Technical Features of MIR Ball Valves R4 Oct 2012
Technical Features of MIR Ball Valves R4 Oct 2012
Technical Features of MIR Ball Valves R4 Oct 2012
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
Body Thickness
Bolting
Face-to-Face
Firesafe
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
Design
Design
Valve overview
Pressure Containing Part
Design
Valve overview
Pressure Containing Part
Design
Valve overview
Pressure Containing Part
Design
Valve overview
Pressure Containing Part
10
Design
Valve overview
Pressure Controlling Part
11
Design
Valve overview
Pressure Controlling Part
12
Design
Valve overview
13
Design
Trunnion mounted
14
Design
Trunnion mounted configurations
Internal trunnion
External trunnion
15
Design
Trunnion mounted configurations
16
Design
Trunnion vs. Floating
Lower torque
No size limits
17
Design
Trunnion vs. Floating
Simpler design
Higher torque
Size limitation
18
Design
Exploded view
19
Design
Exploded view
20
Design
Body construction
Side entry
Top entry
Bolted
Fully welded
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE
21
Design
Body construction
Side entry
Top entry
Forged
Cast
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
26
Features
Valve seating configurations
Self relieving (MIR standard)
Two uni-directional seats:
Bi-directional valve
DBB valve
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
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
29
Features
Bi-directional seat / Double Piston Effect
30
Features
Valve seating configurations
Dual seat design (SR+DPE) (optional)
Two bi-directional seats:
Bi-directional valve
DIB-2, symmetrical behavior
31
Features
DIB-2 (Dual Seat) typical use
Protect the most critical area of the installation with a
double barrier
32
Seat Configurations
34
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
38
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
39
Seat Configurations
Seating Configurations
SR (Self-Relieving) (MIR Standard)
Two unidirectional seats, MIR standard:
Bidirectional valve
DBB valve
41
Seating Configurations
DPE (Double Piston Effect) (MIR optional)
Two bidirectional seats:
Bidirectional valve
DIB-1, symmetrical behavior
42
Seating Configurations
SR+DPE (Self-Relieving + Double Piston Effect)
(MIR Optional)
One unidirectional seat & one bi-directional seat:
Bi-directional valve
DIB-2
43
Closure
Ball
Seat
45
ENP
0.001
Electroless
Nickel Plating
0.003
NiSiC
0.002
NIckel-SIlicon
Carbide Plating
TCC or CCC
Tungsten or
Chromium
Carbide Coating
0.06 on the
seats
0.08 on the
ball
treatment
46
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
High
Medium
High
Medium
Medium
Lower friction
over 5000C / 932 F
Medium
Metal-Seated Ball Valves
Very High
Very High
Very High
Very High
47
MORE
INCREASED
POWERFUL
ACTUATOR
STEM SIZE
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.
50
Manufacturing Considerations
Lapping
Two
phases
Lapping
paste
Compounds of different
grades, finer and finer.
51
Manufacturing Considerations
Manual and Machine Lapping
52
Manufacturing Considerations
Manual Lapping
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
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.
55
Manufacturing Considerations
Testing
Cyclical operations may be required for testing
LAPPING
NO
VALVE ASSEMBLY
TESTING
OK?
YES
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
57
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
58
59
References
Metal-Seated Ball Valves
Manufactured at our Malaysia
and Italy Operations
www.mirvalve.com
61
62
qty 6
6, 8x6, 10
Cl. 2500
Hub Ends
Metal seated
Full duplex
c/w pneumatic
actuators
63
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
64
65
CHEVRON THAILAND
Metal-seated + TCC Full Solid Duplex (Offshore)
Project: Gas Service Satun / Funan BTEX
66
Sealing Options
in Ball Valve Design
O-Rings, Lip Seals, Elastomers, Graphoil
Service Conditions
-500C/
-1010C / +2600C
+2200C
O-Rings
Below -1010C
Over +2600C
www.mirvalve.com
68
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
-46
200
O-Ring
Class 150-2500
NPS 2-60
-46
200
O-Ring
Class150-2500
NPS 2-60
LIP SEALS
-196
220
PTFE+Elgiloy
Spring
Class 150-2500
NPS 2-36
-196
520
Graphite
Class 150-2500
NPS 2-60
www.mirvalve.com
69
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.
www.mirvalve.com
70
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.
www.mirvalve.com
71
The elastomers usually absorb the gas they are in contact with in a manner
inversely proportional to the molecular size of the gas.
www.mirvalve.com
72
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
Lip Seal
www.mirvalve.com
74
Lip Seal
PTFE
PTFE Graphite filled
PTFE Glass fiber
filled
FEP
KEL-F
www.mirvalve.com
Stainless Steel
Elgiloy
Inconel
Hastelloy
75
RMS=416
Graphite Gasket
Resilient form of graphite that has
excellent properties as a gasketing
material.
environment.
www.mirvalve.com
76
Triple barrier
Two O-rings
One graphite seal
77
Redundant barrier
rPTFE Vee-pack
78
Graphite seals
Adjustable packing
Live-load
79
Corrosive service
80
What is Cladding?
Cladding
82
Cladding
83
Cost example
full material vs. cladded with Inconel
14000
12000
10000
8000
6000
12000
4000
2000
0
1600
400
2200
4500
Cladding
84
Cost example
full material vs. cladded with SS
2500
1200
2000
500
400
0
Carbon Steel+SS.W/O
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.
85
Cost Variations
Smaller diameters more
competitive in full exotic
material
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
Corrosion resistance
Long life
High reliability
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.
Cladding
88
Materials
Cladding
89
Cladding
90
Seat Pockets
Cladding
91
Seat Pockets
Drain plug
MKTG-005 R0 Uncontrolled Doc.
Property of MIR VALVE.
Cladding
92
Closure
Ball
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
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.
99
IOOC 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
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.
102
Features
Stem retention (Standard)
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)
105
Features
Stem retention (Optional)
Unscrew
& pull up
Move
towards
the stem
Pull up
106
Features
Equalizing hole
The design allows for the pressure
equalization between body cavity
and the valve bore in open
position.
107
Features
Equalizing hole vs Pressure relief hole
Equalizing hole
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.
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.
110
Features
Drive train
All parts of a valve required to open / close the valve (excluding the operator).
Stem
Stem key
Ball
Dowel
pins
111
Features
Drive train
Standard solution
Stem key
Tang
Optional
Stem key
Pins
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.
113
Features
Drain & Vent
Standard
MKTG-007 R4 Oct.2012, Uncontrolled.
Property of MIR VALVE
Optional
Optional
Optional
114
API 6A
Valves
API 6D
Valves
WELHEADS
X-MAS TREES
PIPELINE
MKTG-006 R0 Sept.2013, Uncontrolled.
Property of MIR VALVE
116
Design
Size
Class
Application
MV9
1 13/16-11
1 13/16 9
MV11
MV13
Through-Conduit
Gate Valve (Forged)
1 13/16-11
API 2,000-15,000
MV4
3/4-11
3-4-9
Onshore
Offshore
Subsea
117
Full / Reduced
Bore
Soft/Metal
Seated
RF / WE / Hub
Ends
Independent
Stem
SR/DPE/DPE+SR
Antiblowout
Stem
Triple Stem
Barrier
Double Body
Barrier
Stem Injection
Fitting
Seat Injection
Fitting (optional)
Overlay
(optional)
Firesafe Design
118
What is PSL
(Product Specification Level)
Levels
1 (lowest) to
4 (highest)
Define
Testing
119
Standard Testing
Hydrostatic Body (PSL 1, PSL2)
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
121
temperature cycling
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
123