1

Valve Requirements in the

Oil Sands
- Specifications and Learnings in a
Mining and Upgrader Operation

Brian A. Lade, P.Eng.
Syncrude Canada Ltd.
2
Valve Requirements in the Oil Sands
- Specifications & Learnings in a Mining
and Upgrader Operation

Abstract: This presentation outlines the wide range
of valve types, sizes and metallurgies needed
within an integrated, self-contained Oil Sands
operation that includes utilities, mining, bitumen
capture and cleaning, upgrading the bitumen to
form light sweet synthetic crude oil, and the safe
management of waste streams. Quality and
reliability challenges and trends are highlighted.

3
Who I am:
Brian Lade, P.Eng.
Senior Technical Specialist Mechanical Quality
Advisor, Technical Quality Assurance
Licensed Professional Engineer in Alberta Canada since
1978.
Employed by Syncrude Canada Ltd. since 1975, with a
career focused on pressure equipment/ process plants in
Design, Maintenance, Operations, Quality Assurance
and in Project Development and Execution roles in a
variety of technical specialist and leadership positions.
Current owner of key Specifications and AMLs for
pipe, piping components and valves.
Seconded to Alberta Government in late 1990s for 2
years for legislative updates and oversight of the ABSA.
4
View of Syncrude Mildred Lake Complex
during UE-1 Project Construction

5
Views of Aurora North plants
6
Integrated, self-contained and complex
Syncrude is basically self-sufficient except for
importing natural gas and a range of chemicals;
and for the intake of fresh water.
Our facilities are designed to operate 24/ 7/ 52 in
an ambient environment that demands a design
temperature range of 56
o
F to 92
o
F, with approx.
7 months of winter resulting in a frost depth >10 ft.
We internally generate BFW, steam and hot water;
produce compressed air, nitrogen and hydrogen;
create and process fuel gas; and generate
electricity to match our operating needs.
7
Integrated, self-contained and complex
We mine Oil Sands within 2 mining sites with most of
the feed converted near the mine face to a warm water
slurry in 6 crushing & preparation trains.
Separation and capture of the bitumen takes place
adjacent to each mine area; and then the bitumen is
combined, heated & thinned with diluent, and cleaned
in a single large facility.
Bitumen Upgrading requires separating and recycling
the diluent, changing the ratio of carbon to hydrogen,
and in breaking up the complex long-chain molecules.
Syncrude uses 3 Fluid Cokers, a large Vacuum Tower,
a Fluidized Bed Hydrocracker, and 6 Hydrotreaters to
accomplish those tasks.
8
Integrated, self-contained and complex
Our diluent is naphtha. Newer bitumen production
complexes typically use imported NGL/condensate
fluids for internal bitumen processing and for
pipeline transport. Many of their valves must then
deal with the associated increase in volatility/ RVP in
their stem seal designs and in leak tightness.
Other Upgraders, whether integrated or stand-alone,
may use multiple trains of Delayed Cokers, or use
Fluidized Bed Hydrocrackers to lighten and
desulphurize their products.
Auxiliary process units treat fuel gas, wash SO
2
&
H
2
S from the fluids, treat sour water, clean flue gas,
transfer heat between units and sites, etc. Other
units process byproducts liquid sulphur, coke,
ammonium sulphate fertilizer, and gypsum.
9
Integrated, self-contained and complex
Provision of an initial level of redundancy for
reliability, and then staged growth for 3 decades has
produced a central complex of 53 process units at
Syncrudes Mildred Lake site; along with 30 large
storage tanks providing ~ 12 M BBls of hydrocarbon
storage.
Our last major growth step (2000 2005) was a
> $ 7.5 Billion project called UE-1, which added 20
new process units including the largest Fluid Coker
and Hydrogen plants ever built; and the revamp/
upsizing of another 20 process units.
That project purchased ~ 42 k Manual (Isolation)
valves. Analysis of those purchases is a key basis for
this presentation.
10
Complexity and Size both matter
Integrated Utilities including:

7 large Boilers and 2 OTSGs for 4.3 M PPH 900# Steam
and 3.2 M PPH 600# Steam
6 STGs & 4 GTGs, generating up to 525 MW of power
[Equiv. to a city of 300+ k]
12 trains of BFW production generating ~ 9000 GPM
Hot Recycle/ Process Water > 140 k GPM in pipes
running to NPS 48
4 Cooling Water Systems totaling ~ 380 k GPM in pipes
up to NPS 72
5 Flare Systems with Headers at NPS 20 to NPS 54


11
Unprecedented Process Unit Sizes
Diluted Bitumen cleaning capacity of 900 k BPD
using a complex of > 120 Static and Centrifuge
Separators for water, clay, and sand removal
Upgrader feed capacity (Heating and Diluent
Recycle Units) sized at 850 k BPD
3 Fluid Cokers (thermal cracking & carbon
removal) at 50 psig/ >1200
o
F, sized at 100 k BPD
each
A Fluid Bed Hydrocracker (cracking & hydrogen
addition) at 1700 psig & 1000
o
F, 50 k BPD
One Vacuum Distillation Unit at 285 k BPD
12
Unprecedented Process Unit Sizes
2 Naphtha Hydrotreaters at 600 psig, 48 k BPD
2 Heavy Gasoil Hydrotreaters at 1500 psig, 78 k
BPD
A Light Gasoil Hydrotreater at 1700 psig, 100 k BPD
A two stage Light Gasoil Hydrotreater/ ASU at 2500
psig, 80 k BPD
4 SteamMethane Reformers generating > 400 M
scfm of Hydrogen, with the newest unit being the
worlds largest at 200 M scfm
13
Valves used in Syncrude
7,000 Pressure Safety Valves
15,000 Control Valves, Dampers and Large
Actuated Isolation Valves
> 150,000 Manual (Isolation) Valves

Both the PSVs and the Control Valves are individually
numbered and are managed within a database. A size
analysis for the Control Valves is included in this
presentation.

The breadth & characteristics of the Manual/ Isolation
Valve population is illustrated by analysis of the UE-1
purchases which represented approx. 25 30 % of
todays estimated in-service population.
14
Control Valve Population

0
200
400
600
800
1000
1200
1400
1600
1800
N
u
m
b
e
r

i
n

e
a
c
h

S
i
z
e

Valve Sizes ( in Inches)
Control Valve Size Distribution (ALL Classes & Metallurgies)
15
Control Valve Population

CV population reflects pressure classes and metallurgy
selections that are described in more detail for the
Isolation Valves in the slides which follow
Quality requirements also follow a logic that is similar to
that used for the Isolation Valves, but with an additional
shift towards RT verifications based on typical low volume
purchases & fabrication
NPS 24 to 30 population is predominately Knife-gate
valves used in slurry services; many are a specialty
product with hydraulic actuators controlling Y- type branch
isolations
This valve population starts to add Isolation services as
size and dP combine to require automation.
16
Isolation Valve population
















68 % forged, but only 13 % of $ value
32 % cast, but 86 % of $ value


MANUAL ISOLATION VALVES - FABRICATION METHODS
FORGED VALVES
68 %
28,801 items
CAST VALVES
32%
13,396 items
UE-1 Project - 42,197 Valves
Purchased
17
Isolation Valve population

































NOTES:
Small globes are most often used to isolate drains & small branches in HP services
For Class 2500 services almost all valves are globes
FORGED VALVES
- FUNCTION SPLITS
GATE VALVES
89 %
GLOBE VALVES
8 %
CHECK VALVES
3 %
18
Isolation Valve population
87 % of cast valves are Carbon Steel, with just 5.6 % being Low
Temperature Spec LCC
Remainder are split between Low Alloy [1 Cr, 5 Cr & 9 Cr], and
Stainless Grades [304H, 316, 317L, 347 and 347H, and Duplex SS],
and High Alloys 625, 825, C-276, and Alloy 59.

CAST VALVES
- FUNCTION SPLITS
GLOBE VALVES
5 %
CHECK VALVES
10 %
GATE VALVES
85 %
19
Isolation Valve population
MPI/ LPI are the primary Quality requirements with ~3 % ordered
to RT verification levels per criticality of service locations
0
200
400
600
800
1000
1200
1400
1600
1800
2.0" 2.5" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 30" 36" 42" 48"
N
u
m
b
e
r

o
f

V
a
l
v
e
s

Valve Size in Inches
Size Distribution for CLASS 150 Cast CS Valves
Class 150 CAST CS WCB
Class 150 CAST CS LCC
20
Isolation Valve population
Larger sizes transition to automated Control Valve population
MPI/ LPI continue as the primary Quality requirements with ~9.5 %
ordered to RT verification levels
0
200
400
600
800
1000
1200
1400
1600
2.0" 2.5" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"
N
u
m
b
e
r

i
n

e
a
c
h

S
i
z
e

Valve Size in Inches
Size distribution for CLASS 300 Cast CS Valves
Class 300 CAST CS WCB
Class 300 CAST CS LCC
21
Isolation Valve population
Quality requirements shift to addition of 100 % RT verifications
(partial or full), and many are ordered to ISS spec
0
50
100
150
200
250
300
2.0" 2.5" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"
N
u
m
b
e
r

o
f

I
t
e
m
s

VALVE SIZE in INCHES
CLASS 600 CAST CS VALVES
RF (Quality Level- Full RT)
RTJ (Quality - 95% Partial RT, 5% Full)
22
Isolation Valve population
RT level shifts from 60% Full RT for 900# to 85% Full RT for
1500#, with similar shift to ISS spec
0
10
20
30
40
50
60
70
80
2.0" 2.5" 3" 4" 5" 6" 8" 10" 12"
N
u
m
b
e
r

o
f

I
t
e
m
s

VALVE SIZES in INCHES
CLASS 900 CAST CS VALVES
900# BW & PSB (Full RT)
900# BW & PSB (Partial RT)
23
Isolation Valve Population
0
20
40
60
80
100
120
140
2.0" 2.5" 3" 4" 5" 6" 8" 10" 12"
N
u
m
b
e
r

o
f

I
t
e
m
s

VALVE SIZES in INCHES
CLASS 1500 CAST CS VALVES
1500# CAST CS (Partial RT)
1500# CAST CS (Full RT)
24
Isolation Valve population Manual Globes
Valve population is slightly biased as using them as CV bypasses is reduced
at ~NPS 8 as costs increase
Pressure Class Distribution for Manual Globe Valves
CLASS 150
180 Items, 37.5%
CLASS 300
212 Items, 44.3%
CLASS 600
45 Items, 9.4%
CLASS 900
15 items, 3.1 %
CLASS 1500
27 items, 5.6%
25
Isolation Valve population
Pressure Class Splits for ALL Cast CS Valves
150# WCB
150# LCC
300# WCB
300# LCC
600#
900#
1500#
46.7%
4.5%
34.4%
1.8%
8.2%
2.2% 2.2%
26
Highlights from Specifications
LCC & LF2 Cl.1 use is surprising small. Most Oil Sands
fluids are winterized or are heated to reduce viscosity
(insulation & steam/ electric tracing).
Low Temp spec services are limited to pressurized gases
in utility distributions that have been dried for operation at
ambient temps (N
2
, Natural Gas, IA, etc), and to Classes
150/ 300.
Natural Bitumen has both a sulphur and a naphthenic acid
content, and is associated with saline water. 5 CR/ 9 CR
materials are used at elevated temperatures prior to
hydrotreating to resist sulphidation &/ or naphthenic acid
attack.
Most of the Upgraders cracking operations are low
pressure; so Class 150/ 300 predominate, except where
600# Steam is used for purging or atomization.
27
Highlights from Specifications
Users are encouraged to select Triple Offset Butterfly
valves for sizes > NPS 16, but this is changing very slowly.
UE-1 used ~ 40 such valves, including one each at NPS
54 and NPS 72.
600# Steam is used for process purposes and for smaller
turbine drivers, and is typically specified as Class 600 RF.
[History showed many casting leakers so our specs go to
full RT today]
RTJ flanges are introduced for elevated temperatures at >
750
o
F , and at Class 900.
900# Steam is distributed in 1 CR piping for power
generation and for steam turbine drivers > 15,000 HP.
1 CR piping is also used for hot process streams that
contain Hydrogen.
Flanges are minimized at > Class 900, with a shift to BW
ends or Grayloc type closures, and with PSB designs.
28
Highlights from Specifications
Valve use is minimized in Class 2500 services; with
Globes being used for isolations, and tilting disk checks
used to protect spec change locations.
Welded Seats are a norm and Backseats must be fixed in
all pressure classes!
Most Valve Trim is either full or partial stellite reflecting the
erosive solids that permeate Oil Sands fluids, with priority
being stellite on the body seat.
Ball Valves & Plug Valves are in limited use. Ball Valves
frequently used in hardened versions in Fluidized Bed
Hydrocracker for HP services with erosion challenges.
Drains and small bore connections are typically Y type
Globes at > Class 900.
Bellows Sealed Stems are < 10 % of small forged valves.
[this reflects Syncrudes diluent choice].

29
Reliability is Essential, Quality is King
Oil Sands operations are expensive & challenging.
Freezing in the dark is all too real a risk!
Our culture is one where Safety comes First as a Value,
and Reliability comes first as a priority. Fixed costs,
regardless of production rates, ensure that our business
focus is high availability & maximized volumes. Growth
comes from internally generated cash-flow. Profitability
comes when production reaches and is sustained in the
upper third of our nameplate capacity.
Turnarounds are huge events when they involve a Fluid
Coker @ 40 to 50 days, 2500 tradesmen, as high as 1
Million workhours. Unplanned T/As have a $$ tag > 50M.
PMI must be demonstrated by all pressure envelope
components for every item, if not specd as CS or 304 SS.
30
Reliability is Essential, Quality is King
Syncrude experienced a significant number of functional
valve failures and loss of containment events in the 1980s.
They taught us that compliance with Industry Standards
could not be assumed; and that changes in the supply-
chain for valve castings and assembly was an ongoing
concern.
Our need for continuity of operations often led to high
challenge situations such as building an ASME Section
VIII compliant containment shell around a NPS 16 Class
600 gate valve in superheated steam service with 2 active
leaks in its body; or performing Hot Tap & Bypass tasks
onto or around valves with stem/ gate separations.
An aggressive program for enhanced Quality Management
was implemented which culminated in our L-37 Spec,
adoption of high levels of NDE, a rigorous Qualification
process, and a carefully screened AML.
31
Reliability is Essential, Quality is King
We approve selected Manufacturing Facilities, not Brands.
Our approvals can be size, class, and metallurgy specific.
Integrated casting & assembly plants are preferred; but
long term 3
rd
Party casting sources can be accepted.
Quality Programs must be comprehensive, certified, and
fully implemented!!
Production samples are randomly selected and are tested
by selected 3
rd
Party Failures Labs first against the
requirements of the applicable Industry Standards, then by
lengthened pressure and helium leakage tests & full RT,
and by metallurgical sampling & mechanical testing.
Valves must have Design Registration in Province of
Alberta per CSA Std. B51 (CRNs from the ABSA).
32
Erosive Slurries
Syncrude has more than 125 miles of large diameter
piping carrying erosive slurries. NPS 28 is the norm at
Base Mine, while NPS 30/ 32 are the norm at Aurora.
Long runs of Water transfer systems of NPS 30 to NPS
54 also operate aboveground all year.
These warm water based slurries can carry rocks and
other solids to 5 in size, and they run at 15 18 ft./sec.
Erosion & erosion/ corrosion can leave some CS or Cast
CWI components worn by > 0.50 in just 2000 operating
hours.
Isolated branches must stay dry for winter operability!
Many of the valves that isolate sections of these piping
systems sit remote from infrastructure and at ambient
temperatures in the active mining or waste deposit
areas. Local or portable hydraulic actuators are used to
drive their gates through the slurries.

33
Knife Gates in Erosive Slurries
Old Knife Gates in early Winter

Newer Generation Summer

34
Knife Gates in Erosive Slurries
We have developed a corporate spec for Knife Gate Valves
that builds on the MSS- SP-135- 2010 Industry Standard.
Bi-directional dead-end service capable; internally retained
but replaceable wear rings U/S & D/S (rotatable & useable
in multiple positions); heavy tungsten carbide overlays on
wear rings and gate.
Resilient element used to prevent gate passing leakage.
Designed to prevent gate blowout up to hydrotest
pressures; strong stem to gate attachments.
Weather/ dust protection for gates/ stems.
Optional bonnets designed for full MAWP w. stem seals.
Pressure tested between blind flanges without hydraulic
compression. Actuators good for -40 to 250
o
F.
CRN registered for -20 to 400
o
F & full Class 150/ 300.

35
Current Challenges
Increasing salinity, sodium & calcium in process waters
that are typically recycled 15 20 times
Escalation in piping sizes > NPS 30
Chloride carry-over in Bitumen; and corrosion damage
within Hydrotreaters & support units (ammonium
bisulphide, chlorides at 10 20 k ppm, ammonium chloride
& ammonium sulphate)
Reduced tolerance for risks w.r.t. leakage through single
isolation valves (Albertas OH&S requiring P.Eng. certified
alternatives to DB&B or Block & Blind). Lack of substantive
progress in API Standards!
Cost effective options for shifts from CS to Duplex SS to
High Alloy (C-276 and Alloy 825). Weld overlays vs. solid
castings; alternate coating technologies.
Retrofits for DB&B single valve body options to minimize
piping rework.
Reduced tolerance for V.O.C. leakage
36
Additional Facts about the Oil Sands, and our
environmentally responsible production.
Syncrude information,
including environmental &
social impacts and
restoration activities:
www.syncrude.ca
Oil Sands Industry
Information from Canadian
Association of Petroleum
Producers: www.capp.ca &
www.canadasoilsands.ca &
upstreamdialogue@capp.ca
Alberta Environment:
www.environment.alberta.ca
Oil Sands Developers Group
(OSDG):
www.oilsandsdevelopers.ca
Alberta Biodiversity
Monitoring Institute:
www.abmi.ca
Royal Society of Canada:
www.rsc.ca