Series 30,000 Metal Seated, Zero Leakage, Rotary Process Valves

Transcription

1 Series 30,000 Metal Seated, Zero Leakage, Rotary Process Valves

2 Company Profile Series 30,000 metal Vanessa has been successfully producing and marketing valves worldwide for almost four decades. After having been a subsidiary of Keystone, the company joined Tyco International Ltd. in 1997 to operate within one of its core business segments, Tyco Flow Control. In 2000, Vanessa became part of Tyco Valves & Controls Italia S.r.l., a leading European valve manufacturing group, which includes the Raimondi and Fasani brand names. In 1975 Vanessa was the first company to introduce the revolutionary metal-to-metal seating technology into the market by offering the Series 30,000 Rotary Process Valve, a unique quarter turn, triple offset, zero leakage valve. This has enabled end users to cover a huge variety of applications in many different industries and has given Vanessa an enviable reputation world-wide. High-cycle thrust bearing The high-cycle thrust bearing assembly rigidly fixes a super hardened thrust washer to the shaft while maintaining an intermediate sliding thrust washer, to extend an already long cycle life. Today, as from its inception, Vanessa is the international leader in the manufacture of high technology rotary process valves. The achievements of the Vanessa valve in the international market have allowed a constant growth of the company. The reasons for its success can be attributed to the use of advanced technology, sophisticated quality control systems and above all the exclusive design of the Series 30,000. Vanessa is committed to a constant improvement of its technology and equipment, an attitude which has contributed to the highest levels of performance of its products and the satisfaction of its customers. Resilient metal seal The flexible, resilient metal seal is located on the disc and is secured but not locked in position, so that the metal seal has the freedom to flex. The seal ring is located with a reference pin. Stellite hard-face seat Hardfacing ensures durability in the broadest range of applications, including higher temperatures and dirtier services. Stellite seat is standard on the complete range of valves. 1

3 seated, zero leakage Rotary Process Valves Reinforced flexible graphite bearing protectors Bearing protectors provide the highest level of protection to the bearings from dirty services while extending service life. Two-piece packing gland assembly with standard, externally retained blowout-proof stem This additional anti-blowout device is in full compliance with the most up-to-date standards, such as API 609. Additionally, Vanessa packing may be flexibly arranged into numerous configurations, including packing and bearing flush or packing monitoring. Fugitive emissions are in accordance with the most stringent EPA and TA Luft requirements. 2

4 Design Features Triple Offset A typical high performance butterfly valve is manufactured with either a single or double offset shaft design. These shaft offsets are created by designing the valve with the shaft located behind the centerline of the sealing surface and slightly to one side of the pipe centerline. The purpose of these offsets is to reduce the rubbing and thus the wear between the seat and seal to approximately 20 degrees of travel. Vanessa adds a unique third (inclined cone offset 3) to allow not only camming, but also to completely eliminate all seat-to-seal rubbing throughout the valve s entire 90 degrees of rotation. Resilient Metal Seal The Vanessa Series 30,000 utilizes a resilient, duplex stainless steel seal ring installed in the disc assembly to provide true zero leakage*. The resilience of the seal ring is achieved through the radial compression of the seal ring as torque is applied to the valve shaft. The seal and seat contact surface is cone-in-cone, where both cones are inclined. The angle of contact between the seal and the seat allows the torque applied to the shaft to radially compress the disc seal ring. By maintaining uniformity of contact angles and elasticity in the seal ring, the entire circumference of the seat is evenly loaded to achieve the tightest shutoff with the least amount of torque. Torque seating allows the Vanessa 30,000 valve to shutoff completely, regardless of the direction of flow or line pressure. * Zero Leakage means no visible leakage during test duration as per API 598 and/or API 6D. ➁ Resilient Metal Seal Ring Offset 2 Achieved by placing the shaft offset to one side of the pipe and valve centerline. The purpose of this offset is to drive away the seal from the seat during the 90 of opening. Before seat contact Offset 1 ➀ Achieved by placing the shaft behind the plane of the sealing surface. The purpose of this offset is to have a continuous seat path. Seated ➂ Design Standards 3 Offset 3 Achieved by inclining the seat and seal cone centerline in respect of the pipe and valve centerline. This third offset completely eliminates rubbing. Any chances of associated wear and leakage between the seat and disc-mounted seal ring during travel are non-existent. Vanessa optimizes the contact angle between the seat and seal for enhanced performance. Most gate valves provide a contact angle of between 3 and 6 degrees. Such designs create a locking taper that can cause dangerously high seating or unseating torques. Vanessa s contact angle is above the locking taper range and its geometry eliminates the possibility of jamming, ensuring the forces necessary to seat or unseat the valve do not substantially vary over the service life of the valve. Quality Assurance: ISO 9001 Environmental Management System: ISO Compliance with: Pressure Equipment Directive PED 97/23/EC, category III. Cat. IV mod. H1 available on request. Design: ASME B16.34, API 609, DIN 3840, EN 593 Face-to-Face: ISO 5752, EN 558, ASME B16.10, API 609 Flange Drilling: ASME B16.5, ASME B16.47, ISO 7005, DIN 2501, EN 1092 Testing: API 598, API 6D, ISO 5208 Fire Test: API 607, 4th Edition Marking: MSS SP 25, EN 19

5 Valve Configuration and options Series 30,000 Rotary Process Valve Cryogenic Configuration Body Styles Double Flanged, Lugged, Buttweld, Wafer Temperature range Cryogenic down to 254 C (-425 F) Body Materials CF8M and other stainless steel materials suitable for cryogenic temperatures. Size Range 3 to 112 (80 to 2,800mm) Pressure Ratings ASME 150 to 900 / DIN PN 10 to 100 ISO PN 20 to 150 Body Styles Double Flanged, Lugged, Wafer, Buttweld. Temperature Range 60 to +450 C ( 425 to F) for stainless steel body material. Other temperatures are applicable depending on valve body material. Body Materials WCB, CF8M, LCB, WC6, CF3M, Duplex, Superduplex, Inconel, Alloy 20, Monel, Incoloy, Hastelloy, C5, Titanium. Features Torque generated elastic metal seal provides zero leakage performance, in compliance with API 598 and/or API 6D. Quarter turn non-rubbing design is achieved by triple offset geometry, completely eliminating all seat to seal rubbing throughout the 90 degree rotation of the disc. Stellite hardfaced standard integral seat results in broader applications, longer valve life and less maintenance. Single-piece cast body, with face-to-face dimensions in accordance to ISO 5752, API 609 and ASME B16.10 provides interchangeability with gate, ball and plug valves. Integral position indicators on the stem and on the top mounting flange ensure positive disc position indication, in accordance with API 609. All metal construction and sealing and zero leakage performance translate into an inherently firesafe valve. Long-length hardened bearings, incorporating a standard reinforced, die-formed, flexible and replaceable graphite bearing protector ensure additional reliability. Internally and externally retained, triple blow-out prevention. Features The metal sealing is virtually unaffected by the very low temperatures: the valve performance and the operating torque are the same at both room and cryogenic temperatures. Standard solid seal ring. The cryogenic valve design includes an extended bonnet, removing the packaging from the cold temperature zone. This minimises the risk of fugitive emissions. Vanessa cryogenic valves are type approval tested according to Shell Tec. Spec. no. T , up to ASME class 600 All valves are tested in the fully equipped facilities for cryogenic testing at Vanessa plant. Ideal for any application involving media at very low temperatures, such as LNG, LPG, liquid hydrogen and liquid oxygen. High Temperature Configuration Body Styles Double Flanged, Lugged, Buttweld Temperature range Up to +815 C (+1500 F) Body Materials WC6, CF8M and other stainless steel materials suitable for high temperatures operations. Features Ideal for high temperature application up to +815 C (+1500 F). Customized to compensate the thermal expansion of the valve components and to withstand the creep of materials at temperatures over 600 C (1112 F). Standard solid seal ring. The extended bonnet helps maintain the packing operating temperature at normal levels, and this greatly reduces any risk of fugitive emissions. The actuator remains protected from extremely high line temperature. The reliability of the valve performance is guaranteed by the appropriate high temperature materials selection. The high temperature configuration is widely used in oil and gas processing, power and chemical fields, usually for services involving hot gases and steam. Steam Jacketed and Traced Configuration Body Styles Double Flanged Temperature range Up to +450 C (+842 F) Body Materials WCB, CF8M. Other materials available on request. Features An excellent configuration to prevent any fluid crystallisation in presence of particular media. The heat diffused by valve body jacket reaches all the critical areas, in particular the valve seat and the bearings area. The jacketed valve is manufactured using the double flanged body style. Vanessa recommends the use of a long face-to face pattern which increases the heating action. The jacket is dimensioned according to ASME Boiler and Pressure Vessel Code. For particularly harsh applications, Vanessa advises to use its Steam Jacketed and Traced Trim configuration. The addition of the traced trim provides an internal heating system obtained by drilling the shaft from top to bottom, to maximise the heat transfer to shaft and bearings. The jacketed configuration is targeted to usage in sulphur recovery units, and in any application with high fluid crystallisation risk. 4

6 Pressure/Temperature Ratings in Barg/Psig ASME B16.34 Maximum allowable temperature for Vanessa basic configuration Notes 1. All Vanessa valves are rated fully in accordance with ASME B16.34 or ISO WCB/ is permissible but not recommended for prolonged use above 800 F/425 C (as per ASME 16.34/ISO 7005) ISO 7005 Pressure (barg) Pressure (barg) Temperature ( C) Weight Comparison with Gate and Ball Valves ASME Class ASME Class 150 WEIGHT (Kg) Gate Valve Ball Valve Vanessa Series 30,000 Double Flanged Configuration 10" 12" 14" 16" 18" 20" 24" 30" 32" 36" Size Temperature Leakage Comparison (Seat Tightness Test) WEIGHT (Kg) Gate Valve Ball Valve Vanessa Series 30,000 Double Flanged Configuration 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" Size 5 Isolation Valves Control Valves FCI and IEC Test Pressure = 1.1 * Design Differential Pressure Test Pressure = 3.50 bar = 50.8 psi All Differential Pressures e.g.: Design p = 51bar (4) e. g.: Trim "C" (Cl. 300) (5) All Pressure Classes (7) Valve Size Vanessa API 598 API 598 FCI/IEC IEC FCI/IEC FCI/IEC FCI/IEC IEC mm inches Standard (1) Metal Seated Metal Seated Class V Class VI Class IV Class IV Class V Class VI (Water) (2) (Air) (3) (Water) (Air) (Water) (Air) (Water) (Air) (6) (6) (6) (6) All leakage values are expressed in ml/min. Notes 1. Vanessa performs seat tightness test on each manufactured valve with water and air in both directions, covering all the requirements of API 598, API 6D and ISO According to API 598 standard, 1 ml of water is equivalent to 16 drops. 3. According to FCI 70-2 and IEC standards, 1 ml of air is equivalent to 6.67 bubbles. 4. FCI 70-2 and IEC leak rates depend on the test differential pressure. 5. Class IV leak rates depend on the valve rated capacity, and therefore they are function of the valve trim rating. 6. Leak rates have been extrapolated using the relationship between seat diameter and leakage factors suggested in Note 2 of Table IV of IEC Class VI leak rates depend on the Nominal Diameter, therefore they are independent of the pressure classes.

7 Inherently Firesafe Design The Vanessa Series 30,000 is an all metal valve complete with metal-to-metal sealing elements. It is considered INHERENTLY firesafe by virtue of the fact that its performance does not change during firesafe simulation tests. Tests have been carried out in accordance with the most stringent international firesafe standard such as API 607 and to the specific requirements of major oil companies such as Elf and Exxon. These tests confirm that the valves performance conforms to the standards and does not vary as a result of the fire. The Vanessa valves tested were ZERO LEAKAGE before, during and after the fire test. 6

8 Series 30,000 Metal Seated, Zero Leakage Rotary Process Valves Sectional Drawing - Basic Configuration DISC BRACKET SEAL SHAFT SOLID SEAL (Optional) PACKING PACKING (Optional) BOTTOM BUSHING 7 THRUST BEARING

9 Materials of Construction (ASTM Standard) Basic Configuration Item Note Description Body in Carbon Steel Body in Stainless Steel 1a Body ASTM A216 WCB ASTM A351 Gr.CF8M 1b Body Seat Stellite Gr.21 Weld Overlay Stellite Gr.21 Weld Overlay 2a Disc ASTM A216 WCB Nickel Plated ASTM A351 Gr.CF8M or ASTM A105 Nickel Plated or ASTM A182 type F316 2b Retainer Flange ASTM A516 Nickel Plated AISI 316 2c Screw ISO 3506 A4 (AISI 316) ISO 3506 A4 (AISI 316) 3a Seal Ring UNS S31803 (Duplex) + Graphite UNS S31803 (Duplex) + Graphite 3b Disc Spiral Wound Gasket AISI Graphite AISI Graphite 4a Shaft ASTM A182 F6a ASTM A479 UNS S20910 (Nitronic 50) 4b Disc Key AISI 410 UNS S c Pin AISI 410 UNS S d Pin Retainer AISI 316 AISI 316 5a Packing Graphite Graphite 5b Spacer AISI 316 AISI 316 5c Packing Bushing AISI 316 AISI 316 5d Stud Nut ISO 3506 A2 (AISI 304) ISO 3506 A2 (AISI 304) 5e Stud Bolts ISO 3506 A2 (AISI 304) ISO 3506 A2 (AISI 304) 6a Bottom Flange ASTM A516 ASTM A240 Type 316 6b Screw ISO 3506 A2 (AISI 304) ISO 3506 A2 (AISI 304) 6c Bottom Spiral Wound Gasket AISI Graphite AISI Graphite 7a Thrust Bearing AISI 316 or AISI 410 UNS S b Thrust Bearing Washer AISI 316 AISI 316 7c Key AISI 316 AISI 316 7d Screw ISO 3506 A4 (AISI 316) ISO 3506 A4 (AISI 316) 7e Unloosening Washer AISI 410 AISI 316 8a Bearing AISI 304 Hard Faced AISI 316 Hard Faced 9a Bracket Carbon Steel Carbon Steel 9b Screw Alloy Steel Alloy Steel Options (available upon request) Bearing Protector 8b Bearing Protector Reinforced Graphite Reinforced Graphite Bearing and Packing Flushing 5h Lantern Ring AISI 316 AISI 316 5m Plug AISI 316 AISI 316 Live Loaded Packing 5n Belleville Spring Alloy Steel Alloy Steel Solid Seal Ring 3a Solid Seal Ring UNS S17400 UNS S20910 (Nitronic 50) Notes : The selection between cast or forged material depends on valve size. : Suggested spare parts. The Vanessa Series 30,000 can be manufactured as standard in the following materials: WCB, CF8M, LCB, WC6, CF3M, Aluminium Bronze, Duplex, 250 SMO. Additionally, the Vanessa Series 30,000 can be manufactured also in the following materials: Monel, Incoloy, Hastelloy, Alloy Steel WC6-WC9, Superduplex, Inconel, Alloy 20, C5, Titanium. Contents may change without notice. Stellite is a registered trademark of Stoody Deloro Stellite, inc. 8

10 Series 30,000 Metal Seated, Zero Leakage Rotary Process Valves Vanessa Series 30,000 Double Flanged Valve With OV Manual Gear HIGH PRESSURE SIDE FACE TO FACE With MAGA Manual Gear HIGH PRESSURE SIDE FACE TO FACE Double Flanged installed on Piping Notes 1. Suggested orientation is with the valve shaft horizontal or inclined from vertical. 2. For service above 200 C (392 F) valve body should be insulated to limit body-to-trim differential temperature to 100 C (212 F). 3. All dimensions are in mm and weight is in kilos. 4. Please consult Vanessa for other sizes. Vanessa has manufacturing experience for much larger sizes than those indicated (for example: 112 /CI.150, 56 /CI.300, 48 /CI.600, 36 /CI.900). Please consult factory for further information. 9 Stellite is a registered trademark of Stoody Deloro Stellite, inc.

11 Double Flanged - Face to Face ISO 5752 Table 1 Col.13 - Body Drilling ASME B16.5 Cl Trim B Size Valve Dimensions Gear Type Gear Dimensions Weight mm inch A B E L FT C I X ØV Valve Total OV OV OV OV OV OV OV OV OV OV OV 400ER Double Flanged - Face to Face ISO 5752 Table 1 Col.13 - Body Drilling ASME B16.47 Series A Cl Trim B Size Valve Dimensions Gear Type Gear Dimensions Weight mm inch A B E L FT C I X ØV Valve Total MAGA 1000C MAGA 1000C MAGA 1000C MAGA 2000C MAGA 2000C MAGA 2000C MAGA 14KR MAGA 14KR MAGA 14KR MAGA 18KR Double Flanged - Face to Face ISO 5752 Table 1 Col.13 - Body Drilling ASME B16.5 Cl Trim C Size Valve Dimensions Gear Type Gear Dimensions Weight mm inch A B E L FT C I X ØV Valve Total OV OV OV OV OV OV OV OV 400ER OV 400ER OV 400ER MAGA 400C Double Flanged - Face to Face ISO 5752 Table 1 Col.14 - Body Drilling ASME B16.5 Cl Trim D Size Valve Dimensions Gear Type Gear Dimensions Weight mm inch A B E L FT C I X ØV Valve Total OV OV OV OV OV 400ER MAGA 400C MAGA 400C MAGA 1000S MAGA 1000C MAGA 2000S MAGA 2000C Double Flanged - Face to Face ISO 5752 Table 1 Col.8 - Body Drilling ASME B16.5 Cl Trim E Size Valve Dimensions Gear Type Gear Dimensions Weight mm inch A B E L FT C I X ØV Valve Total OV OV 400ER MAGA 400C MAGA 1000S MAGA 1000C MAGA 1000C MAGA 2000C MAGA 2000C MAGA 14KR

12 Series 30,000 Metal Seated, Zero Leakage Rotary Process Valves Double Flanged Body Style (Face-to-Face ASME B16.10) HIGH PRESSURE SIDE Lug Body Style FACE TO FACE HIGH PRESSURE SIDE FACE TO FACE Wafer Body Style HIGH PRESSURE SIDE Double Flanged Body Style (Face-to-Face ASME B16.10), Lug and Wafer installed on Piping FACE TO FACE 11

13 Double Flanged - Face to Face ASME B16.10 Table 1 Col.7 Body Drilling ASME B16.5 Cl Trim B Size Valve Dimensions Weight mm inch L N FT Valve Total Double Flanged - Face to Face ASME B16.10 Table 2 Col.10 Body Drilling ASME B16.5 Cl Trim C Size Valve Dimensions Weight mm inch L N FT Valve Total Lugged - Face to Face API 609 CL.150 Body Drilling ASME B16.5 Cl Trim B Size Valve Dimensions Weight mm inch L N Valve Total Lugged - Face to Face API 609 Cl. 300 Body Drilling ASME B16.5 Cl Trim C Size Valve Dimensions Weight mm inch L N Valve Total Wafer - Face to Face API 609 Cl.150 Body Drilling ASME B16.5 Cl Trim B Size Valve Dimensions Weight mm inch L N Valve Total Wafer - Face to face API 609 Cl. 300 Body Drilling ASME B16.5 Cl Trim C Size Valve Dimensions Weight mm inch L N Valve Total Notes 1. For the dimensions A, B, E, and for Gear Selection and dimensions, please refer to the relevant figures in the previous Double Flanged tables. 2. Suggested orientation is with the valve shaft horizontal or inclined from vertical. 3. For service above 200 C (392 F), valve body should be insulated to limit body-to-trim differential temperature to 100 C (212 F). 4. All dimensions are in mm and weight is in kilos. 5. Please consult Vanessa for other sizes. Vanessa has manufacturing experience for much larger sizes than those indicated (for example: 112 /CI.150, 56 /CI.300, 48 /CI.600, 36 /CI.900). Please consult factory for further information. 12

14 Superior Manufacturing Expertise Vanessa valves are manufactured at our technologically advanced, purpose-built factory in Northern Italy, where the 30,500 square metre site incorporates: 11,500 sq. m. manufacturing area (of which 1200 sq. m. is the new Integrated Manufacturing Cell see details below) 1,800 sq. m. office accommodation. The utilisation of advanced 3D design software, state-of-the-art machine tools and the most modern production process technology ensures the consistent levels of high performance and quality of production for which Vanessa is well known. Surface treatment system using water based, environmentally low-impact, anticorrosive products Ultrasonic bath cleaning equipment specific for valves in oxidative services Three dimensional measuring machine for maximum measuring accuracy Magnetic particle examination equipment & Spectrotest meter for positive material identification Helium mass spectrometer analyser. Advanced manufacturing facilities include: CNC flexible machining centres for turning, drilling and milling of bodies and discs for all sizes Horizontal CNC boring machining centre with multi-pallet station to machine bodies and discs up to very large sizes (up to 92 ) Welding robot system equipped with several welding stations Full cryogenic testing facilities in-house Final testing machines for any valve size complete with digital instrumentation to monitor the seating torque Quality Audits The Vanessa plant operates under a Quality Assurance system which is in accordance with UNI EN ISO The plant has held approval certificates for many years, from both major customers and independent authorities such as: Det Norske Veritas, Italy (ISO 9001) TUV (Ad-Merkblatt HP 0 TRB 801 nr.45) In addition, DNV has certified the plant to be in compliance with the standard for Environmental Management Systems (UNI EN ISO 14001). Integrated Manufacturing Cell (IMC) The company has invested in a fully independent production facility, known as the Integrated Manufacturing Cell (IMC). The IMC has been conceived as a focused factory, to concentrate exclusively on a selected range of valves (ND 3-24 Cl ) and incorporates advanced manufacturing techniques based on Demand Flow Technology (DFT). Utilising Kanban process systems under a Total Quality Control (TQC) programme, has enabled Vanessa to reduce the manufacturing lead time for the target product range to 2-4 weeks, ex works. 13

15 Industries and Applications Vanessa valves have an impressive track record of service in both isolation and control applications in all process industries including: Oil and Gas Processing Offshore Platforms Refineries Hydrocarbons Storage and Transportation Liquid Natural Gas (LNG) Storage and Transportation Chemical and Petrochemicals Plants Power Generation District Heating Pulp and Paper Steel Mills Sugar Mills Desalination Plants Water Treatment and Distribution Vanessa has extensive experience of supplying valves for a wide variety of fluids including: Hydrocarbons Steam (Saturated and Superheated) Geothermal Steam Hydrogen Oxygen Cryogenic Fluids Hot Gases Sulphur (Tail Gas) Chemical Solvents Chlorinated Solvents Flare Gas 14

16 TycoValves & Controls Italia S.r.l. Vanessa Manufacturing Plant Via Piacenza Lugagnano Val D Arda (Pc) Italy Tel: Fax: VANLT EN