One potential solution to the challenge of achieving a metal-tometal , 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 inservice conditions to validate the product ’ s performance across various temperature and pressure combinations . This approach ensures that the valve design is both costeffective 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 industryrecognized 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 .
For further information , please visit www . valves . co . uk
Issue 73 PECM 97