2. technical features of mir ball valves r4 oct 2012

8/17/2019 2. Technical Features of MIR Ball Valves R4 Oct 2012

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MKTG-007 TECHNICAL FEATURES OF MIR BALL VALVES R4 OCT.2012UNCONTROLLED DOCUMENT, PROPERTY OF MIR VALVE

TECHNICALFEATURES OFBALL VALVES

API 6D, API 6DSS (pipeline valve)

API 6A, API 17D (wellhead valves)


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Codes & Standards

Design

Features

Seat Configurations

Sealings

Contents

MKTG-007 R4 Oct.2012, Uncontrolled.Property of MIR VALVE Technical Features of MIR Ball Valves 2


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Codes & Standards


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Design

• API 6D / ISO 14313

• API 6DSS / ISO 14723

• Customer Specifications

Body Thickness

• ASME VIII-1, VIII-2

• ASME B16.34

Bolting


• ASME B16.34

Face-to-Face

• API 6D / ISO 14313

• API 6DSS / ISO 14723

• ANSI B 16.10

Drive Train Sizing(MAST)


Firesafe

• ISO 10497/API 6FA

• API 607

Codes and StandardsMain

MKTG-007 R4 Oct.2012, Uncontrolled.Property of MIR VALVE 4Technical Features of MIR Ball Valves


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Materials

• ASME II-D

Flanges

• ASME B16.5

NDT

• ASME V

Weld ends

• B16.25

Welding

• ASME IX

Gas Pipeline

• ISO 14141

Sour service

• NACE MR-0175 /ISO 15156

Codes and StandardsOther

MKTG-007 R4 Oct.2012, Uncontrolled.Property of MIR VALVE 5Technical Features of MIR Ball Valves


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Design


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DesignValve overview


Pressure Containing Part


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Pressure Controlling Part


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MKTG-007 R4 Oct.2012, Uncontrolled.

Property of MIR VALVE

Technical Features of MIR Ball Valves 12

Pressure Controlling Part


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DesignTrunnion mounted

Ball pivotally supported bythe trunnions

Floating seats movetowards the ball





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DesignTrunnion mounted configurations

• Ball mounted on trunnions

• Size ≤ NPS 10

Internal trunnion

• Ball mounted on bearing retainers

• Size ≥ NPS 12

External trunnion





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DesignTrunnion mounted configurations





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DesignTrunnion vs. Floating

Lower torque

No size limits

More complex design





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DesignTrunnion vs. Floating

Higher torque

Size limitation

Simpler design





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DesignExploded view





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DesignExploded view





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DesignBody construction

Side entry

Bolted

Fully welded

Top entry





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DesignBody construction

• Forged

Side entry

• Cast or forged

Top entry





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DesignSide entry - Bolted

3 pieces 2 pieces





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DesignTop entry

Cast Forged





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Seat Design


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Self-RelievingSeats (SR)

Double-PistonEffect (DPE)

Dual-SeatDesign (DS)

Seat Configurations



26Technical Features of MIR Ball Valves


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FeaturesValve seating configurationsSelf relieving (MIR standard)

• Bi-directional valve

• DBB valve

Two uni-directional seats:





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FeaturesUni-directional seat / Self-relieving

The force acting on the seats relieves the excess of pressure from the body cavity into the line.





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FeaturesValve seating configurationsDouble Piston Effect (optional)


• DIB-1 , uni-directional seat as 1st barrier, bi-directional as 2nd

One uni-directional seat & one bi-directional seat:

It also provides a double block & bleed action.





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FeaturesBi-directional seat / Double Piston Effect




It forces the downstream seat to seal against the ball.


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FeaturesValve seating configurationsDual seat design (SR+DPE) (optional)


• DIB-2, symmetrical behavior

Two bi-directional seats:

It also provides a double block & bleed action.





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FeaturesDIB-2 (Dual Seat) typical use

Protect the most critical area of the installation with adouble barrier





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Seat Configurations


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Seats & SealingsSoft seat (MIR standard)

Plastic insert (Nylon, Peek, r-PTFE)MKTG-007 R4 Oct.2012, Uncontrolled.




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Seats & SealingsPrimary metal secondary soft seat (optional)

Primary metal to metal seal Secondary protected soft seal





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Seats & SealingsMetal seat (optional)

Hard-faced metal to metal sealMKTG-007 R4 Oct.2012, Uncontrolled.




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

PROPERTY OF MIR VALVE

METAL-SEATED

BALL VALVES


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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

Contents

Metal-Seated Ball ValvesMKTG-036 R0 Oct. 2012, Uncontrolled.


38


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Which applications to use metal-seatedball valves - Service Conditions

Metal-Seated Ball Valves

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

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

LOW MAINTAINANCE SUBSEA, UNDERGROUND ETC.

HIGH DEMAND FREQUENT CYCLING, HIGH TURBULENCE ETC.

MKTG-036 R0 Oct. 2012, Uncontrolled.


39


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Seat Configurations


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Seating ConfigurationsSR (Self-Relieving) (MIR Standard)



41

• Bidirectional valve

• DBB valve

Two unidirectional seats, MIR standard:


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Seating ConfigurationsDPE (Double Piston Effect) (MIR optional)



42

• Bidirectional valve

• DIB-1, symmetrical behavior

Two bidirectional seats:

Seating Configurations


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Seating ConfigurationsSR+DPE (Self-Relieving + Double Piston Effect)(MIR Optional)



43


• DIB-2

One unidirectional seat & one bi-directional seat:


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Key Design ChangesSoft-Seated vs. Metal-Seated


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Key Design ChangesMetal Seat Design



45

Hardfaced sealing surfaces

Closure Ball

Body

Seat


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CoatingPlatingTypes

ENP

ElectrolessNickel Plating

0.001”

0.003”

NiSiC

NIckel-SIliconCarbide Plating

0.002”

TCC or CCC Tungsten orChromium

Carbide Coating

0.06” on theseats

0.08” on the

ball

Key Design ChangesHardfaced Seats and Ball


higher hardness of the ball after heat

treatment



46


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Key Design ChangesHardfacing (Coating/Plating) Types



Metal-Seated Ball Valves 47

ENP NiSiC TCC CCC

APPLYING

MECHANISM Auto-chatalytic

reactionAuto-chatalytic

reactionThermal spray

processThermal spray

process

TEMPERATURE

RANGE

Up to4500C / 842° F

Up to4500C / 842° F

Up to1900C / 356° F

Up to4500C / 842° F

HARDNESS Medium MediumIncreased Hardnessover 5000C / 932° F

Very highOptimal anti-

abrasion behaviour

High

FRICTION High MediumLower frictionover 5000C / 932° F

Very High Very High

REQUIRED

MANUF. TIME Medium Medium Very High Very High


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Key Design ChangesTorque


HIGHER FRICTION COEFFICIENT

HIGHER TORQUE REQUIRED

MORE POWERFUL ACTUATOR

INCREASED STEM SIZE



48


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Manufacturing ConsiderationsMetal-Seated Design


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Manufacturing ConsiderationsLapping


Operation in which twosurfaces are adapted togetherwith an abrasive medium andby hand / machine movement.

It ensures very accurate surfacecontact, therefore it is oftennecessary to achieve therequired tightness.

Lapping time depends ontightness requirements andservice conditions.



50


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Twophases

1. Ball surface lapping with aspecial tool

2. Seat and ball lapping by

reciprocal movement

Lappingpaste Compounds of different

grades, finer and finer.

Manufacturing ConsiderationsLapping



51


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Manufacturing ConsiderationsManual and Machine Lapping



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Manufacturing ConsiderationsManual Lapping



53


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The lapped seatis placed on the

ball and filledwith a liquid

90 psi air isblown from thebottom of the

sealing rim

The liquid ischecked for nobubbles

Manufacturing ConsiderationsBubble Test



54


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Manufacturing ConsiderationsTesting 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 accordingmaterials and process conditions.



55


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• Cyclical operations may be required for testing

Manufacturing ConsiderationsTesting


LAPPING

VALVE ASSEMBLY

TESTING OK?YES

NO



56


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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

Manufacturing Considerations

Testing


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Highertorque

• more powerfulactuator

• more robustand heavier top-work design

Seat and ballhardfacing

Moremanhours forassembly andtesting

Lead Timeand CostImpact

Lead Time and Cost Impact



58


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Proven Design and Technology



59Metal-Seated Ball Valves

MIR VALVE

holds proven

design and

manufacturingtechnology for

metal-seated

valves.


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Manufactured at our Malaysiaand Italy Operations

References


www.mirvalve.com

Exxonmobil Malaysia, offshore

http://www.mirvalve.com/http://www.mirvalve.com/


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y28” CL. 900 FB RTJ, LTCS+Inconel 625 Metal-seated +TCC ZERO LEAKAGE




PETRONAS CARIGALI IRAQ


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




MV1 Top-entry ball valves - offshore


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




qty 66”, 8”x6”, 10”

Cl. 2500Hub EndsMetal seatedFull duplexc/w pneumatic

actuators


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MV1 Top-entry ball valves – onshore


Property of MIR VALVE64


qty 816”, 20”

Cl. 300 - Metal seated

Body: A216 WCBInc.625 weld overlay ondynamic sealsBall: SSStem: Duplex

Seats: SSc/w electric actuators

Kencana / Newfield Malaysia


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Kencana / Newfield, MalaysiaAPI 6DSS 4”Cl. 600 RTJ Full Duplex Peek, subsea gear operator ROV

65

Project: Puteri Pipeline,Malaysia





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CHEVRON THAILANDMetal-seated + TCC Full Solid Duplex (Offshore)

66

Project: Gas Service Satun / Funan BTEX


Property of MIR VALVEMetal-Seated Ball Valves


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O-Rings, Lip Seals, Elastomers, Graphoil

Sealing Options

in Ball Valve Design


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Service Conditions

Technical Features of MIR Ball Valves68

-500C/ +2200C

O-Rings

-1010C / +2600C

Lip Seals & ExtendedStem

Over +2600

CMetal / Graphoil Gasket

Below -1010C

Lip Seals & ExtendedStem

www.mirvalve.com




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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+ElgiloySpring

Class 150-2500 NPS 2-36

FIRE SAFE GRAPHITE -196 520 Graphite Class 150-2500 NPS 2-60

www.mirvalve.com




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Sealing Locations

Location where wewould fit the lip seals, o-rings or a combination ofboth in the design

When overlay is applied,it is in these samelocations.

www.mirvalve.com




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Static / Dynamic Sealing

STATIC SEALThere is essentially no

relative motion between theseal and the hardwaremembers.An example would be a sealclamped between boltedflanges.

DYNAMIC SEALThere is a relative motion between

the two sealing surfaces. A typicalexample would be a rod and pistonseal.

www.mirvalve.com




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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 mannerinversely 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 o-ring.

• This phenomenon is emphasised at Class ≥ 900 and temperature and with CO2

>15%

• Viton AED is suitable for ED

www.mirvalve.com




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• From cryogenic environment (-1960C)

to high temperature (+260 0C)

• Spring-actuated, pressure-assisted

sealing device consisting of PTFE orother polymer jacket, partiallyencapsulating a corrosion resistantmetal spring energizer.

• Spring-loading, assisted by systempressure provides effective sealing atboth low and high pressures.


Lip Seal

www.mirvalve.com




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• Unlike rubber o-ring, Lip seals do

not stretch without damage.Therefore it is desirable to installin open groove design.

• Suppliers: Parker Seals, Saint-Gobain, Trelleborg


Lip Seal

In most seal applications, better overall sealing performancecan be achieved with a smoother sealing surface finish. (MaxRa=0.4)

www.mirvalve.com




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Lip Seal

Materials and Surface Finishing

Jacket Materials• PTFE

• PTFE Graphite filled

• PTFE Glass fiber

filled• FEP

• KEL-F

Spring Materials• Stainless Steel

• Elgiloy

• Inconel

• Hastelloy

Surface Finishing• RMS=416

www.mirvalve.com




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• Resilient form of graphite that hasexcellent properties as a gasketingmaterial.

• The unique chemical and physical

properties combined to make itsuitable to high temperature of up to525 deg Celsius and cryogenic of as lowas -240 deg C service and/or corrosive

environment.

Graphite Gasket


graphite gasket

www.mirvalve.com



S t & S li


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Seats & SealingsO-ring

• Two O-rings

• One graphite seal

Triple barrier




Seats & Sealings


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Seats & SealingsLip-seal + Vee-pack

• rPTFE Vee-pack

Redundant barrier




Seats & Sealings


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Seats & SealingsHigh Temperature

• Graphite seals

• Adjustable packing

• Live-load




Seats & Sealings


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Seats & SealingsCladded sealing areas

Corrosive service





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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.


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Cladding or Weld Overlay

is a welding procedureused to weld material

(usually exotic) oncomponent surface.

What is Cladding?

MKTG-005 R0 Uncontrolled Doc.

Property of MIR VALVE.

82Cladding


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Cladding is an alternative when thecomplete components cannot be fullymade in exotic materials due to high cost.

Cladding is a more economical way to

provide excellent corrosion resistance.

Why use cladding?



83Cladding

Cost example


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4002200

4500

12000

16000

2000

4000

6000

8000

10000

12000

14000

CS+Inc. W/O Cost

Base Material Cost

Cost examplefull material vs. cladded with Inconel



84Cladding

10” Cl. 900 body

Cost example


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400

20001200

0

500

1000

1500

2000

2500

Carbon Steel+SS.W/O Full Stainless Steel

CS+SS W/O Cost

Base Material Cost

Cost examplefull material vs. cladded with SS



85Cladding

10” Cl. 900 body


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Cost VariationsSmaller diameters more

competitive in full exoticmaterial

Larger diameters morecompetitive in cladding

86MKTG-005 R0 Uncontrolled Doc. Property of MIR

VALVE.

Cladding

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


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Corrosive Service

Harsh and hostile environment

Low maintenance application

When is it used?



87Cladding


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Corrosion resistance

Long life

High reliability

What are the advantages?



88Cladding


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The overlay is usually

Inconel 625 or StainlessSteel, and it is mostly

applied on Carbon Steelbase material.

Materials



89Cladding


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The Dynamic Seal Areas

All Sealing Areas

All Wetted Areas (Fully Cladded)

What areas can be cladded?



90Cladding


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Dynamic Sealing Area Cladding



91Cladding

Body coverpacking pocket

Seat Pockets


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All Sealing Area Cladding



92Cladding

Body cover /stem

Seat Pockets

Body cover /bodyBody / closure

Closure RTJ

Drain plug

All Wetted Areas Cladding


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g(Fully Cladded)



93Cladding

Body cover

Body

Ball

Closure


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Final Machining

Weld overlay

Semi-machinedcomponent

Process



94Cladding

Testing


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(Standard or Upon Request)



95Cladding

Dye Penetrant

Ultrasonic Test

PMI

HardnessThickness


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To achieve final thickness of 3 mm and the chemical composition

required, the cladding processconsists of two layers for a totalthickness of 6-7 mm of raw weld

material obtained thru Arc Weldingfollowing approved WPS/PQR.

Thickness



96Cladding


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MIG

TIG (more precise)

Electro-Slag Strip Welding

Welding Processes



97Cladding


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Cladding or weld overlay is outsourced tospecialized and approved subcontractorswith long time experience.

Major subcontractors for cladding areTigMig, Tecnoweld, Tecnosaldature,Comegi Italy

Subcontracted



98Cladding


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MIRVALVEhasextensive

trackrecord inthesupply of

claddedvalves.

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

References



99Cladding


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ADCO UAE Gasco UAEExxonmobil

MalaysiaIOOC Iran

Pars Oil Iran

Murphy Oil

Malaysia PDO Oman

Petronas

CarigaliMalaysia

PetronasCarigali

Pakistan

Petronas GasMalaysia

Sarawak ShellMalaysia

WoodsideAustralia

ChevronThailand

Track record – End-Users



100Cladding


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Other Design Features

Features


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eatu esStem retention - Definition

• Valves shall be designed to ensure thatthe stem does not eject under any

internal pressure condition or if thepacking gland components and/or valveoperator mounting components areremoved.

As specified in API 6D spec. , ch. 7.21:

Anti blow-out design




Features


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Stem retention (Standard)

One set of capscrew for adapter plate

One set of capscrew for body cover




Features


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Stem retention (Optional)

Standard typeOptional type




Features


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Features


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Unscrew& pull up1

Movetowardsthe stem

2 Pull up3




Features


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Equalizing hole

The seat is pushed against the ballby the spring force only, sincethere is no piston effect. Thisresults in lower break-off fromopen position.

The design allows for the pressureequalization between body cavityand the valve bore in openposition.




Features


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Equalizing hole vs Pressure relief hole

• balances pressure betweenbody cavity and valve boreonly when in open position

Equalizing hole

Lower break off from openposition

• reduces overpressure fromthe body cavity to theupstream side of the valve,

with the valve in the closedposition

Pressure relief hole




Features


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Stem grease injection (standard)

Provided between the second o-ring and the gasket totemporarily seal the stem until

the primary seal is restored.

The grease fitting incorporates acheck valve, designed to prevent

leakage towards environment,still allowing grease injection.




Features


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Seat grease injection (optional)

The system is designed to allowsealant grease injection into thevalve in service; the sealant isdistributed on the seating

surface between the seat andthe ball.

An additional a check valve isfitted in the main valve body

thickness, in order to provide asecond barrier to fluid leakage.




Features


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Drive train

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

Stem Stem key

BallDowel

pins




Features


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Drive train

Standard solution• Stem key• Tang

Optional• Stem key• Pins

Optional• Spline• Tang




Features


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MAST

The limiting tolerable torque for all components in the drive train betweenvalve and actuator.

Max Allowable Structural Torque

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

According to API 6D 7.20.1:




Features


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Drain & Vent

Standard Optional Optional Optional





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MKTG-006 TECHNICAL FEATURES OF MIR BALL VALVES R0 SEPT. 2013UNCONTROLLED DOCUMENT, PROPERTY OF MIR VALVE

API 6A BALL AND GATE VALVESFOR WELLHEAD AND CHRISTMAS TREES


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API 6DValves

• PIPELINE

API 6A

Valves• WELHEADS

X-MAS TREES

API 6D vs. API 6A

MKTG-006 R0 Sept.2013, Uncontrolled.


116API 6A Ball and Gate Valves


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API 6A Valve Types and Sizes




Model Design Size Class ApplicationMV9 Top-Entry Ball Valve 1” 13/16-11”

1” 13/16 – 9” API 2,000-10,000API 15,000

OnshoreOffshoreSubsea

MV11 Side-Entry Ball Valve 1” 13/16-11”

1” 13/16 – 9”

API 2,000-10,000

API 15,000

Onshore

OffshoreSubsea

MV13 Through-ConduitGate Valve (Forged)

1” 13/16-11” API 2,000-15,000 OnshoreOffshoreSubsea

MV4 Twin Ball Valve 3/4”-11” 3-4”-9”

API 2,000-10,000API 15,000

OnshoreOffshoreSubsea

For Subsea, the design standard is API 17D


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TrunnionMounted

Full / ReducedBore

Soft/MetalSeated

RF / WE / HubEnds

O-ring / Lip SealDesign

IndependentStem

SR/DPE/DPE+SRAntiblowout

StemTriple Stem

Barrier

Double BodyBarrier

Stem InjectionFitting

Seat InjectionFitting (optional)

Overlay(optional)

Firesafe Design

Ball Valve Design Features




What is PSL


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Levels 1 (lowest) to

4 (highest)

Define Material requirements (mechanical)Non Destructive Testing

Final Testing

TestingPSL Test is a Production Test

(Product Specification Level)




d d


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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)

Standard Testing




dd l


121/125

Torque Test

Endurance Test (cycling)

Firesafe Test

Hyperbaric Test

Other tests, as per customer requirements

Additional Testing




PR2 Qualification Testing


122/125

pressure cycling

temperature cycling

low and high pressure gas tests

PR2 Test is a design validationtest and covers one size up /down

(Performance Requirements)




MV11 API 6A Side-Entry Ball Valve 4” 1/16 API 10000Metal seated, Full Duplex c/w with hydraulic actuator

C ifi i


123/125

API 6A API 17DCE-PED97/23/EC

CE-ATEX94/9/EC

ISO 9001 /API Q1

ACHILLESJQS

IEC 61508UP TO SIL 3

FIRESAFETO API 6FA

Certifications





124/125

Manufactured at MIR VALVE ITALY

For info and inquiries, contact us at:

For Asia-Pacific / Middle East / AmericasMIR VALVE Malaysia at [email protected]

For Europe / CIS / Africa / Americas

MIR VALVE Italy at [email protected]

or visit us at www.mirvalve.com

mailto:[email protected]:[email protected]://www.mirvalve.com/http://www.mirvalve.com/mailto:[email protected]:[email protected]


125/125

For info and inquiries, contact us at:

For Asia-Pacific / Middle East / AmericasMIR VALVE Malaysia at [email protected]

For Europe / CIS / Africa / Americas

MIR VALVE Italy at [email protected]

or visit us at www mirvalve com
mailto:[email protected]:[email protected]://www.mirvalve.com/http://www.mirvalve.com/mailto:[email protected]:[email protected]

2. technical features of mir ball valves r4 oct 2012

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