MANUFACTURER OF VALVES. Ball Valves

Transcription

1 MANUFACTURER OF VALVES Ball Valves

2 MSA, a.s., is important manufacturer of industrial valves from the Czech Republic, Europe. The company manufactures and sells wide range of industrial valves for transport and processing of oil, gas, for power industry, heat and water distribution. All valves meet the strictest quality requirements. MSA has a quality system certified according to EN ISO 9001:2000 and API Spec Q1 (Specification 6D number 0239).

3 C O N T E N T S 1. Manufacturing program 4 2. Ball Valve Design 6 3. Design Details 8 4. Weights and Dimensions Accessories Quality System Application of Standards Research and Development 19

4 1 Manufacturing program Ball valves are used in service conditions which require complete opening or closing of medium flow. Most often used service medium is gas, oil and water. MSA, a.s. manufactures threepiece ball valves with trunnion mounted ball. Individual body pieces are connected by bolts in case of K 83 TB design, or they are welded together in case of K 83 TW design. All ball valves can be supplied also with reduced bore. K 83 TW fully welded design K 83 TB bolted body design 4

5 Class PN 16 and and DN NPS Legend: TB TW 5

6 2 Ball Valve Design Material combinations BODY BALL SEAT STEM CS (A 350 LF2, LF2M, A 105, A 694) SS (A 182 F6A, F 304, F 316, 174 PH) CS + Cr CS + Ni SS CS + Cr CS + Ni SS CS + Ni SS SS + Ni CS + Cr SS SS + Ni CS + Cr CS + Ni SS + Ni CS + Cr CS + Ni SS + Ni MSA, a.s. uses for individual parts only materials, which are suitable for given service medium or ambient temperature. For example, for service medium containing H 2 S, materials which meet requirements of NACE MR0175 specifications are chosen. Some typical material combinations for different environments are listed below. Material specification NO. 1 2 COMPONENT BODY COVER STANDARD DESIGN from 29 C to 120 C ASTM A350 LF2 ASTM A350 LF2, A350 LF2M, A694 F60 LOW TEMPERATURES from 60 C to 120 C ASTM A350 LF2M ASTM A350 LF2M, A694 F BALL ASTM A350 LF2 + Cr or Ni ASTM A350 LF2 + Cr or Ni 5 SEAT ASTM A350 LF2 + Ni ASTM A350 LF2 + Ni 6 STEM A350 LF2M, AISI 4140, ČSN Cr A350 LF2M, AISI 4140, ČSN Cr 7 TABLET BEARING ASTM A105, ČSN ASTM A105, ČSN STUD ASTM A193 B7 ASTM A320 L7 9 NUT ASTM A194 2H ASTM A194 Gr.4 10 ADAPTER PLATE 11 SEALING THERBAN (NITRIL), VITON, DEVLON, PTFE THERBAN (LOW NITRIL), DEVLON, PTFE 12 ORING THERBAN (NITRIL), VITON THERBAN (LOW NITRIL) 13 BEARING STEEL(CS) + PTFE STEEL(CS) + PTFE 14 THRUST WASHER STEEL(CS) + PTFE STEEL(CS) + PTFE 15 FIRE SAFE RING GRAPHITE GRAPHITE 16 GLAND PLATE 17 PIN 18 CAPSCREW 8.8 acc. to EN ISO 4762, A193 B7 8.8 acc. to EN ISO 4762, A320 L7 20 SEAT SPRING AISI 302 AISI STEM KEY AISI 1040, ČSN AISI 1040, ČSN NO. COMPONENT SOUR SERVICE ACC. TO NACE MR 0175 from 46 C to 120 C HIGH TEMPERATURES from 10 C to 200 C 1 BODY ASTM A350 LF2M ASTM A350 LF2 2 COVER ASTM A350 LF2M, A694 F60 ASTM A350 LF2, A694 F60 4 BALL ASTM A350 LF2 OR LF2M + Ni ASTM A350 LF2 + Cr or Ni 5 SEAT ASTM A350 LF2M OR F316 + Ni ASTM A350 LF2 + Ni 6 STEM A350 LF2M + Ni, A182 F316 or PH A350 LF2M, AISI 4140, ČSN Cr 7 TABLET BEARING ASTM A105, ČSN ASTM A105, ČSN STUD ASTM A320 L7M ASTM A193 B7 9 NUT ASTM A194 7M ASTM A194 2H 10 ADAPTER PLATE 11 SEALING THERBAN (NITRIL), VITON, DEVLON, PTFE VITON, DEVLON, PTFE 12 ORING THERBAN (NITRIL), VITON VITON 13 BEARING STAINLESS STEEL(SS) + PTFE STEEL(CS) + PTFE 14 THRUST WASHER STAINLESS STEEL(SS) + PTFE STEEL(CS) + PTFE 15 FIRE SAFE RING GRAPHITE GRAPHITE 16 GLAND PLATE ASTM A350 LF2M, ČSN PIN 18 CAPSCREW 8.8 acc. to EN ISO 4762, A320 L7M 8.8 acc. to EN ISO 4762, A193 B7 20 SEAT SPRING INCONEL 750 AISI STEM KEY AISI 1040, ČSN AISI 1040, ČSN

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8 3 Design Details Ball machining 1 Body Body is made of three forgings, where the individual parts are bolted or welded together. Body dimensions are chosen to meet not only strength and rigidity requirements of corresponding standards, but also to be able to transfer external forces and torques from pipeline. GASKET FIRESAFE 2 Seat (Pict. No. 1) Necessary thrust of a seat to a ball is at low pressure provided by spiral springs. At high pressure the thrust of a seat to a ball is increased by pressure of service medium in pipeline. For gaseous media it is recommended to use PMSS seat (Primary Metal Secondary Soft). Secondary sealing ring is of delta shape, made of HNBR (Therban or Elast O lion) or Viton. For liquid media it is recommended to use seat with hard seal ring inserted in to metal seat ring. Teflon and its modifications (Devlon, Nylon, PEEK etc.) are used for hard seal insertion. Sealing paste, which can be injected between seat and ball, can be used as tertiary sealing (Pict. No. 2). Seats with soft sealing rings are automatically supplied as DPE design (Pict. No. 4). DPE design means, that if upstream seat is damaged, function of a ball valve is still secured by a downstream seat. 3 Stem (Pict. No. 3) Stem is of anti blowout design so it cannot be ejected out of a body due to improper handling. It is primary and secondary sealed by two independent rings. It can be tertiary sealed by sealing paste. Secondary ring can be replaced even under full pressure load with the ball either open or closed. Antistatic Design All internal metal components are conductively connected with ball valve body. GASKET FIRESAFE UP STREAM BODY CAVITY DOWN STREAM 4 ANTISTATIC The design is a groundwork for troublefree functionality and long service life. 8

9 Trunnion detail Seat detail Bodycover sealing detail Double Block and Bleed (DBB) (Pict. No. 5) All ball valves are supplied with DBB feature, which means that it is possible to bleed the body cavity in fully closed or fully opened position. 5 OPEN Lubrication Forces arising due to pressure acting on a ball are caught by selflubricating bearings with low friction coefficient. Thus the ball valves have low torque and do not require any maintenance. External Leakage Theoretical areas of external leakage are bodybonnet joints and trunnion. These parts are therefore designed to meet requirements for emissionfree valves. CLOSED Position Adjustment (Pict. No. 6) Every ball valve, which is supplied without actuator (bare stem), is equipped with a special device, by which it is very easy to adjust ball position even in case when it is not possible to have a look into valve bore. From this reason it is possible to perform installation or removal of actuators on ball valves also after their installation into pipeline. For other ball valves this device must be specified in an order. FireSafe Design MSA ball valves are firetested for the whole manufacture range according to API 607, API 6FA a BS 6755, part 2 standards. Firesafe certificate was issued by an independent international organization. 6 9

10 4 Weights and Dimensions PN 16, 25 CLASS 150 NPS DN D L BW L RF L RTJ Dv E F WEIGHT (kg) mm BW RF, RTJ 2" " " " " " " " " " " " " " " " " " " " " " " " L RF L RTJ L BW E F PN 40 CLASS 300 NPS DN D L BW L RF L RTJ Dv E F WEIGHT (kg) mm BW RF, RTJ 2" " " " " " 12" 14" 16" 18" 20" 22" 24" 26" 28" 30" 32" 34" 36" 40" 42" 44" " "

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12 PN 63 CLASS 400 NPS DN D L BW L RF L RTJ Dv E F WEIGHT (kg) mm BW RF, RTJ 2" " " " " " " " " " " " " " " 30" 32" 34" 36" 40" 42" 44" 48" 56" L RF L RTJ L BW E F PN 80,100 CLASS 600 NPS DN D L BW L RF L RTJ Dv E F WEIGHT (kg) mm BW RF, RTJ 2" " " " " " " " " " " " " " " " " " " 40" 42" 44" 48" 56" D Dv Ball valves according to API 6D Flanges according to ASME B16.5 Butt weld ends according to ASME B16.25 Approximate weights Reducedbore valves also available MSA, a.s. reserves the right to change the content of this catalog without notice 12

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14 PN 160 CLASS 900 NPS DN D L BW L RF L RTJ Dv E F WEIGHT (kg) mm BW RF, RTJ 2" " " " " 10" 12" " 16" 18" " 22" 24" " 28" 30" 32" 34" 36" " 42" 44" 48" L RF L BW L RTJ E F PN 250 CLASS 1500 NPS DN D L BW L RF L RTJ Dv E F WEIGHT (kg) mm BW RF, RTJ 2" " " " " " " " " " " " " " " " " " " D Dv Ball valves according to API 6D Flanges according to ASME B16.5 Butt weld ends according to ASME B16.25 Approximate weights Reducedbore valves also available MSA, a.s. reserves the right to change the content of this catalog without notice 14

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16 5 Accessories POSITION ADJUSTMENT OF UNDERGROUND BALL VALVE 7 Stem extension (Pict. No. 7) Stem extension is available based on customer s request, namely for underground valves. Length of stem extension is not limited, however it must be always specified (see picture). Accessories (Pict. No. 8) V V1 K K1 POSITION ADJUSTMENT OF ABOVE GROUND BALL VALVE MSA furnishes ball valves with further accessories depending on customer s requirements, such as drain, vent, grease fittings, power supply to actuators, pressure relief valves etc. All these accessories are made of stainless steel pipes. Sealant injection lines are terminated by two independent grease fittings. Drain and vent pipes, actuator supplies are terminated by ball valves. Pressure reduction in ball valve body In case that service conditions enable increase of pressure in body cavity higher than nominal pressure, ball valve must be ordered with a device for pressure reduction. This is enabled either by seat modification or by a relief outside the ball valve. When relieving pressure through seat, DPE function is canceled. 8 Drain, vent, emergency grease sealing and relief on a stem extension. 16

17 Pups (Pict. No. 9) MSA ball valves with buttweld ends do not require any pup pieces if operating and installation instructions are observed. However, if pup pieces are required, MSA supplies pup pieces in two possible options: 9 Option A: Pup piece is a forging, which is welded to basic material before final machining. Ball valve is assembled together with the pup piece. This option is used for pup pieces up to 200 mm. Option B: Pup piece is a part of pipe of the same grade and dimensions as pipeline. Ball valve is manufactured and tested with standard dimensions and then pup piece is welded and checked. Pup piece length is not limited for this option, except for transport reasons. However, if pipe of nonstandard grade or sizes is used, it is recommended that the customer supplies the pup material. Actuators Valves are supplied either with or without actuators. Actuators can be of manual, electric, pneumatichydraulic, electrichydraulic, pneumatic or hydraulic type. MSA cooperates with all leading actuator manufacturers. Actuator installation at test room We supply ball valve accessories as per customer s requirements or based on service conditions. 17

18 6 Quality System Inspection of manufacturing process has critical influence on quality. Whole manufacturing process is thoroughly monitored and includes the following tests and inspections: receiving inspection of all raw materials and subsupplies, inprocess inspection during manufacture of individual parts, assembly tests, pressure tests, functional tests, nondestructive tests, final inspection of finished products. Pressure tests All pressure tests are performed in accordance with API 598, API 6D and DIN MSA also performs special tests according to API 6D as a standard, such as low pressure air test, DBB test and DPE test. Acceptance criteria is zero leakage for all the tests. MSA also performs test by full operating pressure as a standard. This is the only test which can reveal possible leakage in the bodycover joint, stem, accessories, grease fittings etc. Ultrasonic test Fire safe test Pressure test Xray of BW ends Special tests MSA performs many special tests, by which we verify properties of our ball valves. All tests are witnessed by independent test institutes. The following tests were performed on MSA ball valves: Fire test according to API 6FA, API 607 and BS 6755, part 2, for Class 150, 300, 600 and 900 Tightness and functional tests at temperature 60 C to +200 C Cycle test test for 5000 cycles (openclose) at full differential pressure with gas containing large mechanical impurities Hydrodynamics and aerodynamics test verification of hydropneumatic and aerodynamic properties is done with simultaneous measurement of torque value in dependence on angle of ball opening Nondestructive tests MSA performs nondestructive tests in its own test rooms and equipment. Nondestructive tests include RT, MT, UT or DP tests. Personnel performing these test is highly qualified and certified according to EN 473 or SNTTC1A. Functional test All ball valves are functionally tested together with actuator. Torque value is verified during this test as well. 18 Certification MSA quality system is based on strict observance of EN ISO 9001:2000 and API Spec Q1 (Specification 6D number 0239).

19 Application of Standards 7 There are different standards used for design, production and testing of valves, based on customer s requirements, such as: ASME/ANSI API MSS BS ASTM ISO DIN ČSN STN B 16.5, B 16.10, B 16.25, B 16.34, B 16.37,ASME section V., VIII. and IX. SPEC Q1, SPEC 6A, SPEC 6D, SPEC 5L, SPEC 6FA, std. 607, std. 598 SP 6, SP 25, SP 53, SP 54, SP , 2080, 5146, 5351, 6755 part 2 material specifications of materials used EN 9001:2000, 5211m EN , NACE MR , 2505, , 2526, 3203, 3230, 3840, material specifications of materials used , , material specifications of materials used , , material specifications of materials used Research and Development 8 MSA specialists deal with research and development activities and before creation of a new product they verify its properties, such as: fitness of materials used design strength and rigidity (FEM method) design functionality with stress on tightness and controllability hydraulic and aerodynamic properties etc. New product is tested both at MSA testing rooms, as well as in real service conditions. Product properties are regularly monitored during its whole service life and findings are applied for development and manufacture of new products. 19

20 MSA, a.s., Hlučínská 41, Dolní Benešov, Czech Republic phone: , fax: