needs has never been easier. Thats throughout demanding markets
KTM
because Tyco Flow Control including oil production and refining,
Kunkle produces solutions for just chemical and petrochemical,
about any flow control pharmaceutical, food and
L&M Valve
problem in virtually any beverage, gas, water, marine and
MCF industry. shipbuilding, and allied industries.
Morin With the strength and experience When you add an unmatched
NeoTecha of over 90 individual brands, commitment to R & D and the most
we offer a level of expertise that extensive distribution and service
Penberthy is second-to-none in providing network in the industry, you get a
Prince innovative solutions to your most complete package providing a single
challenging flow control source for your total flow control
Raimondi applications. needs.
Rovalve
Sempell Total Flow Control Solutions
Vanessa www.tycoflowcontrol.com
Varec
Westlock
Yarway
Flow Control

IN
VMA NEWS
ROSTER GROWS WITH THREE NEW MEMBERS
Fenner Advanced Sealing Technologies, Lined Valve Company and Roto Ham-
mer Industries, Inc. are the latest companies to join the Valve Manufacturers
Association of America.
Lined Valve Company, Inc. manufactures knife gate valves, slide gate
valves, manual hand wheels, bevel gears, pneumatic and hydraulic cylinders
for the wastewater, mining, power, pulp and paper, and food industries. Learn
more about the Woodland, WA-based manufacturer at
www.knifegatevalves.com.
Since 1959 Roto Hammer Industries, Inc., based in Tulsa, OK, has been
providing chain and hand-operated manual valve actuators and impact opera-
Coming Soon! The all new
tors, as well as extension control systems, floor stands and gear operators for ValveMagazine.com
manual valves serving the worldwide petrochemical, power, nuclear, water and Original content
wastewater industries. For more information, visit www.rotohammerinc.com.
Industry News
Fenner Advanced Sealing Technologies (FAST-Houston) is VMAs
newest supplier member. The companies two divisions, CDI Seals and EGC Industry Blog
Plastics, design, manufacture and process high-performance seals, packing, Digital version of
fluoropolymers and other high-performance resins. For more information, Valve Magazine
visit the companys website at www.cdiseals.com.
$/7(51$7,9(9$/9(6IRU$/7(51$7,9()8(/6
American Valves 4000 Series meets the challenges presented

by ethanol and biodiesel processes while offering savings over other
valves normally used in refining operations.
By combining a patented Teflon fused solid ball and the same end-to-end
dimensions as any gate valve, the 4000 Series provides an ideal alternative
to gate, plug, butterfly, and even carbon steel ball
valves. Thousands of end-users and distributors
have discovered our quality without compromise
in a wide range of industries and applications. www.americanvalve.com
1.800.645.0101
E20001-F170-P710-X-7600
Meet the worlds smartest

valve positioner.
Valve positioning plus on-line diagnostics with SIPART PS2.
Visit us at the
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April 2125, 2008
Hall 9, Booth A 72
w w w. s i e m e n s . c o m / h a n ove r- f a i r
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The intelligent positioner SIPART PS2 is your first choice when it comes to precision control of valves in
different industries. As a diagnostic specialist in our Sensor Systems portfolio, it will support you with
security process control, so you are always in the picture regarding valve status. Ensured cost efficiency
through less maintenance and reliability in emergency situations. One of the many benefits of this
positioner is the Partial Stroke Test (PST), a very useful method of detecting possible faults or failing
of on-off-valves. More information: www.siemens.com/sipartps2
Setting standards with Totally Integrated Automation.
Answers for industry.

CONTROL
Back to
BASICS: SYSTEMS
THE SUMMER 2007 ISSUE OF VALVE MAGAZINE CONTAINED A
BACK TO BASICS ARTICLE ON CONTROL VALVES. HERE,THE
AUTHOR EXPANDS ON THIS THEME BY ADDRESSING CONTROL
SYSTEMS. BY JIM CASEY
hile the control valve is the final
W control element of a control
system that directly affects the
process, there may be other devices
for final control, depending upon the
variable that is controlled. Examples
include a variable speed pump or a
roller in a rolling mill. The other ele-
ments of a control loop are the
process sensor, the process controller
and the setpoint input (see Figure 1,
page 14).
The Basic Feedback

Control Loop
Figure 1 represents a system intended
to keep a constant downstream pres-
sure regardless of variable load on the
pump. The example illustrates that if
the system is not demanding flow,
product is recirculated back to the
tank to keep the pump from running
back on its curve.
The pressure is measured by the
pressure transmitter (PT). The con-
troller (PC) compares the measured
value to the setpoint, and sends a
position signal to the final control ele-
ment (PCV) so that the process value
and the setpoint value become the
same. As engineers, we can observe
many control loops in our plant envi-
ronment. Sometimes the components
of the control loop are scattered
throughout the plant, making it diffi-
cult to experience how they all work
together.
One control loop that can be expe-
rienced without much difficulty is the
Technology has changed.

The way we treat customers hasnt.
Remember the days of in-stock product, respon-
sive turnarounds on quotes, and people who have
been in the industry for most of their careers? Stop
reminiscing and call Remote Control. We ship
orders on average within two weeks. A real
person answers the phone so you are quickly
connected with someone to answer your questions
and prepare your quote within 24 hours. And,
most of the team working on your behalf has over
twenty years in the valve automation industry. That
said, weve also taken advantage of the enhance-
ments that technology has brought to our industry.
But its our people and old-fashioned business val-
ues that really make the difference.
REAL GOOD PRODUCTS. | REAL GOOD PEOPLE.
P N U E M AT I C A N D Call (401) 294-1400

ELECTRIC
A C T U AT O R S to start being treated like
the valued customer you are.
TORQUE
RANGES UP TO
1 MILLION IN/LBS
MOUNTING SERVICES
AND ACCESSORIES
Visit our website

for complete product
information.
www.rciactuators.com

B A C K T O B A S I C S : C O N T R O L S Y S T E M S
ator coupled to the throttle plate. The

throttle plate is no more than the auto-
motive equivalent of the butterfly valve.
If you rest your foot lightly on the accel-
erator, you can feel the control system
modulating the position of the throttle
in response to the rise and fall of the
road. When you start uphill and the sys-
tem senses the car slowing, it opens the
throttle. When you start down the other
side of the hill and the car gains speed,
the system closes the throttle. When it
all works properly, the speed variance is
too small to notice (see Figure 2, page
16).
Automotive Cruise Control

All the components of a control loop can
Figure 1 be scattered around the plant, or they
can be combined into one device. A
pressure regulator measures the pres-
cruise control in your vehicle. The to a black box and is compared to the sure by the force against the bottom of
process sensor is usually a magnetic remembered frequency from when you the diaphragm and compares it to the
sensor that infers vehicle speed by the hit the set button. The black box setpoint, which is the spring force
frequency of gear teeth passing a mag- (controller) outputs to a pair of solenoid against the top of the diaphragm. This
netic pickup. This frequency signal goes valves to drive a vacuum-powered actu- modulates the valve disc proportionally
in response to any force imbalance
between the diaphragm and the spring
YELLOW JACKET WEATHER (see Figure 3, page 18).
CAPS EXTEND THE LIFE OF YOUR
Proportional-only Control
PRESSURE RELIEF VALVES Regulators can control pressure, as seen
in Figure 3, and almost any other
SUBSTANTIALLY REDUCES
process variable such as flow, level or
MAINTENANCE COST temperature. But judging from the pro-
liferation of control valves and control
WEATHERCAPS MEET ALL New systems, regulators are not perfect. The
ENVIRONMENTAL REGULATIONS & spring and outlet pressure in a regulator
Improved are only balanced at one position of the
FIVE YEAR WARRANTY disc. The disc can be repositioned only
in proportion to how much the actual
NO TOOLS TO INSTALL, SIZES 0.5
process pressure deviates from the set-
UP TO 24 point.
Assume the Figure 3 diaphragm in
HIGHLY VISIBLE (CHROME YELLOW) the regulator has an effective area of 10
PROVIDING VISUAL EVIDENCE OF square inches and the unbalanced area
VALVE ACTIVATION of the disc is 1 square inch. Full stroke
of the regulator is arbitrarily assigned
at 0.2 inches, and the spring selected
SCIENTIFIC LININGS AND COATINGS has a spring constant K of 500 pounds
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the regulator will be 50 psi x 10 in2 or
DEALER INQUIRIES WELCOME 500 pounds. For the spring to balance
that it must be compressed X=F/K or 1

inch. If the flow rate increases so that

the disc needs to move to 50% of travel
(0.1 inch), then the force on the spring
relaxes by 50 pounds (Kx0.1), and the
pressure would be controlled at 45
pounds. Extrapolating, the outlet pres-
sure would have to go to 40 psi for the
regulator shown in Figure 3 to go to
full-open 0.2 inch stroke. This is the
effect of proportional-only control. Con-
trol texts call this proportional offset
while regulator-specific literature calls
it droop.
Supply Pressure Effect

Another effect seen in regulators is the
variation in outlet pressure caused by
changes in inlet pressure. If the inlet
pressure for the Figure 3 regulator
increases by 100 psi, the disc effective
area is 1 inch, so the additional 100 psi
pressure causes 100 pounds of addition-
al opening force. With the 10 in2
diaphragm, the effective set pressure
Figure 2 would then drop by 10 psi for the sum of
forces to balance again. Regulator liter-
ature either calls this supply pressure
effect or inverse sympathetic ratio.
Improved regulator designs use a bal-
anced disc or a control pilot to increase
precision.
We are concerned here with control.
Some processes need more than just a
proportional control strategy to regulate
the process values within acceptable
limits. There are additional strategies
developed by engineers for better con-
trol. In the pneumatic days, the first was
called reset. Now we call it inte-
gral. Additionally the industry has
developed derivative (formerly
rate), so we usually have three con-
trol strategies combined: proportional,
integral and derivative, or PID. It is
astounding to imagine that engineers
were designing these features into all-
pneumatic controllers in the 1950s,
because now the most mundane elec-
tronic single-loop controller has all
three strategies in its programming as a
matter of course.
Integral control is better described as
reset. Whenever the measured variable
deviates from the set pressure, the con-
troller resets its output so more and
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more corrective signal is added until deviation occurs. Its as close

there is no deviation between the meas- as possible to actually antici-
ured variable and the setpoint. In indus- pating an upset. This is useful
trial control, the adjustment parameter for processes such as tempera-
for integral mode is resets per minute ture control; if there is a quick
where a reset is a correction equal to change in demand the valve
the proportional correction. Dedicated can get ahead of temperature
control engineers have told me that the deviation and bring it back
automotive cruise control from our ear- toward setpoint before the tem-
lier example may operate solely in inte- perature gets too far out of
gral mode. If the vehicle deviates from limits.
the set speed, it just keeps marching in
more correction until youre back on the Feedforward Control
magic number. Yet another option is feedfor-
Adjusting the controller for more ward control. For example, if
resets per minute makes the control the customer needs exactly
action more assertive, until the tuning is 67.42% of valve travel for a
too aggressive and the loop becomes particular process mode,
unstable. he/she can program the DCS
Sometimes process deviations come to output 14.79 milliamps
along suddenly and it is appropriate to blindly to send the valve to
cause the valve to jump to a new posi- that position. This avoids the Figure 3
tion to begin correcting the upset before possibility of various instabili-
the process has even completed its devi- ties encountered with feed-
ation. Derivative control sends a control back loops. There is some divergence to any reason (positioner error, wear, pipe
output proportional to the rate that the be dealt with; if the valve does not, for scaling, etc.), deliver exactly the cor-
rect flow rate, the cumulative results
will deviate from the desired value pro-
Spence Engineering Company gressively after time. It is customary to
Introduces: install a parallel feedback control loop
for trim, allowing instantaneous sta-
3 ble response and accuracy for continu-
P -PistonPower Pump ous duty.
The First and Only Spring-less Non Electric
Condensate Pump! A Misconception
The P3 is the First non-electric pressure driven conden- There is a prevailing misconception I
sate pump that features a revolutionary new mechanism have encountered in the industry, which
with a spring-less design that helps prevent stall and break is that users do not understand digital
down. positioners have an internal PID feature
and are reluctant to use them for fear
the digital positioners PID will inter-
LCV Linear Control Valve fere with their distributed control sys-
Single-Seated, Unbalanced Valve with Cage tems PID. However, the digital con-
Retained Seat. trollers PID loop is only concerned with
Unique Design Allows Maximum Inter- how accurately the positioner/actuator/
changeability of Parts valve work together in response to input
from the plant DCS. An appropriately
QB Rotary Control Valve tuned digital controller only follows the
Designed and Engineered to Handle Nearly control signal more precisely and does
All Industrial Process Control Requirements! not compromise the settings of the DCS
control loop.
In the pneumatic days, instrument
www.spenceengineering.com technicians of the time practiced cali-
1.800.398.2493 bration and tuning procedures that were
more art than science. Now, it is much
Choosing an actuator for critical pipeline applications

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them ideal for ESD and linebreak applications. Designed for a 50 year life with
minimal maintenance, and with an industry-leading 10 year warranty, why pay less
for less? See for yourself at www.EmersonProcess.com/ValveAutomation
simpler: punch the auto-tune button and mized. Control input to the integrated
dont disturb it until calibration is com- control valves merely updates the sys-
plete. Pushbutton auto-tuning is almost tems new goals.
universally featured on any digital con- Valves can contribute to control loop
troller. The auto-tuning algorithms are errors as they degrade with time, wear,
typically conservative and invariably damage or contamination, and valve
they will assign safe, stable values with monitoring technologies are now avail-
a wide safety margin. There are times able. The latest technology provides a
when the controls engineer will find it function block within the digital posi-
appropriate to enhance to PID parame- tioner to continuously monitor the valve
ters for an even better match to the assemblys health continuously. Moni-
process requirements. Make sure you toring the valves continuously spots any
know how to get to restore factory degradation at the earliest moment
defaults before starting any tweaking. when the possibility of an easy and inex-
pensive repair is greatest. Or the opera-
When Deviations Occur tor can view any valve on demand.
What happens if the loop tuning is Enough intelligence is incorporated
incorrect? The process experiences devi- into the monitoring system so that it can
ations outside of acceptable limits, or detect and identify problems with the
the process goes into oscillation. State- valve, actuator or positioner. It can alert
of-the-art, high-tech control valves are the operator of a developing problem in
still marvelously single-minded. They go real time, before the process begins to
where the process control unit tells be affected. The technology is so
them. However, a process controller is a advanced it can even prioritize the
nondescript black box. Chaos can reign faults to be corrected. Repairs can be
inside the controller without being obvi- completed before the damage cascades
ous, unless the user understands the to additional expensive components.
controllers display. The prime indicator Technicians can be sent to work an out-
of an unstable control loop is the control age with only the specific parts needed
valve slamming off its stops. The control for the repairs, saving money on the
valve vendor then gets a call from the parts budget and being sure the required
user who typically believes the valve is parts are on hand before a pair of steel-
cycling. However, valves dont cycle; toed boots is ever laced. Much
control loops do. Valves only go where time/labor/materials can also be saved
they are told. because the valve monitoring system
If auto-tune fails to give acceptable can also identify healthy valves that
results the technician may elect to opti- do not require maintenance during an
mize the tuning parameters. Two useful outage.
texts are Introduction to Automatic Process A valve is just one element of a con-
Control by Robert H. Mollencamp, pub- trol loop, and for the loop to perform
lished by the ISA, and Controller Tuning properly the valve must be sized and
and Control Loop Performance (PID Without selected properly. All the other compo-
The Math) by David W. St. Clair, pub- nents in the loop must also be selected
lished by Straight-Line Control Compa- and calibrated so all the pieces work
ny, Inc. together, both in a continuous and
dynamic sense. Once the loop is opti-
The Latest Technology mized, loop performance and precision
For truly distributed control, some is maintained by keeping the control
valves have the controller function built valves functioning at their optimum
in with just one component to be level. VM
installed. The valve, actuator, positioner
JIM CASEY is Product Manager, Rotary Control
and controller are all one assembly. Products, at Flowserve Corporations
Because everything is done in one place, (www.flowserve.com) Cookeville, TN facility.
time response and accuracy is opti- Reach Casey at jccasey@flowserve.com.

SPECIALIZED DESIGNS FOR

PIPELINE VALVE
ACTUATIONnumber of specialized designs
A of valve actuators have been EXPANSION OF OIL AND GAS PRODUCTION
developed over the years to cope
with specific valve control demands
INTO REMOTE AND INHOSPITABLE AREAS
that are found in the pipeline indus- OF THE WORLD CHALLENGES ACTUATOR
try. Examples include gas-over-oil,
high-pressure gas and electro-
MANUFACTURERS TO PRODUCE RUGGED,
hydraulic actuators, as well as spe- RELIABLE AND OFTEN SPECIALIZED
cialized hydraulic actuators
designed for subsea valves.
PRODUCTS TO MEET THE PIPELINE
While the fundamental principles INDUSTRYS NEEDS. BY MARK CLARK
of design for these actuators are
well established, rapidly advancing
technologies, increasing demands
for reliability, reduced maintenance
and automation from end-user
industries continue to present manu-
facturers with new challenges. In
addition, the expansion of oil and
gas production into increasingly
remote and previously unreachable
areas, combined with the growth of
strategic pipeline distribution net-
works across remote and inhos-
pitable landscapes, places further
pressure on the manufacturer to
provide rugged and reliable valve
actuation solutions.
Testing for Reliability

in the Extreme
The importance of testing cannot be
over emphasized, not only to prove
the long-term performance and reli-
ability of products, but also to gain
specific approvals from end-user
markets without which it would be
difficult or even impossible to bid on
projects.
Some major equipment manufac-
turers testing policies are designed
to reassure the customer that the
quality of its product range is first
class through the achievement of
internationally recognized quality
assurance approvals for design and In one API test performed by a major
manufacture. equipment manufacturer, a scotch-yoke
Running in parallel with these assess- hydraulic actuator with ROV (remote-
ments, equipment manufacturers also operated vehicle) override was operated
subject their products to the test proce- in a hyperbaric chamber under an exter-
dures required for end-user approvals in nal pressure of 3600 psi (240bar-g) to
specific markets and industrial disci- represent the submerged qualification
plines. In these areas there have been depth of 2,400 meters over a period of
significant market-led increases in six weeks. The actuator was selected as a
activity in recent years. representative sample of all the compa-
In addition to the hyperbaric testing nys subsea actuators for the purpose of
of subsea actuators and performance the testing, which was witnessed by a
verification of gas-over-oil actuators third-party inspector. The severity of the
mentioned later in this article, testing testing reflects the crucial nature of sub- Hyperbaric chamber for subsea actuator test
programs in recent years have expanded sea actuator duties and the increasing
to include specific tests such as: depths at which actuators are expected to
IP66M/67M, dust, water jet, perform as exploration moves into new, merged installation at a depth of 45
immersion and deluge testing of more remote offshore fields. meters. The witnessed testing included
pneumatic actuators In the ST-028 hyperbaric test a sim- pressurizing the switchbox with air at
Shell qualification for hydraulic ilar hydraulic actuator fitted with a 75 psi (5bar-g) without any sign of
and pneumatic actuators limit switchbox was subjected to cyclic leakage or bubbles, static torque and
Transco qualification for hydraulic testing to prove its suitability for sub- cycle testing of the actuator at ambient
actuators
HIPPS (high integrity pressure
protection systems) qualification
for control systems
GOST Russian Certificate of Con-
formity and Federal Use Permit
ABS (American Bureau of Ship-
ping)
These are in addition to ATEX explo-

sion-proof certification, PED (European
Pressure Equipment Directive) approval
and SIL (safety integrity level) assess-
ments that also apply to pipeline actua-
tion products.
Subsea Actuators, Testing

In-depth
Subsea valve applications, which often
involve vital fail-safe and associated
safety-related duties, represent an area
of technology demanding the very high-
est levels of quality and product integri-
ty to ensure reliable long-term perform-
ance. It may be prudent to not only test
to API (American Petroleum Institute)
qualification but also to achieve third-
party-witnessed hyperbaric approval to
the international qualification proce-
dure ST-028.
S p r i n g 2 0 0 8 | 23
P I P E L I N E V A L V E A C T U A T I O N
sea equipment, these actuators have to

meet specific project requirements. In
this task the company can also draw on
the experience of an installed base of
designs encompassing pressure-compen-
sated rack-and-pinion, scotch-yoke and
linear actuators for both double-acting
and spring-return duties, equipped with
ROV and/or diver-operated facilities.
Actuator companies often work with
gear manufacturersparticularly ones
with subsea experiencewhich produce
Gas-over-oil pipeline valve actuation a range of subsea gearboxes with diver
or ROV-operable overrides. The combi-
and 75 psi (5bar-g) external pressure nation of products, engineering knowl-
(1,090 cycles at 2400 psi [160bar-g] edge and test facilities provided by the
on each test), final static torque moni- actuator and gear companies provides a
toring, strip down and inspection. This comprehensive subsea solution for both
was a much shorter test, taking only retrievable and non-retrievable applica-
three days to complete, although the tions. For example, on retrievable appli-
combined total operating test, amount- cations such as some SSIV (subsea iso-
ing to over 2,000 cycles, is representa- lation valve) duties the designs provide
tive of a much longer working life. for interchangeability between the actu-
The real life application for this equip- ator and a ROV-operated gearbox by
ment involves units with pressure com- means of transition spools and quick
pensators and manual controls for divers, release methods.
supplied for Phase One of the Ashrafi Gas For ROV-operated overrides another
Lift project on the Red Sea coast. The option is the ability to fit adjustable
project involves onshore facilities, gas extensions between the ISO torque tool
lines and metering systems for 10 gas receptacle (or bucket) and the over-
wells and associated platforms in the ride input drive shaft located on the
Gulf of Suez and is the continuation of a actuator. This enables the receptacle to
development that has been producing gas be remotely positioned from the actua-
since the 1990s. The subsea hydraulic tor to facilitate ROV or diver access
actuators are operating 8-inch (200mm) with the tool.
Class 900 ball valves.
In common with the stringent Gas-over-oil Actuators
demands of all contracts involving sub- The basic principle of operation of the
gas-over-oil actuator involves taking gas
from the pipeline upstream of the valve
and storing it under pressure in a reser-
voir (accumulator). The gas is used to
power one side of gas/oil tanks (one for
each valve operating direction), control-
ling the flow of hydraulic oil to and from
the actuator cylinder to move the valve.
The gas-over-oil actuator is well suit-
ed to respond very quickly to changes in
the physical condition of the pipeline
for example, a loss of pressure or
increase in velocity denoting a line
breakand utilizes the inherent speed
of hydraulic operation to immediately
close (or open) the valve. Because it
Gas-over-oil test rig uses the pressurized pipeline gas as an
Valve Modification,
Repair and Service
United Valve is an authorized Velan Level I service center and is
Delayed Coker experienced in the repair and modification of
Ball Valve Repair delayed Coker isolation and switch valves
from NPS 8 through NPS 30.
For over 40 years, Large valve work is a specialty at United Valve
distributors, manufacturers
and end-users have counted
on quality valve modification
and repair services from
United Valve.
Staff Engineers
30 Ton Crane Capacity
Over 150 Qualified Welding
procedures
CNC & Large Capacity
Machine Tools
Unlimited Pressure Test
Capabilities
Cryogenic Fabrication &
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Alliances with 22 Major
Valve Manufacturers
A Coker valve being repaired
10010 Gulf Freeway, Houston, Texas 77034-1045

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Visit us online at: www.unitedvalve.com
independent, self-contained power a line break or similar event. function manifold block at the center of
source, the actuator can perform this Emergency shutdown, however, is the gas-over-oil system, which inte-
duty when mains power is not available just one of the many duties the actuator grates both the gas and hydraulic func-
or when the loss of mains power triggers may be specified to perform. Virtually tions in order to meet a wide variety of
the immediate failsafe operation of the all pipeline applications demand a con- the control functions that are likely to
valve. Consequently, and combined with trol package specification that is cus- be specified. These include, for example,
its suitability for installation in remote tomized to some degree, so the actuator altering the speed of valve travel, which
locations, many end users see the main must be capable of meeting a diverse may be required very quickly in an
function of the gas-over-oil actuator on range of control and instrumentation emergency but much more slowly to pre-
a pipeline as being the reliable provision requirements without excessive re-engi- vent damage to the pipeline during rou-
of precautionary and emergency shut- neering. tine operations or partial stroking main-
down and isolation duties in the event of One solution is to engineer a multi- tenance programs. Valve operation can
also be preset to activate when a set
point pressure drop value is signalled, or
Your Pipeline to from other data provided locally or

remotely.
In addition, individual gas company
Flange Protection approvals may need to be obtained. In

Russia the GOST certificate of conformi-
ty and federal use permit is required.
Similarly, ENAGAS, the Spanish gas
pipework network operator, and SNAM,
the Italian equivalent, require approvals.
In both cases, two examples of actuators
are required to be subjected to an ardu-
ous program, as this summary of the
main SNAM test illustrates:
Dimensional check of actuator
components before assembly
Pressure test on piston, hydraulic
circuit and pneumatic circuit
Caplugs is one of the largest manufacturers of plastic product protection in Dielectric strength test on the
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Dynamic torque recording at 195
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psi (13bar-g), 375 psi (25bar-g),
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applications to HVAC and oil/gas equipment and services. Caplugs parts can 750 psi (50bar-g) and 1050 psi
be used anywhere valves, piping, pumps and other processing components (70bar-g)
need to be protected. For unique product protection needs, we have full Strain test on main components at
in-house custom capabilities and our engineers will work with you to design 1200 psi (80bar-g)
and develop a part to meet your specific needs. 5 cycles with remote control at
25%, 50%, 75% and 100% of the

maximum torque
5 cycles with manual control at
25%, 50%, 75% and 100% of the
maximum torque
Torque Limiting Device verifica-

tion test (see below)
Low temperature test at -4 F
(-20 C) (functional test and
torque limiting device verification
test)
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operation under either local manual

control or remote electrical control,
with hydraulic manual override. In addi-
tion, each actuator is equipped with
enough accumulator capacity to com-
plete four stand-alone valve strokes.
The valve manufacturer also specified
the torque output from the actuators
should be limited to prevent any risk of
damage to the valve stems. For this
function an innovative solution had to be
developed.
On the pipeline example above a
torque limiting device (TDL) was fitted
to limit the maximum torque output
from the actuator in order to prevent
damage to either the valve stem or the
actuator itself. Mounted between the
gas elements of the manifold block and
the gas/oil tanks, it works by measuring
and limiting the differential pressure
between the gas on the supply side and
the oil on the return side of the tanks.
As the amount of actuator torque is
directly proportional to this differential
Schematic of Torque Limiting Device
pressure, damage to the actuator or
valve might occur if the differential
pressure becomes too great as a result
A Customized Solution The pipeline is owned by the gas of unexpected resistance from the valve
The 135-kilometer-long Shoukar-to- transportation company GASCO, which during travel or when the actuator trav-
Hurghada pipeline is an important was responsible for engineering, pro- el reaches the end stop bolts. Clearly,
strategic extension to the natural gas curement, construction supervision, the risk also increases in proportion to
distribution network in Egypt. Running commissioning and start-up. Construc- the speed of valve operation, so the TLD
southwards along the western coastal tion of the $60 million project, which is pre-set to either the maximum torque
area of the Red Sea, the 24-inch-diame- began in May 2006, was completed in supported by the valve stem or the max-
ter pipeline has an operating pressure of 2007. imum allowable torque produced by the
1050 psi (70 bar) and is designed to Customized actuators were supplied actuatorwhichever is the lower value.
supply natural gas at a rate of up to for block isolation valves, which enable When the differential pressure limit
5MMSCMD (5 million standard cubic segments of the pipeline to be closed is reached, the TLD blocks the gas sup-
meters per day) to power stations and down for maintenance, inspection and ply and at the same time vents the pres-
consumers in the provinces of Shoukar safety reasons. For this application the sure from the gas cylinder and gas/oil
and Hurghada. customer specified double-acting valve tanks on the supply side, reducing to a
minimum the risk of damaging either
actuator or valve.
The Electro-hydraulic Option

The increasingly popular electro-
hydraulic option offers a self-contained
actuator package for pipeline valves,
operated electrically by means of an
integral hydraulic power pack and accu-
mulator. Among other benefits, this
design enables fail-safe and emergency
Electro-hydraulic actuators on pipeline shutdown duties to be performed by an
metering station Gas-over-oil actuators during manufacture electrically powered actuator, with the
THE WM. POWELL COMPANY

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(ASME B16.34) 2500
Size Range: 1/2 to 30 Materials: A105, F22, F11, F5, F9, 316,
Pressure Class: 150, 200, 300, 600, 900, 1500 316L, 304, 304L, F91, and
Materials: Bronze, WCB, WCC, WC6, Special Alloys
WC9, C5, C12, LCC, LCB, 316,
316L, 304, 304L, A-20, Monel, SPECIALS
Hastelloy C, Hastelloy B, Powell has the ability to engineer, design and
and Nickel manufacture unique valve requirements by utilizing
our expertise, experience, worldwide resources
NUCLEAR and over 150 years of valve know how.
Powell is a pioneer in the Nuclear Industry. N
and NPT Stamp Approved.

The Wm. Powell Company 2503 Spring Grove Avenue Cincinnati, Ohio 45214 U.S.A.
Phone: 513.852.2000 Fax: 513.852.2997 www.powellvalves.com
quotes@powellvalves.com
high speed capability inherent in overrides incorporated into sole-

hydraulic operation and with a lower noid valves, or
cost of ownership than other solutions. Locally by the manual hand pump
A number of these actuators have
been installed on the recently completed The speed of the operation is inde-
Baku-Thilisi-Ceyhan strategic pipeline, pendently adjustable in both directions.
which brings up to 50 million tons per The pump/motor/accumulator provides
year of crude from the oilfields of the the hydraulic supply to the solenoid
Caspian Sea to the Mediterranean coast valves and hydraulic pressure is auto-
of Turkey. The actuators described here matically regulated by a pressure
are used for block valve and emergency switch. The motor runs until the preset
A consignment of electro-hydraulic actuators
shutdown (ESD) duties along the length for the Baku-Thilisi-Ceyhan pipeline is on its
maximum pressure is reached and for
of pipeline that traverses Turkey. way to the valve manufacturer. safety a pressure limitation valve is fit-
This application used electro- ted as standard.
hydraulic actuators of the scotch-yoke The hydraulic accumulator system
type, operating ball valves in sizes up to standard, while optional features are ensures operation in the event of pri-
42 inches. Four model sizes were sup- easily integrated. mary energy failure and also facilitates
plied, the largest having a maximum Generally, valve actuation can be fast operating times. A torque control
torque output of 200,000Nm. performed in one of four ways: system to protect the valve and actuator
A modular design of some electro- Remotely via energization/de- from overloading is included as stan-
hydraulic control systems facilitates energization of the solenoid valves dard in all control configurations.
assembly, operation and maintenance of Automatically by control system Actuators supplied to the pipeline
both standard and customized control logic (e.g., low, high or differen- were divided into two groups, ESD
logic solutions. Common functions such tial pressure detection) valves and mainline block valves. In
as local/remote control selection and Locally by either an electrical both cases the specification called for
open/close operation are provided as pushbutton station or the manual stainless-steel control and instrumenta-
A CASE STUDY
AUTOMATED INDUST RIAL PLAN T NEEDS
EXTENDED LIFE ACTUATION.
E XTENDED CYCLE LIFE ACTUATORS ARE USED FOR BFV APPLICATIONS UP TO 30 INCH . T HE
ACTUATORS HAVE PROVIDED OVER 5,000,000 CYCLES OF CON TINUOUS SERVICE RESULTING IN
LOWER OPERATING COSTS AND INCREASED PROFITS . T HE ACTUATORS ACHIEVE 90 DEGREE
ROTATION IN LESS THAN 1 SECOND . U NIQUE END OF ST ROKE DESIGNS REDUCE SHOCK TO BOTH
THE ACTUATOR & THE VALVE EXTENDING THE SERVICE LIFE .
WHAT ABOUT YOU ?

DO YOU HAVE CRITICAL SERVICE
VALVES THAT REQUIRE PROVEN
HIGH CYCLE RELIABILITY?
IMAGINE
A W O R L D O F P O S S I B I L I T I E S
FLO-TORK WILL DESIGN THE

SOLUTION FOR YOU. OUR
PROBLEM SOLVER APPROACH
ANALYZES YOUR NEEDS AND
OFFERS THE BEST SOLUTION.
FOR M O R E I N F O R M AT I O N P L E A S E C O N TA C T S A L E S V M @ F L O -T O R K . C O M G W W W. F L O -T O R K . C O M

tion component parts (solenoid valves, etc.), with marine quali-

ty stainless-steel solenoid valves specified for the ESD actua-
tors in coastal locations.
The stroke (closing) time for ESD valves is 15 seconds while
the stroke time is 7 minutes for the mainline block valves. To
meet the block valve timeessential to prevent the risk of
pipeline damagein the various ambient conditions encoun-
tered, special temperature and pressure-equalized throttle
valves are incorporated.
Each mainline block valve actuator is equipped with a posi-
tion transmitter with eight position switches. The position
transmitter was required to be explosion-proof to EEx IIB
T4which is the enclosure specification demanded for all elec-
trical equipment on the actuatorsand to utilize proximity
switching. Because a transmitter to this specification was not
readily available, the unit was custom designed specifically for
the contract and was Ex certified.
The eight switches on the mainline actuators provide fully
redundant positional control in four positions: fully open, 80%
open, 70% open and fully closed. The 80% and 70% positions
enable the actuator to be partially stroked for function test pur-
poses, with position switch redundancy preventing the risk of
accidental valve closure and consequential pipeline damage.
Due to the pipelines geographical location the actuators are
fitted with earthquake-proof solenoid assemblies, each com-
prising two 90-degree-operated valves to prevent accidental
vibration-induced operation. For the mainline valves both nor-
mally closed (NC) solenoids must be energized to close the
valve, with each under the remote control of a separate PLC.
On the ESD valves both solenoids are normally open (NO) and
de-energizing either one will cause the valve to close, regard-
less of the continued presence of an electrical supply.
All the actuators are equipped with accumulators with the
capacity to provide three valve strokes without the motor and
pump running. In addition, provision is made to attach a
mobile pump to operate the actuator in the event of a motor
failure, while an integral hand pump is also fitted. All actuator
control packages are designed with full cathodic protection and
housed within a watertight stainless-steel cabinet.
Conclusion
The activities described above illustrate how the demands for
safety, efficiency and environmental responsibility from the
contemporary pipeline industry have a significant impact on
the valve actuator manufacturer, creating increasingly innova-
tive design solutions, proven and supported by ever-more strin-
gent testing. The constant expansion of oil and gas exploration
and production into more and more remote areas can only
increase all aspects of this activity for the actuator industry in
the foreseeable future. VM
MARK CLARK has worked in the industrial valve, actuation and instrumentation
industries in the United States and the United Kingdom for more than 35 years.
He is currently a freelance public relations consultant in the UK, specializing in
the valve actuation industry, and wrote this article on behalf of Rotork Controls.
CIRCLE READER RESPONSE #23 Reach him at ftpublicity@aol.com.
FORWARD-ACTING REVERSE-ACTING
RUPTURE DISCS RUPTURE DISCS

BUILDING AN AML
VITAL FOR DOING BUSINESS IN CHINA
PHOTO COURTESY GREG JOHNSON, UNITED VALVE

BY PATRICK A. TOENSMEIER Dimensional verification of
all key valve components is
part of the API RP591
hinas low-cost manufacturing
C has made it the main source of Process Valve
Qualification
commodity valves for most North inspection process.
American end users, service compa-
nies and manufacturers. But cost
doesnt guarantee performance. The
quality standards and process capa-
bilities of foundries in China are far
from uniform. Companies sourcing
valvesprimarily gate, globe, ball
and check valvessay its essential
to develop Acceptable Manufactur-
ers Lists (AMLs) of approved ven-
dors to assure the equipment pro-
duced meets specifications.
The trend to outsourcing com-
modity valves from low-labor-cost
regions is not likely to change any-
time soon. The main reason for this,
of course, is economic. Foundries
that cast valves in low-labor-cost
countries deliver them for substan-
tially less than if they were fabricat-
ed in the United States or Canada.
Experts say that valves manufac-
tured in China cost 25-40% less
than in the U.S. And when valves
made in China are shipped to
Europe and paid for in euros, the
savings are even greater, owing to
the strength of the currency.
At the same time, end users
expect no trade-offs in quality or
performance from low-priced
valves. As suppliers note, customers
want performance and value in the
same package. The only way to In reality, however, sources say developing an AML is a long and costly process
achieve this is by sourcing valves that relies as much on knowing what to look for in a manufacturer and on personal
from countries like China. relationships as it does on reaching supply agreements based on operational capabil-
ities.
Much to Consider A buyer must research a companys history, learn what its customer base is,
On the surface, compiling an AML what specifications these customers have, and if your specs are going to be new to
appears to be straightforward. The them, says Randy Cowart, President, Chairman and CEO of The Wm. Powell Com-
easiest way for any company to pany, a valve manufacturer in Cincinnati, OH.
begin is by drawing up requirements The company has been sourcing commodity valves offshore for years, in Eastern
that manufacturers will need to Europe as well as Asia. Cowarts estimate for how long the process takes in China is
meet to be included on the list. two years at least, a timeframe echoed by others.
Valve
Magazines
Gone Dont
Digital! you get
The all-new digital ver-
sion of Valve Magazine is it?
yours to explore for free!
Just register your digital No? Then why not start a new
subscription at ValveMagazine.com by clicking subscription to VALVE MAGAZINE,
on the link at the top of the home page.
the ONLY publication exclusively
All we need is your email and permission to covering the North American valve
send you a link to a fully functional, digital and actuator industry!
version of the magazine that requires no special
software and no lengthy downloading.
WHY GO DIGITAL?
Its simple.
No need to wait for the print edition to arrive! Go to ValveMagazine.com
Youll be able to read the magazine about 2 week
s or fill out one of the cards
before others.
You dont need special software! Just click on the included in this issue, then fax
link in the email we send when the issue is ready, or mail it in.
and youll be able to access the edition online.
The digital Valve Magazine is like a super ver-
sion of the print edition! You can flip from page Plus, well send you
to page, viewing all ads and editorial. Plus, a
handy search function will help you locate the
a trial subscription to
information. our all-new digital
All weblinks and emails inserted in the text are
live! See an ad and want more info? Just click on edition!
the url found in the ad and go directly to the
advertisers website. Want to ask an author a
question or get more info on a news story? Just SUBSCRIBE ONLINE AT
click on the email link or web address. ValveMagazine.com
Catch up on your reading while away from the
office! No more weighing down your briefcase
with heavy magazines. The latest issue of Valve EDITORIAL QUESTIONS?
Magazine will always be accessible from your Contact Editor Judy Tibbs at jtibbs@vma.org
laptop or any computer.
ADVERTISING QUESTIONS?
RECEIVE BOTH PRINT AND Contact Ad Manager Sue Partyke at
suepartyke@cs.com
DIGITAL EDITIONS FOR A FULL YEAR!
Once you sign up, your digital trial will last for one
yearfour issues. At the end of that period, well CIRCULATION QUESTIONS?
ask you to choose between a print or digital edi- Call 570-567-1193, or email
tion. If you still want the print version, no prob- Valve@PublishersServiceAssociates.com
lemyoull continue to receive it quarterly. If you
prefer the digital edition, youll continue to receive
access to the magazine online, and well stop send-
ing the print magazine... its up to you.
B U I L D I N G A N A M L
There are many reasons why the
PHOTO COURTESY BOB SMITH, MCJUNKIN RED MAN

process is long, involved and expensive.
The main stumbling block, sources say,
is the difficulties most Chinese foundries
experience when working to Western
standards. This is a country thats been
casting materials for hundreds of years,
and in the last 15 years foundries have
been asked to cast according to stan-
dards they never had to meet before,
says Greg Johnson, President and CEO
of United Valve, a valve service compa-
ny in Houston, TX.
The desire for new business and prof-
itability also affects quality. Many Chi-
nese foundries that specialize in wax or
sand castings now try and do both to
increase business. Perfecting a new
process may take more time than the
vendor lets on. The techniques for each Chinese foundry works dip the valve body and bonnet wax molds in slurry prior to covering them
are very difficult, and doing one well with sand. This slurry/sand process is repeated 5 to 12 times (depending on the size of the
doesnt mean the other can be done casting) to add thickness and strength to the mold.
equally well, notes Bob Smith, Direc-
tor of Safety and Quality Management ing major expenditures for heat and op an area for attractive businesses such
for McJunkin RedMan Corporation, electricity. as high-tech, even if this means shutting
Charleston, WV. Adding to these concerns is an indus- down foundries and other heavy indus-
Despite Chinas reputation for low- trial infrastructure that in many parts of tries with viable export businesses. A
cost production, manufacturing costs the country remains a work in progress, buyer could find a foundry that meets
are on the rise. Employees are demand- a factor that affects foundry operations, the requirements of its AML and soon
ingand gettingmore money; prices manufacturing costs and profit margins. discover it has been put out of business
for raw materials are high; and casting There is also the governments policy by local authorities.
operations are energy intensive, requir- of seizing land when it wants to redevel-
Buyer Beware
PHOTO COURTESY BOB SMITH, MCJUNKIN RED MAN
Companies seeking to firm up manufac-

turing deals with foundries in China
must proceed with extreme caution.
A buyer needs to inspect a plants
capacity and power supply, says Ken-
neth Felder, Material Master Manager
and Manager of the Pipe, Valve and Fit-
ting AML for Valero Energy Corp., San
Antonio, TX. He adds that electricity
restrictions mean a lot of metal is
poured at night, which can reduce the
amount of time foundries devote to cast-
ing valves, and tempt some to cut back
on heat treatments and other necessary
operations.
Its also critical to determine where a
foundry sources raw materials. Felder
notes that buyers must be certain a
plant isnt trying to cut corners by using
off-spec metals or inferior scrap from its
Wax molds are baked prior to pouring. Molds must be hot when the metal is poured to prevent own operations or from another
"cold shuts" (metal freezing off narrow passages in the mold). foundrys, much less stolen material.
Productivity enhancing technology for automated valve applications
Asset management:
fast, easy, and powerful
otorks IQ Pro electric valve actuators include powerful data
R logging capabilities that enable you to easily capture and analyze

a wealth of important valve performance information. You can
use the data to manage assets for maximum productivity, monitor
valve performance, and even forecast when valve maintenance might
be required and scheduled.
Historical and current operating data, including valve torque
SUROHVQXPEHURIRSHUDWLRQVYDOYHDQGDFWXDWRUSRVLWLRQVDQGRWKHU
vital performance and operational statistics are stored in the IQ.
Capturing the data is simple. Just point an intrinsically
safe Rotork IQ Pro setting tool at the
actuator.
Within seconds, the information is
downloaded wirelessly and stored into the
setting tool. Then, at your convenience, you
can just as easily upload the data to virtually any
laptop PC or desktop computer. Rotork software
includes many
Rotork provides software for a feature-rich, user- useful screen
friendly interface, so asset analysis and creating reports is 3. views that
make asset
fast and easy. management,
Rotork IQ Pro electric valve analysis,
valve actuators log Rotork IQ Pro actuators are non-intrusive, rugged, and reliable. and predictive
performance and They are used in automated valve applications all over the globe. For maintenance
operational data. easy.
more information about how the IQ Pro and other Rotork actuators
can help you increase productivity, contact us today.
1. At your convenience, upload the

data from the setting tool to a
laptop PC or desktop computer.
Rotork software provides a
powerful user interface.
Simply point the
2.
intrinsically safe
Rotork IQ Pro setting
tool at the actuator
and download the
data wirelessly.You can
also use the setting
tool along with the IQ
Pros text display to
FRQJXUHDQGUHVHW
the actuator locally.

Rotork Controls, Inc.

675 Mile Crossing Blvd.
Rochester, NY 14624
Phone: 585-247-2304
Fax: 585-247-2308
Email: info@rotork.com
www.rotork.com CIRCLE READER RESPONSE #45
B U I L D I N G A N A M L
You dont want your name on a valve they order. (Powell has a no-lead paint the countrys competitiveness as a low-
made from [untraceable] material. requirement for its valves.) If a foundry cost exporter.
Felder says Valero takes certifica- doesnt have the supplier you need, you At the same time, the government
tion a step furtherit not only have to help it find one. has reduced export rebates to 17%
approves foundries but their suppliers. Another issue is valuation of the yuan from 23% and may cut them further.
Every time a manufacturer weve and reduced export rebates. Chinas According to Cowart, the rebates pay
qualified gets a new source, it has to be national currency is rising against the manufacturers for selling products off-
qualified too. U.S. dollar, increasing 8.5% since shore. You can ship products out, sell
These foundries must source their March 2007. Cowart says the yuan them at net-net breakeven prices and
components, Cowart notes, so you reached a value in late February make 17% on the back side, he says.
have to take the time to inspect their $0.14that a Chinese government offi- The more this gets cut into, the more
supply chains, even down to the paint cial told him two years ago would affect costs are added.
The yuans rise against the dollar,
along with the reduction of export
rebates, has most manufacturers scram-
bling to improve profitability.
One major problem in compiling an
AML is that there are no hard and fast
ways of doing so and few organizations
a company can turn to for guidance.
Some industry associations may provide
suggestions and informal guidelines, but
these are mostly through member
exchanges at meetings. Distributors
develop their own AMLs, though
sources say the lists represent products
they want to sell rather than what buy-
Protect ers really need.

Some buyers distribute their AMLs
valves
to select customers to make the valve-
sourcing process transparent. Powell,
for example, has a confidential book
from wear, that lists its vendors and the types of
valves in which they specialize.
corrosion Local Presence a Must

Most experts, though, say theres no
and galling substitute for having a presence in
China and dealing directly with manu-
facturers. This can be done through a
joint venture with a local company,
opening an office there, or at the very
least by finding a reliable representative
Increase The Life Of Valves & Equipment who will check the capabilities of manu-
General Magnaplates coatings transform valves into corrosion and facturers and monitor their operations.
chemical-resistant, superhard, dry-lubricated products that last longer, are The key thing is boots on the
more cost-efficient, and more reliable. General Magnaplate's coatings can ground, and they have to be your
also significantly increase the life of renewable energy parts and tooling. boots, says Johnson. You have to have
people you can trust who will give you
the right answers so the foundries do
what you expect.
Theres a great deal that can
Tel: 800.441.6173 (US & Canada) change about a casting that wont be
www.magnaplate.com apparent when the valve is received,
Smith remarks. Theres a lot of money
involved in making a casting, and or as part of a joint venture.
PHOTO COURTESY GREG JOHNSON, UNITED VALVE

foundries can take shortcuts that are One potential alternative to this is
difficult to detect. The only way to working through a representative in
determine if youre getting what was Japan, a country thats close enough to
specified is to be there and make certain China for regular inspection trips. The
no shortcuts are taken. Japanese have developed a sophisticated
Quality problems cited by buyers valve industry and, like other countries,
often involve aspects of processes that are experienced in sourcing commodity
are undetectable unless a representa- valves from China.
tive is on site monitoring the casting
operation. Testing Standards Are Critical
One such problem is when the Casting quality is determined by vari-
foundry reduces the amount of heat or ous international standards, primarily
Valve casting inspection is important to
material thats applied during process- API RP 591, issued by the American ensure that valves meet the expectation of the
ing to save money. Metals are heated to Petroleum Institute, which includes end user without the need for extensive weld
certain temperatures prior to pouring testing, sampling and inspection proto- repair.
and held there to liberate impurities. cols. All valves have to pass the stan-
Reducing the amount of heat or not dards criteria. ture and other factors. These can be
maintaining it long enough will affect Valero, for one, doesnt rely on one effective, but sources say the programs
valve quality. testing company to evaluate its valves are expensive, require lots of data to be
Similarly, short-pouring a riser, with the API RP 591 standard; it uses input and involve steep learning curves.
which channels molten metal to a valve two testing firms to assure accurate and
as it cools and contracts, or reducing consistent results, Felder says. Relationships Make Good
the size of its gate will raise material Destructive tests are also necessary Business
yield but affect valve density, creating for quality certification to assure the At the end of the day, perhaps the best
the potential for failure during use. castings mechanical properties meet approach is to make certain a foundry
The temptation to cut corners is ASTM and other standards. focuses primarily on the products a
always there. A good foundry pouring a An important test is X-ray inspec- buyer specifies. If youre not in a facili-
3-inch valve may get a 45% yield, says tion, which is done at a set rate of sam- ty thats dedicated to your designs,
Smith. If you short-pour a riser you pling, for example, 1 of every 500 youre going to have problems, Cowart
may push your yield to 50-55%. This is valves. The cost of radiography in says. If a facility is making valves to
big money. China, though, is almost as expensive as lower specs than yours, its going to pull
Foundries that have recently added in the U.S., so this can be done when your product down, not vice-versa.
either wax- or sand-casting should also shipments are received with no major China has no effective civil court sys-
be scrutinized, primarily to make sure financial penalty. A downside of state- temat least not in the way companies
they arent exceeding the capabilities of side testing is if a problem develops, fix- in the U.S. and the West understand it.
the processes when it comes to valve ing it will take longer and possibly If you run into a problem, there isnt
size. Buyers say that wax casting is only involve a high reject rate. anyone to sue. So contracts mean
effective on valves up to 8 inches in Smith says that McJunkin RedMan nothing and lawsuits mean nothing,
diameter. Anything larger needs to be follows a multi-pronged approach to Smith says.
sand-cast. quality assurance: We have a person Ultimately, the best way of assuring
Another feature to note is capacity. A we work with in China whos on retain- quality castings is by developing per-
foundry has to have pouring capability er. We also go to China and test mate- sonal relationships. Buyers say that
and heat-treatment facilities to cast the rial. everything in China boils down to this.
valve sizes and volumes a buyer orders. Nevertheless, as Johnson says, If you have a close relationship with a
Buyers say this is especially important There is still an art to casting, so Chinese businessman, Smith adds,
when valves as large as 60 or 84 inches theres no guarantee that even with non- he will treat you fairly and work well
are specified. destructive tests a part will always be with you.
Most companies assure compliance fully up to spec. Tweaking a process This is why relationship building
by working with local representatives until it is accurate is another reason why should be at the top of any buyers
and making regular trips to China for a buyers on-site presence is beneficial. Acceptable Manufacturers List. VM
inspections and, most importantly, qual- There are software programs that
PATRICK A. TOENSMEIER, based in Hamden, CT,
ity tests. Buyers with the financial simulate the process and help foundries specializes in writing about manufacturing
resources often keep their own people detect quality problems stemming from and technology issues. Reach him at
on site full time, either through an office part size, mold design, pour tempera- toensmeier@sbcglobal.net.
S p r i n g 2 0 0 8 | 39
AUTOMATED
VALVE PACKAGES
INTELLIGENT DIAGNOSTICS DELIVER BOTTOM-LINE BENEFITS
n this article, we explain the
I technology employed by intelli- ADVANCED CONTROLLERS HAVE
gent valve control and monitoring REVOLUTIONIZED AUTOMATED VALVE
equipment, and provide examples of
typical diagnostic features specific PACKAGES BY OFFERING GREATER
to discrete installations. The article INTELLIGENCE AND DIAGNOSTIC DATA
also discusses how diagnostics are
useful in meeting predictive and THAN CONVENTIONAL METHODS.
reliability maintenance improve- BY JACK DIFRANCO
ment objectives.
During the last decade, produc-
tion plants adopted preventive
maintenance strategies in an effort
to reduce their operating expenses,
improve reliability and increase on-
stream performance. In order to
more effectively and intelligently
manage the risks of equipment fail-
ure, many plants have migrated
from a preventive maintenance
schedule to a Predictive Mainte-
nance (PdM) regimen or incorporat-
ed PdM as a component of a Relia-
bility-Centered Maintenance (RCM)
initiative (as defined by the techni-
cal standard SAE JA1011).
Today, end users are looking for
ways to determine which valves
actually require service, and more
importantly, which do not. At a min-
imum, even without interrogating
any performance data, the user can
identify how many successful cycles For example, if an element of the automated valve package has a marginal compo-
were achieved prior to having a fail- nent, the performance data would depict any deviation in the performance curve.
ure. Simply retrieving the cycles
and setting an alarm can be helpful Technology Developments
in scheduling shutdowns for mainte- Despite advancements in process control technology and new strategies for asset
nance and repairs. management, automation end users continue searching for better solutions address-
Modern diagnostics provide ing valve performance issues on the plant floor. From mechanical wear to electronic
users with full visibility of valve and malfunction, devices such as valves, actuators, solenoids, positioners, control moni-
actuator performance behaviors. tors and transmitters all have some calculated failure mode.
This enables prediction of normal MTBF and PFD reports by companies such as Exida can help end users determine
wear-and-tear within the automated the level of probability of failure and safety integrity level of their entire control loop,
package, and also provides early including the final control elementthe automated valve. However, third-party com-
warnings should an anomaly occur. panies that evaluate components of a device cannot be held responsible for selecting
the correct valve and actuator for the ing valve package in order to obtain per- determine the cause and effect of valve
process and environmental application, formance data. The automated valve failureand truly identify the compo-
nor for the vendors quality assurance had to be forced out of its normal con- nent(s) that malfunctioned. There is no
program and unexpected changes that trol region or operating condition in possible way to answer this question in
occur in real-time situations. order to determine its health status. the current article, but I do advise users
Increasingly, industrial operations Such procedures frequently required to identify the difference between behav-
are turning to smart Automatic Valve shutting down the process. Now this is ior analysis and root cause analysis. In
Positioners (AVPs) with fully automated no longer required for capturing, storing other words, a safe objective is to pre-
diagnostic features. The automation and managing real-time data. dict failures in an effort to avoid unnec-
industry introduced the first such Several industry acquaintances have essary downtime.
devices more than 10 years ago. Since asked me if its possible to accurately CONTINUED O N PA G E 43
then, intelligent valve controllers and
positioners have become widely accept-
ed in the market. Powerful diagnostic
features are currently available on
equipment used throughout the control
Around The
valve world.
Automated valve diagnostics provide
the reliability engineer with alerts when
Clock Valve
a deviation from normal operation is
detected. Baseline tests for these diag-
Safety
nostics consist of data taken over an ini-
tial period with the device installed and The Babbitt Safety
operating in normal process conditions. Wheel provides reliable
Performance data are then continuously valve actuation 24
monitored with the valve in operation in
the process. hours a day in refining,
Upon detecting a deviation, the valve processing and power
controller captures a data set encapsulat- plants around the globe.
ing the alert and sends it to the diagnos-
tic tool, which interprets the information
for the user and indicates the source of
the problem. The diagnostic automatical-
ly examines a host of parameters and
variables to identify performance issues
sometimes too subtle for even well-
trained service engineers to distinguish.
Latest Advancements
In the on/off batch-processing arena,
there is a need for more advanced
means of monitoring valve operation.
Unfortunately, users of quarter-turn
valves have never had access to the
same diagnostic solutions offered on
smart control valve positioners. In some
cases, users would install smart posi-
tioners in their applications. Now, dis- Babbitt Steam
crete controllers with continuous 4-20 Specialty Co.,
mA monitoring allow integrating the P.O. Box 51208,
appropriate solenoid for the application New Bedford, MA 02745
with the advanced diagnostics.
Tel: 508-995-9534 Fax: 508-995-2701
Prior to launching on-board diagnos-
tics, devices such as LVDTs and pressure E-mail: sprocket@babbittsteam.com Web: www.babbittsteam.com
sensors had to be connected to the exist- CIRCLE READER RESPONSE #5
S p r i n g 2 0 0 8 | 41
A U T O M A T E D V A L V E P A C K A G E S
Figure 1. Validation of Proper Actuator Sizing
This diagnostic indicates whether the valve actuator is sized with the appropriate safety factor specified by the end user. For example, if an actuator
is required to have a 30% safety factor, the differential curve should be approximately 30% below the instrument air curve across the X &Y until
the valve has reached an open and close position as shown.
The premise of this test is to ensure there is sufficient torque to open and close the valve, as torque values may increase after the valve is
subject to process media. Obtaining a signature prior to shipping and commissioning the automated valve is a huge benefit to both the valve
supplier and the end user. This capability ensures the automated valve meets or exceeds all application specifications. The other components that
could affect the performance curve are improper air supply (pressure and SCFM), tubing size, fittings and other ancillary pneumatic components.
While the device only offers intelligent data that the performance is not optimal, its up to the valve/actuator vendor to determine the root cause
and corrective action.
ASSET MANAGEMENT SERVICES BACKFLOW PREVENTERS BAR STOCK BEAR-

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PING/POLISHING VALVE MODIFICATION VALVE MONITORS VALVE MOUNTING
HARDWARE VALVE OPERATORS VALVE PARTS VALVE POSITION INDICATORS
VALVE REPAIR FACILITIES VALVE TAGS VALVE TESTING EQUIPMENT WELDING
CONTINUED F R O M PA G E 41
From a paradigm perspective, any responded to the needs of batch process- functionalitynot to mention
deviation in the performance curve that ing operations by developing truly intelli- local/remote configuration and auto-cali-
triggers an alarm is certainly worth gent valve controllers for discrete appli- bration capabilities.
spending time to interrogate. Even if the cations. These versatile, The new generation of intelligent
user is uncertain whether the problem microprocessor-based devices are control monitors provides robust diag-
involves any component/package, or a designed to meet a wide range of nostics and data acquisition capabilities
complete valve, actuator, solenoid or rotary/linear valve actuation require- allowing plants to verify the perform-
valve monitor, simply preordering a ments, including simple on/off functions, ance of automated discrete valves in
package to be on site could save hours hazardous operating environments and real-time, thus reducing the potential
and even days of downtimenot to men- emergency shutdown (ESD) systems with for catastrophic failure. Unlike off-line
tion unnecessary expediting fees. Con- partial stroke testing (PST). signatures, users can capture the vari-
versely, the data may allow the expert From a non-contact sensor for precise ables needed to develop a pressure-pro-
(end user or vendor technician) to deter- position feedback, to a fully encapsulated filing baseline dynamicallywhile in
mine that the behavior is linear, which electronics module providing detailed servicethus eliminating the need to
would simply require an adjustment information regarding the performance remove valves from service in order to
and/or replacement of the packing with- of the pneumatic AVP, the new discrete diagnose a performance issue. These
out having to remove the complete auto- controllers have intelligence, speed and controllers use a pass/fail score card
mated package. communication options previously unat- technique to predict and prevent actuat-
tainable in the on/off valve market. They ed valve failures.
Newest Solution incorporate advanced solutions for inte- The latest discrete controllers are
The valve equipment industry has grated valve asset management and PST designed with integrated pressure sen-
Figure 2. Dynamic (Process) versus Function (Nil-Process) Signatures
Open Signature Close Signature
Dynamic Signature developed when the automated packaged is commissioned under normal process conditions.
Performance Signature developed prior to commissioning the automated package, valve/actuator supplier, instrument shop, pre-commission
with Nil-Process.
We see in the Open chart there is an increase in the differential pressure at the break. On the function test plot, it is time 0.095s and dynamic
time 0.0115s. This can be due to the required increase in torque to move the valve against the media in the line. Note the break time increases but
the travel time is very similar.
In the Close chart it takes longer to close and again it requires more differential pressure to put the valve into the seat at the end of the stroke.
A Last (In-Process) Maintenance Signature Function will capture every discrete output command for opening and closing the valve assembly. It
will then be logged as a Last Maintenance Signature and compared to the Baseline Signature. This is where a Dynamic Baseline Signature Function
provides much more accurate data than a Performance Baseline Signature Function. If we were to compare a maintenance signature to the
performance baseline signature, we would already be concerned as the graphs would clearly indicate a deviation from the baseline, but is this
deviation a result of normal process dynamic or impending equipment failure? The objective is to compare true dynamics during commissioning
and break-in so that maintenance signatures are not compared to those that were captured without process.
If the maintenance signature was compared to a dynamic signature, our baseline data already includes dynamic process conditions so any
deviation indicates an issue with the equipment.
S p r i n g 2 0 0 8 | 43
Figure 3. Baseline versus Maintenance Signatures
The Dynamic Baseline Signature Function captures a signature of

the following valve package variables: position versus time;
supply pressure; differential pressure; and actuator exhaust
pressure.
These variables are captured in ambient process conditions.
The dynamic signature can be captured after a break-in period,
which is defined by the end user from 2 cycles to n cycles.
However, the nth cycle must be executed within 50 days of
commissioning the device. Once this dynamic baseline signature
is captured, you have an accurate snapshot of real-time valve
package performance for future comparison to maintenance
signatures.
During the last operation, an alarm was triggered due to a
parameter falling outside the configured allowable hysteresis.
Looking at the information below, note how quickly the suspect
parameter is located. One of the most useful functions of the
latest generation of software diagnostic tools is the intelligent
filtering and presentation of key information.
Figure 4. Run Times sors for developing accurate data for

functional alarms. Plus, they employ an
intelligent alarm management system
that helps eliminate nuisance alarms.
Enhanced alarm logic provides more
meaningful alarms when there are rele-
vant changes in process conditions.
Unlike conventional valve position-
ers, modern control monitors utilize a
Hall Effect sensor to develop a position
feedback signal. This non-contact tech-
nology eliminates linkages, levers and
other rotary-to-linear conversions, while
providing highly accurate and repeat-
able position control and feedback
required for advanced control strategies
and predictive maintenance algorithms.
The use of Hall Effect sensor technol-
ogy also provides the ability to remote-
mount the electronics assembly up to 50
feet away from the remote sensor
assembly mounted to the valve. This fea-
ture enables the monitoring and control
Note that the air pressure dropped from 93.9 to 89.9. The lower instrument air decreased the of valves in areas of environmental
torque output, resulting in a slower breaking time off the seat. Conversely, it took less time to extremes such as high vibration and or
break from open to close as the spring toque will increase with less pressure. high/low temperature.
Dynamic conditions that can change the torque requirements of a valve are one of the many
With the aid of an associated soft-
primary reasons why engineering firms and end users demand a safety margin when sizing
actuators for a specified valve. Unlike a trunion-mounted ball valve, where the process may have ware package, service engineers can
very little affect on the torque requirements, many process valves such as floating ball, plug and calibrate, commission, interrogate and
butterfly are subject to process conditions. Many valve manufacturers offer torque requirements maintain the intelligent discrete con-
based on process conditions, but it can be very difficult to test every possible real-time troller from the safety of a remote loca-
condition in a lab setting.
tion. The controller also provides ESD
Don Sanders, Shell Offshore, attending a recent project meeting, stated, It is very valuable to
know the signature prior to the valve leaving the automated vendors shop, and then have the monitoring and PST capabilities that
ability to compare after the device is installed during pre-commissioning and finally when are time- and date-stamped and validat-
process conditions are present. ed in order to increase plant safety and
Figure 5. Insufficient Air Supply Volume
Baseline Signature Maintenance Signature
This graph can be used to verify that the instrument air requirement is accurate and determine whether there is a volume compliance issue as the
result of a clogged input filter, restricted air line or improperly sized compressor.
Continuous monitoring of instrument air pressure is vital to actuator performance during normal operation. Should the air supply drop below
the minimum requirement, an alarm can be triggered in advance to notify operators of a potential failure. Instrument air is just as important during
valve testing in ESD applications. During a test performed at 60 PSI, the slew speed graph might indicate a 125 mS break (i.e., the time it took to
move the valve). However, if the instrument air increased for any reason to 120 PSI, the break time might increase as well, since it took longer to
exhaust the pressure at 120 PSI than at 60 PSI. This situation could cause an erroneous alarm indicating the valve failed the PST when, in fact,
there was no deviation in valve performancesimply a change in the instrument air.
provide authenticated evidence of these troller using a wireless PDA. This is munications standards allow individual
actions for regulatory validation. especially valuable when the valve is in valves to monitor their own health and
Intelligent control monitors are an area inconvenient or hazardous for signal for help when they start exhibit-
designed to provide valve control, moni- plant personnel to access. Utilizing an ing sub-optimal performance.
toring and diagnostic information, auto-cal function, deadband is automat- The graphs shown throughout this
including performance comparison ically set to match the hysteresis of the article depict typical valve performance
graphs in real-time, either via a field valve actuator and consistent calibra- issues addressed by intelligent controller
network, local RS232 connection or tion characteristics can be written into diagnostics utilizing timing, position
Bluetooth communication. Utilizing the users control scheme. When a valve and pressure variables. The diagnostic
HART with FTD-DTM software, data must be replaced, the technician simply plots were developed from an advanced
exchange, storage and networking is downloads all of the stored data from discrete control monitor with pressure
possible with any HART-based HOST the intelligent field device to a PDA, profiling capability. The same relation-
Managment System. then uploads it to the new device. ships hold for double-acting actuators,
The intelligent field device, with The ability to access a database with but for the sake of clarity, spring-return
associated interrogation and reliability complete information on the valve, actu- actuators are showntypically the open
software tools, enables plant personnel ator and controls from an intelligent cycle only.
to download data from the instrument field device is a huge breakthrough for
and upload this information to a valve end users. Not only does this feature
population management tool for use in enable components and vendors for the User Benefits
establishing, justifying and predicting valve package to be immediately identi- The evolution of discrete valve control
maintenance programs. The controller fied, it also allows technicians to upload technology, as evidenced by the develop-
stores all relevant information for the all stored information should it become ment of intelligent linear/rotary control
valve package in non-volatile memory, necessary to completely replace the dis- monitors, is keeping pace with user
eliminating the possibility of lost data crete controller. demands for lower total cost of owner-
and providing a complete history of the ship (TOC), reduced maintenance, high-
equipment from the day it was installed Performance Issues er reliability and increased process
until the time it is decommissioned. Today, maintenance technicians neednt uptime. These devices benefit process
Field technicians can perform non- assess each valves current operating operations by enabling real-time report-
intrusive auto-calibration and configu- condition with a trip to the field. Rather, ing, optimum asset management,
ration of the intelligent discrete con- intelligent controllers using open com- increased plant efficiency and reduced
S p r i n g 2 0 0 8 | 45
Figure 6. Valve Actuator Stiction
Looking at the Position and Differential Pressure plots, it is immediately apparent that it is taking the valve much longer to come off the seat. A
corresponding increase in Differential Pressure indicates that a greater torque is required, and both are indications of potential change in the
dynamics of the valve and/or actuator. Hence, they are suggesting the probability of potential failure in seat of the valve, packing and/or the
actuator o-ring.
life cycle costs. failures, enhanced maintenance plan- ance comparison graphs assisting with
In addition, the intelligent discrete ning and improved process stability. predictive maintenance strategies. VM
controller has versatile diagnostics
capabilities that help to identify symp- Conclusion JACK DIFRANCO, JR. is Vice President of Sales for
Westlock Controls (www.westlockcontrols.com)
toms before they become serious prob- Thanks to recent advancements in dis-
and has 22 years of industrial field application and
lems. Corrections and adjustments can crete monitoring and control, process sales experience. He holds a B.S. in Software
be prioritized in an organized fashion, managers can verify the performance of Engineering from Colorado Technical University
reducing trips to the field. Early diagno- any pneumatic AVP in the plantwith- and a B.S in IT Network Management. The author
sis and correction of performance issues out having to go into the field. End users would like to recognize Herb Tucker, Jason Moore-
head, Frank Oster, Dan Mrozinski and Leo Miner-
can have a large payback from upgrad- benefit from robust valve control and
vivi from the Westlock Engineering Team for
ed process efficiency and quality, diagnostic information, including real- contributing graphs, related technical data and for
increased reliability, fewer unplanned time self-reporting data and perform- validating this article.
Figure 7. Solenoid Not Shifting
Baseline Signature Maintenance Signature
A command to open the valve was sent. The differential pressure does not begin to move until .285 seconds after the command is sent. This
indicates no pressure is being applied to the energize port until that time. It can also be seen that the supply does not drop to fill the chamber nor
does the closed side of the actuator begin to exhaust.
WHO MAKES WHAT?

75 NORTH AMERICAN MANUFACTURERS, 40 TYPES
OF INDUSTRIAL VALVES, ACTUATORS AND CONTROLS
A SPECIAL EXCERPT JUST FOR VALVE MAGAZINE READERS
FROM THE LATEST EDITION OF THE NORTH AMERICAN
VALVE CATALOGA SOURCEBOOK FOR BUYERS OF VALVES,
ACTUATORS & CONTROLS
Every other year, the Valve Manufacturers Association of America pub-

lishes the North American Valve Catalog, a compendium of VMA member
the
companies that produce valves, actuators and controls. In addition to the
NORTH popular Product Matrix, which you will find on the following pages, the
AMERICAN
Valve catalog contains detailed information on each of the participating compa-
Catalog nies, as well as articles about buying North American valves, actuators
A Sourcebook for
Buyers of Valves,
Actuators & Controls
and controls; the industries in which these products are used; and valve
8TH EDITION
selection tips. Plus, the print edition includes a handy valve specifying
PUBLISHED BY THE
VALVE MANUFACTURERS
ASSOCIATION OF AMERICA checklist.
The 52-page catalog is available for purchase (see page 52 for an order
form). Plus, if you'd like to search online for manufacturers and products,
VMA also offers a companion to the printer version, the Online Valve
Product Finder, on VMA.org.
Just click on the Valve Product Finder link on the home page of VMA.org
to enter the online Valve Catalog. Once there, you have two ways to
search: by product or by company. Lets say you would like to find out
who makes high-performance butterfly valves. Just go to the Product
Search, use the drop-down box to locate that category, and youre taken
to a list of companies that make that particular product. Click on one of
the companies in the list, and youll open a box that contains detailed
information about the company: address, phone numbers, email and web-
site addresses, key personnel, year founded, industries served, other prod-
ucts the company produces and a company profile. Or, if you know the
company youre looking for, you can locate it using the Company Search
function.
We hope you find the Product Matrix on the following pages useful, and it
prompts you to visit the Online Valve Product Finder to learn more about
the quality products made by the members of the Valve Manufacturers
Association of America!
S p r i n g 2 0 0 8 | 47
P R O D U C T M AT R I X
theNORTH AMERICAN
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Valve Catalog
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American Flow Control (A Division of American Cast Iron Pipe Co.)
American RD Valve Co. (Division of McWane)
American Valve, Inc.
ASCO Valve, Inc.
AUMA Actuators, Inc.
Automation Technology, Inc.
Babbitt Steam Specialty
Harold Beck & Sons, Inc.
Bernard Controls, Inc.
Cameron Valves & Measurement
CCI - Control Components, Inc.
Check-All Valve Manufacturing Company
Clow Valve Co. (Division of McWane)
Conval, Inc.
Copeland Industries, Inc.
Cowan Dynamics Inc.
Crane ChemPharma Flow Solutions
Crane Energy Flow Solutions
Curtiss-Wright Flow Control Corporation
DeltaValve (A Division of Curtiss-Wright Flow Control)
DFT Inc.
Dresser Consolidated
Dresser Masoneilan
Dresser, Inc. - Becker Precision Equipment
DynaTorque, Inc.
EIM Controls, Inc.
Emerson - Fisher Controls
Emerson - Valve Automation
Everlasting Valve Co., Inc.
Farris Engineering (A Division of Curtiss-Wright Flow Control)
Flow-Quip, Inc.
Flowserve Corporation
Fluoroseal, Inc.
Global Flow Technologies
High Pressure Equipment Company
Indelac Controls, Inc.
ITT Engineered Valves
Lined Valve Company, Inc.
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D G G G G G H In N N P P P P P R S S A A A A A o
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S p r i n g 2 0 0 8 | 49
theNORTH AMERICAN
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Kennedy Valve Co. (Division of McWane)
KITZ Corporation of America
K-Tork, Inc.
KOSO AMERICA, INC.
M&H Valve Co. (Division of McWane)
Mastergear (Division of Regal Beloit Corporation)
MaxTorque LLC
Metso Automation USA, Inc.
Milliken Valve Company (A Division of Mueller Water Products)
Moog Flo-Tork, Inc.
Mueller Water Products
Parker Hannifin Fluid Control
PBM, Inc.
The Wm. Powell Company
Process Development & Control, Inc.
QTRCO, Inc.
Remote Control, Inc.
Richards Industries - Valve Group, Inc.
Roto Hammer Industries, Inc.
Rotork Gears
Rotork Process Controls
RSVP Actuators & Controls
Samson Controls, Inc.
Sartell Valves, Inc.
Spirax Sarco, Inc.
Tapco/Enpro (A Division of Curtiss-Wright Flow Control)
Target Rock (A Division of Curtiss-Wright Flow Control)
TESCOMEmerson Process Management
Therm-Omega-Tech
Top Worx
Townley Engineering & Manufacturing Company, Inc.
Tyco Flow Control
UniTorq Actuators & Controls
Velan Valve Corporation
Weir Valves and Controls USA, Inc.
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D G G G G G H In N N P P P P P R S S A A A A A o
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S p r i n g 2 0 0 8 | 51
HOW TO ORDER THE LATEST EDITION OF THE NORTH AMERICAN VALVE CATALOG
A Special Thanks to Our ORDER FORM
Catalog Advertisers
The Valve Manufacturers Association North American Valve Catalog 8th Edition
would like to recognize those A Sourcebook for Buyers of Valves, Actuators & Controls
members who helped support the
printing and distribution of the North SPECIAL BONUS:
Receive a FREE COPY of the 2007/08 Valve & Actuator Guide to Suppliers
American Valve Catalog by
becoming display advertisers. Please
be sure to visit the websites of these
fine manufacturers, as well as other YES, Id like to order ____ copies ($29.95 each + shipping/handling) of
the 8th Edition of the North American Valve Catalog, a 52-page
compilation of VMA member companies and their offerings. I understand that I
members of VMA.
will receive a FREE copy of the Valve & Actuator Industrys Guide to Suppliers
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American Valve
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BEYONDVALVES
BY GREG JOHNSON
Putting the P in PVF

f course, the P in PVF stands for ing systems on record, in ancient Rome,
O pipe, those long round things with 2000 years ago, were made of lead. The
the hole down the middle! Learning a industrial revolution and the Iron Age
little bit more about the pipes that con- ushered in the era of iron pipe, which
nect to your valves will help you as a peaked in the 1920s. Although steel is
valve professional. the primary choice for industrial appli-
First, we need to understand how cations, non-metallic piping materials
pipe is sized. Pipe is measured by utiliz- have made huge headway in the water
ing a dimensionless number known as and wastewater industry where iron
nominal pipe size or NPS. These sizes once was king.
run from inch to above 72 inches. If Steel pipe material specifications are
you take a caliper to a 1 inch NPS pipe detailed in ASTM documents, and some
you will be surprised to see that it is not of the more common ones are listed in
1 inch in diameter, rather, it is actually the table below:
1.315 inches in diameter. This oversize
dimensioning applies to pipe through Designation Material Notes
NPS 12 inches. For diameters 14 inch- ASTM A53 Seamless & welded
es and above, the NPS is the actual out- steel pipe
side diameter. When it comes to dimen- ASTM A106 Seamless carbon
sions, pipe should not be confused with steel pipe
tubing. Tubing size is equal to its out-
ASTM A335 Alloy steel pipe
side diameter.
(Cr/Mo, etc.)
These schedules are the approximate
Pipe Schedules expression of 1000 P/S, where P is the ASTM A312 Stainless-steel pipe
Since the strength of pipe is proportion- service pressure and S is the allowable API 5L Line pipe for petrol-
al to its wall thickness, pipe is also cate- stress, both measured in PSI. Pipe eum pipelines
gorized in this way. Initially pipe dimen- schedules begin with 5 and currently
sions were fairly standardized. In fact run all the way up to 160. The most How Its Made
the wall thickness was called stan- common schedules in use today are 40, Another important identifier in steel
dard (STD), or standard wall. As 80 and 160. The old termsstandard, pipe is the process by which it is made,
pressures increased, the designations extra-heavy and double extra-heavy either welded or seamless. Welded pipe
were amended to include thicker walled are still used and they correspond to is made from plate, which is rolled into
pipe called extra-strong (XS) or various pipe schedules, depending upon a circle and then welded down the
extra-heavy (XH). Eventually the the NPS of the pipe. Schedules with an length of its longitudinal seam. Seam-
term double extra-heavy (XXH) or S suffix, such as SCH 20S, refer to less pipe is made by squeezing and
double extra-strong (XXS) was stainless-steel pipe, dimensioned in rolling round bar around a pointed man-
added to the range of pipe wall thick- accordance with ASME B36.19M. drel that pierces the inside of the bar,
nesses as they grew thicker to accom- Steel pipe is dimensioned in accordance creating the pipe bore. Due to the equip-
modate even higher pressures. The three with ASME B36.10M. ment costs involved in seamless pipe
pipe thicknesses STD, XS and XXS manufacturing, it is primarily used in
were inadequate to handle an ever- Materials and Specifications the smaller sizes. For critical applica-
increasing range of fluid pressures, so a Today, the predominant material for tions, however, seamless pipe is almost
new system based upon numbers called industrial piping is steel. However, that always specified, and it is commonly
pipe schedules was devised. was not always the case. The oldest pip- manufactured in sizes through NPS 24.
Connections grooved-end design, combined with a pipe made of exotic materials such as
Pipe can be provided with plain ends, resilient seal and bolting mechanism to Kynar and Kalrez is used.
threads or mechanical connections. lock the joint in place. Mechanical Industrial facilities and power plants
Before the perfection of pipe welding joints are also popular because they require a maze of piping that twists and
techniques 75 years ago, most piping allow for a slight misalignment to per- turns in all directions. Small-diameter
was supplied with threads on each end. mit pipe runs to dodge around obstacles pipe is welded to fittings to achieve
Through the use of couplings and without the use of curved pipe or exces- direction changes in the pipe runs, while
threaded pipe fittings, pipelines and pip- sive use of elbow fittings. larger pipe is bent. Steel pipe of virtual-
ing assemblies were created. Making a ly any size can be bent to any angle.
leak-free connection on a 40-foot joint From Homes to Industry This process creates what is called fab-
of 6-inch threaded pipe took quite a bit If you have walked through a house ricated piping that is formed to the
of muscle power, a bucket of pipe under construction or made a wrong exact geometry called for in the piping
dope and a giant-sized pipe wrench! turn down one of the big box store aisles, blueprints. The prefabricated pipe sec-
Today, virtually all industrial piping you have probably seen white plastic tions are then shipped intact to the job
is welded. Properly welded pipe joints PVC piping. While not allowed in most site where they are joined with other
have high integrity and they are much industrial plants, the plastic pipe forms fabricated sections. This off-site fabri-
faster to make than by threading fittings the basis of nearly all residential piping. cation saves time and money as well
to each piece of pipe. In the waterworks PVC pipe as used in home construction ensuring more accurate construction.
industry mechanical connections are is usually schedule 40, and it is welded
used to join most large diameter water to PVC fittings and valves using a plastic GREG JOHNSON is president of United Valve
and wastewater lines. These mechanical solvent. For some low-pressure, highly (www.unitedvalve.com), a valve service company
in Houston, TX. Reach him at greg1950@
connections employ a bell and spigot or corrosive industrial applications, plastic unitedvalve.com.
ISO 9001:2000
Our Reputation
is Stainless
S p r i n g 2 0 0 8 | 55
MAINTENANCE & REPAIR

BY BART COLLINS
PSV Inspection: Test Only, or Full Inspection and Overhaul?

n todays ever-changing, fast-paced ter for verification of relief pressure and time-consuming depending on the loca-
I world, uptime is at a premium, while seat leakage testing. tion of the valve and the process it is in.
remaining in compliance with govern- In some cases, the valves will be located
mental and plant regulations is a require- In-situ testing in a fresh air application or in an area
ment. With increasing demands placed PROS: In-situ testing gives the end that requires the equipment to be intrin-
on plants to produce, it is necessary to user an economical advantage over sically safe.
look at different ways to perform inspec- other methods as it allows the plant to
tions on pressure relief devices and mini- keep the process unit running while test- Bench testing
mize plant downtime. Many plants in the ing is being performed. While this type PROS: Bench-testing allows a full
United States have opted to modify their of testing is typically more expensive on functional test to be applied to each valve
plant PSM (process safety management) a per-valve basis than bench testing, it by putting the valve into lift (lift may
programs to allow a test only on each is much more economical for the end vary based on volume of test equipment).
pressure relief device in lieu of a com- user in the total overall cost of perform- It also allows the valve to blow down and
plete disassembly and VR overhaul. ing the test. reseat and allows for a seat leakage test.
The intent of this article is to explain the CONS: In-situ testing produces very In addition, the valve is back-pressure
pros and cons of both methods, while little results regarding the total function- tested to inspect for any external leakage
balancing additional demands of produc- ality of the valve. While it does provide a from bolted or threaded joints. While this
tivity, cost, safety and environmental start-to-discharge point (the pressure in is usually the most economical of all PSV
issues. which the valve actually starts to lift), it inspections on a per-valve basis, the end
does not put the valve into lift, does not user typically experiences internal costs
Test Only provide any type of external joint leakage such as loss of production, use of plant
A test only can be performed by two testing (back pressure test), does not manpower to remove and install the
different methods: (1) In-situ online allow for a visual inspection of the inlet valves, additional materials required for
testing while the valve is still in service; and outlet, and typically cannot accu- the installation, and any other peripheral
or (2) bench testingremoving the valve rately inspect for seat leakage. In addi- safety concerns dictated by the location
and sending it to a local repair/test cen- tion, in-situ testing can become very of the valve.
CONS: Bench testing is typically
known as the norm for test-only
inspections; but it also has its own pit-
falls. While it does provide both a full
functional and seat leakage test, it does
not provide the end user with a dimen-
sional and visual examination of the
PSVs internal working components. All
manufacturers of ASME-certified PSVs
provide dimensional tolerances, clear-
ances and visual inspection points that
are required to maintain the valves
integrity and ensure that it is in like
new condition. Additionally, a test
only does not provide an internal visual
inspection for corrosion and/or erosion of
the body and bonnet cavities, internal
parts, bearing points and springall of
which can affect the valves performance
and its total life in service.
Full Inspection and Overhaul United States. In some cases, end users
A process involving a pretest, full disas- will accept a non-VR repair as long as it
sembly, internal inspection and func- meets certain criteria spelled out within
tional test is the only true way to ensure their own PSM program. While the
that your PSV is in the best possible VR is the preferred method, plant spe-
condition. The pretest is performed cific repair criteria may be acceptable
before the PSV is disassembled. The with some end-users. A listing of all
results from the pretest are used to help authorized VR stamp holders can be
gauge whether a valve would have found in the National Boards NB-182.
relieved in service and at what pressure, PROs: As stated above, a full inspec-
whether it would have reseated and tion and overhaul is the only true method
whether it had seat leakage. By per- of determining the condition of a valve.
forming a pretest and then an entire When a valve is disassembled and
overhaul and inspection, each part of inspected, it gives you a full view of the
the PSV is cleaned, inspected, internal condition of the valve, a full
reused/repaired/replaced, assembled, visual and dimensional inspection of all
tested and returned to service. internal parts, verification of the spring
A certified VR overhaul performed number and range, any potential visual
by a certified repair company authorized corrosion or erosion, and a full functional
by the National Board of Boiler and test demonstrating consistent, repeatable
Pressure Vessel Inspectors1 is the com- 1
National Board of Boiler and Pressure Vessel
mon industry standard followed and Inspectors; NBIC www.nationalboard.org
accepted by the majority of regulatory 2
National Board of Boiler and Pressure Vessel
agencies and end users throughout the Inspectors; NB-18 www.nationalboard.org
MSS valve and fitting standards
Engineering
are in use around the world in
virtually every industry from
waste water to oil refining. 86
member companies work in 24
technical committees to develop
Standards and maintain standards that

shape the way flow is controlled.
Creating standards for:

Valves
Fittings
Pipe Hangers
Actuators
Flanges Valve Modifications
Since 1924 Seals
For further information on

MSS membership or MSS
standards, contact Bob ONeill,
MSS executive director at
703/281-6613, or on the web
The Manufacturers Standardization Society at www.mss-hq.com. MSS is
an ANSI accredited standards
of theValve & Fitting Industry
developer.
S p r i n g 2 0 0 8 | 57
MAINTENANCE & REPAIR
performance. Coupled with the pretest PSV Management Software requirements. Determining which
results, this is the only accurate way to Determining the methods and frequen- method is the safest and most practical is
predict frequency of inspections required cies of inspection is not an easy task. As not to be taken lightly. Although cost will
to comply with plant PSM requirements. stated, there are many factorsnot just always be a factor in the decision, safety,
CONs: There are two main downsides the pop-point of a PSVthat affect quality and efficiency considerations
to a full inspection and overhaul; addi- whether inspection frequencies should be should play an equal (if not greater) role
tional time and cost of repair. To properly shortened, extended or maintained. in determining PSM frequencies and
overhaul any PSV, there are certain Managing all of this information can methods.
requirements that must be followed in be a daunting task. Having an internal A PSV is a plants last line of defense
order to provide a VRd valve. This database or using a repair/testing facility when it comes to protecting life and
method can take 3-4 times longer (time that is equipped with the proper database property. A properly maintained PSV
may vary based on the size and condition is essential to a successful PSV program. will ensure that the end user, the commu-
of the valve) than that of a test only. The ability to manage this information, nity and the environment will not be
Additionally, there are additional labor help predict frequencies of repair, and exposed to equipment failure resulting in
costs for the repair, as well as costs asso- assist in tracking history and total life a catastrophic situation.
ciated with transportation, plant labor cycle cost for each PSV is a critical com-
(for removal and installation) and unit ponent of the PSM process. BART COLLINS is the General Manager for Preci-
sion Services, Inc. of Louisville, KY and Corporate
downtime. These factors need to be taken
Operations Manager for its parent company, Pre-
into consideration along with production Summary cision Pump and Valve Service, Inc.
schedules to maintain a true and accu- There are many methods of PSV inspec- (http//ppvs.com) of Charleston, WV. Reach him at
rate PSM program. tion that are used to meet end-user PSM 502.499.8250 or bcollins@ppvs.com.
3UBSEARELIABILITYFROM2OTORK'EARS
4HE337RANGEOFMANUALGEAROPERATORSFROM2OTORK'EARSCANMEET
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COMPLIANCEANDPRESSURECOMPENSATORS
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PRODUCTS INCLUDING CAST IRON AND ALUMINUM WORM GEARS BEVEL GEARS
SPURGEARSANDPNEUMATICOVERRIDEGEARBOXESFORJUSTABOUTANYMANUAL
APPLICATIONNEEDYOUMAYHAVE
7EHAVEAWELL TRAINEDSTAFFANDSTRATEGICALLYLOCATEDASSEMBLYFACILITIES
TOPROVIDEYOUWITHPROMPTPROFESSIONALANDWORLD CLASSSERVICE
&ORMOREINFORMATIONCONTACT
#LAY(IGHTOWER
2OTORK'EARS!MERICAS'ENERAL-ANAGER
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% MAILCLAYHIGHTOWER ROTORKGEARSCOM
TAKE THE
VMA TEST
IS YOUR COMPANY ELIGIBLE FOR MEMBERSHIP
in the only organization supporting and representing the interests of the
North American industrial valve, actuator and controls industry?
Find out by taking this short quiz!

Are you a manufacturer of valves, actuators Yes If you answered yes, youre probably eligible
and controls with more than 50% of your to be a full member of the Valve Manufacturers
value added in North America? No Association of America (VMA).
Do you produce products and services used by Yes If you answered yes, you could become an
North American manufacturers of valves,
actuators and controls? No associate member of VMA.
Do you provide OEM-certified service, Yes If you answered yes, you may qualify for
maintenance and repair for North American-
manufactured valves, actuators and controls? No membership in the Valve Repair Council (VRC).
IF YOU ANSWERED "YES" to any of the above questions, here's

why you need to join the Valve Manufacturers Association:
Its simple. Your investment will pay for itself many times over in the years to
come. Here are just a few of the benefits that come with membership:
Significant discount off of advertising in Valve Magazine and other VMA publications!
Free listings in the North American Catalog of Valves and Guide to Suppliersboth in the print editions
and online product finders!
Invitations to an array of VMA meetings and networking events open only to members, including
the VMA/VRC Annual Meeting, Market Outlook Workshop, Manufacturers Workshop and more!
VMAs popular members-only e-newsletter, QuickRead, delivered to your computer every Friday!
Participation in VMAs extensive statistical programs, providing you with data not available any-
where else!
FIND OUT MORE ABOUT VMA REGULAR OR ASSOCIATE MEMBERSHIP! Go to VMA.org and click on the About VMA link for a
complete list of benefits, qualifications, dues and an online application. For additional information, contact Bill Sandler at
wsandler@vma.org or call 1-202-331-8105 ex 306.
FIND OUT MORE ABOUT VRC MEMBERSHIP! Go to VMA.org and click on the Valve Repair Council link. For additional information,
contact Marc Pasternak at mpasternak@vma.org or call 1-202-331-0104.
M A T E R I A L S Q & A BY DON BUSH
QUESTION: ings have been made). Indentations ured is superficial, and therefore may not
Are portable hardness testers should be 3-4 mm in diameter (although be representative of the bulk hardness.
adequate for verifying the ASTM A833 only specifies that the Finally, since virtually no specifications
hardness of parts for indentations not exceed 4.2 mm), and reference Leeb hardness requirements,
compliance to industry such large indentations may not be the resulting hardness values must be
standards such as the NACE acceptable on many parts, especially converted to another scale. ASTM E140
sour service standards? smaller ones. Finally, the resulting includes no hardness conversion tables
Brinell hardness value must often be con- that include Leeb values, so one must rely
ANSWER: verted to another scale, likely Rockwell B on tables provided by the vendor for con-
There are a number of portable hardness or C, which can introduce uncertainty in version, which introduces more uncer-
testing devices on the market. These some situations. However, since ASTM tainty than when using tables published
devices are attractive to manufacturers E140 includes some conversion tables in ASTM E140.
and repair companies for several reasons, that include Brinell and Rockwell values,
such as: there is at least a standardized basis for Ultrasonic Contact Impedance (UCI) Testers
Portability: The units can be easily those conversions for some materials. Ultrasonic contact impedance testers,
used throughout the shop or in the covered by ASTM A1038, utilize an
field for hardness testing of compo- Leeb Testers ultrasonically-excited, spring-loaded
nents that cannot be easily brought Leeb testers, covered by ASTM A956, Vickers diamond indenter and a device to
to a bench-top hardness tester. bounce an indenter off of a part and use measure the frequency shift that occurs
Large components: They can be the difference in the inbound and out- when the indenter penetrates the speci-
used on components that are too bound velocities to determine the hard- men. The change in frequency is used to
large to test with a bench-top ness. The value measured is a Leeb hard- determine the size of the indentation,
tester.
Cost: The devices typically cost less
than a bench-top tester. Portable hardness testers have their place in
production and field applications, as well as in
There are several popular portable
laboratory environments. However, like all hardness
devices on the market. Three common
devices are described below: testers, they need to be used with careful
consideration of their capabilities and limitations.
Comparison Hardness Testers
Comparison hardness testers, covered by
ASTM A833, feature a device that incor- ness number. Generally, this Leeb which is then used to determine the Vick-
porates a Brinell ball and a square cross- hardness number is then converted to ers hardness.
section bar of known Brinell hardness. some other scale (such as Rockwell or Drawbacks of UCI Testers: UCI test-
A hammer is used to strike the device Brinell) using conversion charts to deter- ing requires the part have a minimum
against the part to be measured. Indenta- mine if the material meets some specified weight of at least 300 g (0.7 lbs). There
tions are produced in the part and in the requirement. are restrictions regarding minimum wall
known bar. An equation or slide-rule Drawbacks of Leeb Testers: Leeb test- thickness and part stiffness to ensure the
device is used to determine the Brinell ing requires that the part have a certain part itself is not excited by the ultrasonic
hardness of the part based on the inden- minimum weight, ranging from 1.5 kg (4 vibration. There are minimum surface fin-
tation diameters in the known bar and lbs) to 15 kg (40 lbs) depending on the ish requirements that are dependent upon
the specimen and hardness of the known device type and the thickness of the part. the test load and the hardness of the spec-
bar. There are minimum surface finish imen. The accuracy of the measurement is
Drawbacks of Comparison Testers: requirements, ranging from 0.4 m (16 dependent upon the surface finish. For
Comparison hardness testing requires the in) Ra (corresponding to 500 grit emery example, calibration blocks are required
use of calibrated, consumable bars of paper) to 7 m (250 in) (corresponding to be finished to 0.4 m (16 in) or better
known hardness (i.e., the bar must be to 65 grit emery paper) depending upon for accuracy. The hardness measured is
replaced after a certain number of read- the impact device. The hardness meas- superficial, and may not be representative
U.S. ALLOYS, INC

Since 1976, Round Bar Supplier for Valve & Fitting Manufacturers
of
Petrochemical / Power Generation / Nuclear / Aerospace
of the bulk hardness. Since most specifi- Round Bar Stock
cations do not list Vickers hardness
requirements, the resulting Vickers hard- GRADES:
ness values must often be converted to (Domestic and Import)
another scale. ASTM E140 includes
some hardness conversion tables that 304/304L A105 F-11
include Vickers values, but conversion 316/316L A350 LF2 F-22
tables do not exist for all materials and 317/317L SA105 F-5
hardness ranges. 321/321H A675 GR 70 F-9
347/347H A696 GR C F-91
Summary
Hopefully, this information is not taken
to indicate these testers should never be
SIZES:
used. All of these devices have their place 7/8 to 24
in production and field applications, as
well as in laboratory environments. How- Cut to length 7/8 24 OD
ever, like all hardness testers, they need ASTM/ASME/(Latest editions)
to be used with careful consideration of NACE MR01-75/DIN.3.1.B/EN 10204
their capabilities and limitations. They
really cannot be used to replace all of the Phone (713) 644-1983 Fax (713) 644-9889 www.usalloys.cc
bench-top hardness test devices. The
main reason for this is that hardness con- CIRCLE READER RESPONSE #159
version to the scales called out in specifi-
cations is not a simple and straightfor- Your Source for
ward matter. A future column will cover
the topic of hardness conversion issues in Through Valve Leak Detection
more detail. VM
Portable 5131-VPAC & Online 1278-VPAC
DON BUSH is a Principal Materials Engineer at
Emerson Process Management-Fisher Valve Divi- For a Wide Range of Applications & Industries
sion (www.emersonprocess.com). Reach him at
Don.Bush@Emerson.com. The author wishes to
acknowledge the assistance of Thomas Spence, Save Time and Money. . . . Identifies through valve gas/process
leaks
Director of Materials Engineering, Flowserve Cor-
poration (www.flowserve.com). Identifies & quantifies leak rates
ROI typically on first use,

demonstrated savings of millions
REFERENCES: per year
1. ASTM A833 Standard Practice for Indentation
Most sensitive, reliable & practical
Hardness of Metallic Materials by Comparison Through Valve Leak measurement
Hardness, ASTM International, West Con- method available today
shohocken, PA
2. ASTM A956 Standard Test Method for Leeb
Hardness Testing of Steel Products, ASTM Inter-
national, West Conshohocken, PA
3. ASTM A1038 Standard Practice for Portable
Hardness Testing by the Ultrasonic Contact Imped-
ance Method, ASTM International, West Con-
shohocken, PA
4. ASTM E140 Standard Hardness Conversion
Tables for Metals Relationship Among Brinell Hard- Loss rate formula developed by major petrochem company
ness, Vickers Hardness, Rockwell Hardness, Super-
ficial Hardness, Knoop Hardness, and Scleroscope 195 Clarksville Road, Princeton Junction, NJ 08550 USA
Hardness, ASTM International, West Con- Phone: (609) 716-4000 Fax: (609) 716-0706
shohocken, PA Email: sales@pacndt.com www .pacndt.com
S p r i n g 2 0 0 8 | 61
NEW
PRODUCTS
Dual Control Valves
Flowserve Corporation introduces the Valtek ShearStream SB
segmented v-port type ball control valve, as well as the newly upgraded
ShearStream HP with heavy-duty seat.
The new ShearStream SB control valve is the standard choice for
segmented v-port ball control valve applications. Standardized designs
provide the most cost competitive ShearStream solution in a rugged
design.
The ShearStream HP design offers a broader array of options,
which allows for higher temperatures, higher pressures, unique
materials and special designs. The HP is newly upgraded with a heavy-
duty seat option. For applications with high-pressure drops, the heavy-
duty seat provides tight shutoff and reliability.
CIRCLE READER SERVICE #28
Flat Yoke Valve Actuators Severe Service Ball Valves

Known for providing high quality, minimal maintenance valve actuators, Global Flow Technologies offers a new
QTRCO has designed, and now offers, the superior FLAT YOKE actuator series of valves: PBV Series Z1, Z2 & Z3
with an unlimited torque range. one, two and three-piece metal-seated
Available in ductile iron, stainless-steel and high alloys, the FLAT severe service ball valves, engineered for
YOKE features long life, seismic suitability, tunable torque curve, zero-leakage and critical applications.
turnover action reversal and captured springs. All PBV valves are manufactured of the
The only wearable seals are commonly available, low cost piston o- highest quality materials with state-of-the-
rings, which are replaceable while the actuator remains mounted on the art CNC machines to assure critical accura-
in-line valve. Downtime is reduced while costs of removal, disassembly, cy required for high-performance, zero-
remounting and re-calibration are eliminated. leakage metal-seated ball valve
CIRCLE READER SERVICE #42 construction. PBV match-laps all balls and
seat surfaces for bubble tight sealing, plus
all universal mounting brackets are
machined to ISO standards. One-piece
metal seated ball valves are suitable for
high-pressure severe service applications
including power and oil and gas.
Mechanical Isolation Valves

BS&B Pressure Safety Management, LLC introduces the Type IVE Mechanical
Isolation Valve to guard against the passage of hot particles, glowing embers and
flames through interconnecting piping that may ignite a deflagration or a fire from
one vessel to the next.
In process systems, there are situations where a deflagration can spread from
the initiating site to connected machinery through interconnected piping. In some
applications, it may be feasible and desirable to detect, isolate and quench prior to
ignition. In both situations, a fast response explosion isolation valve offers the best
means to accomplish the tasks.
Check Valves with Poppet Option Universal Control

Danfoss Flomatic Corporation introduces its new Valves
Enviro check valves with an upgraded poppet system The M-Series globe control valves
option. The valve option is a 316 stainless-steel from Spirax-Sarco are general pur-
internal poppet system and is available in a size pose and can be engineered to solve
range of 1 to 4 inches and replaces the standard both complex and basic require-
bronze or plastic WCR poppet. The unleaded ments. Their construction makes
bronze-body, high-temperature check valves are them long lasting and easy to main-
designed to be maintenance free and suitable for tain, while their modular design
installation in any position. makes them easy to specify, reduc-
All of the components ing spares inventory requirements.
have a sturdy correction- The body materials are manufac-
free construction, capable of tured from carbon steel, stainless
withstanding repeated nor- steel, bronze, chrome and special
mal operation without fail- alloys, ideal for high-pressure and
ure or excessive wear. These extreme temperature conditions.
valves are well-suited for There is a choice of 2-port globe, 3-
hot water applications and way globe, 2-port angle and sweep angle, in sizes ranging from
are designed to operate at a DN15 to DN400. The M-series has been specially designed for
maximum water tempera- applications within the petrochemical, mining, food and beverage,
ture of 400 F. pulp and paper, and power generation industries.
CIRCLE READER SERVICE #71 CIRCLE READER SERVICE #52
MEDIA
New Valve Catalog Available

Conval recently published its new, full-color, 40-page 2008 catalog containing informa-
tion on the companys line of Camseal ball valves and Clampseal ball, bellows, bonnet-
less, check, gate, globe, throttling and urea service valves. The catalog is available free
of charge, in electronic or hard copy formats.
Valve configurations are available for various plants and applications including: fos-
sil power, nuclear power, refineries, petrochemical plants, gas separation, pulp and
paper plants, recovery boilers, marine boilers, cryogenic systems, oil patch steam
injection, thin gas service, water treatment and hydraulic systems.
The new Conval catalog contains U.S. and metric specifications, exploded views,
flow and pressure charts, dimensions, engineering diagrams, photos, typical applica-
tions, accessories, how to order information, class rating descriptions and a brief his-
tory of the company. For more information, go to: www.conval.com or circle Reader
Service #15.
Online Configuration Tool

ASCO recently introduced an online tool for its 8290 Series actuated globe valve assembly that can significantly reduce
configuration time. At www.ascovalve.com/8290Configurator, users can quickly select an actuated globe valve, solenoid
pilot valve and position indicator in an assembly specifically suited to their applications.
This online configurator permits customers to easily configure factory-approved and tested valve assemblies in min-
utes, not months, with no engineering is required.
In addition to real-time configuration, the highly compact 8290 series globe valve has a faster response time and is
more durable and reliable. It handles aggressive media, such as hot water, steam, solvents and slurries, and is ideal for
power generation, water/wastewater and industrial dispensing applications.
S p r i n g 2 0 0 8 | 63
NEW PRODUCTS
Large Diameter Butterfly Valves Curved Bill Check Valve

GF Piping Systems has introduced the new Type 567 But- The Curved Bill Tideflex TF-1 Check Valve is designed to
terfly Valve in large diameter sizes up to 12 inches. The enhance sealing, especially in low-lying areas with little back-
new corrosion-resistant valve incorporates a double- pressure. The valve is constructed entirely of rubber, making
eccentric operating principle that provides improved it virtually immune to rust, corrosion and weathering.
wear and easier operation over traditional eccentric-style The curved bill of the TF-1 seals without backpressure,
butterfly valves. allowing for a tighter seal that eliminates gapping issues. The
Key to the valves double-eccentric disk design is the flexible bill also seals around entrapped debris. The headloss
off-center shaft that allows the disc to completely disen- of the valve remains exceptionally low. It also has a strong
gage from the disc seal, even when partially open. This spring steel spine, enabling it to handle long-term water
reduces seal friction and improves seal wear characteris- weight. The spine is at a greater vertical angle, making the
tics, resulting in longer service life, minimal maintenance TF-1 able to withstand the cantilever effect when water is
and better protection against pressure surges. The double- flowing through the valve.
eccentric design also lowers the torque required to operate Applications include highway runoff,
the valve, making for easy manual operation and use of flood control CSO/SSO systems,
smaller actuators at a significantly reduced cost. site drainage, stormwater
Typical applications include industrial water treat- discharge, sewer systems,
ment, potable water treatment, swimming pools, water coastal discharges, odor
parks and waste water systems in such industries as control or any application
chemical, chemical distribution, electroplating and power requiring backflow pre-
plants. vention.
CIRCLE READER SERVICE #10 CIRCLE READER SERVICE #167
CASE STUDY:
Double Block-and-Bleed Ball Valves Enhance Safety in Texas Refinery
A major oil refinery in Texas was looking to repair or replacement from the high-temper-
IMAGE BY DIANE YEAGERS, PBM
optimize isolation of process flow ature process flow stream.

measurement instrumentation on a FCC PBM Inc. offered a fast operating, quar-
(fluid catalytic cracking) unit. The flow ter-turn, double block-and-bleed ball valve
measurement design used a solid wedge critical if a leak or instrument failure
meter, which is a section of pipe containing required a quick shutoff. PBMs 2-inch full-
a weir that creates an obstruction of flow, bore, 300# flanged, double block-and-bleed
causing a change in line pressure between valves installed on each side of the weir
the upstream and downstream side of the could handle the abrasive process fluid at
weir. By measuring the difference in elevated temperatures and provide a tight
upstream and downstream pressures using a shutoff. These double block-and-bleed, sin-
differential pressure transmitter, the flow rate of the gle-bodied valves contained two ball valves in a single
product can be calculated. body with a bleed port to permit release trapped process
The process flow stream, which can reach tempera- fluid between the two balls. The use of two valves in a
tures near 720 F, contains abrasive carbon solids and single body provided a redundant safety feature. In the
fines. Traditionally, a multi-turn rising stem valve was event one valve failed, the other would continue sealing
used on each side of the weir to isolate the pressure tap against the process flow. With both valves closed, the
on the wedge meter and the input to the pressure trans- bleed permits dissipation of process fluid trapped in the
mitter. The multi-turn valves over time struggled to pro- small cavity between valves. Extended locking lever han-
vide tight shutoff due to the build-up of carbon grit and dles were used to allow for insulation clearance.
fines in the seat and packing area. Tight shutoff is critical For more information, visit www.pbmvalve.com
to safety when the need arises to isolate instruments for or circle Reader Service #40.
NEW PRODUCTS
FOCUS: OFFSHORE APPLICATIONS

Stainless-steel Valve Controller enables processing equipment modules to be installed on any
TopWorx announces the launch of its newest discrete valve subsea tree at any time and provides a universal interface.
controller the Valvetop DXS. This rugged new product fea- POSSibilities software is used to compare numerous pro-
tures an impressive 316L stainless-steel enclosure and is duction optimization solutions and configurations throughout
designed for durability in extreme hazardous environments the life of the field to determine an optimum solution. The BP
where traditional aluminum is not adequate. The Valvetop King project is the first multiphase pump installation in the
DXS is designed to Gulf of Mexico and the first field application of both the
withstand salt MARS and POSSibilities technologies.
spray, humidity, In addition to multiphase pumping, MARS has been select-
corrosives and ed by Shell for subsea well stimulation operations in the North
caustic washdown, Sea and by Total for subsea multiphase metering in West
and is made for off- Africa.
shore, chemical and The MARS technology has also been the recipient of sever-
petrochemical al industry awards including the American Society of
applications. Mechanical Engineers Distinguished Innovation Award and
It offers a wide World Oils New Horizons Idea Award.
variety of bus networks (i.e. Foundation Fieldbus, DeviceNet, CIRCLE READER SERVICE #16
AS-Interface), sensor options (GO Switch, proximity, mechan-

ical, P+F, 4-20mA transmitter with auto calibration feature) Offshore Flow Meter
and integral pilot valves. The Valvetop DXS is globally certi- Engineers in a tight spot over where to locate liquid and gas
fied for Explosion Proof and Intrinsically Safe (Class I, Div. 1 flow meters aboard offshore platforms, FPSO vessels and sub-
& 2, Zone 0 & 1) applications. sea installations will find the self-conditioning V-Cone Off-
CIRCLE READER SERVICE #55 shore Flow Meter from
McCrometer requires a
Safety Valve Controllers pipe straight-run that
Emerson Process Management has announced enhancements is up to 70% less than
to its SIL 3 certified Fisher Fieldvue DVC6000 digital valve other meters, resulting
controller for safety instrumented systems (SIS). The in significant real
enhancements help improve reliability, flexibility and avail- estate and installation
ability of emergency shutdown (ESD) valve solutions. cost savings that can
The ESD final control system components are integrated actually exceed the
with safety-certified sensors and SIL3 rated systems in Emer- cost of the instrument
sons digital smart SIS solutions. The instrument is also avail- itself.
able in stainless-steel constructions for harsh offshore envi- The advanced V-
ronments and severe service constructions. Cone operates over a
CIRCLE READER SERVICE #25 wide flow range of
10:1 with low headloss
Innovative Subsea Processing and supports line sizes from 0.5 to greater than 120 inches.
Technologies Accuracy is +0.5%, with a repeatability of +0.1%. Petrole-
Two of Camerons CAMFORCE Subsea Processing technolo- um production engineers can rely on the V-Cone Flow Meter
giesMARS (Multiple Application Reinjection System) and for long life and low cost of ownership because it requires vir-
POSSibilities (Production Optimization Simulation Soft- tually no recalibration or maintenance. Easy to locate and
ware)have been successfully used as part of the BP King mul- easy to install, this versatile flow meter is ideal for new equip-
tiphase pumping project in the Gulf of Mexico. ment designs, expansion projects or retrofits requiring new
MARS serves as the interface between the subsea produc- meters. It is compatible with the demanding standards set by
tion tree and the processing equipment modules (pumping, the oil/gas production, delivery and refining industry. And, the
metering, separation or well stimulation) and has been testing of the V-Cone Flow Meter now conforms to the Ameri-
described as a USB port for subsea production trees. The can Petroleum Institutes API 22.2 Testing Protocol for dif-
technology has been developed and supplied by DES, a wholly ferential pressure flow measurement devices.
owned subsidiary of Cameron. The patented MARS system CIRCLE READER SERVICE #76
S p r i n g 2 0 0 8 | 65
VMA MEMBER
Everlasting Valve Co. Inc. American RD Valve Co.
South Plainfield, NJ Anniston, AL
www.everlastingvalveco.com www.american-rd.com
Flow-Quip, Inc. Clow Valve
Tulsa, OK Oskaloosa, IA
www.flowquip.com www.clowvalve.com
ROSTER
Flowserve Corp. Kennedy Valve
Irving, TX Elmira, NY
www.flowserve.com www.kennedyvalve.com
Flowserve, Cookeville M&H Valve Co.
Cookeville, TN Anniston, AL
Go to www.vma.org for a complete list of VMA members www.MH-valve.com
Flowserve, Springville
American Cast Iron Pipe Co. Crane ChemPharma Springville, UT Metso Automation USA Inc.
Birmingham, AL Flow Solutions Flowserve, Raleigh Shrewsbury, MA
www.acipco.com Cincinnati, OH Raleigh, NC www.metsoautomation.com
www.xomox.com www.edwardvogt.com Valvcon Corporation
American Valve, Inc. www.resistoflex.com
Greensboro, NC Flowserve, Lynchburg Milford, NH
www.saundersvalve.com Lynchburg, VA www.valvcon.com
www.americanvalve.com
Curtiss-Wright Flow Control www.limitorque.com Moog Flo-Tork, Inc.
ASCO Valve, Inc.
Florham Park, NJ
Corporation Flowserve, Sulphur Springs Orrville, OH
Falls Church, VA Sulphur Springs, TX www.flo-tork.com
www.ascovalve.com www.cwfc.com www.nordstromaudco.com Mueller Water Products
AUMA Actuators, Inc.
Canonsburg, PA
DeltaValve Fluoroseal Inc. Atlanta, GA
South Jordan, UT Montreal, Quebec, Canada www.muellerwaterproducts.com
www.auma-usa.com
Enertech www.fluorosealvalves.com Milliken Valve Company, Inc.
Automation Technology, Inc. Brea, CA Bethlehem, PA
Industry, TX Global Flow Technologies www.millikenvalve.com
www.atiactuators.com Farris Engineering Stafford, TX
Brecksville, OH www.globalflowtech.com Oseco Inc.
Babbitt Steam Specialty Broken Arrow, OK
Company Peerless Instrument Co., Groth Corporation www.oseco.com
New Bedford, MA Inc. Houston, TX
www.babbittsteam.com East Farmingdale, NY www.grothcorp.com Parker Hannifin Fluid Control
New Britain, CT
Harold Beck & Sons, Inc. Tapco/Enpro High Pressure Equipment www.parker.com
Newtown, PA Houston, TX Company
www.haroldbeck.com Erie, PA PBM, Inc.
Target Rock Irwin, PA
Bernard Controls, Inc. East Farmingdale, NY www.highpressure.com
www.pbmvalve.com
Houston, TX Indelac Controls, Inc.
www.bernardcontrols.com DFT Inc. The Wm. Powell Company
Exton, PA Florence, KY
www.indelac.com Cincinnati, OH
Cameron Valves and www.dft-valves.com www.powellvalves.com
Measurement ITT Engineered Valves
Houston, TX Dresser, Inc. Process Development &
Addison, TX Lancaster, PA
www.c-a-m.com www.engvalves.com Control, Inc.
www.dresser.com Coraopolis, PA
CCI Kitz Corporation of America www.pdcvalve.com
Rancho Santa Margarita, CA Becker Precision
Equipment, Inc. Stafford, TX
www.ccivalve.com www.kitz.com QTRCO, Inc.
Elk Grove Village, IL Tomball, TX
Check-All Valve Mfg. Co. KOSO America, Inc. www.qtrco.com
Des Moines, IA Dresser Consolidated
Houston, TX West Bridgewater, MA
www.checkall.com www.kosoamerica.com Remote Control, Inc.
Dresser Masoneilan N. Kingstown, RI
Conval, Inc. K-Tork, Inc. www.rciactuators.com
Somers, CT Avon, MA
Dallas, TX
www.conval.com DynaTorque Inc. www.ktork.com Richards Industries-Valve
Muskegon, MI Group, Inc.
Copeland Industries, Inc. Cincinnati, OH
Houston, TX www.dynatorque.com Lined Valve Company, Inc.
Woodland, WA www.jordanvalve.com
www.copelandballvalves.com EIM Company, Inc.
Missouri City, TX www.knifegatevalves.com
Cowan Dynamics Roto Hammer Industries, Inc.
Montreal, Quebec, Canada www.eim-co.com Mastergear, Division of Tulsa, OK
www.cowandynamics.com Emerson Process Management Regal-Beloit Corporation www.rotohammerinc.com
Marshalltown, IA South Beloit, IL
Crane Valve Group www.mastergearworldwide.com Rotork Process Controls
Stamford, CT Fisher Controls Rochester, NY
www.craneco.com/business/ Marshalltown, IA MaxTorque, LLC www.rotorkprocesscontrols.com
crane_valves.cfm www.fisher.com Limerick, ME
www.maxtorquegears.com Rotork Controls
Crane Energy Flow Valve Automation Division Canada Ltd.
Solutions St. Louis, MO McWane Valve and Hydrant Calgary, Alberta, Canada
The Woodlands, TX www.emersonprocess.com/ Group
www.craneenergy.com Rotork Controls
valveautomation Elmira, NY Canada Ltd.
www.mcwane.com Mississauga, Ontario, Canada
Rotork Gears TopWorx Associate Members Lone Star Fasteners

Rochester, NY Louisville, KY Spring, TX
www.topworx.com Amerikam www.lonestarfasteners.com
Rotork Process Controls Grand Rapids, MI
Milwaukee, WI Townley Engineering & www.amerikam.com Matrix Metals LLC
www.jordancontrols.com Manufacturing Company, Inc. Richmond, TX
Candler, FL DeLoro Stellite Inc. www.matrixmetalsllc.com
R.S.V.P. Actuators & Controls www.townley.net Belleville, Ontario, Canada
Hempstead, TX www.stellite.com Scientific Linings & Coatings
www.rsvpactuators.com Tyco Valves & Controls San Antonio, TX
Houston, TX Fenner Advanced Sealing
Samson Controls, Inc. Technologies www.weathercap.com
www.tycovalves.com
Baytown, TX Houston, TX Simrit
www.samsoncontrols.com UniTorq Actuators & Controls www.cdiseals.com Plymouth, MI
Duluth, GA www.simritna.com
Sartell Valves, Inc. www.unitorque.com The Flexitallic Group, Inc.
Sartell, MN Houston, TX Solon Manufacturing Co.
www.sartellvalves.com Valvtechnologies, Inc. www.flexitallic.com Chardon, OH
Houston, TX www.solonmfg.com
Spirax Sarco, Inc. www.valv.com FlowserveFlow Solutions Div.
Blythewood, SC Irving, TX Steel Industries Inc.
www.spiraxsarco-usa.com Velan Valve Corporation www.flowserve.com Redford, MI
Montreal, Quebec, Canada www.steelindustriesinc.com
Spirax Sarco Canada Ltd. www.velan.com Garlock Sealing Technologies
Concord, Ontario, Canada Palmyra, NY VanAire, Inc.
Therm-Omega-Tech, Inc.
Weir Valves & Controls-USA www.garlock.com Gladstone, MI
Salem, MA www.vanaireinc.com
Warminster, PA www.weirvalveusa.com Highland Foundry Limited
www.thermomegatech.com Surrey, British Columbia, Canada
WEY Valve, Inc. www.highlandfoundry.com
Nettleton, MS
www.weyvalve.com
For information on joining the Valve Manufacturers Association, contact Bill Sandler at 202.331.8105 or wsandler@vma.org.
MEMBERS OF THE VALVE REPAIR COUNCIL An affiliate of the Valve Manufacturers Association of America
Allied Valve CWFC Farris Engineering Furmanite The Wm. Powell Company
Chicago, IL Brecksville, OH LaPorte, TX Cincinnati, OH
www.alliedvalveinc.com www.cwfc.com www.furmanite.com www.powellvalves.com
AVP Valve, Inc. Desselle Maggard Groquip Thorco, Inc.
Lakeland, FL Baton Rouge, LA Geismar, LA Tulsa, OK
www.avpvalve.com www.4dmc.com www.groquip.com www.thorcoinc.com
Bay Valve Service, Inc. Dowco Valve Company Gulf Coast Modification, LP Tyco Valves and Controls
Seattle, WA Hastings, MN Houston, TX Stafford, TX
www.bay-valve.com www.dowcovalve.com www.gulfcoastmod.com www.tycovalves.com
Cameron Dresser, Inc. Gulf Coast Valve, Inc. United Valve
Houston, TX Addison, TX Corpus Christi, TX South Houston, TX
www.c-a-m.com www.dresser.com www.gulfcoastvalve.net www.unitedvalve.com
CCI Dresser Consolidated Kirksey Machine Valve Reconditioning
Rancho Santa Margarita, CA Alexandria, LA Houston, TX Service Co.
www.ccivalve.com Dresser Direct www.kirkseymachine.com Melvindale, MI
Deer Park, TX
CFM/VR-TESCO LLC Dresser Masoneilan Metso Automation Wal-Tech Inc.
Elgin, IL Avon, MA Shrewsbury, MA Mobile, AL
www.globalfield.net www.metso.com www.wal-tech.com
Chalmers & Kubeck North ECI/ICE Valve and Instrument Midwest Valve Services, Inc. Ware, Inc.
Westfield, MA Services Minooka, IL Louisville, KY
www.candknorth.com Monessen, PA www.mwvalve.com www.wareinc.com
www.service-solution.com
Crane Valve Services Precision Pump &
Houston, TX Fisher Controls International, Valve Service
Inc. VRC ASSOCIATE MEMBER
www.cranevalves.com Charleston, WV
Marshalltown, IA www.ppvs.com Quality Valve
Crane Valve Services www.fisher.com Mobile, AL
Benicia, CA Southeast Valve Inc. www.qualityvalves.com
www.cranevalves.com Flowserve Corporation Charlotte, NC
Houston, TX www.sevalve.com
Crane Valve Services www.flowserve.com
Thorofare, NJ
www.cranevalves.com Formosa Plastics For further information on the VRC, please contact Marc Pasternak,
Point Comfort, TX
at 202.331.0104 or via email at mpasternak@vma.org.
www.fpcusa.com
S p r i n g 2 0 0 8 | 67
INDEX TO
ADVERTISERS
PG COMPANY RSC # T H E L A S T P A G E BY JUDY TIBBS
10 American Valve 1
15 AUMA Actuators, Inc. 3
41 Babbitt Steam Specialty Co. 5
Alternative Energies a Big Draw
21 Cameron Valves & 16 at VMA Technical Seminar
Measurements he topic of Preparing the Valve Industry for
26
33
Caplugs
Continental Disc Corporation
145
85
T Alternative Energies & Fuels was clearly a big
draw and prompted the largest attendance at a VMA
C4 Crane Energy Flow Solutions 67 Technical Seminar in recent history. This event is the only
31 Curtiss-Wright Flow Control 17 VMA-sponsored meeting open to non-members; it took
7 Delta Valve 11 place in Tampa, FL, early in March.
32 EIM Controls 23 The revival of nuclear power, the growing ethanol Pete Kundin of Rotork
19 Emerson Process Management 24 manufacturing industry, the role of tank car valves in Controls explained the role of
networking in nuclear plants:
Valve Automation transporting ethanol and the prospects for developing a
If you dont map it out, if you
C2 Flexitallic 26 hydrogen fueling infrastructure were among the subjects dont have a plan, youre not
24 FluoroSeal, Inc. 70 addressed: going to have a workable
17 Garlock Sealing Technologies 29 Energy Policies: Regarding the potential for a nuclear system. Go down to the field
38 General Magnaplate 117 energy revival, Times have never been more ripe. Biofuels level, and then come back up.
23 Growth Capital Partners 123
will play an increasing role in meeting transportation
energy demand. Thomas White, U.S. Department of Energy
55 Highland Foundry Ltd. 31
Valves for GTL Facilities: Plenty of challenges exist in building gas-to-liquid
16 Jim Ray Company, Inc. 132
plants, including the large upfront investment, cost and availability of catalyst, and
57 Manufacturers 164 operating and maintenance costs. On the positive side is Shells Flawless start-up
Standardization Society
program, which requires all contractors and vendors to identify areas where potential
27 Metso Automation/Jamesbury 38
flaws may occur that could adversely impact the construction, commissioning and
30 Moog Flo-Tork, Inc. 27
start-up, and then to mitigate or eliminate those flaws. Ron Manson, Cameron Valves
61 Physical Acoustics Group 161 & Measurements
C3 The Wm. Powell Co. 138 The Nuclear Renaissance: Tremendous
29 The Wm. Powell Co. 138 WOULD YOU LIKE opportunities exist in the nuclear industry, but
13 Remote Control, Inc. 43 TO LEARN MORE? getting involved is extremely complex. As for what
If you missed the VMA Technical
37 Rotork Controls, Inc. 45 Seminar, you can order a bound lies ahead, We could see 50 to 100 plants in 30
58 Rotork Gears 46 manual with copies of presentations yearsor we could see three! Gary Wolski,
and papers from the seminar. The Curtiss-Wright Flow Control Nuclear
14 Scientific Linings & Coatings 139 complete proceedings are available
11 Siemens 48 for $300 + shipping/handling. Use Safety Considerations in Nuclear Power
20 Solon Manufacturing Co. 50 the order form found on VMA.org at: Designs. Although the current technology offers a
https://www.vma.org/Resources/ doc- lot of safety features, some weaknesses still exist.
18 Spence Engineering Co. 105 uments/2008PublicationsOrder
Form.pdf or email abrown@vma.org Active safety systems must be maintained and that
9 Tyco Flow Control 57
for more information. adds to the cost of the fleet; there is a weakness in
61 U.S. Alloys, Inc. 159
screen designs on containment sumps; and analog
25 United Valve 59 control systems and control room designs are antiquated. Dan Churchman, Black &
53 Valve World 64 Veatch
2 Velan Valve 63 Nuclear Power Technologies: A new requirement has emerged with new nuclear
power designsEMC (electro-magnetic) requirements. All electric actuators inside
Do you want to market your products and and outside containment must now be tested to specific EMC requirements. Also,
services to 27,000 users, buyers, specifiers, preference will be given for inside containment electric actuators that previously
distributors and manufacturers in the indus- tested and qualified for use in older technology nuclear power plants. Earnie Carey,
trial valve industry?
Flowserve Limitorque
If you are a U.S. or Canadian valve, actuator Fuel Ethanol Manufacturing: The U.S. Energy Policy Act is a big boon to the
or control manufacturer, or if you sell servic-
es and supplies to valve, actuator and control industry; expect plenty of valve orders. Its safe to say the ethanol industry is here
manufacturers, you could be eligible to to staywere not a hobby anymore. Bear with us over the next 10 years as we
advertise in Valve Magazine. learn: Its going to be a heck of a ride! Greg Hausmann, ICM
To find out if you qualify, please contact Sue The Hydrogen Infrastructure: The number one challenge is metering. When we
Partyke at 540-374-9100 or via email at go from 10,000 psig storage to a fuel tank that may have a couple 100 psig and fill
suepartyke@cs.com.
in two minutes, there is no current flow meter to accurately measure the H2. There
are issues with components designed for high-pressure storage and fueling. Finally, if
H2 fueling happens on a large scale, the product and station costs need to come
closer to current gasoline costs. Tom Elsey, Air Products & Chemicals VM
Can you ever be

completely sure
about the quality
of your valves?
Yes, with Powell Valves!

ALL Powell bolted bonnet and
pressure seal chrome valves are
radiographed per ASME B16.34
Par.8.3.1.1 with acceptance
criteria per B16.34 Appendix I.
This ensures the product

you receive is reliable,
dependable, and of the
highest quality
every time.
Contact Powell Valves for

all your valve requirements
in Class 125 to 4500
Sizes 1/4" to 60"
The Wm. Powell Company | 2503 Spring Grove Avenue | Cincinnati, OH 45214
513.852.2000 PH | 513.852.2997 FAX | www.powellvalves.com
Brands
you know
Technology
you want
Solutions
you need
PTFE Monel Hose)
Applications carrying aggressive chemicals
needing secondary containment or where media
permeation reacts with the atmosphere or shell
High working pressure at elevated temperature
Crane ChemPharma Flow Soutions Crane Energy Flow Solutions

4444 Cooper Road 9200 New Trails Drive, Suite 200
Cincinnati, OH 45242-5686 The Woodlands, TX 77381-5291
T: 513-745-6000 T: 281-298-5463
F: 513-745-6086 F: 281-298-1920
Website: www.xomox.com Website: www.craneenergy.com

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