LNG

Ball valve lifted out of the cryogenic test bench for

fugitive emission testing (leakage to atmosphere).
Photo courtesy: Neway Valves.

Valves in LNG service

With LNG (Liquefied Natural Gas) becoming popular as a clean fuel there has been tremendous investment in LNG
plants whilst additional significant investments are expected in the future as well. In any process plant valves are always
at the heart of all operating and isolation philosophies, so when the discussion is about a highly flammable fluid like LNG
then it is no surprise that the valves need and receive special attention.

By Neeraj Batra (Piping Materials Engineer) and Hitoshi Suzuki (Technical Leader-Material Technology & Management group),
Chiyoda Corporation

Common terminology
A short discussion about terms related to
cryogenic services will help the readers
to have enhanced understanding about
cryogenic valves and especially valves in
LNG service.
Cryogenic fluid: a gas that can be
changed to a liquid by removal of heat by
refrigeration methods to a temperature
at -100 °F (-73 °C) or lower. Ethylene
(boiling point -104 °C at atmospheric
pressure), methane (boiling point -162 °C at
atmospheric pressure) and nitrogen (boiling
point -196 °C at atmospheric pressure) are
some common examples of cryogenic fluids.
Cryogenic temperature: a temperature
range of -100°F (-73 °C) to -425 °F (-254 °C)
is considered cryogenic in the valve
industry.
Cold box: an enclosure that insulates a
set of equipment from the environment
without the need for insulation of the
individual components inside the cold
box. A cold box is quite common in air
separation units.
Cold box extension: a valve body/
bonnet extension section that removes the
operating mechanism of the valve outside
the cold box and is required to be longer
than a non-cold box extension. Although
dictated by standards, this length is usually
the distance between centerline of valve
and bottom of stuffing box/packing
chamber.
Non-cold box extension: a body/bonnet
extension that is used for valves that are
normally individually insulated. Although
dictated by standards, this length is
usually the distance between top of
body bonnet joint and bottom of stuffing
box/packing chamber. In this article, the
focus will be on individually insulated
valves so all references to the bonnet
extension will imply a non-cold box
extension.

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Drip plate: a circular plate welded to the

bonnet extension to protect the insulation
from condensation/rain.
Gas column: that portion of the body/
bonnet extension that allows for the
formation of an insulating column of
vapour. This distance is not defined by any
standards and is generally the vendor’s
recommendation (drip plate location on
the bonnet).
LNG: the abbreviation for liquefied natural
gas, which is mainly methane (90-95%) with
small amounts of ethane, propane, butane
and nitrogen. Natural gas is converted into
a liquid at cryogenic temperature (below
-162 °C) to reduce its volume (LNG in its Fig. 1: FEM simulation for testing effectiveness of the bonnet extension and gas column. Photo courtesy:
liquid form occupies 1/600th of the volume AEV Valves Belgium.
of the equivalent amount of gas). Reduced
volumes facilitate transport by LNG tankers Cavity relief mechanism: required for
from remote operating plants to the actual valves with a cavity (floating and trunnion
usage location where gas is not otherwise mounted ball valves as well as wedge, slab
readily available. Qatar, Indonesia, Malaysia, and expanding gate valves). This feature
Australia are some of the biggest LNG prevents any fluid trapped inside the valve
producers while Japan, Korea, India and from causing an excessive pressure in
China are the major consumers of LNG. the event that surrounding heat causes it
to gasify. (LNG will expand 600 times at
ambient temperature. See Fig. 3)
Special design requirement
for cryogenic valves *The following methods are used for
The following features differentiate achieving self-cavity relief in valve:
cryogenic valves (especially valves in LNG Floating ball and wedge gate:-a hole is
service) from standard commodity valves. drilled in the ball/wedge which will balance
Bonnet extension: this is required the pressure in the cavity with the high
to isolate the valve packing from cold pressure side during isolation of the valve.
cryogenic temperatures since a frozen Trunnion ball valve:-a combination of SPE Fig. 3: Ball valve with cavity where LNG could be
packing will render the valve inoperable. (single piston effect) and DPE (double trapped. A = cavity (gap between ball and body);
Also, Ice ball formed on the valve’s hand piston effect) seats are used. SPE is used B = body shell; C = ball.
wheel/gearbox will also restrict the valve
usage by operator. The vapourized LNG in to relieve the pressure on the high pressure
the bonnet extension acts as an insulation side during the Isolation activity. SPE
for packing. and DPE seat mechanisms are basically
The length of bonnet extension is defined differentiated by the seat construction
in standards like BS 6364 (Valves for and the arrangement of the lip seals
cryogenic service), MSS SP-134 (Valves for (see Fig. 4) in the grooves of the seat.
cryogenic service, including requirements
for body/bonnet extension), and ISO
28921-1 (Industrial valves-isolating valves
for low-temperature applications).
For sizes not covered in these standards,
vendors use FEM analysis to verify the
temperature profile across the bonnet and
packing area (see Fig. 1).
≥45
≥45º

Finally the vendor’s recommended bonnet

º

extension and gas column length are verified

during the cryogenic testing of the valves.
Valve installation: the recommended
valve installation is limited to a maximum
of 45 degrees from the vertical position Fig. 2: Reference: ISO 28921 Industrial valves-
when handling LNG, in order to prevent isolating valves for low temperature applications,
cryogenic liquid entering the valve packing showing the recommended bonnet orientation for
area (see Fig. 2). non-cold box installation. Fig. 4: Lip Seals. Photo courtesy Neway Valves.

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The seat designs are such that cavity SS 316 is used for the valves due to the
pressure will either push the seats away better behaviour of the valve function and
from the ball (SPE seats) or push the seats trims at subzero temperatures. Although
towards the ball (DPE seats). LNG is very clean, gate and globe valves
The cavity relief mechanism for slab gate are generally specified “half Stellite”
and expanding gate valve will not be since LNG is very dry and hence non-
discussed here since these valves are not lubricating.
common in LNG service. If a soft material is required in the ball valves
then PCTFE (Polychlorotrifluoroethylene)
*Additional considerations for valves is used as seat insert (see Fig. 6) and PTFE Fig. 6: PCTFE Seats. Photo courtesy Neway
equipped with cavity relief mechanism: (Polytetrafluoroethylene) and SS 316/Inconel Valves.
1. The direction of cavity relief shall be is used for the sealing material (commonly
clearly indicated on the P&ID & the called lip seals). One important consideration for triple
valve (see Fig. 5). One good location O-rings made of elastomeric materials are offset butterfly valves is the selection of
for indication of direction is on the drip not used in cryogenic valves due to their seat ring which is basically responsible
plate. Finally the valve installation on low temperature usage restraints (generally for providing tight shut-off between the
site shall be according to this direction. limited to -40 °C). body seats and disc. To obtain optimized
sealing performance, it is good engineering
practice and indeed recommended by most
Venting direction shall be indicated as follows:
leading valve vendors to select solid seal
ring in SS 316 austenitic stainless steel.
: When item to be isolated is located upstream of MBV This material grants long-term sealing
capabilities in cryogenic applications.
: When item to be isolated is located downstream of MBV Auxiliary connections: such as drains
and vents shall not be provided on the
Fig. 5: Typical indication of the cavity relief direction of valves in P&IDs (*MBV-Manual block valve) valves unless they are accessible. Normally
(Arrangement shown for a gate and ball valve). valves in LNG service are insulated with

2. Drilling a hole on the closing member

or providing SPE seat on the valve will
render the valve uni-directional. So,
maintenance shall not be carried out
on the cavity relief side. Some valve
manufacturers can argue that SPEXDPE
seated ball valves are bi-directional if
the cavity is properly drained off prior
to maintenance activities. However, in
practice it can be very difficult to drain
off the valve cavity completely due to
access problems to the bleed valve
(which will be under the insulation if
provided).
3. The diameter of the drilled hole shall be
specified by valve specification engineer.
Normally a 3mm size is recommended
although larger sizes may be seen on
floating ball and gate valves.
4. SPEXDPE seats are not covered by any
standard. So, if you have relied on SPE
seats for cavity relief, then the working
shall be checked during cavity relief
test and supporting documents shall
be available from the vendor describing
how this mechanism was achieved.

Material selection for cryogenic

conditions: the most common material
for cryogenic service valve is austenitic
stainless steel (SS 316). Although SS 304
is the preferred material for pipes and IMI Orton BWT triple offset metal seated valve after tight shut-off cryogenic pressure test (side top entry
fittings in LNG service for onshore plants, design).

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LNG
thicknesses of 100-250 mm and hence
these connections are not accessible.
If drain/vent connections are required for
testing purpose, then the connections
shall be seal welded with an impact-test
qualified WPS. It is important to note that
although impact testing is not required on
base metal for temperatures up to -255 °C
per Table-A1M of ASME B31.3, the welds
are required to be impact tested if the
temperature is below -29 °C since the filler
metals are intentionally added with delta
ferrite to avoid solidification cracking/hot
cracking problem in SS.
End selection: historically, flanged valves
have been used in LNG service. However,
increasing safety requirements and the
efforts to minimize fugitive emissions and
cryogenic spillage have dictated the use
of butt-welded valves in most of the LNG
plants under construction.
*Additional considerations for BW valves in
LNG service:
1. Maintenance aspects shall be
considered. Top entry ball valve and
butterfly valves shall be selected.
Provisions for temporary scaffolding
space shall be considered in material
handling. Handling of big sized balls,
gate valve wedges and butterfly valve
discs shall be considered.
2. If valves are manufactured from castings,
then the end connection of the valves
shall be radiographic tested since small
casting defects on the butt-welded ends
can aggravate during the welding process.
3. For top entry butterfly valves, the type
of top entry (true top entry or side top
entry) and its maintenance aspects shall
be discussed with the vendor.
Type of valves: this topic is too broad to
be covered in this article and needs separate
attention. Historically, floating and trunnion-
mounted ball valves have been used in LNG
service due to their tight shut off capability.
However, with the advancement of triple
offset butterfly valves and eccentric ball
valves, end users have been specifying these
valves for isolation since they are inherently
cavity free (see Fig. 7). Also, as opposed
to ball valves which are pressure seated,
these valves are torque seated. Technically
speaking, it is always better to rely on torque-
seated cavity free valves instead of pressure-
seated valves with a cavity for which the
cavity relief design is non-standard and varies
from manufacturer to manufacturer.
Ultimately, it is the end user’s experiences
which dictate the valve selection philosophy.
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Fig. 7: The eccentric cavity free “C” ball valve minimizes the risk of catastrophic failure. Photo courtesy:
AEV Valves Belgium.
Cryogenic testing of valves
The following standards are widely used
for the cryogenic testing of valves:
• BS6364-Valves for cryogenic service
• MSS SP-134-Valves for cryogenic
service, including requirements for
body/bonnet extensions
• ISO 28921-1-Industrial valves-
isolating valves for low-temperature
applications
This requirement is too broad to be
covered in this article. However, cryogenic
testing is very important to verify that i) the
valve bonnet extension and length of the
gas column is sufficient and the packing
remains at ambient temperature during
testing, ii) the valve sealing members
provide the required shut off or not,
iii) any fugitive emission from the valves
are under the acceptable limit or not,
and iv) valve seating/unseating and
operating torque are within human
capabilities, etc.
Testing and installation at
the construction site
Dedicated preservation procedures shall
be prepared for cryogenic valves. It is
necessary to protect the valves from any
dirt or moisture. Also, the valves should
be pneumatically tested (as a part of a
piping test package if required) at the
construction site since it is very difficult
or even impossible to remove entrapped
water from the cavity. If any water does
become trapped in the valve cavity, then it
will freeze during operation and will render
the valve in-operable.
Summary and conclusion
Valves in LNG service are very special valves
and need dedicated attention when it
comes to design, selection and testing.
These valves handle extremely flammable
liquids and any valve failure could lead
to a catastrophic failure and operation
downtime. Although CAPEX reduction
has become the prime focus with the
downturn in both crude oil prices and
LNG prices, these valves still need special
attention and need to be procured from
experienced valve suppliers.
A carefully selected, designed and tested
valve will mitigate any potential risks.
About the authors
Mr. Neeraj Batra and Mr. Hitoshi Suzuki.
This article was written by Neeraj
Batra (Piping Materials Engineer)
and Hitoshi Suzuki (Technical Leader-
Material Technology & Management
group) from the Chiyoda Corporation.
Chiyoda is a global leader in the LNG
business and has built various plants
and executed numerous projects in
over forty countries world-wide since
its foundation in 1948.
January/February 2016