Severe Service Control Valves

Abstract:-

The article describes various aspects of the Severe Service Control Valves including its definition to the selection &
sizing. The document is prepared for the technical knowledge sharing among the valve experts.

Introduction:-

The normal name we generally come across in many of our EPC applications is the control valve and the next
danger name is Severe Service Control Valve.
A wealth of industry standards exist to set specifications and thresholds for valves in various applications. This is
the area where no standards currently exist is for defining severe service valves. Severe service valves are
commonly identified by the applications in which they are used — applications that may alter a valve’s ability to
meet its acceptable levels of performance.
If we use a valve that isn’t strong enough to do the job in these applications then we will end up spending more
time and money on repairs than we’d like to. In such scenario, we may also be putting the plant, equipment, and
personnel at serious risk if the valve doesn’t function correctly.
Thus, there is extreme need to think about the valves’ function depending on the severity of its application. The
severity may be temperature, pressure or any application specific. This is what we need to look into in detail.

Definition:-

No clear or universal industry definition or mechanism exists to describe and accurately define severe service
valves (SSVs) from general purpose valves, yet such a definition would allow clients/users to benefit from
improved process performance, increased profitability, safety and environmental protection. This is to offer an
objective definition. Most experts agree that SSVs are identified by applications, and that these applications are
challenging to the valve’s ability to provide a minimum acceptable level of performance over a minimum
acceptable duration. Severe service valves can be found in non-return, isolation and control functions, although it
is recognized that Severe Service Control Valves (SSCVs) do have reasonable industry agreement on what can
define severe service. Severe Service Isolation Valves (SSIVs) do not have nearly as clear agreement or
understanding. Non-return (check) valves for severe service applications should be treated as control valves and
sized so that their operation is consistent with the flow-rates of the process rather than the pipe size they are
typically selected for. Control valves take energy out of a piping system; isolation valves contain the energy and
non-return valves delay and reduce the energy from its full effects on the isolation and control valves. All valve
design functions require basic information, but those valves destined for severe service require a deeper
understanding of all of the factors that affect their in-service performance.
 Explanation:-

Though the two terms often go together, they aren’t exactly the same thing.
• Severe service refers to the challenges levied on the valve itself, such as very high pressures and temperatures.
• Critical service refers to the potential consequences of the valve not working properly. For example, nuclear
service is a critical service application because a bad actor can lead to serious environmental damage or safety
risks.

Identification of severe service conditions for control valves may be determined by performing sizing calculations
using IEC 60534-2-1or ISA 75.01.01 with the following information: • Fluid state (liquid, gas, vapour, 2-Phase,
multi-phase, slurry) • Flow rate at max, normal and min conditions (Q) • Upstream pressure at max, normal and
min conditions (P1) • Differential pressure at max, normal and min conditions ((P1-P2) or (dP)) • Vapour pressure
of liquids (Pv) • Temperature (T1) • Valve size.

A determination of whether severe service exists for a control valve can be applied through thresholds expressed
in Table 1. It should be cautioned that the potential for severe service is an indication rather than a proof and
 further examination and analysis should be performed. However, it is clear that the further beyond the threshold
one gets, the more severe the service. Excellent tools exist to reduce risk and time to perform the multiple
calculations that are required to test for the condition thresholds; one of the best is Flowserve’s Performance!,
which uses a Valve Selection Guide to significantly reduce sizing and selection inaccuracies and provides clear and
abundant data to assist in defining the conditions within and around the control valve. When any of the above
conditions violate the thresholds in Table 1, the application should be considered as severe service and the
selection of the SSCV should be made by suppliers who specialize in control applications using valves designed with
severe service trims and features. Additional process information should also be reviewed.

Severe service conditions always apply to the following:

• Autoclave let-down

• Boiler Feedwater

• Choke valves

• Coal gasification

• Compressor anti-surge

• Engine test stands

• Fluids with high out-gassing potential

• HP separator drains

• Minimum flow recycle

• Solar power molten salt

• Slurry control

• Toxic/Lethal Service

• Turbine by-pass

Whether or not valves are considered severe service depends on their application. Here are some examples of
conditions that require severe service valves:
• Very high pressure or high pressure drops
• Very high or very low temperatures
• Flashing gas, which can cause erosion damage
• Outgassing, which can cause a sudden increase in flow volume
• Corrosive environments
• Contaminated media
• High vibration
Here are a few examples of industries that make frequent use of severe service valves:
• Power generation
• Chemical, where corrosive media is common
• Pulp and paper, where high pressure drops and corrosive environments are common

Control valves that do not violate any of the conditions in Table 1 or are not identified in the above list of severe
service applications can be identified as general purpose control valves. Isolation valves perform a different
function than control valves. During much of their installed life they are static, like the pipe flange they are
installed within. Typically the valve datasheet provides us with adequate information for valve selection for this
state. As with control valves for severe service applications, more and deeper information and consideration is
required to select a Severe Service Isolation Valve (SSIV) Industry adheres to codes like ASME B16.34, B31.1 and
B31.3 to protect for this static state, but these do not provide much guidance for when the valve is in dynamic
situation. An important element in selecting SSIVs is the consideration of what can occur while the SSIV is
transitioning from its static normal state to the other (Open to Closed, Closed to Open); when it is in dynamic
conditions. During this dynamic state, conditions can be vastly different than when static. For example, closing a
valve against a normal flow rate from its fully opened position will accelerate the fluid up and until it is stopped by
the closed valve.

If a valve has an allowable leakage rate like most metal seated valves have, then the fluid can become erosive if the
energy level (differential pressure) is high enough to propel the fluid past the closure element, and severe
degradation of the sealing elements can occur. Isolation valve datasheets also often fail to provide a goal or target
for installed performance during the valve’s useful life other than the risky assumption that the required valve
closure test from API 598, ISO 5208 or MSS-SP-61 can translate a similar quality into the valve’s actual duty and
performance in service. Therefore more attention should be focused upon arriving at a reasonable Severe Service
Isolation Valve (SSIV) definition, as it is in our opinion, the more difficult task. A severe service isolation valve data
sheet lists the key elements that should be identified in order to properly select the type, materials and options of
the SSIV, including the information required to determine the effects of the dynamic status. SSIVs should: • Isolate
over a minimum installed period of time to a minimum quality of isolation

The severe service conditions always apply to the following isolation applications:

• Autoclave Block

• Boiler ERV, Drains, Vents

• Catalyst • Delayed Coking

• Emergency Shut-Off Valves (ESDs)

• Ethylene Furnace Isolation

• FCCU

• Fire Isolation Valves

• H-Oil
• High Cycle Switching/PSA

• High Pressure Slurry Block

• HIPPS

• Hydrocracking

• Hydrogen

Molecular Sieve/Dehydration • Reactor Isolation • SIL Rated Service • TEOR Steam • Toxic/Lethal Service By using
suppliers who specialize in severe service valves, applying a series of steps in qualifying them and separating
general purpose from the more challenging applications, greater and longer success for a facility’s valve population
is achievable. Severe service valves will be objectively defined in the next few years. We will all benefit.
Selection & Applications:-

Critical and severe service valves need to be durable and require as little maintenance and repair as possible. They
also need to perform to incredibly high standards, such as zero leakage and abrasion resistance.
Metal-seated ball valves are ideal for these conditions because they are less susceptible to damage than soft-
seated ball valves. The key to metal-seated ball valve success is two-fold: 1) precision lapping techniques for
precisely mating the ball with its seats, and 2) the development of ultra-hard and abrasion-resistant ball and seat
coatings. These two areas of design advancement enabled the ball valve to perform feats of closure not
successfully attained before. This allowed the metal-seated ball valve to become the severe service valve of
choice for many applications.

Recognizing Severe Service Applications :-

There is sufficient operational experience that can be pooled together to recognize severe service valves. Some of
the guidelines for doing so are given below. 1. User experience - If there is a continuing operational, maintenance
or reliability problem with control valves in a given application. 2. Application experience - Valves in many
applications in nuclear plants are known to experience severe service conditions. Some of the applications in
nuclear plants are: · Pump minimum flow recirculation · FW Control valves · Turbine Bypass (atmospheric dumps or
condenser dumps) · Emergency Heater Drain Level control · RCIC, HPCI, RWCU, Core Spray · CVCS Letdown · HX
Bypass · SG Blow down · Service Water Flow control 3. High Vibration 4. High Noise 5. Poor process control at
design or off-design conditions 6. Leakage 7. Mechanical damage to valve components 8. Damage to the system
around the valve 9. Environmental Qualification - High reliability requirement in harsh environments for a control
valve application can also be treated as a category of severe service valves.

Approach for Eliminating Problems in Severe Service Applications :-

Having established these guidelines for recognizing severe service applications, one can then turn to the
requirements that valves must meet in order to provide good long term performance. The traditional approaches
to addressing such problems have been by continual maintenance or brute force or both. The brute force
approach covers “solutions” such as using harder materials where there is erosion, covering up with insulation to
reduce noise, more supports to reduce vibrations, and so on. These merely try to cover up the symptoms. They do
not address the root cause at all. Sometimes just changing to another valve is tried without thoroughly evaluating
if the solution being tried truly eliminates the root cause of the symptoms observed. This is risky, because the
result could very well be no improvement to marginal improvement, and expensive, because of what it takes to
change out valves in nuclear plants. The most reliable way of eliminating problems is by addressing the root
cause(s).
Identifying Root Cause of Problems:-

Identifying the root cause of the problems is the first step in ensuring that the technology in the valve is suitable
for the specific application, whether in existing valves or in terms of potential in new application. As stated earlier,
all severe service applications are not exactly the same. This makes the details of the application requirements all
the more important.

However, most of the causes of problems in severe service applications fall in five categories :

· excessive fluid energy along the flow-path

· inadequacies in actuation system

· design details

· valve-piping interface

· poor maintenance/incorrect calibration.

The last issue of maintenance and calibration is not a valve technology related issue. No amount of maintenance or
calibration will offset the shortfall in performance because of the first four items indicated above. Most
importantly, it should not be used, or allowed to be used, as an excuse for continuing valve problems.

Another important aspect for control valves is actuator selection. This has been a focus of major work in the
nuclear AOV Users Group (AUG). Much effort has been directed towards ensuring that the valve operators are
reliable and will act when called upon to do so. In critical service applications, in addition to being adequate as far
as operability for a control valve, actuator sizing and selection is important in four areas : · tight shutoff capability, ·
good controllability under normal operating conditions, · good controllability during transients, and, ·
environmental qualification.

Operability only means that a valve can be modulated when required to do so. It does not ensure adequate thrust
for shutoff or being able to control the process satisfactorily. Since guidelines for achieving the required tightness
of shutoff are not covered by any standards, it is critical to spell out quantitative criteria in ensuring that the
actuator has sufficient thrust. In principle, even small positive force is adequate for tight shutoff if the sealing
surfaces are perfectly machined. This is not practical because the real world is far from perfect in this respect. Even
then, in the valve industry, the range of variation in recommended thrust for tight shutoff is wide; for e.g., for ANSI
class IV shutoff, the recommended shutoff thrust varies from 40 PLI, or pounds per lineal inch of seat
circumference, to 400 PLI. Experience shows that sufficient conservatism in shutoff thrust is necessary where
tightness of shutoff is important. This ensures that the tightness of shutoff is maintained for long-term service, well
beyond just the factory test. Again, generic guidelines are available to ensure that such conservatism is built into
the sizing and selection. Operability has another aspect, which is good controllability under normal operating
conditions. It is often overlooked that control valves are the “final” control elements in process control. Even the
most sophisticated digital control systems (DCS) can not make up for limitations in the control valve performance.
Small hysteresis and dead band, quick response to small signal changes and stable dynamic response are all key
parameters that define good performance. All, or some, of these are essential depending on the service; for
example, feed-water control applications require all these characteristics.
Solution:-

Longer service life and lower maintenance costs are made possible through precision engineered valve and trim
options — even in corrosive, erosive and high-velocity applications. A range of advanced anti-erosion, noise
reduction and anti-cavitation selections neutralizes the detrimental wear and tear that too often reduce valve life
or lead to failures. Maximum flexibility is achieved through severe service products that incorporate a range of
material, pressure and temperature options.

Following are some of the trims available in market from different vendors for better service options:

ChannelStream (Valtek) trim prevents cavitation from forming and minimizes

hydrodynamic noise even in the most challenging liquid applications. Staged pressure drops eliminate cavitation by
maintaining pressure above the vapor pressure—never allowing cavitation to form.

CavControl (Valtek) valve trim lowers cavitation damage by controlling the

location and concentration of cavitation vapor bubble implosions in an area away from metal parts. CavControl
trim utilizes a number of small, diametrically opposed flow holes through the walls of a special seat retainer.

CavStream (Valtek) valve trim lowers cavitation damage by controlling the

location and concentration of cavitation vapor bubble implosion in an area away from metal parts. CavStream trim
utilizes a number of small, diametrically opposed flow holes through the walls of a special plug.
These Valve range (by Koso) was developed to overcome the problems associated with control, cavitation and
noise that would otherwise cause premature mechanical wear and failure of components on conventional
Butterfly and Ball Valve designs.

Just like these, there are several complex and application specific designs available in the market from various
vendors. i.e. To say, the solution is to address the trim design. More efficient the trim design is to the specific
application more away the problem will be.

For a single application, the vendors shall come up with different designs with various trims, variety of materials of
construction, different noise values and with fantastic valve characteristics. The choice of the best performing
valve shall be based on two important aspects i.e. valve size & valve noise. Lesser the valve size, lesser will be the
cost and lesser the valve noise, better will be the plant environment. While considering these two, rest all
considerations i.e. characteristics, rating, materials, controllability, leakage, etc. are assumed taken care.
Conclusion:-

In conclusion, severe service applications must be treated differently from general service control valves. In
addition, different severe service applications have their own specific set of requirements for high performance.
The performance limits of a control valve in such services is clearly a function of the technologies it features. In
order to avoid control valve problems in severe service, it is important to evaluate if the technology in it, is suitable
for the specific application. Generic guidelines, which include quantitative and verifiable design rules that address
the root cause of problems in severe service applications are available. Adherence to these rules narrows the
selection of technologies to those that would result in good long-term performance, high reliability and eliminate
the plant losses associated with these valve applications. Finally, incorporation of specific design rules in the valve
specification provides objective and verifiable criteria that can be used to “qualify” the technology for good valve
performance in service.

Vendors are the experts for their own valve designs. There are many experts for the severe service control valves
and we need to carefully extract the right information from the right expert that will really help to select the
correct valves for our applications.

Thus, depending on the application requirements, vendors suggest their best suitable option and provide
appropriate solutions. While selecting a valve for particular severe service application, the design engineer shall
need to take thorough look into the valve sizing calculation including valve noise, differential pressure, valve inlet
pressure, cavitation index, fugitive emission, temperature, etc. A careful study of the valve calculations, process
data and the options available in the market (designs offered by vendors) shall help to select the correct valve for
solving the severe service application problems.
References:-

http://www.koso.co.in/kent_butterfly_valve.php

https://www.flowserve.com/en/products/valves/severe-service-control-valves/cavitation-solution-
control-valves/cavitation-solution-control-valves-cavstream

https://alliedvalveinc.com/the-valve-expert/when-do-you-need-severe-service-valves/

https://pro-
quip.com/images/proquip/PDFs/Library/ValtekLiterature/Severe%20Service/Valtek%20Channel%20Stre
am.pdf

https://catalog.dft-valves.com/item/control-and-block-valves/dft-hi-100-severe-service-control-valve/dft-sup-sup-
hi-100-control-valve

https://pro-
quip.com/images/proquip/PDFs/Library/ValtekLiterature/Severe%20Service/Valtek%20CavControl.pdf

https://cgis.ca/media/2015/08/Defining-Severe-Service-Valves.pdf

http://www.iceweb.com.au/Valve/SevereServiceValves/TechinSevereServControlValves.pdf

https://www.flowserve.com/en/products/valves/severe-service-control-valves

http://www.ccivalve.com/~/media/Files/C/CCI/pdf/959-TP-Severe-Service-Power-Applications-Handbook-low-
res.pdf

http://www.ccivalve.com/products/~/media/Files/C/CCI/pdf/326-drag-800d-control-valves-for-severe-service-
applications.pdf

http://www.vmcs.eu/assets/kki-severe-service.pdf

http://industrial.dft-valves.com/hi-100-control-valve-catalog-download-dft-inc

Edited by:

Anupam A. Gandhewar

https://www.linkedin.com/in/anupam-gandhewar-3b571358/