2. Why Is Valve Maintenance Important?
FLOW STOPPING (CRITICAL) VALVES HAVE TO CLOSE SMOOTHLY AND
SEAL PROPERLY IN THE EVENT OF A PIPELINE FAILURE OR FACILITY
EMERGENCY 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
3. Introduction
SafeSeal Valve Systems Corp. is the designer of the patent
pending SafeSeal360 Valve Greasing System. Our valve greasing
system is designed to be used in the regular maintenance of
critical valves used in pipeline and oil and gas facilities
throughout Canada, the United States and internationally.
The SafeSeal360 system helps ensure that the valve integrity
required for proper operation is maintained during the life of a
valve.
The SafeSeal360 system also reduces the frequency for pipeline
and facility valve refurbishment and replacement costs, costs
which are far greater than the cost of a SafeSeal360 system.
4. Pipeline Quick Facts
94% - Percentage of transportation demand in Canada supplied by petroleum
products
3 million - Barrels of crude oil transported by transmission pipelines in Canada
every day - the equivalent of 200 Olympic sized swimming pools
97% - The percentage of Canadian natural gas and crude oil production
transported by transmission pipelines
2.5 - Number of times Canada’s natural gas and liquid transmission pipelines
would circle the earth if laid end-to-end
30 -35 - Number of days it takes for oil to travel by pipeline from Alberta to
southern Ontario
Up to 40 km per hour - Speed natural gas moves through a pipeline
75 kilometers - The length of train that would be required to transport the 3
million barrels of crude oil transported by pipeline in Canada every day
825,000 kms - Estimate of Canada’s underground natural gas and liquids
pipeline network (gathering, transmission and delivery lines)
425,000 kms - Estimate of Alberta’s underground pipeline network (over half
of Canada’s total)
5. Types of Pipelines
Gathering Lines
These lines travel short distances gathering products from wells and
move then to oil batteries or natural gas processing facilities. From
101.6mm to 304.8mm (4 in. to 12 in.)
Feeder Lines
Feeder lines move products from batteries, processing facilities and
storage tanks in the field to the long-distance haulers of the pipeline
industry, the transmission pipelines.
Transmission Pipelines
Transmission lines are the energy-highways, transporting oil and natural
gas 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 Pipelines
Local distribution companies (LCDs) operate natural gas distribution
lines. From 12.7 mm to 152.4 mm (1/2 in. to 6 in.)
6. The Natural Gas Delivery Network
Natural gas moves
through a pipeline at
speeds of up to 40
kilometres per
hour, about the
speed of an Olympic
sprinter.
7. The Crude Oil Delivery Network
Crude oil moves
at a speed of 5
kilometres per
hour via
pipeline, roughly
walking speed.
10. Pipeline Valves
The world’s vast pipeline network is controlled by several types of valves that are
installed at intervals along pipelines or at facilities and can be closed to stop the
flow of gas or oil for maintenance, ruptures or leaks. As pipelines approach
heavily populated areas, the frequency of valves that can stop the flow of gas or
oil 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 changes
Only properly maintained valves will close fully and seal completely when
required to do so.
11. Why Valves Leak
Dehydrated natural gas offers little, if
any, lubrication
Internal elastomeric seal tends to dry out, harden
and then stick to the sealing surfaces
Common perception is that because the valve
was tested in the factory, the valve should seal
perfectly for many years in the future. Proper valve
maintenance is essential to the reliability and
integrity of the entire pipeline system
The personnel often assigned to perform valve
A poorly maintained valve
maintenance often have no prior training or Corrosion & leaking
experience
12. Why Valves Leak
Solid contaminants such as pipe scale, welding slag,
hot tap cuttings, sand and dirt create tiny scratches
on the mated sealing surfaces. These scratches erode
into progressively larger leak passageways.
Valves are rarely lubricated according to
manufacturer’s specifications. A typical valve requires
2 oz of product per inch of valve diameter. A small 4”
valve would require 8oz of product to properly grease
the valve. A hydraulic hand gun requires 25 strokes to
move 1 oz of product. A 4” valve would require 200
strokes to deliver the right amount of product.
Because of lack of training, remote locations , cost and Scratches like these erode
lack of manpower in the field, this is rarely achieved into progressively larger leak
which reduces valve life and increases risk of leakage. passageways
13. Proper Valve Maintenance
Why It Is Crucial
Almost all valve failures and loss of valve life can be
attributed to lack of proper, routine maintenance-the
most important being lubrication and cleaning.
Every time a valve is cycled some lubricant is lost
downstream.
Forcing a hard to operate valve to open or close can
cause damage to internal components.
Cycling a valve when internal surfaces are dry can
cause scarring on the ball and seat surfaces leading to
leakage.
Higher pressures in a pipeline also accelerate Normal wear & tear on
lubrication loss with every application. well-maintained valve
14. 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 ranges
from $45-65,000 delivered to location
Manpower & Equipment-Depending on the location of
the valve, the cost of moving the heavy equipment and
housing manpower can vary greatly. Estimates range from
$50-250,000.
Cost of Lost Gas-During a valve replacement, gas has to
be vented or flared to the atmosphere. Estimates range
from $50-100,000 per valve.
Lost Revenue for Operator-When a pipeline goes out
of service revenue is not being generated and fixed costs for
operations are constant.
Environmental Impact-Extending valve life means a
valve has to be replaced less, therefore reducing the amount
of gas that is vented or flared to the atmosphere.
16. How SafeSeal360 Works?
Claps to the pipeline near the valve
or comes with a stand
Connects to the valve using high
pressure hoses to each button head
fitting of the valve
Uses 4000psi of pressure to deliver
the proper amount of grease in 360
degrees to the left side of the valve
Automatically recharges to deliver
grease to the right side of the valve
Can be operated by pushing a
button on-site or remotely
17. Where Is SafeSeal Used?
The SafeSeal360 Valve Greasing System is ideal for use on:
All ESD valves
Pigging valves & pig launchers
Remote valve locations
Facility valves
Offshore platform valves
Valves near river crossings or
waterways
Valves near any populated area
Valves near environmentally sensitive
areas
Any valve that is cycled (open & closed)
regularly
18. Advantages of SafeSeal
Reduces the risk of valve leakage and
potential environmental clean-up costs
360 degree seat grease pressure system
ensures grease is distributed evenly
Extends valve life & reduces valve repair
and expensive downtime costs
Can be easily mounted beside each
critical valve whether in remote areas or in
plant facilities
19. Advantages of SafeSeal
Can be activated by the push of a button
or remotely, delivering the proper amount of
lubrication and sealant necessary for
efficient valve operation
Valves can be greased properly according
to manufacturer’s specifications
SafeSeal’s system grease is both a
lubricant & sealant
Refillable grease canisters
