ANALYSIS AND DESIGN OF CRYOGENIC BALL VALVE

Dong-Soo KIM*, Myoung-Sub KIM*

*Roll-to-Roll PEMS Team, Nano Mechanical Systems Research Division
Korea Institute of Machinery & Materials
171, Jang-Dong, Yuseong-Gu, Daejeon, Korea
(E-mail: [email protected])
ABSTRACT
Natural gas is being hailed as alternative energy sources for a petroleum, because it is almost no emissions of pollutants
in the environment. Use of equipment for liquefied natural gas, along with increased demand for natural gas is also
growing. Cryogenic ball valve is used to control the liquified natural gas which temperature is -196 , supplied pressure
is 168kg/cm
2
. To acquire the safety along with durability of cryogenic ball valve, we should consider the structural
mechanics such as stress, deformation and dynamic vibration characteristics and identify those important aspects in the
stage of preliminary design engineering. For the cryogenic ball valve, the assurance of structural integrity and
operability are essential to meet not only normal, abnormal loading conditions but also functionality during a seismic
event. In this study, analytical approach and results using finite element analysis and computational method are herein
presented to evaluate the aspects of structural integrity along with operability of cryogenic ball valve. Moreover, we
have done the optimal design through special processing and heat treatment and so on. Finally, we designed the high
pressure cryogenic ball valve that accomplishes zero leakage.
KEY WORDS
LNG, Cryogenic, Ball valve, Analysis, Design
NOMENCLATURE
D : Stiffness matrix
o : Stress
c : Strain vector
c : Supposition Strain vector
I : Boundary
ku : Elastomer stress vector
g
u : Displacement stress vector
b
t : Boundary stress vector
MPa : Young module coefficient
kg/cm
2
: Pressure
kg/mm
3
: Density
I/ : Thermal Expansion coefficient
W/mm : Heat conduction
1. INTRODUCTION
The process of the formation of natural gas (NG) is
similar to that of coal. NG can be produced from oil
wells as assistant gas; however, most of it is produced as
non-assistant gas. 80~85% of NG is methane (CH
4
),
whose low concentration of hazardous substances
makes it a valuable energy resource. However, because
NG is difficult to store in large quantities and mass
transportation requires a pipeline, technology for NG
liquefaction has been developed to solve these problems,
enabling mass storage and transportation over long
distances. The demand for facilities for the storage,
transportation and control of liquefied natural gas
397
Proceedings of the 7th JFPS International
Symposium on Fluid Power, TOYAMA 2008
September 15-18, 2008
P1-26
Copyright 2008 by JFPS, ISBN 4-931070-07-X
(LNG) is rapidly increasing in line with the rising
demand for LNG [1-2].
Most of the high-pressure, cryogenic ball valves are of
the side-entry type, the insulation of which has to be cut
open to carry out repairs. Therefore, top-entry type
cryogenic valves have been adopted recently [3].
Top-entry type, high-pressure, cryogenic ball valves are
subject to safety verification to prevent the types of
accidents that can be caused by earthquake, fire, or
explosion. Their specifications regarding leakage, being
very strict, are satisfied by only a few products in the
world.
In this study, a numerical analysis is conducted for the
structural safety and the distribution of thermal stress
and deformation by thermal shock under high pressure
and very low temperature conditions, in order to assess
the safety and reliability of the ball valves for LNG to
provide a basis for the design and manufacturing
of products which are safe from leakage under
conditions of extreme temperature variance.
Figure 1 Photo of the valves are installed on vessels
2. Finite Element Analysis (FEA) on Ball Valves
2.1. Theoretical Equation for Analysis
Eq. (1) is a finite element equation for 3-dimensional
loads[4].
0
0
0
xy xx xz
yx yy yz
zy zx zz
x y z
x y z
x y z
o o o
o
o o o
o
o o o
o
c c c
+ + =
c c c
c c c
+ + =
c c c
c c c
+ + =
c c c
(1)
In order to obtain a variational equation for the
numerical analysis of the finite element method (FEM),
eq. (1) can be transformed into eq. (2) in a weak form.

0
T
u
d o
O
A O =
)
(2)
Using Green's Theorem, we obtain eq. (3), where is a
virtual deformation vector and is the boundary.

0
T
u
T
d td
c
o
O I
O I =
) )
(3)
In order to substitute the boundary condition, the stress
vectors can be represented by eq. (4).

( )
g b
t k u u t = +
(4)
Substituting eq. (4) into eq. (3), we obtain eq (5).
( )
T T
u u
T
g b
D d kud ku t d
c
c
O I I
O I = + I
) ) )
(5)
Eq. (6) is the finite element equation, and eq. (7) and (8)
represent the stiffness matrix K and external force
vector f, respectively.

Kd f =
(6)
( )
1
e
T T
e
e e
i
K B D B d N K N d
O cO
I
=
= O + I
_
) )
(7)
( )
1
( )
e
T
e
i
b g
K N t ku d
O
I
=
= + I
_
)
(8)
2.2. Analyses of Thermal Stress and Resistance against
Earthquake
Figure 2 shows the result of the finite element modeling
of a 12-inch cryogenic ball valve using HYPERMESH,
which is an exclusive item of software for finite element
analysis, and ANSYS, which is a commercial FEA
software for structural analysis and evaluation. In order
to conduct the optimal simulation of a real 12-inch
cryogenic ball valve with the FEA model, a tetrahedron
solid element was used and the solid45, which is an
element for isotropic materials. The solid elements have
an average size of 9mm and comprise 609,706 elements
and 135,396 nodes. The x, y, and z axes were defined to
represent the lateral, longitudinal and vertical
398 Copyright 2008 by JFPS, ISBN 4-931070-07-X
coordinates, respectively.
The material of the valve was stainless steel A351-CF3.
One pipe joint was fixed and the other was assumed to
be movable in the direction of flow. The internal
pressure and temperature were assumed to be
1.68kg
f
/mm
2
and -196, respectively. The external
temperature was assumed to be 20. Figure 3 shows
the result of the thermal analysis at the normal operating
temperature, wherein the maximum stress of
23.9kg
f
/mm
2
appears at the center of the ball.

Figure 2 Result of the finite element modeling

Figure 3 Result of the thermal analysis
2.3 . Earthquake-proof Analysis
The finite element modeling and its boundary
conditions were conducted under the same conditions as
those established for the thermal stress analysis, added
with the conditions for earthquake-proof. The load
conditions were classified into the empty weight of the
device, internal pressure, temperature, Operating Basis
Earthquake (OBE), and Safety Shutdown Earthquake
(SSE). The OBE is an earthquake that does not force the
LNG facility to stop operation, on the assumption that it
will occur five times during the lifespan of the facilities.
Therefore, the maximum stress exerted under an OBE is
less than the elastic limit. The SSE, however, is a strong
earthquake that may occur once throughout the lifespan
of the facility. In this study, the device was applied with
maximum acceleration in the x, y, and z directions, as
presented in Table 1. The cases of the OBE and SSE
include the earthquake accelerations in the vertical and
horizontal directions, which are 2.0g, including the
device weight, and 1.5g, in the vertical and x-y
directions respectively. In this study, the loading
conditions of an SSE were applied to obtain a
conservative result. Figure 4 shows the results of the
earthquake-proof analysis taking an earthquake into
consideration. A maximum stress of 25.3kg
f
/mm
2
was
generated at the center of the ball, similar to the figure
obtained when the earthquake was not considered.

Figure 4 Results of the earthquake-proof analysis
Table 1 Seismic load condition for OBE and SSE
Vertical 0.7g (dead weight : 1.0g)
OBE
Horizontal 1.0g
Vertical 1.0g (dead weight : 1.0g)
SSE
Horizontal 1.5g
2.4. Flow Analysis
The flow analysis on the ball valve was carried out
using FLUENT, which is a commercial CFD code with
a model that includes 5 times the diameter to the
upstream and 10 times the diameter to the downstream.
Figure 5 shows the grid system for the numerical
analysis. The grid system - a hybrid grid system - was a
combination of arranged and non-arranged grids. The
grids were allocated densely on the boundary wall to
obtain a more precise prediction. The grid's density was
made to be higher at the inlet and outlet to analyze eddy
flow. The grid had 600,000 nodes for numerical analysis.
399 Copyright 2008 by JFPS, ISBN 4-931070-07-X
The entrance conditions of the analysis model, which
were the pressure inlet conditions, were 168kg/cm
2
and
80kg/cm
2
, and the exit condition was the atmospheric
pressure. The internal temperature was set at -196,
which is the temperature of LNG. The fluid was
assumed to be methane, which accounts for
approximately 90% of the composition of LNG
(Alaskan). Table 2 presents the physical properties of
methane.
Figure 5 Computational grid system of Ball valve
Table 2 Properties of Methane
Properties Ball Valve Properties Ball Valve
Molecular
weight
16
Critical
pressure
45.8atm
Specific
gravity
0.55
Explosion
range
5~15%
(in Air)
Boiling
point
-161.5
Ignition
point
550
Critical
temperature
-82.1
Melting
point
-182.4
Figure 6 shows the path lines and velocity distribution
vector of the fluid particles. The path lines show
relatively uniform velocity distribution, which can be
identified by the velocity vector. It can be seen that the
speed of the current accelerates after the valve. Figure 7
shows the velocity distribution at a cross-section when
in a fully open state. It can be seen that the flow profiles
of the cross-sections are similar, and faster, at the center.
Figure 8 shows the velocity distribution at the distances
of 100cm, 250cm, and 500cm from the valve outlet. On
the graph, it can be seen that the velocity is distributed
uniformly before and after the valve, and increases as
the LNG flows downwards. The velocity profile takes
the form of a parabola, which is the typical
representation of velocity distribution.
(a) Path lines (b) Velocity
Figure 6 Path lines & Velocity of fully opened state
Figure 7 Velocity distributions of cross sectional area
(a) y-direction (b) z-direction
Figure 8 Velocity distribution graphs
3. Design and Fabrication of Parts
3.1. Body Design
In general, the most important factor to be considered in
designing a cryogenic valve is to obtain sufficient
strength against internal pressure. This is the most
important factor in the design of the pressure vessels; a
valve body cannot be designed without careful
consideration of the structural strength. In this study, the
structural strength, contraction according to the valve
configuration, and heat transfer with the extremely low
temperature of LNG were analyzed and designed by
simulation of the valve body.

Figure 9 Analysis of Body
400 Copyright 2008 by JFPS, ISBN 4-931070-07-X
3.2. Design and Fabrication of the Seat
In top-entry type cryogenic ball valves, the most
important component is the seal, which is very difficult
to design and manufacture. Figure 10 shows the
structure of a U-cup seal seat, whose test results at very
low temperature are presented in Table 3. As the
shrinkage rates of a U=cup seal and graphite are lower
than that of stainless steel, leakage occurs at the seal at
temperatures lower than -196. It can be seen that,
although leakage under such conditions meets the BS
6364 Standard, it does not meet the specifications of the
Korea Gas Corporation and LNG container vessels.
Therefore, the seal was modified into a bellows-shape,
which is shown in Figure 11.
Internal leakage through the seat was tested after
assembling the seat, and there was almost no leakage
through the bellows-type seat.
Figure 10 Structure of U-Cup Seal Seat
Table 3 Result of Leakage test
Standard
Valve
Size
Test
Result
BS 6364 KOGAS
LNG
vessel
2" 200 cc/min 300 cc/min 10 cc/min 20 cc/min
4" 580 cc/min 600 cc/min 20 cc/min 40 cc/min

Figure 11 Structure of Bellows Seal Type Seat
3.3. Bonnet Design
A bonnet positioned at the central axis of a valve
connects the handle and ball. If icing occurs at the
packing, which is located in the upper part, due to low
temperature in the lower part, then the LNG may leak.
Therefore, a method of preventing icing and a design
which can insulate the packing from low temperature in
the valve are required. In this study, a heat insulating
plate was used and the bonnet length was optimized
through analysis and testing. Figure 12 shows the
exterior configuration and temperature distribution of
the bonnet. Figure 13 shows the measurement of heat
transfer to the various parts of the bonnet.

Figure 12 Temperature distributions of Bonnet

Figure 13 Measuring temperature distribution
3.4. Ball Design
Figure 14 shows the appearance and thermal
deformation of the ball. It can be seen that the
deformation caused by temperature variance has a
constant distribution.

Figure 14 Thermal deformations of Ball
401 Copyright 2008 by JFPS, ISBN 4-931070-07-X
3.5. Spring Design
In a bellows-seal type seat, the pressure on surface of
the bellows increases as the internal pressure of the
valve increases, because the internal pressure is exerted
on the effective area of the bellows. However, as the
spring force of the bellows is weak at low pressure, a
spring is required to press the bellows in order to
prevent leakage from the seat during low pressure by
maintaining the proper seating force. Table 4 presents
the design data of the spring.
Table. 4 Design data of Spring
Item
Dia.
(mm)
active
coils
(turns)
Spring
Constant
(kg
f
/mm)
Free
length
(mm)
Length
(mm)
Quantity
(es)
Setting
Force
(kg
f
)
Value 14.1 5 10.71 33 28 20 1,071
3.6. Fabrication of the Ball Valve
A high-pressure, cryogenic ball valve capable of
ensuring zero-leakage was designed, as shown in Figure
15, after analysis the thermal stress, resistance against
earthquake, and flow characteristics, and ensuring the
optimal design of each part.
Figure 15 Cryogenic ball valve fabricated in this study
4. CONCLUSION
In order to examine the performance characteristics of
the parts of high-pressure, cryogenic ball valves,
numerical analyses of the strength and thermal shock
were conducted and the seat structure was investigated
and tested. The following conclusion was obtained.
1. According to the thermal stress analysis conducted at
high pressure and very low temperature, a maximum
stress of 23.9kg
f
/mm
2
occurred at the center of the ball.
2. The resistance against earthquake was analyzed at a
maximum acceleration of 2.0g in the vertical direction
(z axis), including the self-weight, and 1.5g in the x and
y axes, at high pressure and very low temperature, to
obtain a maximum stress of 25.3kg
f
/mm
2
at the center of
the ball.
3. The flow characteristics of the ball valve were
analyzed with inlet and outlet pressures of 168kg/cm
2
and 80kg/cm
2
, respectively, to obtain the velocity
distribution and eddy flow of LNG according to the
valve position.
4. The design of the constituent parts of the ball valve,
including the body, seat, bonnet, ball and spring, were
optimized.
5. In this study, a high-pressure, cryogenic ball valve
that can achieve zero leakage was designed.
ACKNOWLEDGEMENTS
This study is a part of the "Top Entry Type
High-Pressure, Cryogenic Ball Valve Development
Project," which is a parts and material development
technology project sponsored by the Ministry of
Commerce, Industry and Energy.
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contaminant sensitivity effect using two
contaminants", SAE TP 910960, pp459464.
2. Thompson G, Askari, A.R. 1986, "Air leak detection
through ball plug valves by vibration monitoring",
Noise & Vibration control worldwide, V17,
pp140-143.
3. Rouss, Gino james Janna, William S. 2003,
"Determination of discharge coefficient for ball
valves with calibrated inserts", 2003 ASME
Mechanical engineering congress, pp 1~10.
4. Merati, P., Macelt, M.J, 2001, Flow investigate
around a v-sector ball valve, 2001 ASME Fluids
engineering, vol.123, no.3, pp662~671.
402 Copyright 2008 by JFPS, ISBN 4-931070-07-X