Technical Features of MIR Ball Valves R4 Oct 2012

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TECHNICAL

FEATURES OF
BALL VALVES
API 6D, API 6DSS (pipeline valve)
API 6A, API 17D (wellhead valves)
MKTG-007 TECHNICAL FEATURES OF MIR BALL VALVES R4 OCT.2012
UNCONTROLLED DOCUMENT, PROPERTY OF MIR VALVE

Contents
Codes & Standards
Design
Features

Seat Configurations
Sealings
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

Codes & Standards

Codes and Standards


Main
Design

Body Thickness

Bolting

API 6D / ISO 14313


API 6DSS / ISO 14723
Customer Specifications

ASME VIII-1, VIII-2


ASME B16.34

ASME VIII-1, VIII-2


ASME B16.34

Face-to-Face

Drive Train Sizing


(MAST)

Firesafe

API 6D / ISO 14313


API 6DSS / ISO 14723
ANSI B 16.10

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

ASME VIII-1, VIII-2

Technical Features of MIR Ball Valves

ISO 10497/API 6FA


API 607

Codes and Standards


Other
Materials

Flanges

NDT

ASME II-D

ASME B16.5

ASME V

Weld ends

Welding

Gas Pipeline

B16.25

ASME IX

ISO 14141

Sour service
NACE MR-0175 /
ISO 15156
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

Design

Design
Valve overview
Pressure Containing Part

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

Design
Valve overview
Pressure Containing Part

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

Design
Valve overview
Pressure Containing Part

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

Design
Valve overview
Pressure Containing Part

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

10

Design
Valve overview
Pressure Controlling Part

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

11

Design
Valve overview
Pressure Controlling Part

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

12

Design
Valve overview

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

13

Design
Trunnion mounted

Ball pivotally supported by


the trunnions
Floating seats move
towards the ball

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

14

Design
Trunnion mounted configurations

Internal trunnion

External trunnion

Ball mounted on trunnions


Size NPS 10

Ball mounted on bearing retainers


Size NPS 12

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

15

Design
Trunnion mounted configurations

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

16

Design
Trunnion vs. Floating

More complex design

Lower torque

No size limits

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

17

Design
Trunnion vs. Floating

Simpler design

Higher torque

Size limitation

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

18

Design
Exploded view

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

19

Design
Exploded view

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

20

Design
Body construction
Side entry

Top entry

Bolted
Fully welded
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

21

Design
Body construction

Side entry

Top entry

Forged

Cast

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

or forged
22

Design
Side entry - Bolted

3 pieces
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

2 pieces
Technical Features of MIR Ball Valves

23

Design
Top entry

Cast
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Forged
Technical Features of MIR Ball Valves

24

Seat Design

Seat Configurations

Self-Relieving
Seats (SR)
Double-Piston
Effect (DPE)
Dual-Seat
Design (DS)
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

26

Features
Valve seating configurations
Self relieving (MIR standard)
Two uni-directional seats:
Bi-directional valve
DBB valve

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

27

Features
Uni-directional seat / Self-relieving

The force acting on the seats relieves the excess of pressure from the body cavity into the line.
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

28

Features
Valve seating configurations
Double Piston Effect (optional)
One uni-directional seat & one bi-directional seat:
Bi-directional valve
DIB-1 , uni-directional seat as 1st barrier, bi-directional as 2nd

It also provides a double block & bleed action.


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

29

Features
Bi-directional seat / Double Piston Effect

It forces the downstream seat to seal against the ball.


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

30

Features
Valve seating configurations
Dual seat design (SR+DPE) (optional)
Two bi-directional seats:
Bi-directional valve
DIB-2, symmetrical behavior

It also provides a double block & bleed action.


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

31

Features
DIB-2 (Dual Seat) typical use
Protect the most critical area of the installation with a
double barrier

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

32

Seat Configurations

Seats & Sealings


Soft seat (MIR standard)

Plastic insert (Nylon, Peek, r-PTFE)


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

34

Seats & Sealings


Primary metal secondary soft seat (optional)

Primary metal to metal seal


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

Secondary protected soft seal


35

Seats & Sealings


Metal seat (optional)

Hard-faced metal to metal seal


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

36

METAL-SEATED
BALL VALVES
MKTG-036 METAL-SEATED BALL VALVES R1, FEB. 2013
UNCONTROLLED DOCUMENT, EP/GBA/SP
PROPERTY OF MIR VALVE

Contents
Which applications to use metal-seated ball valves
Seat Configurations
Key differences between soft-seated and metal-seated ball valves
Manufacturing considerations
Lead time & costs
References
MKTG-036 R0 Oct. 2012, Uncontrolled.
Property of MIR VALVE

Metal-Seated Ball Valves

38

Which applications to use metal-seated


ball valves - Service Conditions

SEVERE SERVICE
DIRTY AND ABRASIVE I.E. PARTICLES, SLURRIES ETC.

HIGH TEMPERATURE
OVER 200 C TO 450C / 400 F TO 850F

LOW MAINTAINANCE
SUBSEA, UNDERGROUND ETC.

HIGH DEMAND
FREQUENT CYCLING, HIGH TURBULENCE ETC.
MKTG-036 R0 Oct. 2012, Uncontrolled.
Property of MIR VALVE

Metal-Seated Ball Valves

39

Seat Configurations

Seating Configurations
SR (Self-Relieving) (MIR Standard)
Two unidirectional seats, MIR standard:
Bidirectional valve
DBB valve

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

41

Seating Configurations
DPE (Double Piston Effect) (MIR optional)
Two bidirectional seats:
Bidirectional valve
DIB-1, symmetrical behavior

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

42

Seating Configurations
SR+DPE (Self-Relieving + Double Piston Effect)
(MIR Optional)
One unidirectional seat & one bi-directional seat:
Bi-directional valve
DIB-2

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

43

Key Design Changes


Soft-Seated vs. Metal-Seated

Key Design Changes


Metal Seat Design
Body

Closure

Ball
Seat

Hardfaced sealing surfaces


MKTG-036 R0 Oct. 2012, Uncontrolled.
Property of MIR VALVE

Metal-Seated Ball Valves

45

Key Design Changes


Hardfaced Seats and Ball
Coating
Plating
Types

ENP

0.001

Electroless
Nickel Plating

0.003

NiSiC

0.002

NIckel-SIlicon
Carbide Plating
TCC or CCC
Tungsten or
Chromium
Carbide Coating

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

0.06 on the
seats
0.08 on the
ball

higher hardness of the ball after heat

Metal-Seated Ball Valves

treatment

46

Key Design Changes


Hardfacing (Coating/Plating) Types
APPLYING
MECHANISM

TEMPERATURE
RANGE

HARDNESS

FRICTION

REQUIRED
MANUF. TIME

ENP

NiSiC

TCC

CCC

Auto-chatalytic
reaction

Auto-chatalytic
reaction

Thermal spray
process

Thermal spray
process

Up to
4500C / 842 F

Up to
4500C / 842 F

Up to
1900C / 356 F

Up to
4500C / 842 F

Medium

Very high

Increased Hardness
over 5000C / 932 F

Optimal antiabrasion behaviour

High

Medium

High

Medium

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Medium
Lower friction
over 5000C / 932 F

Medium
Metal-Seated Ball Valves

Very High

Very High

Very High

Very High
47

Key Design Changes


Torque
HIGHER FRICTION COEFFICIENT

HIGHER TORQUE REQUIRED

MORE

INCREASED

POWERFUL
ACTUATOR

STEM SIZE

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

48

Manufacturing Considerations
Metal-Seated Design

Manufacturing Considerations
Lapping
Operation in which two
surfaces are adapted together
with an abrasive medium and
by hand / machine movement.
It ensures very accurate surface
contact, therefore it is often
necessary to achieve the
required tightness.

Lapping time depends on


tightness requirements and
service conditions.
MKTG-036 R0 Oct. 2012, Uncontrolled.
Property of MIR VALVE

Metal-Seated Ball Valves

50

Manufacturing Considerations
Lapping
Two
phases

1. Ball surface lapping with a


special tool
2. Seat and ball lapping by
reciprocal movement

Lapping
paste

Compounds of different
grades, finer and finer.

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

51

Manufacturing Considerations
Manual and Machine Lapping

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

52

Manufacturing Considerations
Manual Lapping

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

53

Manufacturing Considerations
Bubble Test
The lapped seat
is placed on the
ball and filled
with a liquid
90 psi air is
blown from the
bottom of the
sealing rim

The liquid is
checked for no
bubbles

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

54

Manufacturing Considerations
Testing Requirements
API 6D 11.4.3
For metal seated valves the leakage rate shall not exceed ISO 5208:1993 ,Rate D.

If Rate C or Rate B are requested, the feasibility shall be evaluated according


materials and process conditions.
MKTG-036 R0 Oct. 2012, Uncontrolled.
Property of MIR VALVE

Metal-Seated Ball Valves

55

Manufacturing Considerations
Testing
Cyclical operations may be required for testing
LAPPING

NO

VALVE ASSEMBLY

TESTING

OK?
YES

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

56

Manufacturing Considerations
Testing
Hydrostatic Seat Test
Hydrostatic Shell Test

Functional Test
Low Pressure Air Seat Test
High Pressure Gas Test
Fugitive Emission Test (according to SPE 77/312)
Mktg-035 R1, Oct. 2012

Technical Features of MIR Gate Valves

57

Lead Time and Cost Impact

Seat and ball


hardfacing

More
manhours for
assembly and
testing

Lead Time
and Cost
Impact

Higher
torque
more powerful
actuator
more robust
and heavier topwork design
MKTG-036 R0 Oct. 2012, Uncontrolled.
Property of MIR VALVE

Metal-Seated Ball Valves

58

Proven Design and Technology


MIR VALVE
holds proven
design and
manufacturing
technology for
metal-seated
valves.

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

59

References
Metal-Seated Ball Valves
Manufactured at our Malaysia
and Italy Operations
www.mirvalve.com

Exxonmobil Malaysia, offshore


28 CL. 900 FB RTJ, LTCS+Inconel 625 Metalseated +TCC ZERO LEAKAGE

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

61

PETRONAS CARIGALI IRAQ


MV3 Side-Entry Ball Valves 4-18 CL. 600/1500 FB/RF Metal-seated
CS/SS/Duplex, high pressure testing, HIPPS installation
FCP OFFSITE FACILITIES FOR GARRAF OPERATIONS, Offshore

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

62

MV1 Top-entry ball valves - offshore


Global Flow Technologies, USA - Dragados, Spain
South Arne Phase III Project, Gas

qty 6
6, 8x6, 10
Cl. 2500
Hub Ends
Metal seated
Full duplex
c/w pneumatic
actuators

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

63

MV1 Top-entry ball valves onshore

qty 8
16, 20
Cl. 300 - Metal seated
Body: A216 WCB
Inc.625 weld overlay on
dynamic seals
Ball: SS
Stem: Duplex
Seats: SS
c/w electric actuators

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

64

Kencana / Newfield, Malaysia


API 6DSS 4Cl. 600 RTJ Full Duplex
Peek, subsea gear operator ROV
Project: Puteri Pipeline,Malaysia

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

65

CHEVRON THAILAND
Metal-seated + TCC Full Solid Duplex (Offshore)
Project: Gas Service Satun / Funan BTEX

MKTG-036 R0 Oct. 2012, Uncontrolled.


Property of MIR VALVE

Metal-Seated Ball Valves

66

Sealing Options
in Ball Valve Design
O-Rings, Lip Seals, Elastomers, Graphoil

Service Conditions

-500C/

-1010C / +2600C

+2200C

Lip Seals & Extended


Stem

O-Rings

Below -1010C

Over +2600C

Lip Seals & Extended


Stem

Metal / Graphoil Gasket

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

68

Technical Features of MIR Ball Valves

Soft Seal Material Specifications


MATERIAL

TEMPERATURE O C

SEAL TYPE

VALVE RATINGS

VALVE SIZES

HNBR (Therban)

-50

180

O-Ring

Class 150-2500

NPS 2-60

FKM A, B ( VITON A, B )

-29

220

O-Ring

Class 150-2500

NPS 2-60

FKM GLT ( VITON GLT )

-46

200

O-Ring

Class 150-2500

NPS 2-60

FKM AED ( VITON AED )

-46

200

O-Ring

Class150-2500

NPS 2-60

LIP SEALS

-196

220

PTFE+Elgiloy
Spring

Class 150-2500

NPS 2-36

FIRE SAFE GRAPHITE

-196

520

Graphite

Class 150-2500

NPS 2-60

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

69

Technical Features of MIR Ball Valves

Sealing Locations
Location where we
would fit the lip seals, orings or a combination of
both in the design
When overlay is applied,
it is in these same
locations.

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

70

Technical Features of MIR Ball Valves

Static / Dynamic Sealing


DYNAMIC SEAL
There is a relative motion between
the two sealing surfaces. A typical
example would be a rod and piston
seal.

STATIC SEAL
There is essentially no
relative motion between the
seal and the hardware
members.
An example would be a seal
clamped between bolted
flanges.

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

71

Technical Features of MIR Ball Valves

Seals in Explosion Decompression Service


O-RING RESISTANCE TO RAPID DEPRESSURISATION IN GAS SERVICE (E.D.)

The elastomers usually absorb the gas they are in contact with in a manner
inversely proportional to the molecular size of the gas.

Following a rapid decompression the gas absorbed by the o-ring tends to


expand (explosion) and to create cracks and blisters on the surface of the oring.
This phenomenon is emphasised at Class 900 and temperature and with CO2
>15%
Viton AED is suitable for ED

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

72

Technical Features of MIR Ball Valves

Lip Seal
From cryogenic environment (-1960C)
to high temperature (+260 0C)

Spring-actuated, pressure-assisted
sealing device consisting of PTFE or
other polymer jacket, partially
encapsulating a corrosion resistant
metal spring energizer.
Spring-loading, assisted by system
pressure provides effective sealing at
both low and high pressures.
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

www.mirvalve.com

73

Technical Features of MIR Ball Valves

Lip Seal

In most seal applications, better overall sealing performance


can be achieved with a smoother sealing surface finish. (Max
Ra=0.4)

Unlike rubber o-ring, Lip seals do


not stretch without damage.
Therefore it is desirable to install
in open groove design.
Suppliers: Parker Seals, SaintGobain, Trelleborg

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

74

Technical Features of MIR Ball Valves

Lip Seal

Materials and Surface Finishing


Jacket Materials

Spring Materials Surface Finishing

PTFE
PTFE Graphite filled
PTFE Glass fiber
filled
FEP
KEL-F

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

Stainless Steel
Elgiloy
Inconel
Hastelloy

75

RMS=416

Technical Features of MIR Ball Valves

Graphite Gasket
Resilient form of graphite that has
excellent properties as a gasketing
material.

The unique chemical and physical


properties combined to make it
suitable to high temperature of up to
525 deg Celsius and cryogenic of as low
as -240 deg C service and/or corrosive
graphite gasket

environment.

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

www.mirvalve.com

76

Technical Features of MIR Ball Valves

Seats & Sealings


O-ring

Triple barrier

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

Two O-rings
One graphite seal
77

Seats & Sealings


Lip-seal + Vee-pack

Redundant barrier

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

rPTFE Vee-pack
78

Seats & Sealings


High Temperature

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

Graphite seals
Adjustable packing
Live-load
79

Seats & Sealings


Cladded sealing areas

Corrosive service

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

80

Cladding / Weld Overlay


MKTG-005 Sept. 2013 R0. Uncontrolled
This document is sole property of MIR VALVE SDN. BHD. and cannot be reproduced in any form without written permission from MIR VALVE SDN.BHD. Exec. Management.

What is Cladding?

Cladding or Weld Overlay


is a welding procedure
used to weld material
(usually exotic) on
component surface.
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

82

Why use cladding?


Cladding is an alternative when the
complete components cannot be fully
made in exotic materials due to high cost.
Cladding is a more economical way to
provide excellent corrosion resistance.

MKTG-005 R0 Uncontrolled Doc.


Property of MIR VALVE.

Cladding

83

Cost example
full material vs. cladded with Inconel
14000

10 Cl. 900 body

12000
10000
8000
6000

12000

4000
2000
0

1600
400

MKTG-005 R0 Uncontrolled Doc.


Property of MIR VALVE.

2200

4500

Cladding

CS+Inc. W/O Cost


Base Material Cost

84

Cost example
full material vs. cladded with SS
2500

10 Cl. 900 body


2000
1500
CS+SS W/O Cost
1000

1200

2000

Base Material Cost

500
400
0
Carbon Steel+SS.W/O
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Full Stainless Steel


Cladding

85

Cost Variations
Smaller diameters more
competitive in full exotic
material

Larger diameters more


competitive in cladding

It is on a case by case basis and it is specified at quotation stage.


MKTG-005 R0 Uncontrolled Doc. Property of MIR
VALVE.

Cladding

86

When is it used?
Corrosive Service
Harsh and hostile environment
Low maintenance application
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

87

What are the advantages?

Corrosion resistance
Long life
High reliability
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

88

Materials

The overlay is usually


Inconel 625 or Stainless
Steel, and it is mostly
applied on Carbon Steel
base material.
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

89

What areas can be cladded?


The Dynamic Seal Areas
All Sealing Areas
All Wetted Areas (Fully Cladded)
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

90

Dynamic Sealing Area Cladding


Body cover
packing pocket

Seat Pockets

MKTG-005 R0 Uncontrolled Doc.


Property of MIR VALVE.

Cladding

91

All Sealing Area Cladding


Body cover /
stem
Body cover /
body
Body / closure
Closure RTJ

Seat Pockets

Drain plug
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

92

All Wetted Areas Cladding


(Fully Cladded)
Body cover
Body

Closure

Ball

MKTG-005 R0 Uncontrolled Doc.


Property of MIR VALVE.

Cladding

93

Process
Semi-machined
component

Weld overlay

Final Machining
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

94

Testing
(Standard or Upon Request)
Dye Penetrant
Ultrasonic Test

PMI
Hardness
Thickness
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

95

Thickness
To achieve final thickness of 3 mm
and the chemical composition
required, the cladding process
consists of two layers for a total
thickness of 6-7 mm of raw weld
material obtained thru Arc Welding
following approved WPS/PQR.
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

96

Welding Processes
MIG

TIG (more precise)


Electro-Slag Strip Welding
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

97

Subcontracted
Cladding or weld overlay is outsourced to
specialized and approved subcontractors
with long time experience.
Major subcontractors for cladding are
TigMig, Tecnoweld, Tecnosaldature,
Comegi Italy
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

98

References
MIR
VALVE
has
extensive
track
record in
the
supply of
cladded
valves.
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Largest cladded valve to date: 36


Highest pressure class: 2500
800 valves to date

Onshore, offshore, subsea


Top-entry and side-entry ball valve, gate valve
Cladding

99

Track record End-Users


Exxonmobil
Malaysia

IOOC Iran

Pars Oil Iran

Murphy Oil
Malaysia

PDO Oman

Petronas
Carigali
Malaysia

Petronas
Carigali
Pakistan

Petronas Gas
Malaysia

Sarawak Shell
Malaysia

Woodside
Australia

ADCO UAE

Gasco UAE

Chevron
Thailand
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.

Cladding

100

Other Design Features

Features
Stem retention - Definition
As specified in API 6D spec. , ch. 7.21:
Valves shall be designed to ensure that
the stem does not eject under any
internal pressure condition or if the
packing gland components and/or valve
operator mounting components are
removed.

Anti blow-out design


MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

102

Features
Stem retention (Standard)

One set of capscrew for adapter plate


One set of capscrew for body cover
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

103

Features
Stem retention (Optional)

Optional type
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Standard type
Technical Features of MIR Ball Valves

104

Features
Stem retention (Optional)

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

105

Features
Stem retention (Optional)

Unscrew
& pull up

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Move
towards
the stem

Technical Features of MIR Ball Valves

Pull up

106

Features
Equalizing hole
The design allows for the pressure
equalization between body cavity
and the valve bore in open
position.

The seat is pushed against the ball


by the spring force only, since
there is no piston effect. This
results in lower break-off from
open position.
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Technical Features of MIR Ball Valves

107

Features
Equalizing hole vs Pressure relief hole
Equalizing hole

Pressure relief hole

balances pressure between


body cavity and valve bore
only when in open position

reduces overpressure from


the body cavity to the
upstream side of the valve,
with the valve in the closed
position

Lower break off from open


position

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

108

Features
Stem grease injection (standard)
Provided between the second oring and the gasket to
temporarily seal the stem until
the primary seal is restored.

The grease fitting incorporates a


check valve, designed to prevent
leakage towards environment,
still allowing grease injection.

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

109

Features
Seat grease injection (optional)
The system is designed to allow
sealant grease injection into the
valve in service; the sealant is
distributed on the seating
surface between the seat and
the ball.
An additional a check valve is
fitted in the main valve body
thickness, in order to provide a
second barrier to fluid leakage.

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

110

Features
Drive train
All parts of a valve required to open / close the valve (excluding the operator).

Stem

Stem key

Ball

Dowel
pins

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

111

Features
Drive train
Standard solution
Stem key
Tang

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Optional
Stem key
Pins

Technical Features of MIR Ball Valves

Optional
Spline
Tang

112

Features
MAST
Max Allowable Structural Torque
The limiting tolerable torque for all components in the drive train between
valve and actuator.

According to API 6D 7.20.1:


The design thrust or torque for all drive train calculations shall be at least
two times the breakaway thrust or torque.

MKTG-007 R4 Oct.2012, Uncontrolled.


Property of MIR VALVE

Technical Features of MIR Ball Valves

113

Features
Drain & Vent

Standard
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE

Optional

Optional

Technical Features of MIR Ball Valves

Optional
114

API 6A BALL AND GATE VALVES


FOR WELLHEAD AND CHRISTMAS TREES
MKTG-006 TECHNICAL FEATURES OF MIR BALL VALVES R0 SEPT. 2013
UNCONTROLLED DOCUMENT, PROPERTY OF MIR VALVE

API 6D vs. API 6A

API 6A
Valves

API 6D
Valves

WELHEADS
X-MAS TREES

PIPELINE
MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE

API 6A Ball and Gate Valves

116

API 6A Valve Types and Sizes


Model

Design

Size

Class

Application

MV9

Top-Entry Ball Valve

1 13/16-11
1 13/16 9

API 2,000-10,000 Onshore


API 15,000
Offshore
Subsea

MV11

Side-Entry Ball Valve 1 13/16-11


1 13/16 9

API 2,000-10,000 Onshore


API 15,000
Offshore
Subsea

MV13

Through-Conduit
Gate Valve (Forged)

1 13/16-11

API 2,000-15,000

MV4

Twin Ball Valve

3/4-11
3-4-9

API 2,000-10,000 Onshore


API 15,000
Offshore
Subsea

Onshore
Offshore
Subsea

For Subsea, the design standard is API 17D


MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE

API 6A Ball and Gate Valves

117

Ball Valve Design Features


Trunnion
Mounted

Full / Reduced
Bore

Soft/Metal
Seated

RF / WE / Hub
Ends

O-ring / Lip Seal


Design

Independent
Stem

SR/DPE/DPE+SR

Antiblowout
Stem

Triple Stem
Barrier

Double Body
Barrier

Stem Injection
Fitting

Seat Injection
Fitting (optional)

Overlay
(optional)

MKTG-006 R0 Sept.2013, Uncontrolled.


Property of MIR VALVE

Firesafe Design

API 6A Ball and Gate Valves

118

What is PSL
(Product Specification Level)

Levels

1 (lowest) to
4 (highest)

Define

Material requirements (mechanical)


Non Destructive Testing
Final Testing

Testing

PSL Test is a Production Test

MKTG-006 R0 Sept.2013, Uncontrolled.


Property of MIR VALVE

API 6A Ball and Gate Valves

119

Standard Testing
Hydrostatic Body (PSL 1, PSL2)

Hydrostatic Seat Test (PSL 1, PSL2)


Extended Hydrostatic Body Test (PSL 3, PSL 3G, PSL4)
Extended Hydrostatic Seat Test (PSL3, PSL3G, PSL 4)

High Pressure Gas Seat Test (PSL 3G, PSL 4)


High Pressure Gas Back Seat Test (PSL 3G, PSL 4)
Drift Tool Test (PSL1, PSL2, PSL3, PSL 3G, PSL4)
MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE

API 6A Ball and Gate Valves

120

Additional Testing
Torque Test
Endurance Test (cycling)

Firesafe Test
Hyperbaric Test
Other tests, as per customer requirements
MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE

API 6A Ball and Gate Valves

121

PR2 Qualification Testing


(Performance Requirements)
pressure cycling

temperature cycling

low and high pressure gas tests

PR2 Test is a design validation


test and covers one size up /
down
MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE

MV11 API 6A Side-Entry Ball Valve 4 1/16 API 10000


Metal seated, Full Duplex c/w with hydraulic actuator

API 6A Ball and Gate Valves

122

Certifications
API 6A

API 17D

CE-PED
97/23/EC

CE-ATEX
94/9/EC

ISO 9001 /
API Q1

ACHILLES
JQS

IEC 61508
UP TO SIL 3
MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE

FIRESAFE
TO API 6FA

API 6A Ball and Gate Valves

123

Manufactured at MIR VALVE ITALY


For info and inquiries, contact us at:

For Asia-Pacific / Middle East / Americas


MIR VALVE Malaysia at [email protected]
For Europe / CIS / Africa / Americas
MIR VALVE Italy at [email protected]
or visit us at www.mirvalve.com

For info and inquiries, contact us at:

For Asia-Pacific / Middle East / Americas


MIR VALVE Malaysia at [email protected]
For Europe / CIS / Africa / Americas
MIR VALVE Italy at [email protected]
or visit us at www.mirvalve.com

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