KEY-CRotary Control Ball Valves

December 2016

KEY-C: Identity Card

Valve Type: Quarter turn Rotary Ball Valve

Design Standard: API 6D & B16.34

Size: from 3” up to 48”

Pressure Class: from 150# – 2500#

Construction: Forged Body & Caged Ball Trim

Service:Flow Control /Level ControlPressure ControlAntisurgeFast BlowDown operation

Standard Body Materials:- Carbon Steel / Stainless Steel /Duplex & specialAlloys

Standard Trim Materials:- Stainless Steel + Tungsten Carbide on Seat AreasMaterials comply to NACE/ MR0175

Fire Safe: API 6FA/607 and ISO 10497

24”x20” ASME 150 Bronze Mat.2014 - Project TEN FPSO / End User: Tullow Ghana / EPC: MODEC

Control valves Overview

The main common control valve was Globe

type

Still today Globe valves represent 70 % of

control valves

The Globe valve was used for all type of

applications

Due to low valve capacity, line sizes are big

Valves are now part of complex automation

system

Controllers are becoming Digital

Accuracy & Repeatability are key features

Processes require severe controls (with

high pressure & high velocity)

The correct valve selection & sizing is

fundamental for each process

Noise Limitation shall be considered

Historically Today

Rotary Control Ball valves improve performances of conventional LargeSize Single Seated Globe valves

KEY- C: Benefits

Higher capacity

Higher rangeability

More Compact package

Low Noise & vibration

Better wear resistance

Tight shutoff capability

Longer intervals between maintenance

Longer service life

Why?

Single Seated Globe Valves Limitations

Low Flow Capacity & limited Cv

High Pressure loss across the valves

Low regulation ratio

High risk of Cavitation and Flashing,under severe conditions

No Noise & vibration abatement device

High Risk of stem leakage

Not suitable for Fugitive Emission

Request of periodic maintenance

High Forces for valve shutoff

Plug obturator & Rising Stem design lead to:

Cavitation

Flashing

Ideal Control Valve

P1

V1

Vvc

Inlet Outlet

V2

P2

Pvc

VALVE

Pressure

Velocity

CavitationPv

Flashing

Optimal Curve

Pressure recovery

STD Ball Valve for Control ServicePressure & Velocity profile across Ball Valve

Full Bore - extremely high Cv

Min pressure Drop at fully open position

Easy installation: Std Face to Face andbidirectional mode

Ideal solution for tight shut off

Rotary stem increases valve reliability

Poor control between 10-50% of thestroke under severe conditions

Risk of Cavitation and Flashing

High Noise

Advantages

Disadvantages

KEY-C Valve for Control ServicePressure & Velocity profile across KEY-C Valve

Full Bore - extremely high Cv

Min pressure Drop at fullyopen position

Easy installation:Std Face to Face and bidirectional mode

Ideal solution for tight shut off

Rotary stem increases valve reliability

VERY GOOD Control between 10-50%of the stroke

Reduction of Risks of Cavitation andFlashing

LOW Noise

Advantages

KEY-C Trim: Working Principle

KEY-C trim has a multistage design, composed bya series of holed plates, partializing the pressuredrop

KEY-C trim guides the flows path to self dissipatethe kinetic energy, limiting the velocity,preserving the mechanical integrity and reducingthe noise

The gap between plates are expansion chambers,which gradually allow the flow to pass through thevalve without increase its velocity

Multi holes increase the total number of passagesreducing the Noise through the valve

KEY-C Trim: Optimization

KEY-C Trims are optimized using themost advanced CFD simulationtechnologiesSeveral cases were analyzed to reachthe optimal configuration,considering:

Number of holes in the plates

Hole diameter

Plate number

Plate distance

Plate inclination

Additional holes for gas expansionanalysis

Pressure Drop Control Velocity check

Torques determination Noise prediction

KEY-C: Valve Characteristic

Valve Characteristic according to: IEC 534-2

ISA S75.01 & S75.02

Noise level calculated according to:

VDMA 24422 (liquid)

IEC 534-8-3 (gas)

Typical Inherent Characteristic Curve

FL- Liquid pressure recovery factoris an important characteristic of acontrol valve, which shows the pressurerecovered from the vena contracta tothe valve outlet relative to the generalpressure drop across the valve

The closer the FL is to 1.0, the lessthe pressure recovery is.

KEY-C: Features in Detail

Unidirectional FlowValve with one seat

upstream

DPE Seat forbidirectional

tightnessTrunnion mounted

design for sustaininghigh pressure drops& torques reduction

Metal to Metal seats,with TC coating

performed betweenball and seatscontact area toincrease wear

resistance

Emergency sealinginjection on seat

and stem foremergency purpose

Stem Packing forLow Fugitive

Emission

Leakage rateaccording ANSI/FCIClass IV, Class V &

Class VI

Mounting Flange as perISO 5211 for an easy

interface with actuators

Cycle of Operations

Ste

msealle

akag

e

KEY-C: Summary Comparison

Rated Cv KEY-C >> Rated Cv Globe

Rangeability is much higher compareto globe

Thigh shutoff capability

With KEY-C Valves, same controlconditions can be reached with 2SIZE less than Globe valve

Actuator size is also smaller

After 5000 operations, the stemleakage from KEY-C is 40 times lessthan Globe

Longer intervals between maintenance

Longer service life

!! TOTAL COST SAVING 40% !!

Common Globe SingleSeated Solution

KEY-C AlternativeSolution

KEY-C: Case of Study

Project: HAIL Surface facilities

EPC:

Valve Application: Flow Control

KEY-C: Case of Study

Project: HAIL Surface facilities

EPC:

Valve Application: Flow Control

Common Globe SingleSeated Solution

KEY-C AlternativeSolution

Common Globe SingleSeated Solution

KEY-C AlternativeSolution

KEY-C: Case of Study

Project: HAIL Surface facilities

EPC:

Valve Application: Flow Control

KEY-C: Case of Study

Project: HAIL Surface facilities

EPC:

Valve Application: Flow Control

Common Globe SingleSeated Solution

KEY-C AlternativeSolution

Dimensions Saving:

FtoF: from 708 mm to 404 mm 42%height: from 1594 mm to 1049 mm 35%

Weight Saving:

from 664 kg to 420 kg 38%

Price Saving:

from 15.000 Euro to 9.500 Euro 40%

KEY-C: Actuation

16” ASME 900 CS Body / SS TrimPneumatic Double Acting SY Actuator withSmart Positioner2012 - Project Xinjinang Hutubi Gas Field

Main common Quarter Turn Actuators types:

Pneumatic Scotch Yoke Spring Return / Double Acting

Hydraulic Scotch Yoke Spring Return / Double Acting

Rack and Pinion for small valves

Electric control actuator

Manually operated (e.g. Laminating flow control)

! IMPORTANT !

Not all actuator types are suitable for control duty, due totheir poor control features as:

large Hysteresis / low Accuracy / low Repeatability

LIMITS of common SY Actuators

Nonlinear characteristics

Minimum torques in the middle of the stroke

Low efficiency due to the high internal friction

on prismatic joints

Stick slip effect

Low mechanical Efficiency

No useful for heavy duty cycles

Scotch Yoke limits arise when rotary valves are used for control service since the fluid-dynamicsbehavior contributes highly to increasing the valve torques along the stroke

Disadvantages SY Transmission

ALTO: Adaptive Linear Torque Output

Linear Torque Characteristic

Constant & High Efficiency

Wide Torques range

Pneumatic & Hydraulic configuration

Spring Assisted for Emergency Action

True modular design for maximumflexibility

Full range of override options: manual,geared, and hydraulic

The revolution of Simplicity

Innovative transmission system based on the principle to drive a

pulley by two anchored cables, ensuring the development of a linear

torque throughout the valve stroking cycle & high reliability on heavy

duty cycles

PATENTED

ALTO: Working Principle

Supply Mode Fail Mode

The ALTO transmission system converts the cylinder’s linear motion into a quarter-turn rotation by creating aconstant transmission ratio and constant mechanical efficiency along the entire stroke

The fluid pressure supply in the cylinder, puts tension on thecable and produces a clockwise quarter-turn rotation of thepulley along with the compressing the antagonist spring

In the case of an emergency, the supply fluid is released fromthe cylinder, allowing the antagonist spring to produce acounterclockwise quarter-turn rotation of the pulley.

ALTO: Features in Detail

ENP on cylindertube to ensureperfect dynamicseal, corrosionresistance, and

low friction

A rotatable elementconfigured to control

the position ofquarter turn valves

Two antagonistpreloaded cablesanchored on thepulley, to avoidany Backlash

Rolling bearingsinstead ofbushing toincreaseefficiency

Few elementsunderload,all slidingfrictions

eliminated

Coated spring forminimal bindingand corrosion

inhibition

Springs are guided andsupported to reducewear and to ensureproper alignment forintense repeatability

task

Two lateral ports for easy checkinspection and maintenance

Centre Body with a robust &compact construction, designed

for maximum rigidity andtoque transferinterface inaccordance with ISO 5211

Two externally adjustabletravel stop, mounted directly

on the Centre Body, toensure a correct alignment of

the valve obturator in theopen and closed positions

Designed to be the simplest, but efficient and safe

ALTO: Benefits

Q0° Q90°Stroke

Torq

ue

D S.M.

ALTO ActuatorScotch Yoke Actuator

Torques Characteristic comparison between PCA andconventional Scotch Yoke Actuator. PCA Actuatorprovides big advantages in terms of Safety Marginsalong the whole stroke, maximizing this contribution

in the middle.

Linearity increases Torques S.M. during running stroke

Actuators Size Reduction

Better matching with Butterfly Torques Curve

High Efficiency (Rolling << Sliding friction)

High Accuracy

High Repeatability

Zero Backlash

Low complexity

Rolling friction instead of Sliding friction

Few elements underload

Requirements for Control Applications

Requirements for Longer Life & less Maintenance

30%

ALTO: Case of Study 1

Actuator Sizing

Valve: KEY-C 10” ASME 300

S.M. 30%

Safety position: CLOSE

Option I: Common SY Actuator

Option II: ALTO Actuator

the fluid-dynamics behaviorcontributes highly to increasingvalve torques along the stroke

Nm

ALTO: Testing Results

Linearity Torque @ Stroke

Actuator has been tested in accordance with EN15714

Endurance Test: 100.000 cycles under load successfully performed

ALTO: Specifications

Design temperature

Standard range: -29°C to 100°C

Low temperature: down to -60°C

High temperature: up to 148°C

Design pressure

Pneumatic cylinder: up to 12 barg

Hydraulic cylinder: up to 210 bargNo standard pressure ranges are available upon request

Supply mediaInstrument air, nitrogen, or sweet gasNACE compliance for sour gas applications

Torque rangeSingle acting spring return: up to 50.000 Nm

Certifications/approvals

Actuator sizing as per API 6DX

Designed in accordance with EN15714

Pressure components as per ASME VIII

IP66 per EN60539 (IP68 upon request)

Compliance with PED 97/23/EC

Compliance with ATEX

SIL 3 Certified (upon request)

ALTO: Control System

X - Pneumatic supply connectionY - Pneumatic connection to actuatorZ - Electric connection to SOV coilK - Electric connection to the positioner

Controls packages full customizable for the most criticalpneumatic and hydraulics applications:

Filter regular (Al and SS316)

Relief valve (SS316)

Check valve (SS316)

Solenoid valve, auto reset or manual reset (Al and SS316)

Pilot valve (Al and SS316)

Quick exhaust valve (SS316)

Unidirectional and bidirectional flow regulator (SS316)

Booster (Al and SS316)

SMART positioner for regulation

Working with the latest control technology in

accordance with international standards

ALTO: Summary Comparison

Pneumatic & Hydraulic conf. Available Available

Modular Solution Yes Yes

Assembly Configuration Horizontal Horizontal

Spring Assisted Yes Yes

Design Complexity Low Medium

Torque Range Wide Wide

Torque Characteristic Linear U curve

Efficiency Constant 97% 70-90%

Control Accuracy GOOD POOR

Zero Backlash Yes No

Reliability High Medium

Maintenance Low Medium

KEY-C: Applications in Oil & Gas

Separation & Treatment System: Level & Pressure control and blowdown

Compressor Surge Prevention / Recirculation Valve

Metering Station FCV and PCV’s

Pig Launcher & receiver: Pig Back pressure control

Crude Oil Loading Arms Control Valve

Common Requirements:

Larger than 3” valve size

High Pressure drop to control

Pressure rating ASME 300 and over

High cavitation risk with high potential noise

Large mass flow to manage

Accurate flow control required

Tight shutoff capability

KEY-C: Projects Reference List

REFERENCES VALVE CLASS VALVE SIZE

CUSTOMERCONTRACTOR

ENGEND USER PROJECT DESTINATION YEAR

Min

Max

Min

[in

ch

]

Max

[in

ch

]

TO

T.

QN

T

SOLBERG & ANDERSEN AKER - SRU Unit Ghana GHANA 2010 ASME 150 ASME 150 6 6 6

INTEGRACION DE SISTEMAS COTEMAR - Offshore platform MEXICO 2010 ASME 150 ASME 600 2 4 3

SOLBERG & ANDERSEN AKER PETROBRAS FPSO – MV22 BRAZIL 2010 ASME 300 ASME 300 8 8 4

FORTUNE CONTROLS - - - UAE 2010 ASME 600 ASME 900 4 8 3

AKER SOLUTION AKER SOLUTIONS UN-RIO / ATP - ROPlatform P-62

BRAZIL 2010 ASME 150 ASME 150 8 8 3

AKER SOLUTION AKER SOLUTIONS UN-RIO / ATP - RO Platform P-58 BRAZIL 2010 ASME 150 ASME 150 8 8 4

SOLBERG &ANDERSEN BW OFFSHORE FPSO Waimea BRAZIL 2011 ASME 150 ASME 150 6 6 1

SOLBERG &ANDERSEN AIBEL STATOIL Offshore Platform NORWAY 2011 ASME 2500 ASME 2500 2 2 1

TANGENT CONTROLSXinjinang Hutubi Gas

FieldCHINA 2012 ASME 600 ASME 900 12 16 5

ENDRESS + HAUSER CONSORCIO LPGLPG PROJECT

ECUADORECUADOR 2012 ASME 300 ASME 300 6 12 26

VALEX ENGINEERING Gas Storage CHINA 2012 ASME 600 ASME 600 12 16 3

VALEX ENGINEERING GangQing Pipeline 3# CHINA 2013 ASME 600 ASME 600 10 10 1

VALEX ENGINEERING WATANG CHINA 2013 ASME 600 ASME 600 4 4 1

MRC SAAS MODEC GHANA LTD Platform JUBILEE GHANA 2014 ASME 300 ASME 300 8 8 2

MODEC Offshore MODEC Tullow Ghana FPSO TEN GHANA 2014 ASME 150 ASME 150 24 24 1

MRC SAAS MODEC GHANA LTD Platform JUBILEE GHANA 2014 ASME 300 ASME 300 8 8 2

MODEC Offshore MODEC PETROBRAS FPSO MV-29 BRAZIL 2015 ASME 150 ASME 600 6 20 26