40 SERIES BALL CONTROL VALVES

Transcription

1 40 SERIES BALL CONTROL VALVES HIGH PERFORMANCE BALL CONTROL VALVE: intelligent field devices for efficient field based architecture HEAVY TRUNNION DESIGN SEVERE SERVICE HIGH VERSATILITY CUSTOMIZABLE SOLUTIONS LOW NOISE AND CAVITATION CONTROL WITH RMT TRIMS 1

2 RMT CONTROLS a division of RMT VALVOMECCANICA GIVA GROUP Via dei Patrioti Solbiate Olona (VA) Italy Ph: Fax: info@rmtvalvomeccanica.com 2

3 INDEX 1. GENERAL FEATURES TECHNICAL DESCRIPTION BODY/CLOSURE BONNET PACKING STANDARD LOW EMISSION PACKING LIVE LOADING LOW EMISSION PACKING TRIM COMPONENTS TRUNNION/STEM AND BEARINGS SEAT RING AND BALL ELEMENT SEAT RING CONFIGURATION SEAT RING SEALING CONSTRUCTION BALL MATERIAL OF CONSTRUCTION SEALING COMPONENTS (STATIC AND DYNAMIC) O RING SEALS LIPSEALS GRAPHITE PACKING AND SPIRAL WOUNDS FIRE SAFE DESIGN RMT CONTROL TRIMS FOR 40 SERIES SERIES: V CUT BALL CONTROL VALVE SERIES FOR EXTREME EROSIVE APPLICATIONS: 45SS SERIES: MULTISTAGE BALL CONTROL VALVE : NOISE ABATEMENT CAVITATION CONTROL RMT 43 SERIES BALL CONTROL VALVES FOR CAVITATION AND NOISE CONTROL SERIES: BALL CONTROL FOR EXTREME NOISE CONTROL SERIES FLEX DESIGN FOR QUICK CHANGE AND EASY MAINTENANCE ACTUATORS AND CONTROLLING DEVICES ACTUATORS POSITIONERS AND PANELS PRODUCT QUICK SPECIFICATION SERIES RATING/CONNECTION TABLES MATERIAL SELECTION GUIDE FLOW CHARACHTERISTICS REVISION DESCRIPTION PREPARED APPROVED DATE A FIRST ISSUE MARCO FUSCA MATTEO ROSSI 01/07/2015 3

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5 1. GENERAL FEATURES The 40 series is the RMT product line of trunnion mounted ball valve for control application. 40 series control valve couple: the advantages of a ball valve design, typically applied for on/off service: excellent tightness high flow capability heavy duty construction, suitable for extreme severe pressure/temperature combination the advantages of an engineered control trim: extremely high rangeability cavitation control capabilities noise abatement and sound emission control capabilities anti-clogging design for dirty and viscous fluid applications Moreover 40 series ball control valve are designed to offer: quick change trim for easier maintenance operations even if they have a side entry construction low torque design, for compact actuation with higher performance both in terms of smooth control and quick positioning compact design with short end-to end dimensions of our flex design. You can use it in Oil & Gas as Upstream: onshore and offshore Midstream: transportation, filtering, reduction, metering, storage Downstream: petrochemical, refineries, LNG Distribution networks and also in many other industrial applications: Chemical applications Power Water: potable and desalination plants Everywhere you need a process control. 5

6 40 SERIES HAS THE AIM TO OFFER: HIGH PERFORMANCE SOLUTIONS TO SUIT CUSTOMER REQUIREMENTS: high tightness capabilities and high flow capacities; design flexibility thanks to the wide range of trim option, actuation and instrumentations solutions; the goal to suit customer request at every process condition, even the most severe ones; HIGH RELIABILITY: solid design and attention to materials selection to provide wear resistance and long life even in severe conditions; COMPACT DESIGN: design attention to reduce overall costs and offer easy handling and installation. HIGH PERFORMANCE SOLUTIONS TO SUIT CUSTOMER REQUIREMENTS HIGH TIGHTNESS CAPABILITIES 40 series make possible to reach the higher classes of tightness according to ISA standard, up to a zero leakage design typical of an on/off ball valve. HIGH CAPACITY DESIGN Ball design make possible to maximize flow capacity. TRIM CONSTRUCTION Trim is engineered to offer a smooth behavior even under the most severe conditions, making possible reduction in thrust requirements and actuator sizing high pressure drop capabilities facing up of cavitation matters noise abatement dealing with dirty, sticking or slightly abrasive fluids very smooth valve operations thanks to design and quality control to ensure precision of machining parts; all this means also low operating costs excellent flow control through different design of the ball and seating elements: precise contouring of the V profiles offer modified equal percentage flow characteristics suited to specific application. WIDE RANGE OF PACKING SOLUTIONS In order to satisfy any special requirement in term of low emission, different suitable packing solutions are provided: Low emission packing (LEM) Live loading low emission packing (LL-LEM) Have a look to packing section. ACTUATION AND ADVANCED DIGITAL POSITIONING CONTROL Pneumatic piston are typically used in actuation of 40 series valves: typically rack & pinion for size up to 3 (DN80) and scotch yoke pneumatic piston actuators for bigger size and high shut off applications. In addition, hydraulic or electric actuators are available on request too. Pneumatic actuator may be of DVG automation construction (a well known sister company inside the industrial group that holds RMT Valvomeccanica) or other main manufacturer. Actuator selection is always performed carefully to match the valve design features and offer excellent valve positioning for the best process control. Advanced valve diagnostic is available. Smart communication hardware and software provide real-time preventive and predictive diagnostic data. Best brands are available and skilled technicians at complete disposal. 6

7 DIFFERENT CONSTRUCTION TYPES AND WIDE RANGE OF TRIM SOLUTIONS FOR EFFICIENT VALVE OPERATION RMT has engineered three design types in order to be able to suit every kind of applications of ball control valves, even the most severe ones: - 45 Series: is the V cut series of RMT ball control valves. A V cut design is performed to make possible have a perfect equal percent characteristic. V cut shape allow high rangeability, up to 150:1: in this way is possible to optimize control both during high turndown processes (low flow requirements) and during normal operational phases when maximum CV shall be provided (high flow rate required). Moreover the V cut shapes assures an intrinsically self-cleaning and non-clogging design Series: is the multistage series of ball control valve. A multistage labyrintic trim is built inside the ball element, thus making possible to realize a multistage approach to pressure reduction across the valve. A multistage approach make possible to control noise matters and especially cavitation phenomenon. In this way we are able to couple the advantages of a ball design with those of a multistage approach customized on the particular process. Cavitation control trims CCT43-42 Series: is the low noise series of RMT ball control valves. The concept design is to realize a multipath approach for noise abatement. These valves are therefore provided with special diffusers for noise control. Noise control trims NCT42 Trim and constructive tips combined with suitable material selection make 40 series suitable for a wide range of applications, even the most severe one in terms of pressure/temperature combination and type of fluid: No Erosion / corrosion applications (sour liquids or gases) High Temperature operations Low Temperature operations: CRYO service. 7

8 HIGH RELIABILITY In order to offer the best wear resistance and a long working life, following key feature characterize the 40 series control valves. WIDE RANGE OF MATERIAL The 40 series control valves have been developed to cover a wide range of applications with practically no limit in pressure and temperature. Great attention is put into material selection, especially in severe service applications where erosion or corrosion problems may be present. Sour service material class possibilities and Exotic materials, solid tungsten carbide and ceramic materials can be provided for trim components. As a brand of GIVA Group, RMT is perfectly integrated with the still mills, forges, foundries and machining shops of the company. RMT has the full support of an own advance metal testing laboratory located next to the factory. MATERIAL SELECTION We put a great attention into material selection, especially with reference to the trim ones. We can guide you through the best choice at the best cost even under the most severe conditions of fluid temperature/pressure combination. Materials are available for application involving sour liquids or gases. Design can be in compliance with NACE MR Forged raw materials are the standard of construction, thus assuring an higher quality rather than casted components. DESIGN CONSTRUCTION AND TRIM SELECTION The variety of design construction types and the different trim solutions let us to develop a valve that is able to suit the customer process conditions. 40 series are able to face up and control the effects of flashing, cavitation and noise matters, even in the most severe service conditions: high or low temperature applications, corrosive atmospheres, erosion matters, SEAT TIGHTNESS Seat leak class IV of ISA reference is our standard, but we can also achieve class V, class VI up to a zero leakage design, depending on the customer request. COMPACT DESIGN 40 series ball control valve up have been engineered with a compact assembly up to NPS 12 (DN 300) and rating #600: upper and lower trunnion construction for 2 pieces body-closure design. For above mentioned size/rating combination short face to face dimensions make possible - global cost reduction - simplified handling and installation - quick change for easier maintenance, that means also lower maintenance costs. Valve packing offers a easy maintenance top entry design and the possibility of a quick change. There is no need of any special components during assembly or disassembling operations. 8

9 1. BODY 2. CLOSURE 3. BODY STUD 4. BODY NUT 5. STEM/UPPER TRUNNION 6. LOWER TRUNNION 9. BALL 10. SEAT RING 12. BONNET 13. PACKING FLANGE 14. PACKING STUD 15. PACKING NUT 16. PACKING FOLLOWER 18. YOKE/ISO FLANGE 19. PACKING GLAND BOLT 23. LOWER FLANGE 24. LOWER FLANGE BOLT 27. YOKE STUD 28. YOKE NUT 30. SPRINGS 61. AXIAL BEARING 62. RADIAL BEARING 71. PACKING RINGS 72. PACKING END RINGS 81. PACKING GLAND FIRE SAFE GASKET 82. PACKING GLAND O RING 83. LOWER TRUNNION O RING 84. LOWER TRUNNION FIRE SAFE GASKET 85. BODY-CLOSURE O RING 86. BODY-CLOSURE FIRE SAFE GASKET 87. SEAT O RING 88. SEAT FIRE SAFE GASKET 2. TECHNICAL DESCRIPTION 45 SERIES STANDARD CROSS DRAWING: TWO PIECES CONSTRUCTION UP TO NPS 12 (DN 300) AND RATING #600. 9

10 45 SERIES API 6D CROSS DRAWING: THREE PIECES CONSTRUCTION FROM NPS 12 (DN 300) UP TO NPS 48 (DN 1200) UP TO RATING #

11 2.1 BODY/CLOSURE Design. Bodies of 40 series valves have a side entry design as standard. Pressure/temperature ratings and mechanical design are according to ASME B Materials of constructions. As standard, forged raw materials are used. The choice depends on the combination of fluid type, pressure rating and design temperature. Carbon Steel and stainless steel, Duplex, Nickel alloys and other exotic material (DIN, ASME or ASTM specification) can be provided. RMT Valvomeccanica have the full support of the steel mills forges and of the holding (GIVA) group for high quality standards. Weld overlay (SS 316 or Inconel 625 as standard) of the wetted parts is possible for the best corrosion resistance at the lower cost. Size and rating. Dimensions up to NPS 12 (DN 300) and rating #600 are provided with a two-pieces bolted execution (body & closure). Out of this size/rating combination standard design is according API 6D, with three pieces bolted execution (body & upstream/downstream closure). End to end connections. Flanged body-closure is the standard construction. Short face-to-face dimensions are provided for the compact design, that is up to NPS 12 (DN 300) and rating #600. Out of this size/rating combination standard end-to-end dimensions are according API 6D. Flow direction. Standard flow design is unidirectional. NON STANDARD EXECUTION POSSIBILITIES: - top entry design - fully welded design - casting bodies - flangeless construction - bi-directional flow type For rating tables, refer to product spec. section. For material choice, refer to material selection guide. 2.2 BONNET Forged or rolled steels are used for bonnet raw material. Bolted design with valve body is provided as standard. Standard execution cover applications where the temperature of the controlled fluid is between -30 C and 600 C making use of different packing type solutions. Refer to packing section for detailed explanation. NON STANDARD EXECUTION ARE AVAILABLE: - extension for high temperature application, in order to lower packing and operator temperature: in this cases graphite based solutions are available for packing; - extension in order to increase packing and operator temperature for low temperature application, down to -196 C ( cryogenic); - special constructions with grease injection points for emergency sealing may be provided; - customizable solutions. As a standard of construction, bonnet material is the same of body. Weld overlay (SS 316 or Inconel 625 as standard) of the wetted parts is possible for the best corrosion resistance at the lower cost. For material choice, refer to material selection guide. 2.3 PACKING 40 series have been developed with different suitable packing solutions that make possible to control fugitive emissions levels. Due to the modulating service of a control valve packing has been designed to allow adjustment over the servicelife of the valve. Packing is designed to offer: limitation in the loss of process fluid, thus increasing efficiency; reduction in environment contamination; respect of the criteria of most restrictive legislations, avoiding connected sanctions Fire Safe design is allowable on request STANDARD LOW EMISSION PACKING Low Emission (LEM) packing meets the criteria of ISO : CC3 class. It is made by a series of pre-formed braided rings PTFE or GRAPHOIL based with two anti-extrusion terminal solid rings. PTFE based rings can be adopted from -30 C up to 200 C with a plain bonnet and from -30 C up to 300 C with an extended one; max allowable pressure is 250 Barg. 11

12 GRAPHOIL based can be adopted from -30 C up to 600 C with a plain bonnet and from -100 C up to 600 C with an extended one; there are no practical limitation in max allowable pressure. Furtherly it s possible to introduce to standard design: leak-off in order to provide the possibility of measuring the emission level; packing follower with a dual O-ring design that allows very high performances with extremely volatile gas LOW EMISSION PACKING (LEM) WITH LEAK OFF AND DUAL OPTIONAL O RING STANDARD LOW EMISSION PACKING (LEM): PTFE BASED 13. PACKING FLANGE 14. PACKING STUD 15. PACKING NUT 16. PACKING FOLLOWER 71. PACKING RINGS (PTFE BASED - CRANE 285K) 72. PACKING END RINGS GLASS LOADED) LIVE LOADING LOW EMISSION PACKING Live Loading Low Emission packing (LL-LEM) can maintain to optimal levels the leak performance practically during all life service of the valve. This is possible by the use of bellows springs that maintain a constant sealing force within the packing box. The results is constant low leakage performance with minimal field adjustment. STANDARD LOW EMISSION PACKING (LEM): GRAPHITE BASED 13. PACKING FLANGE 14. PACKING STUD 15. PACKING NUT 16. PACKING FOLLOWER 71. PACKING RINGS (GRAFOIL BASED) 72. PACKING END RING (SOLID GRAPHITE) LIVE LOADING LOW EMISSION PACKING (LL-LEM) 12

13 2.4 TRIM COMPONENTS Different constructive tips make 40 series of ball control valves capable to suit a wide range of applications, even the most severe. Different trims solutions have been applied to 40 series in order to be able to couple the advantages of a ball control valve solution with the capability to face also up: - applications where risk of flashing/ cavitation could occur: RMT Controls have developed 43 series of multistage ball control valves; - applications affected by noise matters and, UPPER AND LOWER TRUNNION CONSTRUCTION consequently, its abatement: RMT Controls have developed 42 series of ball control valves for a multipath approach to noise abatement and, eventually, a multistage approach too where necessary; - applications characterized by the presence of dirty, sticking or slightly abrasive fluids: 45 series of V Cut Ball Control offers not only an effective way for customized characterization of valve flow characteristic, but also a self-cleaning and anticlogging design in case of dirty applications; - applications where corrosive or high abrasive fluids are involved: for these application special STEM AND BEARING RETAINER DESIGN solutions with unconventional ceramic materials have been developed. The main goal is to obtain a smooth control and a precise positioning from one side, and guarantee high performances and reliability along the all Stainless steel materials are used for trunnions while carbon steel ones for bearing retainers. Anti-blow out design is a standard of construction with reference to upper trunnions/stem execution. service life of the valve. Antistatic device is possible on request according to API 6D and ISO 17292: TRUNNION/STEM AND BEARINGS throw a small spring loaded ball electrical continuity between the stem and the valve body is ensured. Two different constructions are provided for Two kind of bearing are used: stem/trunnion: - radial bearing to allow components rotations with low - upper trunnion and lower trunnion (standard friction; execution in case of 2 pieces body-closure design) - axial: to hold the thrust due to internal pressure, using characterize by short face to face dimension; antifriction washers. - stem and bearing retainer in compliance with API Special bearing materials are used to lower friction, 6D face to face dimensions. thus obtaining a smoother control, and reduce wear, for lower maintenance costs and enhanced reliability. Heavy duty trunnions make possible longer service RMT Controls works continuously in partnership with life with reduction in terms of maintenance. well-known bearing manufacturers to select the best Torque for ball positioning is transmitted by the choice for the required application. upper trunnion / stem that can be a spline shaft (with Refer to material section guide for standard materials DIN grooved profile) for enhanced precision into of construction. positioning. 13

14 2.4.2 SEAT RING AND BALL ELEMENT SEAT RING CONFIGURATION Since the modulating type of service, RMT 40 series are single seated as a standard of construction Standard design of seat configuration is single piston effect and the flow is therefore with a preferred direction. Independent floating spring loaded seat is in contact with the ball when the pressure comes from the upstream line, thus providing an effective seal even at low differential pressure. In case of reverse flow direction standard single piston seat configuration is no more capable of sealing, since the seat would release the pressure (self relief). SINGLE PISTON EFFECT STANDARD CONFIGURATION Customizable solutions are available as nonstandard execution: double seat configuration and/or double piston effect configuration may be provided. In double piston effect, configuration independent floating spring loaded seat is always in contact with the ball to provide an effective sealing, even at low differential pressure. In case of n on standard double seat construction, a combination of single piston effect on upstream seat ring and a double piston execution on the downstream ring are possible, as an alternative to a relief valve for avoiding overpressure at the body cavity. SINGLE PISTON AND DOUBLE PISTON EFFECT COMPARISON SEAT RING SEALING CONSTRUCTION Depending on pressure/temperature combination, and considering the type of fluid and application, two main construction are possible: METAL TO METAL SEAT This design make possible to offer high performances in terms of leakage capability: - in applications where dirty and/or abrasive fluid are involved; - in applications where high design temperature are required. A metal to metal seat offers also lower maintenance costs and longer field life. METAL TO METAL SEAT CONSTRUCTION Leakage class. Leakage class up to class V according to ANSI/FCI 70-2 and IEC is possible. SOFT SEAT This design make use of relisient insert that make possible to reach higher leakage classes. This design is mainly limited by - the service temperature: max 250 C; - the type of fluid: not suitable in case of abrasive applications. DOUBLE PISTON EFFECT: NON STANDARD CONFIGURATION 14

15 SOFT SEAT CONSTRUCTION Special execution may be provided with injection points for emergency sealing in case of any failure up to seat replacement. LUBRIFICATED SOFT SEAT CONSTRUCTION Leakage class. Leakage class better than class VI according to ANSI/FCI 70-2 and IEC is possible BALL Ball is the plugging element of the 40 series. Mechanical design is according to ASME B Materials of constructions. As standard material of constructions are the same of the seating ring. Forged materials are used as standard construction but also ball from casting is possible. Cladding with highly corrosion resistance material is possible (SS 316 or Inconel 625 as standard) for the best corrosion resistance at the lower cost: both for wetted parts and especially for dynamic seals areas. Carbide coating on sealing area may be performed on metal to metal construction, thus enhancing valve reliability against wear. - tungsten carbide coating TCC for service temperature up to 350 C (120µm and over); - chromium carbide coating for service temperatures higher than 350 C(120µm and over). Stellite overlay is possible as a non standard execution that couple an high wear capability with greater corrosion resistance than carbide coating. Since stellite is a welding overlay it s characterized by cracking risks: therefore this operation has to be performed with such technologies and procedures by skilled personnel that highly affect the valve cost. Special materials and technological way of constructions are possible for application where highly abrasive fluids are involved: for instance fully tungsten carbide obtained by tungsten sintered powders or similar. RMT Valvomeccanica have the full support of the steel mills, forges and metal testing laboratories of the holding group GIVA, for higher quality standards. Antistatic device is possible on request according to API 6D and ISO 17292: throw a small spring loaded ball electrical continuity between the ball and the valve body is ensured MATERIAL OF CONSTRUCTION The choice depends on the combination of fluid type, pressure rating and design temperature. Carbon Steel and stainless steel, Duplex, Nickel alloys and other exotic material (DIN, ASME or ASTM specification) can be provided.. Finite element analysis are performed to offer customized and effective solution for the specific application. 15

16 2.4.3 SEALING COMPONENTS (STATIC AND DYNAMIC) The choice for sealing components is mainly based on the combination of pressure/temperature from one side and fluid type from the other O RING SEALS O ring are the standard seals (both dynamic and static) for temperature between -46 C and +250 C. Standard sizes from the market (section/id) are used for an easy replacement all around the world. As a standard of construction anti explosion decompression (AED)compound are chosen. For high pressure applications back up rings are used. The choice of the compound is performed by technical department considering both the operating conditions and the type of fluid, in order to ensure performance and reliability for lower maintenance costs: Fluoroelastomers Viton, Hidrogenated nitrile HNBR, Perflouroelastomers (Kalrez), etc LIPSEALS GRAPHITE PACKING AND SPIRAL WOUNDS Standard seals for high temperature applications are: - graphite rings, self energized by fluid pressure, for dynamic seals (seat & packing) - spiral wounds for static seals: they ae made of graphite & SS316 rings, energized at assembly by a pre-compression. O RING SEALS LIPSEALS Lipseals are the standard seals (both dynamic and static)for low temperature application, between C and +250 C. They are made of an elastomeric jacket preenergized by an helicoidal spring that works being self energized by the pressure of the fluid. For high pressure applications back up rings are used. The choice of the compound is performed by technical department considering both the operating conditions and the type of fluid, in order to ensure performance and reliability for lower maintenance costs: Reinforced PTFE (RPTFE) jacket + Elgiloy spring,etc GRAPHITE RINGS & SPIRAL WOUND FIRE SAFE DESIGN Together with the basic seals for different pressure/temperature/fluid applications, fire safe design is possible, upon request, according to API6FA,API 607 and ISO A fire safe design is characterized by the use of graphite based sealing. They can be used as a primary sealing elements and/or as a secondary sealing elements, which can prevent for uncontrolled pressure relief in case of failure of the primary seals, due to excessive high temperatures. 16

17 2.5 RMT CONTROL TRIMS FOR 40 SERIES SERIES: V CUT BALL CONTROL VALVE The 45 series is the V Cut series of ball control valve. The V Cut is the shape of the discovered downstream area. Through the good design of the V is possible to perfectly customize the valve behavior both from a flow capacity point of view (CV) and with reference to the flow characteristic: - V cut may be tailor-suited to process flow requirements: high rangeability, high flow capacity or dealing with low flow conditions is possible (micro V cut); - a near equal percentage behavior is possible; - precise positioning through a low friction design of the whole trim; - capability to deal with dirty fluids, with a nonclogging design; - through the proper selection of materials, treatments and the good engineering of the whole trim, is possible; - dealing with highly erosive applications; - dealing with sour service process conditions: high corrosion resistance materials may be chosen, in compliance with NACE MR0175 requirements. V CUT SEAT RING V CUT ELEMENT ON BALL: INTEGRAL AND SEGMENTED Moreover, the V cut may be performed on the following components depending on the design: - obtained on the seat ring: this is our standard design of construction. Seat ring can be easily replaced with a different V cut design for valve adapting to different process conditions; - obtained on the ball element; - obtained on a V-cut diffuser placed downstream to the valve: DOWNSTREAM V CUT DIFFUSER 17

18 SERIES FOR EXTREME EROSIVE APPLICATIONS: 45SS For applications were severe conditions occurs from an erosive point of view, a special valve design with two seating rings is possible. 45 SERIES FOR EROSIVE APPLICATIONS: 45SS The upstream seat ring (blue marked) is the sealing element. The downstream seat ring is the modulating V Cutted element: it performs the pressure reduction. Immediately downstream this modulating element there will be the minimum passage area, that is the vena contracta, where the fluid reaches the maximum velocities: in this zone there are no internal trim components but only a straight line pipe, so that all the internal parts of the valve are preserved from any erosion problem. The two seat are engineered in such a way that pressure drop occurs only at downstream seating ring, when the upstream seat ring has already being discovered, thus being protected from high velocities occurring during initial modulating phase. Downstream V Cutted seat ring is built with an advanced technique of sintering ceramic powders, characterized by extreme hardness (for instance fully tungsten carbide with 1200 HV). In order to protect valve body a bushing made in the same material is located downstream to the modulating seat ring. This design make possible to obtain: - a great rangeability: we are able to keep the ability of regulate a small Cv (high pressure drop and valve near to closed position) and a high Cv (low pressure drop and valve nearly completely opened). The valve can pass from one condition to another without the need of changing internal trim; this high rangeability is very difficult to be reached with a traditional globe style choke valve; - high tightness performance: since the type of service, high leakage class is required, generally better then class V. Through this special design we are able to ensure leakage performance and reliability for all the service life of the valve; we don t need particular trim solutions (such as bi-tight trim in the globe solutions) to protect from wear the sealing element; - 45SS has been engineered to offer a low torque for a smooth control action; - the no erosion design makes this ball control valve able to deal with two phase flow without problems of erosion due to high velocities related to gas expansion. This ball valve is suitable for severe service conditions typical of a choke service, for instance flashing conditions. 18

19 SERIES: MULTISTAGE BALL CONTROL VALVE It s undoubtable that when extremely high differential pressure occurs into the process, a globe valve solution offer the possibility to control the whole pressure drop with extremely precision. This is the reason why globe valve solution is often the preferred choice in extremely critical operations, such as pump recirculation services, turbine by-pass control valves, etc. Our 43 series has the following purpose: extend the concept of the multi stage design, typical of a globe valve for low noise application or high DP cavitation control, to a ball valve solution. In this way, we are able to extend the typical high Cv of a rotary control valve with axial flow, to moderate severe service applications, in which a standard segmented ball or butterfly control valve can t be used : NOISE ABATEMENT As a regulating device, a control valve is a noise source. In fact pressure waves produced by flow turbulences are responsible of the aerodynamic noise, and it s impossible to control the flow of a fluid without introducing turbulences. Mechanical vibrations are too potential noise sources, but they can be easily avoided for a ball valve through a good design. In fact, comparing to a globe, a ball solution has much less problems of vibrations due to the rotary design of the stem and the consequent lower friction and damage of the packing. Aerodynamic noise is generally a problem to be faced with gases and vapors rather than liquids. Liquids noise matters depends on another more critical phenomenon: the cavitation. For liquids avoiding cavitation means basically to control also the generated noise. Furthermore, noise power is related to the stream power of mass fluid that depends on the square of fluid velocity. And gas/vapors velocities are much more higher than liquids. There are two approach for noise abatement in a ball control valve. MULTIPATH APPROACH Noise attenuation is obtained by breaking the flow into a great number of multiple jets. Physically a multipath trim make possible to decrease the geometrical factor (Fd) of the valve and this permit to shift to higher values the peak frequencies (fp) of the generated noise. The higher will be noise peak frequencies respect to piping ring frequencies (fr),the higher will be the noise attenuation obtainable by the pipe itself (fp>fr). The purpose is to maximize the flow breaking into multiple independent jets. The independence of the flow jets is the greatest limitation of this kind of approach. MULTISTAGE APPROACH Noise reduction can be achieved also with a different technique: the multi-stage approach. If the whole pressure drop is divided into multiple stages of pressure reduction, it will be possible to change in favor of a noise reduction the acoustic efficiency of the valve. Small pressure drops p1/p2 make possible to control fluid expansions and velocities keeping always the last stage in sub-critical conditions. This is mandatory for the noise abatement. Multistage approach is very effective from a theoretical point of view. Unfortunately, it has some practical limitation, related to the number of feasible stages. Furthermore, there are limitations to the obtainable expansion section ratios to proper control the fluid velocities. 19

20 CAVITATION CONTROL Cavitation is a phenomenon that characterizes liquid flow behavior when pressure value becomes lower than the saturation Pv point. When cavitation occurs the liquid begins to flash and steam bubbles are generated. This condition is obtained in the so called vena contracta -where the pressure reach the lowest value and the velocity reach the peak values- before the recovery of pressure that occurs downstream to the reduce passage. Pressure recover, quantified by the parameter FL in IEC standards, cause the bubble to implode when the valve outlet pressure becomes again higher than the vapor tension. Bubbles collapse can seriously damage solid surfaces because of the high amount of energy released with this phenomenon. Cavitation highly affects both performances (vibrations, noise, etc.) and reliability: metal surfaces undergo an inevitable pitting damage if this process is not controlled. In order to face up this problem is necessary to break the pressure drop into a convenient amount of smaller pressure stages inside the ball valve. This is shown in the following. VALVE INLET inlet pressure STANDARD CONTROL TRIM vena contracta area VALVE OUTLET inlet velocity flashpoint outlet velocity outlet pressure velocity pressure vapour pressure VALVE INLET inlet pressure MULTI STAGE CAVITATION CONTROL TRIM vena contracta area VALVE OUTLET inlet velocity flashpoint outlet velocity outlet pressure velocity pressure vapour pressure 20

21 RMT 43 SERIES BALL CONTROL VALVES FOR CAVITATION AND NOISE CONTROL 43 Series has been engineered to offers a strong ball valve solution to face efficiently up both cavitation and noise matters, on the basis of the physical greatness involved in this two phenomena. With reference to cavitation matter, 43 Series make possible to break the whole pressure drop into multiples stages. The adoption of a multiple stage design allow to avoid the cavitation beginning since the pressure is kept always higher than the flashpoint limit, by an engineered control of the fluid velocities. This is obtained by the insertion of parallel perforated plates inside the ball that realize the multiple breaking of the entire pressure drop. During valve moving 43 Series trim act as a variable resistant trim. This make possible to greatly increase valve rangeability. break the flow into multiple jets thus coupling the advantages of a multistage approach with those of a multipath one in the noise abatement, as well described previously. In order to make the plates work properly it s necessary to control the grade of opening for the valve: an optimal opening would be lower than degrees. This is necessary to avoid the fluid to by-pass the plate and reach the downstream side vanishing their effect. The good design of the plates offer our 43 series the possibility to suit the particular process conditions, for a customized design and improved performances. Detailed calculation is always performed and made available to the customer as a guarantee of the good engineering of the valve. Great attention is put into material selection, procurement and quality control. As a brand of GIVA Group, RMT is perfectly integrated with the still mills, forges and foundries of the company. RMT has the full support of an own advance metal testing laboratory located next to the factory. We can guide you through the best choice at the best cost with reference to fluid temperature/pressure combination. 43 SERIES BALL CONCEPT The parallel plates are offset by an optimally designed angle and allow to control fluid velocities thus obtaining an improvement in terms of: - fluid stability, that means better performances and lower and more balanced torques (with consequently gains in term of smaller safety factors and overall cost); - noise emission. Furthermore the engineered design of the holes (disposition, diameter, number, etc) make possible to 43 SERIES BEHAVIOUR 21

22 SERIES: BALL CONTROL FOR EXTREME NOISE CONTROL For extreme noise control, 42 series of ball control valve make use of a downstream attenuator. The goal is a great noise abatement through a multipath approach. Together with the noise reduction the attenuator, that consists in a spherical cage as a standard of construction, make possible vibration control for increased flow and therefore process stability. Downstream spherical cages (one or more) represent fixed stages for pressure reduction. The 42 series cannot face only up noise matters, but it can also be used for liquids. In this last application, attenuator acts as a flow diffuser with stabilizing capability and may help in case of cavitation problems. The variety of orifices in the cage allows to achieve a precise control even with high pressure drop and small flow rate. Shape and number of the openings can be customized to get optimal results in every condition. Noise abatement up to 20 Db is possible with a single cage construction and up to 25 Db with a double cage execution. Standard construction is full bore (to maximize drilled available area of passage) with single seat and single downstream attenuator. Optional constructions are possible to suit customer requirements: - two or more attenuator for extreme control requirements; - reduced passages; - double seat construction; - double block and bleed execution; - bidirectional attenuation capability. Drilled spherical cage can be also located inside the ball element, thus coupling of 43 series variable multistage approach with the attenuation capabilities of the 42 series. 42 SERIES Moreover combination of multiple and fixed stages approaches is possible, for suited solution with the goal of an optimal process control. 22

23 SERIES FLEX DESIGN FOR QUICK CHANGE AND EASY MAINTENANCE In order to make possible quick change of the valve trim easy maintenance where necessary without losing the constructive features and the control capabilities of 40 series, a special flex designed has been designed for the different types of RMT ball control valves: 45,43 and 42 series. This design is characterized by a single seat design and an integral body construction with flange connections. End to end dimensions are according to ASME B16.10 with reference to short pattern design. NPS size up to 12 (DN 300) and rating up to #600 are the standard of construction. Customize size/class combinations may be engineered. Ball valve may be placed and removed from the upstream side of the valve, while the seat ring is kept in position by a retainer ring. During installation, retaining screws and washer are removed and the retainer ring is kept in position through a wafer design between valve body upstream flange and pipeline flange. All the constructive tips of RMT 40 series and all the trim combinations of 45,43 and 42 series may be adopted in this Flex design. 1. BODY 2. RETAINER RING 3. STEM 4. STUD 5. NUT 6. O RING 9. BALL 10. SEAT RING 10. B. SPRING 11. O RING 12. PACKING GLAND 13. PACKING FLANGE 14. STUD 15. NUT 16. PACKING FOLLOWER 17. PIN (NOT SHOWN) 18. COUNTERFLANGE 19. BOLT (NOT SHOWN) 20. LOWER TRUNNION 21. O RING 22. O RING 23. BOLT 24. LOWER FLANGE 25. PIN 71. PACKING 72. PACKING END RING 81. AXIAL BEARING 82. RADIAL BEARING 85. RETAINING WASHER 86. RETAINING SCREWS 87. WASHER 45 SERIES FLEX CROSS DRAWING: INTEGRAL BODY CONSTRUCTION: UP TO NPS 12 (DN 300) AND RATING #

24 3. ACTUATORS AND CONTROLLING DEVICES 3.1 ACTUATORS Pneumatic piston are the standard in actuation of 40 series valves: rack & pinion for size up to 3 (DN80); a working package suitable for customer requirements with the goal of a precise positioning for stable process control, even in the most severe service conditions. Advanced valve diagnostic is available. Smart communication hardware and software provide realtime preventive and predictive diagnostic data. Best brands are available and skilled technicians at complete disposal. scotch yoke pneumatic piston actuators for bigger size and high shut off applications. 3.2 POSITIONERS AND PANELS Advanced digital positioner and controller are available for enhanced performance and control. This make possible improved process yields and real time diagnostic features to offer real-time preventive and predictive diagnostic data. Both HART and Fieldbus communication protocol are available making reference to the best positioner brands on the market. In addition, hydraulic or electric actuators are available on request too. Pneumatic actuator may be of DVG automation construction (a well known sister company inside the industrial group that holds RMT Valvomeccanica) or other main manufacturer. The coupling of correct actuator choice and valve high quality in design and manufacturing make possible to obtain Dedicated positioner s manufacturer software is provided. Great variety of control panel configurations and wide range of available accessories to offer you the best equipment for your 40 Series operation: filter regulators (standard), gauges, solenoid valves, boosters, limit switches, Our technical department is at you complete disposal and skilled technicians are available for service and positioners/control panels trainings. 24

25 4. PRODUCT QUICK SPECIFICATION SIZES* RMT BALL SERIES RATING TABLE up to 48 [up to DN1200] PRESSURE RATINGS* ASME B16.5 up to #2500 [up to PN 420] DESIGN TEMPERATURES* -196 C up to 565 C [-320 F up to 1049 F] *Standard codes of reference: IEC60534 general design code ASME B EN strength design code ISA ANSI/FCI 70-2 IEC60534 tests and inspections RMT BALL CONNECTION TABLE END CONNECTIONS: ASME B16.5 * RAISED FACE RF RING JOINT RJ BUTT WELD SOCKET WELD * Standard codes of reference: IEC end to end dimensions MSS SP-6 surface finishing X X X (not for Flex design) *special on request (not for Flex design) RMT BALL PERFORMANCE TABLE FLOW COEFFICIENT CV RANGEABILITY Up to according to ISA 75 series IEC SEAT LEAKAGE Up to class VI according to ANSI/FCI 70-2 and IEC NOISE AND CAVITATION CONTROL according to ISA 75 series and IEC FUGITIVE EMISSION CONTROL OPERATING PERFORMANCES Up to class A according to ISO according to ANSI/ISA and IEC

26 5. 40 SERIES RATING/CONNECTION TABLES STANDARD 40 SERIES STANDARD 40 SERIES ASME 150 CLASS [PN 20] ASME 300 CLASS [PN 50] ASME 600 CLASS [PN 100] SIZE DN RF RJ THD SW BW RF RJ THD SW BW RF RJ THD SW BW 1 up to 2 3 up to 12 DN25 up to DN50 DN80 up to DN 300 STANDARD 40 SERIES ASME 900 CLASS [PN 150] ASME 1500 CLASS [PN 250] ASME 2500 CLASS [PN 420] SIZE DN RF RJ THD SW BW RF RJ THD SW BW RF RJ THD SW BW 1 up to 48 DN25 up to DN SERIES FLEX DESIGN 40 SERIES FLEX DESIGN ASME 150 CLASS [PN 20] ASME 300 CLASS [PN 50] ASME 600 CLASS [PN 100] SIZE DN RF RJ THD SW BW RF RJ THD SW BW RF RJ THD SW BW 1 up to 48 DN25 up to DN SERIES FLEX DESIGN ASME 900 CLASS [PN 150] ASME 1500 CLASS [PN 250] ASME 2500 CLASS [PN 420] SIZE DN RF RJ THD SW BW RF RJ THD SW BW RF RJ THD SW BW 1 up to 48 DN25 up to DN 1200 * Standard Flange Finish is Ra between 3.2 and 6.3 micrometers [125 and 250 micro inches] * Customized flange faces and surface finish are available on request 26

27 6. MATERIAL SELECTION GUIDE 27

28 As a brand of GIVA Group, RMT is perfectly integrated with the still mills, forges and foundries of the company. RMT has the full support of an own advance metal testing laboratory located next to the factory. Throw the combination of following material tables is possible to suit every condition with reference to fluid/pressure/temperature application. PART DESCRIPTION CARBON STEEL MARTENSITIC STAINLESS STEEL AUSTENITIC STAINLESS STEEL DUPLEX STAINLES S STEEL OTHER STAINLESS STEEL NICKEL ALLOYS 1-2 BODY/ CLOSURE A105 A350 LF2 A350 LF3 *1 *2 A182 F6a (AISI 410) AISI 316 AISI 321 A182 F44 A182 F51 A182 F53 A183 F55 - MONEL 400 INCONEL BODY/ CLOSURES/ BONNET STUD AND NUTS A193 B7 / A194 2H A193 B7M / A194 2HM A193 L7 / A194 GR4 A193 L7M / A194 GR4M *5 *6 *7 - A193 B8 / A194 GR8 A193 B8M/A194 GR8M A182 F51 A182 F53 A183 F55 A453 GR STEM 9-10 BALL & SEAT AISI ENP 75 µm A105 + ENP 75 µm A350 LF2+ ENP 75 µm A350 LF3+ ENP 75 µm *3 A182 F6a (AISI 410) *4 A182 F6a (AISI 410) *3 *4 AISI 316 A182 F XM 19 *4 AISI 316 A182 F XM 19 *4 A182 F51 A182 F53 A183 F55 *4 A182 F51 A182 F53 A183 F55 *3 *4 17-4PH *4 17-4PH *3 *4 MONEL K500 INCONEL 718 MONEL 400 MONEL K500 INCONEL BONNET A105 A350 LF2 A350 LF3 *1 *2 A182 F6a (AISI 410) 13 PACKING FLANGE - - AISI 316 AISI 321 A182 F44 AISI 316 A182 F51 A182 F53 A183 F55 - MONEL 400 INCONEL PACKING FOLLOWER 18 YOKE/ISO FLANGE 23 LOWER FLANGE YOKE STUD AND NUTS - - A105 A350 LF2 (Fe based Zinc Plated) A105 A350 LF2 A350 LF3 *5 *6 A193 B7 / A194 2H A193 B7M / A194 2HM A193 L7 / A194 GR4 A193 L7M / A194 GR4M *5 *6 *7 - AISI 316 AISI AISI A193 B8 / A194 GR8 A193 B8M/A194 GR8M A182 F SPRINGS *1 overlay on dynamic seal areas *2 overlay on wetted areas * 3 hard coating (tungsten carbide or chrome carbide) on seating contact surfaces (120 µm and above) INCONEL 750 INCONEL 718 *4 e lectro nickel plating (25 µm and above) *5 z inc plating (25 µm and above) *6 hot dip galvanized HDG (ASTM A153 or ISO 1461) *7 Fluorocarbon coated 61 AXIAL BEARING PTFE BASED- 62 RADIAL BEARING AISI LOW FRICTION PACKING RING REFER TO PACKING SECTION 8x SEALS REFER TO SEALING SECTION Combination of the above material is possible. Sour service materials and related certifications are possible. Exotic materials, solid tungsten carbide and ceramic materials can be provided for customized trim solutions. 28

29 7. FLOW CHARACHTERISTICS 45 SERIES 43 SERIES 42 SERIES DN Max CV DN Max CV DN Max CV 1'' 45 1'' 32 1'' - 2'' 164 2'' 113 2'' 58 3'' 374 3'' 306 3'' 139 4'' 683 4'' 499 4'' 269 6'' '' '' 636 8'' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' Flow characteristic is equal percentage. Customized solution on specific process condition. 29

30 RMT CONTROLS a division of RMT VALVOMECCANICA GIVA GROUP Via dei Patrioti Solbiate Olona (VA) Italy Ph: Fax: info@rmtvalvomeccanica.com 30