Oliver Valves Supplies Injection Double Block and Bleed Valves for West Qurna 1 Gathering System Project in Iraq
Oliver Valves is proud to announce our contribution to the West Qurna 1 Gathering…
Read MoreThe global need for reliable, clean energy is indisputable and becoming increasingly urgent. However, there is ongoing debate about the most effective processes for producing green energy, and even the precise definition of green energy remains contested. This debate is likely to continue for many years, if not decades. Despite these uncertainties, the demand for clean energy solutions is ever-present. The evidence of global sea temperatures rising and the increased frequency and severity of extreme weather events worldwide underscores the necessity for immediate action.
Green energy projects are gaining traction across the globe. Numerous pilot schemes are being implemented to demonstrate proof of concept, indicating progress in the right direction. However, the question remains whether these efforts are sufficient. Can the planet afford to wait for standard committees to determine the best course of action when the impacts of climate change are already being felt?
Decarburizing the entire energy chain presents a monumental challenge. The transition from long-established processes, which have been refined over several decades, to green alternatives will not happen overnight. This move involves considerable risk and requires careful planning and execution. The complexity and scale of this task highlights the need for a coordinated and sustained effort to achieve a future with truly sustainable energy.
One aspect of the complex challenge of decarburizing the energy sector is the development of reliable and cost-effective valves. According to the Environmental Protection Agency (EPA), over 60 percent of fugitive emissions originate from gas valves. This raises the question of how to develop a safe and reliable product in an emerging market when the standards governing such products have yet to be established.
A British company, Oliver Valves, has developed an advanced metal-seated pipeline valve range designed to address these challenges.
Ball valves are known for their simple quarter-turn operation and unrestricted flow path. Features such as non-rising stems and compact geometries make them a common choice for many operators across various processes. The metal-seated variant of the ball valve offers several advantages over the more commonly used soft seat or polymer sealing alternatives, including enhanced resistance to abrasives, increased reliability, and a longer service life. Additionally, the design of metal-seated ball valves makes them suitable for applications involving temperatures above 200 degrees Celsius.
The development of metal-seated ball valves represents a step forward in creating reliable, high-performance components essential for the energy sector. This innovation addresses the need for improved valve technology to reduce fugitive emissions and support the transition to greener energy systems.
Creating a metal-to-metal, gas-tight seal is a complex and challenging task that requires a comprehensive understanding of several critical factors. This includes the topography of the components, the stresses involved, and the relative displacements needed to maintain the necessary contact stress for achieving a gas-tight seal. Achieving this level of precision and reliability is essential, particularly in high-pressure environments where even the smallest leak can lead to significant issues.
Engineers at Oliver Valves have developed substantial expertise in metal-to-metal sealing over more than thirty years, particularly through their work on sub-sea gate valves. These valves are known for their high performance and reliability in demanding conditions, providing valuable insights and experience that inform their current developments.
However, in the context of pipeline ball valves, special considerations must be made regarding the size and geometry of the ball and seat. Both components are inherently complex in shape, and their often-asymmetrical nature complicates the prediction of deflection under pressure. Unlike soft, more compliant seats, a metal seat must deflect at the exact same rate as the ball when subjected to full working pressure to maintain sufficient contact stress and create a reliable seal. These deflections, although microscopic, can contribute to leaks if not managed correctly.
Ensuring that the metal seat and ball deflect in unison requires meticulous design and precise engineering. This challenge underscores the importance of understanding the intricate behaviours of materials under stress and the need for advanced engineering solutions to achieve reliable, gas-tight seals in metal-seated pipeline valves. The expertise developed by Oliver Valves in this field highlights the critical role of experienced engineering in addressing the complex requirements of modern energy systems.
One potential solution to the challenge of achieving a metal-to-metal, gas-tight seal in pipeline ball valves is to greatly increase the size and rigidity of the ball and seat. This approach aims to minimize deflection under pressure. However, this method would significantly raise the associated costs of product assembly. Increasing the ball diameter necessitates a larger cavity size, which subsequently enlarges the pressure boundary between the valve body and its ends. This, in turn, increases the sealing diameter of the end connector, thereby amplifying the blowout force on the end connector. To manage this increased force, either larger fasteners or a greater number of fasteners would be required.
Furthermore, these fasteners must be accessible using conventional tightening equipment, which can add to the overall size and cost of the finished product. To avoid a cascade of increasing sizes and associated costs, it is essential to determine the optimum size of the ball. This ensures the most cost-effective and reliable solution is achieved.
Advanced Finite Element Analysis (FEA) techniques have been employed to derive the optimum size of the ball and the geometry of the seat. These analyses take into account the strengths of materials suitable for hydrogen applications. The derived optimum sizes and geometries have then been tested under in-service conditions to validate the product’s performance across various temperature and pressure combinations. This approach ensures that the valve design is both cost-effective and capable of maintaining reliable performance in demanding applications.
At the Oliver R&D facility in Cheshire, a specialized team of engineers focuses on developing cutting-edge valve products. This facility has established a unique hydrogen test standard, which integrates industry-recognized fugitive emissions tests and simulates in-service conditions, including prolonged operational scenarios.
The qualification process developed at the facility is tailored to address the specific needs of pipeline valve applications. This rigorous process includes comprehensive operational and seat leakage tests conducted at both maximum and minimum rated temperatures. During these tests, fugitive emissions are closely monitored to ensure compliance with stringent environmental and safety standards. The objective is to verify the valve’s performance and reliability under the most demanding conditions.
To further demonstrate the robustness and effectiveness of their zero-leakage metal sealing range, the qualification process was extended to include an endurance test of 3,000 operations. This extended testing period is designed to replicate the long-term operational stresses that valves would encounter in real-world applications. After completing the 3,000 operations, the valves were evaluated for their ability to maintain a bubble-tight seal at working pressure and to remain within acceptable fugitive emissions rates. The results confirmed that the valves met and exceeded performance expectations, maintaining their integrity and functionality throughout the testing process.
This thorough and objective testing approach ensures that the valves developed at the Oliver R&D facility adhere to high standards of performance, reliability, and environmental compliance. By subjecting the valves to such rigorous testing, the engineers can confidently validate their designs and ensure that the products are capable of performing reliably in demanding conditions, thereby contributing to the advancement of valve technology in the energy sector.
Nick Howard, Director of Market Development at Oliver Valves, highlights the company’s approach to developing advanced valve technology. By leveraging years of expertise in metal sealing and combining it with a deep understanding of hydrogen applications, Oliver Valves has developed metal-to-metal sealing ball valves. These valves aim to offer the reliability and prolonged service life typical of metal-seated valves while achieving sealing performance comparable to soft-sealing valves. This development represents a significant advancement in valve technology, particularly for applications involving hydrogen.
Valves are a small yet critical component in the broader context of addressing complex energy challenges. As such, it raises the question of whether additional initiatives should be provided to companies to accelerate the development of innovative products. The transition to green energy and the reduction of fugitive emissions requires not only new ideas but also effective methods to bring these ideas to fruition.
Encouraging further innovation in valve technology could involve offering incentives such as research grants, tax benefits, or collaborative opportunities with academic and research institutions. Such initiatives could expedite the development and implementation of advanced solutions, facilitating more rapid progress towards achieving environmental and energy goals.
Moreover, enhancing the support for research and development in the valve industry could lead to broader advancements in energy systems. Valves, while a small component, play a crucial role in ensuring the efficiency and safety of various processes. Improved valve technology can contribute to reducing emissions, enhancing operational reliability, and optimizing performance across different sectors.
In conclusion, while the development of advanced valves like those by Oliver Valves and others represent a milestone, broader support for innovation is essential. By fostering an environment that encourages research, collaboration, and the practical application of new technologies, the energy industry can more effectively address its complex challenges and move towards a sustainable future.
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