MV1 Cert. No. 224939 License No. 6D-0840 0062 Malaysia s 1st API 6D Ball & Gate Valves & Actuators Manufacturer
INTRODUCTION MIR VALVE Sdn. Bhd. (MIR VALVE) was incorporated on 27 December, 2006, obtained its Manufacturing License on 5 July 2007 and commenced business operations on 1 August 2007. MIR VALVE is the 1st Malaysian company to design, manufacture and supply a complete range of API 6D Ball & Gate Valves and actuators for the oil, gas, petrochemical and power industries. Our proud achievement of making the mission possible was through much hard work and dedication of the experienced and qualified personnel and concerted assistance from AST S.p.A, our established Italian technology partner cum shareholder (20% shareholding), via a 20-year Technology Agreement. Our modern plant is located at Lot 3-4, Jalan Tanjung Keramat 26/35, Section 26, Shah Alam, Selangor, Malaysia, which is only 30 minutes drive from Kuala Lumpur city centre. Both the KLIA International Airport and Port of Klang are 45 minutes drive from the plant. Our manufacturing and quality management systems have obtained ISO 9001:2000 (Certificate No: 224939) and CE-PED certification from Bureau Veritas. The American Petroleum Institute (API) has awarded us an API License (License No: 6D-0840) for our manufactured ball and gate valves to carry the API monogram. OUR PROMISE Our principal business charter is customer satisfaction. Our commitment is to provide our valued customers with products and services of the highest quality, on-time delivery and competitive price. We are fully committed to provide the same high level of attention for any phase of the product life; from quotation to field service. 1
OUR PRODUCT MIR top-entry ball valves are suitable for various applications. Installations include for exploration fields and transportation system for oil and gas. MIR top-entry ball valves are manufactured with favorable combination of design and quality elements. Demanding market and technological requirements have been adhered to during our design and manufacturing of the valve. PRODUCT RANGE Class 150 300 400 600 900 1500 2500 Size 2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 40 42 46 48 54 56 60 MV1-1 MV1-2 2
GENERAL INFORMATION APPLICATION Our top-entry ball valves are manufactured for a wide range of diameters and pressure classes. In the standard version, these valves are suitable for transmission pipelines, pumping, compression and re-injection units, offshore platforms, onshore terminals, pig traps, measuring stations and surge reliever skids. Our top-entry ball valves have complete flexibility in the use of materials for body and trim, along with seal gasket selections. Hence, they are suitable for the most severe applications encountered both onshore, offshore and in the process industry. They are also sized to withstand the external loads from the pipeline or from the manifolds even when the bonnet, the ball and the seats are removed for maintenance. They can be welded directly onto the pipeline or the manifold assembly. The bonnet-body construction uses various grades of carbon steel, stainless steel and alloys for the most severe service conditions. Our top-entry ball valves can also be adapted for special applications such as abrasive fluids, low temperature service, sequencing service (low and high tmperature), subsea installations and LNG plants. 3
DESIGN FEATURES STANDARD FEATURES Triple-barrier stem seals Factory positioned external stops Anti-blow-out stem design Stem emergency grease fitting Low friction metal-backed self- lubricating PTFE sleeve bearings and thrust washers Trunnion-mounted ball Plastic polymer insert for seat sealing Double-Piston-Effect seats (DPE) Relief valve in the body cavity Electroless nickel coating on pressure controlling parts and stem Body thickness in accordance with ASME B16.34 End flange ensions in accordance with API Standard 6D In-line maintenance BODY/BONNET CONSTRUCTION The body to bonnet joint is sized in accordance to ASME VIII Div. 1. The ASME B16.34 body thickness makes the structure of the pressure containing parts extremely robust, allowing for a wide selection of gasket types to be utilized whenever required ( i.e. low temperature sour gas). It also allows for the inclusion of additional grapite seals to further guarantee the tightness under fire conditions. OPTIONAL FEATURES Self-relieving seats Lubricated seats Features for vertical installation Special flanges or end connections in accordance with customer s requirements Special face-to-face and bore sizes PTFE spring-energized lip seals for stem sealing. Anti-static device Metal-to-metal seat sealing Double-block and bleed Explosive decompression resistant seals. Fire-safe graphite gaskets Inconel 625 ovelay on sealing areas 4
DESIGN FEATURES SEAT SEAL The standard design of the seating surfaces of our top-entry ball valves features a plastic insert which ensures low friction and effective performance throughout the life of the valves. Since the seat rings are floating and the ball is trunnion mounted, the sealing at low pressure is ensured by the seat springs. The block-and-bleed and the double-block and-bleed (DBB) features are available on all sizes and classes of our top-entry ball valves. DPE seats are standard on our top-entry ball valves. Hence, in the event that one seat is damaged, the other seat is still able to seal (double barrier in both directions). Whenever otherwise required, the valve can be supplied with self relieving seats. Independent sealing on upstream and downstream seats is also available upon request. STEM CONSTRUCTION The stem construction can either be integral with the ball or separate from the ball depending on the type of service and trim materials selected. In either cases, the stem anti-blowout configuration prevents stem ejection by internal pressure. Due to the stem to ball rugged connection, the maximum allowable drive train torque easily exceeds the requirements of the API Standard 6D. The stem design includes a triple barrier sealing system (O-rings and graphite rings), which is provided as a standard configuration. The outer seal can be replaced with the line under pressure, provided that the body cavity is fully vented. Sealant can be injected into the bonnet cover through a grease injection fitting, to allow temporary sealing until required maintenance is carried out. BALL POSITION For lever-operated valves, the open and closed positions are assured by corresponding stops on the bearing housing. The stops of the either manual or powered operators fitted onto the valves are usually set at the factory as primary stops. Open and closed indicators are also provided. FULL IN-LINE MAINTENANCE Our top-entry ball valves are designed to be maintained in line. The bolted construction allows disassembly on-site for inspections and possible repairs. Clearing the bonnet off the valve allows free access to the ball and the seats, which can simultaneously be taken out without the need for any special maintenance tools. Very little space is required around the valve body, hence allowing our top-entry ball valves to be installed in areas where space is a limiting factor. For maintenance, the tightness of the seating surfaces can be assessed by pressurising the body cavity before any repressurisation of the pipeline. 5
DESIGN FEATURES VALVE ASSEMBLY & CROSS SECTION 132 160 131 9 32 189 10 134 123 136 97 150 5 142 287 325 307 135 6 168 8 4 20 31 1 39 Item Description 1 Body 4 Ball 5 Stem 6 Seat Ring with Insert 8 Body O-Ring 9 Bonnet Cover 10 Bushing 20 Lower Bearing 31 Body Stud 32 Body Nut 39 Drain Valve 97 Bonnet 123 Stem Key VALVE PARTS Item 6 Description 131 Bonnet Cover Capscrew 132 Adapter Plate Capscrew 134 Stem O-Ring 135 Seat O-Ring 136 Bonnet Cover O-Ring 142 Spring 150 Upper Washer 160 Adapter Plate 168 Upper Bearing 189 Stem Grease Fitting 287 Spring Holder Ring 307 Seat Thrust Ring 325 Seat Thrust Ring Gasket
MATERIAL SPECIFICATIONS MATERIALS SELECTION The quality of the valve depends also on the material selection. Our top-entry ball valves are designed in accordance with material requirements in API Standard 6D and allows for the selection of various combinations of materials upon service conditions. After reviewing the service conditions, the selection is carried out with respect to the mechanical and chemical characteristics of the materials. A complete bill of materials is submitted at the quotation stage addressing each component. WELD OVERLAYS In case of corrosive service, sealing surfaces and other critical parts of the valve can be weld overlaid. Most used materials are AISI 316L and Inconel 625. The process is qualified, so that the final thickness after machining can guarantee the chemical composition as per the relevant ASTM Standard. NDT is then carried out by the PT method. NACE REQUIREMENTS On request, MIR top-entry ball valves can be supplied in accordance with NACE MR0175 requirements. SEVERE WET SOUR GAS SERVICE Compliance with requirement in NACE MRO 175 requirement. For resistance to sulfide stresscracking, the following specification are met: DUPLEX STAINLESS STEELS METALLURGY met: qualification tests are available:
DESIGN SPECIFICATIONS Design : API 6D / ISO 14313 ASME VIII-2, AD-132.1 MESC, PETRONAS, EPEMI Body Thickness : ANSI B16.34 Maximum Allowable Structure Torque (Mast) Sizing : Bolting : Fire Safe : API 6D / ISO 14313 ASME VIII-2, II-2, AD-132.1 Guarantees the weakest es point of drive train is external of valve s body ASME VIII-2, II-2, AD-132.1, ASME B16.34 ISO 10497 / API 6FA / BS 6755 PT.2 Top Works : EN ISO 5211 Face To Face Dimension : API 6D ANSI B16.10 End Connections Flange End - ASME B16.5 Weld End - ASME B16.25 Hub End - PROPRIETARY 15
ENGINEERING DATA VALVE TESTING Leakage Rates Standard Soft-Seated Metal-Seated Cryogenic API 6D ISO 5208 Rate A ISO 5208 Rate D (1) (1) Please consult MIR VALVE personnel Standard Performance Tests Visual & dimensional check High pressure hydrostatic shell test High pressure hydrostatic seats test Low pressure air seats test Stem torque check Rating & Test Pressures at Ambient Temperature ASME RATING (1) BODY TEST H.P. SEAT TEST AIR SEAT TEST CLASS psi bar kg/cm² psi bar kg/cm² psi bar kg/cm² psi bar kg/cm² 150 275 19 19.3 413 28.5 29 303 20.9 21 100 6 7 300 720 50 51 1080 75 77 792 55 56 100 6 7 600 1440 99 101 2160 148.5 152 1584 108.9 111 100 6 7 900 2160 149 152 3240 223.5 228 2376 163.9 167 100 6 7 1500 3600 248 253 5400 372 380 3960 272.8 278 100 6 7 2500 5988 413 421 8982 619.5 632 6587 454.3 463 100 6 7 (1) Typical only - Rating pressure may change for different materials. Conversion Factors 1 bar = 14.50 psi & 1 bar = 0,981 kg/cm² & 1 bar = 100 kpa 1kg/cm² = 14.22 psi 1 F = ( 1.8 x C ) + 32 & 1 C = ( F - 32 ) / 1.8 PRESSURE TESTING TO API 6D Type Part Sequence Area Pressure (1) Duration (1) Description A 1.5 x P.R (2) NPS 6 ~ NPS 10 Shell hydrostatic test with valve half-open as follows ; 5 Minutes *obtain hydrostatic test pressure* reduce pressure by B 1.5 x P.R (2) NPS 12 ~ NPS 18 50% reset hydrostatic test pressure after stabilization 15 Minutes and hold it for the duration. C 1.5 x P.R (2) NPS 20 ~ NPS 60 30 Minutes HYDROSTATIC SEAT SHELL A B C 1.1 x P.R (2) A 1.1 x P.R (2) B C A 5 Minutes 5 Minutes Seat seal test at "C" end towards body "B" Seat seal test at "A" end towards body "B" B 5 Minutes Seat air seal teat at "C" end towards body "B" AIR (3) C A 80 psig (5.5 bars) 80 psig (5.5 bars) B 5 Minutes Seat air seal teat at "A" end towards body "B" C (1) Minimum values (2) P.R. = Pressure Rating (3) Supplementary test to be carried out on request Blue = Liquid Yellow = Air 16
ENGINEERING DATA QUALITY STANDARDS American Petroleum Institure - API API 6D API 6FA API 598 API 607 API 605 American Society of Mechanical Engineering - ASME ASME B 16.5 ASME B 16.10 ASME B 16.25 ASME B 16.34 ASME B 31.33 ASME B 31.8 ASME B 46.1 International Organization for Standardisation - ISO ISO 9001:2000 ISO 14313 ISO 5211 ISO 10497 17
MATERIAL SPECIFICATIONS BODY AND TRIM MATERIAL BOLTS & NUTS 18
MATERIAL SPECIFICATIONS SEAT INSERT & SEALS MATERIAL OPERATING LIMITS MATERIAL TEMPERATURE OC PRESSURE CLASS MIN. MAX SEAT INSERT SEAL SEAT INSERT NYLON SMX -40 120 2500 N/A NPS 60 N/A NYLON 12-G ( LAURAMID) -60 100 2500 N/A NPS 60 N/A NYLON 6 ( DEVLON-V API) -60 140 2500 N/A NPS 60 N/A PEEK -60 220 2500 N/A NPS 36 N/A PTFE GLASS FILLED (25%) -100 200 600 N/A NPS 24 N/A PTFE CARBON FILLE D (25%) -100 180 300 N/A NPS 24 N/A PCTFE -196 150 2500 N/A NPS 36 N/A HNBR - Therban -40 150 600 2500 NPS 60 NPS 60 FKM A ( VITON A) -29 180 600 2500 NPS 60 NPS 60 FKM GLT (VITON GLT) -40 180 600 2500 NPS 60 NPS 60 FKM AED ( VITON AED) -29 180 600 2500 NPS 60 NPS 60 PTFE+ELGILOY SPRINGS -196 200 N/A 2500 N/A NPS 36 FIRE SAFE GRAPHITE -240 520 N/A 2500 N/A NPS 60 SIZE SEAL PLATING / COATING NACE REQUIREMENTS 19
QUALITY QUALITY ASSURANCE PROGRAM We operate under a high level quality assurance program to ensure all our products are designed and manufactured to the highest standards available, using the latest technology. MIR Quality Assurance Program covers the entire operation, from order entry to final inspection and field service in accordance with: Cert. No. 224939 License No. 6D-0840 0062 HIGH PRESSURE GAS TESTING rate (if any) is verified by means of a mass spectrometer. Leakage through the seats (if any) is verified performed to customer s specified critical conditions. We have maintains test facilities for various valve sizes and classes. INSPECTION AND TESTING requested. ISO 9001 : 2000 / CE-PED / API 6D / FIRESAFE / ATEX CERTIFICATES 20