Why Is Valve Maintenance Important?FLOW STOPPING (CRITICAL) VALVES HAVE TO CLOSE SMOOTHLY AND SEAL PROPERLY IN THE EVENT OF A PIPELINE FAILURE OR FACILITYEMERGENCY TO PROTECT PEOPLE , PROPERTY & THE ENVIRONMENT.“Almost all valve failures can be attributed directly to a lack of proper, yet inexpensive, maintenance procedures-the most important being lubrication and cleaning.”Pipeline Industry, December 1986
IntroductionSafeSeal Valve Systems Corp. is the designer of the patentpending SafeSeal360 Valve Greasing System. Our valve greasingsystem is designed to be used in the regular maintenance ofcritical valves used in pipeline and oil and gas facilitiesthroughout Canada, the United States and internationally.The SafeSeal360 system helps ensure that the valve integrityrequired for proper operation is maintained during the life of avalve.The SafeSeal360 system also reduces the frequency for pipelineand facility valve refurbishment and replacement costs, costswhich are far greater than the cost of a SafeSeal360 system.
Pipeline Quick Facts94% - Percentage of transportation demand in Canada supplied by petroleumproducts3 million - Barrels of crude oil transported by transmission pipelines in Canadaevery day - the equivalent of 200 Olympic sized swimming pools97% - The percentage of Canadian natural gas and crude oil productiontransported by transmission pipelines2.5 - Number of times Canada’s natural gas and liquid transmission pipelineswould circle the earth if laid end-to-end30 -35 - Number of days it takes for oil to travel by pipeline from Alberta tosouthern OntarioUp to 40 km per hour - Speed natural gas moves through a pipeline75 kilometers - The length of train that would be required to transport the 3million barrels of crude oil transported by pipeline in Canada every day825,000 kms - Estimate of Canada’s underground natural gas and liquidspipeline network (gathering, transmission and delivery lines)425,000 kms - Estimate of Alberta’s underground pipeline network (over halfof Canada’s total)
Types of PipelinesGathering LinesThese lines travel short distances gathering products from wells andmove then to oil batteries or natural gas processing facilities. From101.6mm to 304.8mm (4 in. to 12 in.)Feeder LinesFeeder lines move products from batteries, processing facilities andstorage tanks in the field to the long-distance haulers of the pipelineindustry, the transmission pipelines.Transmission PipelinesTransmission lines are the energy-highways, transporting oil and naturalgas within a province and across provincial or international boundaries.From 101.6mm to 1,212 mm (4 in to 48 in.) About half are 457.2 (18 in.)or larger, and about one third are 254 mm (10 in.) or smaller)Distribution PipelinesLocal distribution companies (LCDs) operate natural gas distributionlines. From 12.7 mm to 152.4 mm (1/2 in. to 6 in.)
The Natural Gas Delivery NetworkNatural gas movesthrough a pipeline atspeeds of up to 40kilometres perhour, about thespeed of an Olympicsprinter.
The Crude Oil Delivery NetworkCrude oil movesat a speed of 5kilometres perhour viapipeline, roughlywalking speed.
Pipeline ValvesThe world’s vast pipeline network is controlled by several types of valves that areinstalled at intervals along pipelines or at facilities and can be closed to stop theflow of gas or oil for maintenance, ruptures or leaks. As pipelines approachheavily populated areas, the frequency of valves that can stop the flow of gas oroil increases.Three Primary Types of Flow-Stopping Valves: •Manual Valves: Opened and closed by hand •Remote Valves: Opened and closed remotely from a pipeline flow control centre •Automatic Shut-off Valves (commonly called an ESD): Shut-off valves that close automatically if pipeline pressure drops or if gas flow direction changesOnly properly maintained valves will close fully and seal completely whenrequired to do so.
Why Valves LeakDehydrated natural gas offers little, ifany, lubricationInternal elastomeric seal tends to dry out, hardenand then stick to the sealing surfacesCommon perception is that because the valvewas tested in the factory, the valve should sealperfectly for many years in the future. Proper valvemaintenance is essential to the reliability andintegrity of the entire pipeline systemThe personnel often assigned to perform valve A poorly maintained valvemaintenance often have no prior training or Corrosion & leakingexperience
Why Valves LeakSolid contaminants such as pipe scale, welding slag, hot tap cuttings, sand and dirt create tiny scratcheson the mated sealing surfaces. These scratches erodeinto progressively larger leak passageways.Valves are rarely lubricated according tomanufacturer’s specifications. A typical valve requires2 oz of product per inch of valve diameter. A small 4”valve would require 8oz of product to properly greasethe valve. A hydraulic hand gun requires 25 strokes tomove 1 oz of product. A 4” valve would require 200strokes to deliver the right amount of product.Because of lack of training, remote locations , cost and Scratches like these erodelack of manpower in the field, this is rarely achieved into progressively larger leakwhich reduces valve life and increases risk of leakage. passageways
Proper Valve Maintenance Why It Is CrucialAlmost all valve failures and loss of valve life can beattributed to lack of proper, routine maintenance-themost important being lubrication and cleaning.Every time a valve is cycled some lubricant is lostdownstream.Forcing a hard to operate valve to open or close cancause damage to internal components.Cycling a valve when internal surfaces are dry cancause scarring on the ball and seat surfaces leading toleakage.Higher pressures in a pipeline also accelerate Normal wear & tear onlubrication loss with every application. well-maintained valve
Valve Replacement Costs (from Sealweld Corporation study) Extending Valve Life Pays Off!!New Valve Costs-A new valve can cost from $1,200-$2,000 per inch of valve diameter. A 36” ball valve rangesfrom $45-65,000 delivered to locationManpower & Equipment-Depending on the location ofthe valve, the cost of moving the heavy equipment andhousing manpower can vary greatly. Estimates range from$50-250,000.Cost of Lost Gas-During a valve replacement, gas has tobe vented or flared to the atmosphere. Estimates rangefrom $50-100,000 per valve.Lost Revenue for Operator-When a pipeline goes outof service revenue is not being generated and fixed costs foroperations are constant.Environmental Impact-Extending valve life means avalve has to be replaced less, therefore reducing the amountof gas that is vented or flared to the atmosphere.
How SafeSeal360 Works?Claps to the pipeline near the valveor comes with a standConnects to the valve using highpressure hoses to each button headfitting of the valveUses 4000psi of pressure to deliverthe proper amount of grease in 360degrees to the left side of the valveAutomatically recharges to delivergrease to the right side of the valveCan be operated by pushing abutton on-site or remotely
Where Is SafeSeal Used?The SafeSeal360 Valve Greasing System is ideal for use on:All ESD valvesPigging valves & pig launchersRemote valve locationsFacility valvesOffshore platform valvesValves near river crossings or waterwaysValves near any populated areaValves near environmentally sensitive areasAny valve that is cycled (open & closed) regularly
Advantages of SafeSeal Reduces the risk of valve leakage andpotential environmental clean-up costs360 degree seat grease pressure systemensures grease is distributed evenlyExtends valve life & reduces valve repairand expensive downtime costsCan be easily mounted beside eachcritical valve whether in remote areas or inplant facilities
Advantages of SafeSealCan be activated by the push of a buttonor remotely, delivering the proper amount oflubrication and sealant necessary forefficient valve operationValves can be greased properly accordingto manufacturer’s specificationsSafeSeal’s system grease is both alubricant & sealantRefillable grease canisters