Valve fugitive emissions

Ville Khknen
Sales manager
Metso Automation

Standards
Certification
Education & Training
Publishing
Conferences & Exhibits

ISAAutomationConference2013EMEA
(Dammam,SaudiArabia)December1012,2013

Content
General aspects of different emission standards

TA-Luft
Clean Air Act
FCI-91-1
Shell 77/312
ISO 15848-1

Detailed view of ISO 15848-1 emission standard

GENERAL ASPECTS OF
DIFFERENT EMISSION
STANDARDS Brief history

TA-Luft
Clean Air Act
ISO 15848-1
FCI-91-1
Shell 77/312
Technical comparison of valve emissions
standards

ISAAutomationConference2013EMEA(Dammam,SaudiArabia)December1012,2013

Historical background of emission regulations

Emissions from valves

Typicalemissionsfromvalvetypes

Regulatingcontrolvalvesrepresent~70%ofvalve

emission

Gate,globevalvesensitivebydesign
Plug,ball,bflyvalvelesssensitivebydesign
>Rotaryvalvesareinherentlylessleakingvalvetype

Typicalreasonsforleakage(**)

Corrosion
Scratches
Erosion
Bent
(**)source:Bello,C.E&Siegell,J.H.WhyValvesLeak:AsearchfortheCauseofFugitiveEmissions.EnvironmentalProgress.Spring1997.Vol16.No1
p1315

Historical background of emission regulations

Current status of industrial valve emission standards

Nowadays we have many valve emission related test

standards set by:

National legislation (CAA & TA-Luft)

Standardization organizations (ISO 15848-1 & 15848-2)
Guidelining standards (FCI-91-1, API 624 (pending) )
End users specs (Shell 77/312, ChevronTexaco)

TA-Luft (Technische Anleitung zur Reinhaltung der Luft)

Legislation

= Technical Instructions on Air Quality Control

It is Germanys national regulation for air pollutants to protect general public and
environment
TA-Luft sets limits for different air pollutants like dust, sulfur dioxide, nitrogen oxides
& other harmful and toxic matters
Different industry areas have regulations for industry specific pollutants
TA-Luft history begins from year 1964 and latest revision has been done on 2002

Meaning of TA-Luft 2002 for industrial valves:

Chapter 5: Requirements to Provide Precautions against Harmful Effects on the

Environment
5.2.6.4 Shutoff Devices
In order to seal shaft bushings of shutoff devices such as valves or gates,
metal bellows with a high-grade seal and a downstream safety packing gland or
sealing systems of similar effect shall be used.
Sealing systems shall be deemed to be of similar effect if the temperature-specific
leakage ratios can be kept during the proof procedure pursuant to VDI Guideline 2440 (November 2000 version).

VDI 2440 defines equivalency to bellow seals by leakage rate of flat gasket

10e-4 mbar*l / (s*m) for temperatures <250degC

10e-2 mbar*l / (s*m) for temperatures >=250degC
Test medium is helium, several measuring methods accepted

Measuring conditions have been defined at ...pressures, temperatures and

spindle and shaft movements which cover operating conditions.

Clean Air Act (USA)

Legislation

It is USAs national law that defines EPA's responsibilities for protecting and
improving the nation's air quality and the stratospheric ozone layer. (EPA =
Enviromental Protection Agency)
CAA history begins from 1963. Latest amendment has been done on 1990.
Meaning of CAA (1990) for industrial valves

CAA Title V - Permits, sets fugitive emissions to be determined acc. to EPA

40 CFR (Code for Federal Regulations) Parts 60 and 63

Authorized a program to control 189 toxic pollutants, including those previously regulated
by the National Emission Standards for Hazardous Air Pollutants

The emission level is 500ppm or 100ppm (state dependent)

Measuring will be done at current useage conditions -> test medium is hydrocarbon
Measuring method shall be EPA Method 21
No endurance classes or other classification

LDAR (Leak Detection And Repair) program is included into legislation. The
purpose is to find and repair leakers by regular inspections

FCI-91-1
Informative standard

Developed by Fluid Control Institute (FCI) to evaluate sealing properties of

a stem seal design under defined conditions
The standard has been published first time on 1991 and latest revision has
been done on 2010. It is no longer ANSI standard.
Classification has been done by:

Endurance class
including thermal cycling (3pcs): A=100k, B=25k, E=5k
excluding thermal cycling: C=100k, D=25k

Leakage classes

1=100ppm
2=500ppm

Packing adjustment allowed only on endurance class E

Allows use of a test bench instead of a valve

Bending loads must be simulated

Emission measurement is done acc.to EPA Method 21

Test fluid is methane (allowing air or nitrogen at elevated temp)

Shell MESC SPE 77/312

End user specification

Shells standard specifies requirements for emission production testing. It is

used at oil refineries, chemical plants etc if it is specified at purchase order
MESC SPE 77/312 is a production acceptance test
It specifies amendments to ISO 15848-2 production acceptance test
First revision has been published on 2005 and latest revision has been done on
2010.

MESC SPE 77/312 requires succesfull passing of ISO 15848-1 (amendent

by MESC 77/300 if needed)
Testing will be done for a certain percentage (2-5%) of purchase lot valves
% is defined by leakage class
0 pcs failed valves

Classification has been done by leakage classes A and B for stem and
bonnet leakages

Class A (stem) limit is 1,78 * 10e-7 mbar*l/s*mm dia

Class B (stem) limit is 1,78 * 10e-6 mbar*l/s*mm dia

Other criteria

On-off valve 5 cycles acc. to ISO 15848-2

Control valves 500 cycles (SPE 77/312 requirement)
Stem adjustment is allowed one time
9

ISO 15848-1 & ISO 15848-2

International Standard

The need to clarify valve emission related issues led to the birth of ISO
15848 standard
ISO 15848-1 and -2 have been published by International Standardization
Organization at 2006

Part 1: Type acceptance test

Part 2: Production acceptance test

The purpose of ISO 15848-1(& -2) standard is to evaluate of industrial

valves external packing and body joint(s) leakage
Classification has been done by:

Leakage (A, B, C), endurance (500-2500, 20k-100k) and temperature class (-196 to 400degC)
On-off and control valves have their own endurance classes
Allows pre-defined re-tightening of the packing

10

ISO 15848-1 & ISO 15848-2

International Standard

Measuring conditions include

thermal cycling
several measuring methods.

Test fluid is either helium or methane

Classification of the valve, for example
ISO FE BH CC3 - SSA 1 t(RT, 400C) CL300 ISO 15848-1

11

TECHNICAL COMPARISON OF
VALVE EMISSION STANDARDS

ISAAutomationConference2013EMEA(Dammam,SaudiArabia)December1012,2013

Technical comparison
Valve emission standards

Comparison table

13

Technical comparison
Test gases

Two different test mediums have been specified

Different test mediums do not behave similar way

Factors affecting leakage values

Molecule size, diffusion ability, viscosity

Three leakage routes: A,C =surface flows, B=diffusion

Factors affecting packing endurance

Helium
Methane

Lubrification ability of the flow medium

Methane based tests due working safety

is not preferred

14

Technical comparison
Leakage units

Different standards specify or allow different measuring methods

Global methods: vacuum or flushing, for example

Local method: sniffing
Expressed leakage value of measuring methods is different
Global methods express in (mass) flow per time unit, for example mbar*l/s
Local methods express in concentration, for example ppmv

Comparison of mbar*l/s vs ppmv is difficult

However, it can be done with a certain accuracy from mbar*l/s to ppmv.

It is needed to know mbar*l/s leakage and corresponding sniffing value & flow properties of
sniffing device
A conversion formula can be used to evaluate ppmv value it is device dependent
Ppmv to mbar*l/s is not possible to convert

15

Technical comparison
Leakage test methods

It is needed to understand capabilities of different measuring methods

The most common measuring methods are:

global methods like vacuum and flushing method

local method like sniffing

Vacuum method
Very accurate, the reference for other methods
For example, ISO 15848 Class A allowed only to be
measured with vacuum method

16

Technical comparison
Leakage test methods

Flushing method

Quite accurate
For ISO Class B, C, TA-Luft etc
There are three variables which affect indicated
leakage result

Qflushing gas
Qleakage
Qdevice

17

Technical comparison
Leakage test methods

Sniffing method
Not very accurate, however correlation exist
Factors like person, wind & device affect the result
It is very easy to use and provides quick indication
of a leaking device
CAA, FCI-91-1

18

Technical comparison
Thermal cycling & endurance of the test

Thermal cycling affect packing (and bonnets) sealing ability

Packing design
Live loaded design to compensate thermal cycling and material relaxation

Packing material selection

Different definition for 1 cycle (open-close) makes difficult to compare

endurance of packing

ISO 15848-1: +- 10% control valves, 100% on-off valves

ISO 15848-2, Shell SPE 77/312: fully open and close
Note: production acceptance tests

TA-luft, CAA: not defined

19

Technical comparison
Leakage limit values

20

Technical comparison
Leakage limit values

Real life leakage values for d=25mm stem size:

ISO Class A = 0,014L per year (volume of d=3cm ball)

TA-Luft <250C = 0,3L per year (a Coca Cola can)
ISO Class B = 1,4L per year (~ Large soft drink bottle)
TA-Luft =>250C = 30L per year
ISO Class C = 140L per year

21

Technical comparison
Valve emission standards

Generally, ISO 15848-1 Class A can be considered the most stringest

standard at the moment.

TA-luft <250C leakage limit is string.

Amount of operations, including cycle and temperature cycles are defined

High temperature and long duration tests are available
The most accurate measuring method
Amount of operations and temperature cycles are not defined,
Measuring devices can be not so accurate type

Shell MESC SPE 77/312 Class A, ISO 15848-1 Class B is about same
level
EPA 40 CFR 60 and FCI-91-1 100ppm limits fall between ISO Class B and
C

22

DETAILED VIEW OF ISO 15848-1

EMISSION STANDARD

23

ISAAutomationConference2013EMEA(Dammam,SaudiArabia)December1012,2013

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

Emission class

Normal production tests are performed to the test valve

Body pressure and trim leakage testing

A passed test will result following classification:

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

FE BH = Class B leakage performance, test gas helium

Leakage classes are referred:

First letter defines leakage performance: A, B or C

Second letter defines test gas: H= helium, M= methane
No intended correlation between helium or methane classes
Class A equivalent to bellows type sealing element (vacuum)
Class B equivalent to PTFE type sealing element (vacuum or flushing)
Class C equivalent to graphite type sealing element (vacuum or flushing)

Leakage from body seals must be <= 50ppm

Sniffing method, must be separated from the packing leakage if possible

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

Endurance class

CO1 = endurance class of the test

On-off valves have classes CO1, CO2 and CO3
500, 1500, 2500 cycles
100% stroke

Control valves have classes CC1, CC2 and CC3

20k, 60k and 100k cycles
+-10% stroke at 50% opening

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

Stem adjustments

SSA1 = number of stem seal adjustments

In case of exceeding the leakage limit, the stem can be adjusted
Adjustment allowed once for each qualification stage
CO1 and CC1 allow one adjustment
CO2 and CC2 allow two adjustments
CO3 and CC3 allow three adjustments

Number of adjustments must be reported

The number of adjustments indicates
Packings ability to resist relaxation -> need of service in use
However, actual conditions may vary lot compared to test conditions

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

Temperature class
t(RT, 200C) = covered temperature area
Temperature classes: -196C, -46C, RT, 200C and 400C
RT covers from -29C to 40C
Appropriate P/T values must be used
Temperature and pressure must be +-5% of set point (not exceeging
+15C)
No cycling during heat up

Two tests are needed to cover below RT temperature range

To cover range -46C to 400C requires two tests: -46C to RT and RT to
400C

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

Temperature class

Temperature class is determined by location x (1)

sensor
No artificial cooling is allowed

ISO FE BH CO1- SSA 1 t(RT, 200C) CL300 ISO 15848-1

Pressure class

CL300 = pressure class indication

Pressure class can be expressed
using ASME or EN PN classes
Using bars at room temp and at elevated temp (40/30)

Finally, the certification covers

Valve types comparable to the tested valve (ball / bfly etc)
Shaft size range 50-200%, using same design parameters
Pressures and temperatures up to classification values

ISO 15848-1 PRACTICAL ISSUES

30

ISAAutomationConference2013EMEA(Dammam,SaudiArabia)December1012,2013

ISO 15848-1 practical issues

ISO 15848 test requirements from manufacturer

Heating and cooling time sets test total lenght

Noartificialcoolingisallowed

Oneheatcycle,fora08valve,incl.125cycles,requires160000s=2days
>CO1testrequiresmorethanaweek,CO3test~twoweeks

31

ISO 15848-1 practical issues

ISO 15848 test requirements from manufacturer

ISO158481,RTto400C,CC3testforrotaryplugvalve(3#300)
Testdurationwasonemonthtoachieve100000cycles&400C

32

Summary
Many different standards
Comparison is not easy
Which standard defines what?

ISO 15848-1 can be concidered most strict because the

temperature and cycle range is definet and also the
testing method

ISAAutomationConference2013EMEA(Dammam,SaudiArabia)December1012,2013

Thank you!
ville.kahkonen@metso.com

34