Prototypes of Trunnion ball valves fitted with Scotch Yoke actuators have been submitted to opening and closing cycling tests so as to monitor and analyze their operation under critical conditions in order to evaluate their failure modes. The prototypes were arranged so as to collect data related to pressures, torques, temperatures and angular positions from the valve balls during the tests. Pressure signatures of the hydraulic actuator and stem torques were generated through the data collected and analyzed using the moving variance method. Also analyzed were the upstream and downstream pressure signature profiles of the valves throughout the test. It was found that the critical components for these pieces of equipment were the seals, called seats, which are produced from reinforced polytetrafluoroethylene (RPTFE). The seats showed considerable plastic deformations under the test conditions, which eventually lead to the rupture of the sealing band, resulting in leakages. When combining the analysis of the moving variance method with the analysis of the pressure signature profiles, changes were detected in the behavior of the prototypes throughout the tests, in addition to indicating the moment of failure. This methodology can be useful for prototype evaluations and even for valve instrumentation in the field, so as to ensure greater reliability, prevent unnecessary maintenance and provide safer operating conditions.
IntroductionBy definition, industrial valves are mechanical devices specifically designed to direct, initiate, block, mix or regulate the flow, pressure or temperature of fluids in industrial processes [1].The growing demand for fossil fuels, in particular oil and gas, has led to exploration in increasingly deeper waters, making operations more susceptible to components failures. The increased risk of failure and its consequences result in increased maintenance and increased repair costs of components [2,3].Among the numerous components required for exploration in underwater and refineries, hydraulically-actuated valves, such as the Emergency Shut Down Valve (ESDV), play an important role as safety elements, and are used to allow or interrupt flow in the pipeline. They are conventionally called Fail Safe Close (FSC) and Fail Safe Open (FSO) depending on their operating characteristics