Control Valve Styles
Control Valve Styles
6.3.1. Control Valve with safety function Type 3241-1 and Type 3241-7 ��������������020
6.4.1. Control valves with forged steel or forged stainless steel bodies ��������������025
6.10.11. Angle Valve for Urea and Melamine Type 3256 S ��������������������������������� 125
6.10.14. Control Globe and Angle Valve Type RVG Flange �������������������������������� 134
6.10.15. Control Globe and Angle Valve Type RVG with Multi-stage plug ���������� 136
6.10.16. For natural gas and offshore applications Valve Type VNG ����������������� 137
6.11.2. Spray Water Nozzle for steam temperature reduction with continuous
control ������������������������������������������������������������������������������������������������������� 147
6.11.3. Spray Water Nozzle for steam temperature reduction with continuous
control ������������������������������������������������������������������������������������������������������� 148
6.11.4. Steam converting valves ������������������������������������������������������������������������� 152
6.17.3. Ball valves seat ring and gasket principles: �������������������������������������������� 183
6.17.5. Forged steel Ball Valves produced by Company Starline Spa ����������������� 192
6.17.5.5 Floating �������������������������������������������������������������������������������������� 197
6.17.5.16 Trunnion �����������������������������������������������������������������������������������208
6.21.1. PTFE coated Ball and Butterfly Valves sizing and application limits. ������269
6.22.1. What is a rotary plug valve and what are its advantages? ���������������������� 276
Diaphragm Three-Way
Pinch or Clamp
Full Ball
Valve Style
Ball
Segmented Ball
Centric
Triple eccentric
Cylindrical Plug
Eccentric Plug
A first essential distinctive characteristic or feature is the movement of the throttling part,
the so-called obturator or plug. It executes either a linear movement as for globe valves,
or a rotary movement between 50° and 90° as for butterfly valves or ball valves.
To the group of control valves with a linear movement of the plug belong the so-called
standard globe valves which are available in numerous valve options. The rated travel of
these valves is usually between 10 and 100 mm. The rated travel are fixed for SAMSON
on nominal size in steps of 7.5, 15, 30, 60, and 120 mm.
With control valves of the second group the plug makes a rotary motion, meaning that
the actuator drives the valve shaft with a rotary motion usually within a maximum range
of 90 degrees. Butterfly valves, rotary plug valves as well as ball and cock valves belong
to this group.
Figure 6.1.-2: Globe valve (left), Angle valve ( middle), and Three-way valve (right)
Another important differentiating feature is the shape or style of the valve body and the
manner in which the pipe is connected to the valve body. Most common valve styles are:
Standard globe valve for installation into a straight pipe,
Angle valve for installation into a pipe moved around 90 degrees,
Three-way valve with three pipe connections for mixing or diverting fluids.
Another distinctive characteristic is, in addition, the manner in which the obturator or plug
is guided:
Plug guided on both sides
Plug guided only at the top
Finally, the trim of the control valve is a critical and distinctive characteristic. One
differentiates here between:
Single-seated type
Double-seated type
Trim with pressure balance
Low noise trim etc.
Furthermore a typical differentiator is the manner of connection within the rigid piping
system, in order to enable an easy interchangeability of the control valve:
Flanged connection with numerous variants
Screwed connection (for small nominal sizes only)
Welded connection (preferred in power stations)
Other end connections (e.g. clamped)
The essential control valve constructions are briefly explained below, normal availability
with regard to nominal sizes and pressures is indicated and the typical advantages and
disadvantages of the different designs are listed in table 6-1.
Valves
Self operated
Control Valves
controller
Figure 6.2.2.-1: Single seated valve with top and bottom guided plug and four flange body
The self-acting closing or opening of the valve with failure of the auxiliary energy is
achieved by a return spring in the pneumatic actuator. The predetermined fail safe position
plays an important role in the process automation industry. Since pneumatic diaphragm
actuators were, in the early days, not yet reversible, the reversal had to be carried out in
the valve itself, i.e. bottom flange and bonnet flange had to be exchanged and the valve
body turned around 180° in relation to the center of pipe.
The plug had internal threads on both sides so that a connection with the valve stem also
became possible in the opposite position. After the assembly of the actuator in its new
position, the fail safe position was thus reversed by this procedure, i.e. a control valve
formerly open at air failure was changed into a closed valve, on air failure.
Pneumatic controllers and diaphragm actuators were always fitted with the standard
spring range of 3 to 15 psi or 0.2 to 1.0 bar at comparatively low supply pressures.
However, often the actuator force resulting from this configuration was so low, that a
single seated valve (Figure 6.2.2.-1) above DN 50 could frequently not close against the
actual differential pressure. This led to the development of the double seat valve type
which enables a pressure balance and requires only moderate actuator forces. This valve
type was therefore applied particularly with large nominal sizes and with high pressure
differentials (Figure 6.2.3.-1).
Figure 6.2.3.-1: Double seated valve with flow through both valve seats1
1 http://www.arca-valve.com
Double seated valves with two seats and two throttling areas are not only complicated and
very expensive at the production process stages but also revealed serious weaknesses
in practical applications:
A high seat leakage could be caused by production inaccuracies and thermal influences.
Actually, the double seated plug is in direct contact with only one of the associated seat
rings. The other plug part touches the seat only in exceptional circumstances, because
a really exact fit for reasons of different thermal expansions of valve body and plug is
not achievable.
With double seated valves the differential pressure acts on one of the plugs in an
opening direction and on the other plug in a closing direction. With a static consideration,
i.e. valve closed, the forces resulting from the fluid pressure are almost balanced.
Under dynamic conditions, however, considerable forces can appear which may lead
to instabilities and poor control.
In flow to close applications, as it happens (unavoidably) at one of the two seats, there
is an unfavorable set of conditions with regard to unpredictable whistling even at small
pressure differentials as well as heavy stem vibrations at higher pressure differentials
and in case of liquids early cavitation and noise generation.
This problem led to the development of pressure balanced three-flange-valves. This type
is applied today more often with big nominal sizes and high pressure differentials. The
guides and seat diameters are approximately the same and the piston type plug contains
a pressure balancing hole. One or more piston rings in the guiding shaft avoid a major
escape of the fluid to the low pressure side of the valve.
The higher seat leakage of pressure balanced valves is - as for double seated valves
- an unavoidable disadvantage of this construction. In this case the leakage is mainly
determined by the accuracy of fit and the slot width of the metallic piston rings.
p1
p2
p1
Figure 6.2.4.-1: Standard valve with three-flange body and pressure balanced plug (previous version)
New version
With graphite With PTFE
Ring nut sealing ring sealing ring
Screwed-on
carrier element
Pressure balancing
holder, screwed
Advantages:
Retrofit
Higher leakage classes for
PTFE max. Class V, for Graphite
max. Class IV possible.
Adjustable pre-stressing of
sealing rings after assembling
with Ring nut or clamping ring.
Figure 6.2.4.-3: Pressure balancing for 150 mm seat bore and larger
The design of the pressure balancing for the Series 3240 and 3250 Valves was changed
fundamentally.
In contrast to the previous pressure balancing system, the carrier element in the new
design is now screwed to the bonnet. When an old pressure balancing is to be replaced
with a new one, the bonnet with carrier element must be changed.
The PTFE or graphite seals are pressed into their proper position by a ring nut or a
hexagonal bolt. With PTFE pressure balancing, a coil spring is used to achieve a defined
force. Friction values for actuator sizing remain unchanged. The new pressure balancing
is available for 80 mm seat bore and larger, with Cv100 - value / Cv120 - value. For further
restrictions refer to the Cv100 - value tables in the associated data sheets.
Anti cavitation design, minimized number of parts - reduced spare cost, seat guided
plug with screwed in the seat.
The pressure balance design is unique due to the sealing elements in the bonnet top
work which avoid dirt attacks in the throttling area.
Figure 6.2.4.-4: Globe Valve Type 3251 with AC-1 trim NPS 8, Class 600, pressure balance.
①
② ①p1
③
p2
②
p1
Principle drawing of a pressure balance Dirt and slimes are above the sensitive
trim system, which is not dirt sensitive. guiding gap and can cause jamming. ①
The guiding gap and sealing element Suitable only for clean fluids.
① are above the critical zone of dirt and The retainer need a sealing gasket and
slimes location. ② a spiral wound gasket ③ for balancing
Minimized number of parts - reduced the retainer elongation in case of
spare cost seat guided plug with temperature changes.
screwed in seat design. Many parts and gaskets. Very high
spare cost.
Figure 6.2.4.-5: SAMSON pressure balance Figure 6.2.4.-6: Cage retained seat pressure
(principle drawing) balance design
Thanks to the new design, the leakage class for PTFE and graphite pressure balancing
of plugs with metal seal is increased to leakage class IV. For PTFE pressure balancing of
high-performance plugs with metal seal, the leakage class is increased to leakage class
V (formerly lapped-in plugs).
The pressure balance design of SAMSON is not comparable with the traditional pressure
balanced cage retained seat valve of other valve manufacturers.
The unique features of the SAMSON pressure balance design versus common cage
retained seat valves of other manufacturers are shown inFigure 6.2.4.-4, Figure 6.2.4.-5,
Figure 6.2.4.-6 and Figure 6.2.4.-7.
②
①
Traditional cage design suitable only for Lack of commissioning under time
clean fluids. pressure:
① Spiral wound gasket and an additional No proper pipe and valve flushing
flat gasket process take place before start up; no dirt
② Pressure balance sealing system filters installed at valve upstream for a
(friction loaded) longer operation time after start up.
The traditional cage pressure balance type is applied today more often with bigger nominal
sizes and higher pressure differentials. The guides and seat diameters are approximately
the same and the piston type plug contains one or several pressure balancing holes.
Soft sealing rings, metallic piston rings or double seat design (Figure 6.2.4.-6) in the
guiding shaft or piston avoid a major escape of the fluid to the low pressure side of the
valve. The higher seat leakage of pressure balanced valves is - as for double seated
valves - an unavoidable disadvantage of this construction.
The leakage is mainly determined by the accuracy of fit and the slot width and the
compression of the soft (O-ring, PTFE-, Graphite sealing element) or metallic piston rings
sealing system Figure 6.2.4.-7.
In contrast to earlier decades of the common leak Class III for pressure balance in our
days metal to metal seat leak rates of Class IV and V are more often required in the oil
and gas industry.
This means for class IV and V leak rates a more narrow slot width and additional high
compressed sealing elements replacing the design of Figure 6.2.4.-6. The cage balanced
trim system also becomes more sensitive to dirt and pipe forces, which calls for rigorous
anti-dirt measures like a traditional pipe flushing process during commissioning and dirt
filters for the first operation time as well as pipe force compensators in case of high
temperatures.
Here the cage shaped, fix clamped guide bushing has different purposes:
It guarantees the piston-shaped plug an extremely stable guiding over its complete
travel. For this reason this construction is particularly suitable for high differential
pressures.
It enables, by design, dimensions, profile and number of window openings, the desired
characteristic of the control valve. Usually the cage has (dependent on the nominal
valve size) between 2 to 8 opposingly placed windows.
The retainer need a spiral wound gasket for balancing temperature material elongation
and an additional flat gasket for sealing in contrast to Figure 6.2.4.-6. Risk of body
leak, if the spiral wound gasket is not replaced after it`s life cycle time.
Cage retained seat pressure balanced trim, where the dirt sensitive guidance gap
is located below possible dirt and slimes attacks. See Figure 6.2.4.-7. Lack of
commissioning. Many parts and gaskets. Very high spare part cost.
Manufacturer independent:
High trim system friction if seat leak rate class IV (V) is required.
For an acceptable long term controllability another actuator sizing philosophy should
take place in general.
An actuator sizing of a balanced system only for the maximum shut down pressure
results in too small actuator sizes. To overcome the high friction of the balanced trim
system needs a high actuator stiffness as a result of the diaphragm area multiplied
with the spring signal range. For an acceptable controllability of the valve-positioner
system only a much larger actuator size can limit the hysteresis to a recommended
value below 30%. See sizing example of „Chapter 18.2 Calculation and selection of
a control valve for steam“.
The demand to reduce manufacturing cost and to permanently improve devices in process
automation industries led to a new valve type in the seventies, namely the so-called “easy
series” with a particularly light weighted three flange valve body and a top guided plug.
Because of vibrational tendencies of seat sizes > 1 inch SAMSON AG had developed a
more beneficial top and seat guided plug for all globe valve Series 3240 and 3250 and
furthermore the first compact multi-spring pneumatic actuator. Series 3240 was the world
most compact globe control valve in that time. See Chapter 6.3.
During nearly four decades Series 3240 became a leading control valve in the chemical,
pharmaceutical and food & beverage industry and was continuously updated to the
demands of larger plant sizes, stronger fugitive and noise emission regulations, and to
more effective severe service solutions for the oil-and gas industry. Today Series 3240
suits the majority of applications in the industrial process automation industry and provides
an optimal cost/performance ratio (Figure 6.2.-5).
For the majority of standard applications where ∆p is limited to 10 bar SAMSON AG in
the last decade again launched in the market the most economical control valve system
called V2001. See Chapter 6.5.
The plug stem of Series 3240 is guided in the valve bonnet, and the V-Port plug in the
screwed-in seat Figure 6.2.-5. The ports of the V-Port plug are asymmetric in order to
suppress any oscillations.
These features corresponded particularly well to
the requirements of the chemical industry with
costs as low as possible, compact dimensions
and low weight, but otherwise a comparable
functionality with former valve series. At this
time new demands were also highlighted with
Guide regard to the protection of the environment
which was almost unknown in those days:
High level of tightness,
Noise level as low as possible,
Ecologically beneficial valve materials.
These new „standard control valves“ are mostly top-guided and single-seated, in order to
achieve compact dimensions, low weight and tight shut-off capabilities, i. e. leakage rates
in accordance with class IV or better.
Thanks to their modular design, the control valves can be equipped with various
accessories: positioners, limit switches, solenoid valves and other accessories
according to IEC 60534-6 and NAMUR recommendation.
The most common pneumatic diaphragm actuator corresponds today (with reverse fail-
safe action, air-to-open) only in rare cases to the standard signal or spring range of 3 to
15 psi or 0.2 to 1.0 bar, because pneumatic or electro-pneumatic positioners are almost
obligatory. These devices provide an exact positioning of the valve stroke in relation to
the electric or pneumatic input signal, independent of the spring range of the actuator.
Advances in the design of synthetic rubber materials and corresponding fabric inserts
allows nowadays extreme environmental temperatures between - 60°C to +130°C and
high supply pressures up to 90 psi or 6,0 bar. These features mean that with the most
common valve sizes between DN 15 (1/2 inch) and DN 100 (4 inch) the costly double
seated valve type or even pressure balanced trims become unnecessary.
Figure 6.2.4.-1: SAMSON AG developed worldwide the first actuator with parallel spring design which
seems to be the state-of-the-art on long term.
Figure 6.2.-5: Control valve of an „easy valve type“ with compact dimensions and field
reversible pneumatic diaphragm actuator with multiple springs
Type 3731-x
Type 3241-7
Body: Forged steel
Diaphragm cases: Stainless steel
Positioner Type 3730-x external
parts: Stainless steel
Type 3244-1
Series 3240
Control valve for process engineering and industrial applications.
3241-1/-7
Globe Valve Type 3241-1/-7 3241-1/-7 3241-1/-7
Type tested
Three-way 3244-1/-7
Standard DIN
version ANSI
Water and
-196 to 450 °C -196 to 450 °C -196 to 450 °C -196 to 450 °C
⋆Temperature steam up to
–320 to 842 °F –320 to 842 °F –320 to 842 °F –325 to 800 °F
350 °C
⋆Type tested acc. to
DIN 32730
DN 15 to 150 200 to 300 15 to 80 15 to 150 15 to 150
Nominal sizes
NPS ½ to 6 8 to 12 ½ to 3 ½ to 6
Nominal PN 10 to 40 10 to 40 10 to 40 16 to 40 16 to 40
pressure Class 125 to 300 125 to 300 125 to 300 150, 300
Linear
Characteristic: Equal %
On-Off
Metal sealing IV IV IV IV 0.05 % Cv100
Metal sealing
Seat meeting stricter V V V
Plug requirements
Soft sealing VI VI VI
Pressure-balanced IV/V IV/V IV/V
⋆Body material ⋆ ⋆ ⋆Forged steel ⋆
Insulating section
Bellows seal
Option
Heating jacket
Flow divider
Flanges DIN or ANSI DIN or ANSI DIN or ANSI DIN or ANSI DIN or ANSI
Ends
Welding ends
Special end connections ANSI ANSI
Valve pictures
Technical data and ⋆For all further data, accessories, and industry codes see the associated
accessories technical data sheet.
Table 6.3.-1: Series 240 Control valves
Series 3240
Control valve for process engineering and industrial applications.
Gas Oil DWA/PSA
Globe Valve Type
3241-1/-7 3241-1/-7 3241-1/7/9
Angle valve 3249-1/-7 RG 41
DIN ⋆DVGW
Standard
version ANSI, ASME
ANSI
and ASTM
-20 to 220 °C up to 350 °C –29 to 220°C –10 to 160°C -10 to 135 °C
⋆Temperature
-4 to 428 °F up to 662 °F –20 to 430 °F 14 to 320 °F 14 to 275 °F
Low flow rates
Type tested for gas, DIN
Aseptic
EN 161
Liquid fuels, DIN EN 264 15 to 100
DN 15 to 150 15 to 100 15 to 150 ½ to 4 25 to 125
Nominal sizes ½ to 3
NPS ½ to 6 10
½ to 6
Nominal PN 40 16, 40 10 to 40 150 16 to 25
pressure Class 300 125 to 300 125
Linear
Characteristic: Equal %
Shut-off IV
Metal sealing VI
Metal sealing
Seat
meeting stricter V ⋆V
Plug
requirements
Soft sealing VI VI VI ⋆ VI
⋆Body material ⋆ ⋆ ⋆ ⋆
Insulating section
Bellows seal
Option
Heating jacket
Flow divider
Flanges ⋆
Ends
Welding ends ⋆
Valve pictures
Technical data ⋆For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.3.-2: Series 240 and special control valves
Standard DIN
version ANSI
-10 to 160 °C –10 to 150 °C –50 to 250 °C –10 to 180 °C –200 to 450°C
⋆Temperature
14 to 320 °F 14 to 300 °F –58 to 482 °F 14 to 356 °F –328 to 842 °F
Low flow rates
Pharmaceutical industries
Food industries
DN 15 to 150 15 to 125 15 to 100 15 to 50
Nominal sizes
NPS ½ to 6 ½ to 5 ½ to 4 ½ to 2 10,15,25
Nominal PN 10, 16 16 16 to 40 40 ⅛ to 1
pressure Class 125/150 240 150 and 300 300 40 to 400
Linear 150 to 2500
Characteristic Equal %
On-Off
Metal sealing IV
Plug
Soft sealing VI VI IV
Diaphragm seal V
⋆Body material ⋆ ⋆ ⋆ ⋆
Body Special material ⋆
Insulating section
Option
Bellows seal
Flanges
⋆Welding ends
Ends Threaded Female thread
⋆Special end
connections
Valve pictures
Technical data ⋆For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.3.-3: Series 240 Control Valves for special applications
Series 3240 Control Valves are available in nominal sizes ranging from DN 15 to DN 300
(NPS ½ to 12) and up to a nominal pressure PN 40 (Class 300). Control valves in the
standard version are suitable for temperature ranges between –10 and +220 °C (15 and
430 °F). An insulating section allows the temperature range to be extended to –200 and
+450 °C (–325 and +840 °F).
The plug stem is sealed either by a self-adjusting PTFE V-ring packing or an adjustable
packing. To meet stricter emissions control requirements, a stainless steel bellows is
used. The Type 3241 Control Valve can be equipped with a heating jacket that may also
include the bellows.
Globe valves allow easy installation in straight pipelines. For nominal pressures up to PN
40 and nominal sizes up to DN 300, three-flanged bodies of the Series 3240 are mainly
used.
6.3.1. Control Valve with safety function Type 3241-1 and Type 3241-7
The typetested control valve consists of a Type 3241 Globe Valve with:
Type 3271 Pneumatic Actuator and a solenoid
valve (Type 3241-1 Control Valve)
Type 3277 Pneumatic Actuator and a solenoid
valve (Type 3241-7 Control Valve)
Threaded
Forged body Cast body
connections
Valve Type 3241, Valve Type 3241, Valve Type 3241, Valve Type 3241,
Actuator Type 3271, Actuator Type 3277, Actuator Type 3277, Actuator Type 3277,
threaded connections, Positioner Type 3730, Handwheel, Positioner Type 3731,
Cast body, flange connections, Positioner Type 3730, Metal bellows,
V-port plug. Cast body, flange connections, Flange connections,
Micro plug. Forged body, Cast body
AC-1 Trim. Parapolic plug.
Figure 6.3.2.-1: SAMSON modular design for Series 3240 and 3250
This module system makes it possible to design the optimal valve up to PN 40, size
DN 300 or ANSI Class 300, size 12” from components of the Series 240 to meet the
requirements of your specific application. Components are certified according to IEC
61508 for use in safety-instrumented systems up to SIL 3.
Cast valve bodies made of the commonly used materials, such as cast iron, spheroidal
graphite iron, cast or carbon steel, different stainless steels, duplex, and nickel base
alloys, can be supplied from stock.
Interchangeable valve trims enable you to select the best suited Cv coefficients and valve
characteristics for your specific application.
Different flow dividers effectively reduce the noise levels and high-velocity erosion.
Figure 6.3.3.-1: Type 3241 with metal bellows seal and with body material forged steel.
1,600,000
1,500,000
1,400,000
1,200,000
1,000,000
800,000
600,000
400,000
100,000
Travel mm
10 11 12 13 14 15
60 % 80 % 100 % Travel %
Figure 6.3.3.-2: Life cycle time for SAMSON metal bellows seal.
Min. 100,000 cycles at full travel amplitudes (on-off) up to 1.5 mill at 60 % travel amplitude (control)
Bellows seal
In case, stricter emissions control requirements must be met, e.g. German Clean Air Act
(TA-Luft) or in vacuum applications, a metal bellows is used to seal the plug stem. The
plug stem is additionally sealed with a packing at the top flange. This packing serves as
a backup packing.
The metal bellows can be monitored for leakage or a sealing medium can be applied by
means of a test connection.
Insulating section
The application range of a standard packing can be extended to an operating temperature
of less than –10 °C or over +220 °C by using an insulating section.
Bellows seal Short insulating section Long insulating section
The bellows seal can be ∗The temperature ranges of the various valves series
used for valves of are:
Series 3240
–200 to +400 °C –50 to +450 °C –200 to +450 °C
Series 3250
–200 to +450 °C –200 to +500 °C –200 to +500 °C
Series 3280
–200 to +450 °C max. +500 °C max. +500 °C
∗The temperature ranges specified above may be restricted by the materials used as
per the pressure-temperature diagram (see Information Sheet T 8000-2 EN).
Table 6.3.3.-3: Bellows seal and insulation sections
6.4.1. Control valves with forged steel or forged stainless steel bodies
Despite an on-going progress in foundry practice, shrinkage cavities and thus possible
leaks can never completely excluded.
Particularly annoying for the manufacturer is
the fact that leaks in the cast body become
visible only after the final machining process.
Since welding or other possibilities of a
post-processing are generally not permitted,
scrapping of the entire body is the only
option. Last but not least the much discussed
European pressure vessel regulation which
addresses itself at these criteria and requires
numerous inspections to establish the
suitability of the pattern and of the foundry, in
order to achieve high quality bodies.
Unquestioned is the fact that faultlessly
cast valve bodies are qualitatively not any
worse than forged valve bodies. In order to
avoid the numerous inspections and tests,
SAMSON AG first of all offer for nominal sizes
up to DN 80 (NPS 3) forged valve bodies.
(Figure 6.4.1.-1).
To be desired is the close fine-grained structure and the smooth surface. The higher effort
for machining is balanced with lower cost in comparison to the increasing casting quality
control process today.
The technical data like Cv values and other sizing parameters are comparable within
negligible deviations.
Figure 6.4.1.-3: Vacuum (300 mbar) process in the Potassium sulfate dryer / Methanol recovery
Figure 6.4.1.-4: CRACKER STORAGE TANK ▪ Pump area ▪ Ethylene Storage Bullets for
BASF-YPC Company (BYC), Nanjing, P.R. China. Photo: Tractebel Gas Engineering
Figure 6.4.2.-1: Control valve Type 3241-9 with Type 3275 Piston Actuator (see T 8314 EN),
for integral positioner attachment and / or limit switch
The actuators Type 3275 are mainly used with Type 3241 Valves in pressure swing
adsorption systems and are characterized by:
Small overall height
Powerful thrust due to the supply pressure of max. 6 bar
Low friction
Temperature range from −30 to 80 °C
The actuator is fixed to a yoke which is designed to hold a pneumatic or electropneumatic
positioner.
This type of direct attachment has the following advantages:
Tight and accurate linkage
Adjustments are not affected during transport
Travel pick-off protected against touching and external influences, meeting the
requirements of the German Accident Prevention Regulations (VBG 5).
Easy pneumatic connection between actuator and positioner
The double-acting Type 3275 Piston Actuator does not have a fail-safe action
(see T 8314 EN).
Type 3275
bar
6
6
5
cm 2
5
2
4 4
cm
490
4
m2
80
3
c
314
3
2 2
1
1
0
0 10 20 30 40 50 kN
18.4 29.4 47.3
Type 3275 Piston Actuator Force diagram for Type 3275 Piston Actuator
1 Piston rod
2 Yoke for direct attachment of positioner / limit switch
3 Plain bearing
4 Seal
5 Piston bearing strip
6 Piston
Figure 6.4.2.-3: Type 3275 Piston Actuator
Fail-safe position
Depending on the arrangement of the compression springs in the actuator (8) (see Data
Sheet T 8310-1 EN for details), the control valve has two different fail-safe positions
effective upon air supply failure:
Actuator stem extends (FA)
The valve is closed upon air supply failure.
Actuator stem retracts (FE)
The valve is opened upon air supply failure.
Other versions with:
Extension bonnet for temperatures from –200 to +450 °C (–328 to 842 °F),
with special material up to +650 °C (1200 °F)
−5 mbar ⋅ l
Metal bellows seal up to Class 1500 with a sealing performance ≤ 10 , higher
pressure ratings on request s
Handwheel
Electric actuator · On request
NPS ½ to 1 Pressure Class 150 to 2500 NPS ½ to 1 Pressure Class 150 to 2500
NPS ½ to 1 Pressure Class 150 to 2500 NPS ½ to 1 Pressure Class 150 to 2500
Micro-flow Valve Type 3510 for high and low temperature service
Extension bonnet
Type 3510 Micro-flow Valve with extension bonnet and metal bellows seal
Control valve specially designed for controlling small flow rates in
Application
pilot plants and technical research facilities
Nominal size Nominal pressure Cv100 value Material
G, NPT and RC
Valve data female thread ANSI Class 150
∗ ∗
in NPS ⅛ ∙ ¼ ∙ to Class 2500
⅜∙½∙¾
Temperatures –200 to +450 °C, –328 to 842 °F
Actuator Type 3271-52 with 60 cm2 Area
Stroke 7.5 mm
Spring ranges
without 0.2 to 1.0 bar 0.4 to 2.0 bar 1.4 to 2.3 bar 2.1 to 3.3 bar
pretension
Connections Welding ends, flanges NPS ½ · ¾ · 1
Technical data ∗For all further data, accessories, and industry codes see the
and accessories associated technical data sheet.
Figure 6.4.3.-6: Micro-flow Valve with extension bonnet and metal bellows seal
Type 3510 with Positioner Type 3731 Type 3277-5 with 120 cm2 area with hand wheel
Positioner Type 3730 standard mounting parts 3510-1 with extension bonnet and positioner Type
acc. NAMUR 3730 standard mounting parts acc. NAMUR
Figure 6.4.3.-11: Micro-flow valves Type 3510 with mounting parts
Micro-flow Valve Type 3510 according NACE standard 01-75 NACE or ISO version
2.4610 2.4610
Sach-Nr. 0310-1911 Sach-Nr. 0340-2014
2.4610
2.4610 2.4610
2.4610
Thick-walled components (e.g. body, bonnet, bellows seal bonnet and insulating section)
as well as other wetted internal parts (e.g. sealing rings, packing washers, threaded
bushings and the stem of the insulating section) must be made of WN 2.4610 (corresponds
to Hastelloy C-4).
For micro-flow valves with bellows seal bonnet, the bellows is to be made of WN 2.4819
(corresponds to Hastelloy C-276).
Stellite is approved for versions complying with ISO 15156 and NACE MR 0103-2007.
As a result, valve trims made completely of Stellite can be used with Cv100 coefficients
between 0.00063 and 0.0001 (Cv100 S between 0.00075 and 0.00012).
The valve trim materials WN 1.4122 and WN 1.4112 do not meet the restricted hardness
requirements stipulated in ISO 15156 and NACE MR 0103-2007.
Plug and seat also available in stellite.
2.4610 2.4610
Sach-Nr. 0310-1911 Sach-Nr. 0340-2014
2.4610
1.4571 2.4610
2.4610
Figure 6.4.3.-13: Micro-flow Valve Type 3510 according NACE standard NACE MR 0175
Thick-walled components (e.g. body, bonnet, bellows seal bonnet and insulating section)
can be made of WN 1.4571 (corresponds to A 479316 Ti).
All wetted internal parts (e.g. sealing rings, packing washers, threaded bushings and the
stem of the insulating section) must be made of 2.4610 (corresponds to Hastelloy C-4).
For micro-flow valves with bellows seal bonnet, the bellows is to be made of WN 2.4819
(corresponds to Hastelloy C-276).
Valve trims made completely of Stellite or of WN 1.4122 and WN 1.4112 do not meet
the restricted hardness requirements stipulated in NACE MR 0175. As a result, only Cv
coefficients between 1.6 and 0.001 (Cv100 between 2.0 and 0.0012) can be selected.
Method cleaning
CIP (Cleaning-in-Place)
Automated wet cleaning system of a line and/or individual equipment in a closed
circuit without dismantling.
Cleaning-in-Place is advancing in the food industry. Cost savings due to less down
time and automated cleaning procedures have facilitated this advance.
Critical for the effectiveness of CIP is hygienic design, i.e. the clean ability of the
processing equipment.
SIP (Sterilization-in-Place)
A process aimed at removing or killing all forms of micro-organisms, including
bacterial spores.
DIP (Drying-in-Place)
Cleaning which does not involve any use of water, a technique which can be used as
a preventive measure to reduce risks of microbial development in equipment and in
the environment. It also reduces risk of contamination with e.g. residues of aged or
modified product. Mostly done manually using brushes and/or vacuum cleaners.
Aseptic design
Hygienic equipment which is in addition impermeable to micro-organisms. A process
using equipment sterilized before use, and which, in running conditions, is protected
against recontamination by micro-organisms that may harm the safety and suitability
of the specific product that is made.
Figure 6.5.-1: Type 3347-7 Valve with bar Figure 6.5.-2: Type 3347-7 Valve with
stock with threaded end connections hollow-mold cast body with welding ends
1 http:// www.fda.org
2 http:// www.ehedg.org
Equipment certification
Authorized EHEDG institutes are offering certification to the benefit of both equipment
suppliers and food manufacturers:
Equipment suppliers:
Their equipment can be approved by EHEDG authorized organizations to be in
compliance with EHEDG criteria. In certain cases, approval may only be granted after
testing by a laboratory accredited by a notified body, using EHEDG test methods.
Food manufacturers:
They may select hygienically designed equipment although acquires must still validate
that such equipment is adequate for its intended use.
1 http://www.3-a.org
Construction
Note: 1 Ra value ≤ 1.0 µm (0.8 µm) is necessary for the product-contact surfaces
Different finishes:
Standard finish Ra 1,0 or 0,8
Polished Ra 0,6
Polished Ra 0,4
Types of connection
Unchangeable connection Changeable connection
Figure 6.5.1.-5: Connections for the pharmaceutical and food processing industries
Type
Distribution Valve
3347 or 3249
Medium Different media
Nominal size Nominal pressure Cv100 value Body material
See Type See Type
Valve data DN 15 to 125 316L
3247 / 3249 3247 / 3249
Trim material: 316L
Application Distribution or injection line in food or pharmaceutical industries
Options Materials, connections: see Type 3247 / 3249
References Amersham (now GE Health care)
For all further data, accessories, and industry codes see the
associated technical data sheet.
Figure 6.5.4.-1: Distribution Valve Type 3347 or Type 3249
Figure 6.5.6.-1: Pneumatic Control Valve Type RG 41 with Pneumatic Actuator Type 3271
SAMSON Valves
All the pre-set cleaning parameters such as temperature, flow, time and conductivity are
monitored fully automatically with SAMSON control valves.
1 http://www.krones.com
Germs don’t stand a chance in the cavity-free body of the Type 3347 Sterile Valve as all
wetted parts are made of corrosion resistant, polished high-alloyed steel. A special PTFE
bushing reliably prevents germs being transferred at the actuator stem. An additional
steam line connection is available to meet even stricter standards of cleanliness. In the
Type 3249 Valve, the EPDM diaphragm together with a backup packing provide the
perfect protection against germ transfer.
Valve material and design comply with the most stringent international standards including
EHEDG conformity for both valve body styles, FDA conformity for wetted seal materials,
and 3-A compliance for the ball-body version. The valve bodies are also suitable for CIP
and SIP procedures.
SAMSON Bellows
The result is a modular, low cost, high quality bellows
seal with high pressure-temperature capabilities and
an extra-ordinarily long cycle lifetime; guaranteed for
a minimum of 100,000 full cycles in all sizes NPS 1/2
to 6.
The bellows seal is extensive tested with helium and
provides the best flexible zero leakage stern seal.
The design features a double wall seamless bellows
which is manufactured in one full-length piece and
Figure 6.5.8.-1: The SAMSON Lethal
Service Valve Type 3241-1 LS consists plasma welded only at the upper seal ring and lower
of globe valve Type 3241 and pneumatic stern connection.
actuator Type 3271.
Noise Reduction
By means of flow dividers Type ST
I or ST III, significant reductions in
noise levels can be achieved. The
flow divider Type ST I a perforated
metal insert will reduce the noise
level by up to 10 dB(A). lt can be
used for both liquids and gases.
The flow divider Type ST I is also
used for valve body protection
with cavitating fluids.
Test connection
Pressure switch for alarm signal
Pressure gauge for visual alarm
Note: Bellows Pressure Ratings
As a result of the process pressure being applied to the outside area of the bellows, the
bellows is pressure rated in excess of the valve body rating, without danger of collapse.
Extensive tests of up to 3000 psi have been conducted without rupture.
Environmental concerns
Environmental protection and the careful use of resources have become key issues in
modern society. Regulations such as the Clean Air Act in the United States or its German
equivalent “TA-Luft” aim to restrict emissions produced by industrial plants.
The most effective sealing solution is the metal bellows, a ground-breaking invention
originally developed by SAMSON. The engineering expertise that goes into the in-house
design and manufacture of multi-layered bellows results in bellows seals recognized for
their quality.
The sealing quality of SAMSON metal bellows remains unsurpassed over its entire life
cycle. For special applications, the bellows can be heated or flushed to prevent deposits
from clogging up the bellows. Its friction-free sealing ability can last over a valve’s entire
service life even in critical applications without the need for any maintenance and still
guarantee absolute zero leakage.
Series V2001
Type 3374
Type 3371
Type 3372
Type 3321-IP
Type 5824
Type 3323-E1
Type 3321-IP
for DN 65 and larger
Nominal PN 16 16 / 40 16 / 40 16 / 40 16 / 40
pressure Class 150 150/300 150/300 150/300 150/300
Characteristic :
Equal percentage
Electric 5824-30
Actuator Type: 3374-xx
Valve pictures
Valve pictures
DIN
Standard version
ANSI
-10 to 220 °C -10 to 220 °C -10 to 220 °C -10 to 220 °C -10 to 220 °C
⋆Temperature
14 to 430 °F 14 to 430 °F 14 to 430 °F 14 to 430 °F 14 to 430 °F
DN 15 to 50 15 to 50 15 to 50 15 to 50 15 to 50
Nominal sizes
NPS ½ to 2 ½ to 2 ½ to 2 ½ to 2 ½ to 2
Nominal PN 10 to 40 10 to 40 10 to 40 10 to 40 10 to 40
pressure Class 150 / 300 150 / 300 150 / 300 150 / 300 150 / 300
Characteristic Linear
Seat
Metal sealing
Plug
Leakage
Metal sealing: 0.05 % of Cv 0.05 % of Cv 0.05 % of Cv 0.05 % of Cv 0.05 % of Cv
Class
Mixing / Diverting
Option Mixing valves in DN 15 to 25 / NPS ½ to 1 can also be used for
Note:
flow-diverting service.
Electro-
pneumatic 3372-03xx
Actuator Type:
Pneumatic 3372-01xx
Actuator Type: 2780-2
Actuator area 120 cm2
Electric 5824-30
Actuator Type: 3374-xx
Valve pictures
Technical data ⋆For all further data, accessories, and industry codes see the associ-
and accessories ated technical data sheet.
Table 6.6.-3: Series V2001 with mixing and flow-diverting valve designed.
Standard DIN
version ANSI
-10 to 350 °C -10 to 350 °C -10 to 350 °C -10 to 350 °C -10 to 350 °C
⋆Temperature 14 to 660 °F 14 to 660 °F 14 to 660 °F 14 to 660 °F 14 to 660 °F
Extended temperature range down to -70 °C / -94 °F on request.
DN 15 to 80 15 to 80 15 to 80 15 to 80 15 to 80
Nominal sizes
NPS ½ to 3 ½ to 3 ½ to 3 ½ to 3 ½ to 3
Nominal PN 16 / 25 16 / 25 16 / 25 16 / 25 16 / 25
pressure Class 125 / 150 125 / 150 125 / 150 125 / 150 125 / 150
Characteristic:
Equal percentage
Metal
Seat-plug
sealing
Leakage Class IV IV IV I IV
Bellows seal
Electro-
pneumatic 3372-03xx
Actuator Type:
Pneumatic 3372-01xx
Actuator Type: 2780-2
Actuator area 120 cm2
Electric 5824-30
Actuator Type: 3374-xx
Valve pictures
Connection Flanges EN 1092-1 Form B1, Ra 3.2 to 12.5 μm · EN 1092-1, groove Form D
Fail-safe position with pneumatic or electric actuators see the associated
Fail-safe position
technical data sheet.
Technical data ⋆For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.6.-4: Valve Series V2001 for Heat Transfer Oil
Standard DIN
version ANSI
-10 to 350 °C -10 to 350 °C -10 to 350 °C -10 to 350 °C -10 to 350 °C
⋆Temperature
14 to 660 °F 14 to 660 °F 14 to 660 °F 14 to 660 °F 14 to 660 °F
DN 15 to 50 15 to 50 15 to 50 15 to 50 15 to 50
Nominal sizes
NPS ½ to 2 ½ to 2 ½ to 2 ½ to 2 ½ to 2
Nominal PN 10 to 40 10 to 40 10 to 40 10 to 40 10 to 40
pressure Class 150 / 300 150 / 300 150 / 300 150 / 300 150 / 300
Characteristic Linear
Seat-
Metal sealing
Plug
Leakage
Metal sealing: 0.05 % of Cv 0.05 % of Cv 0.05 % of Cv 0.05 % of Cv 0.05 % of Cv
Class
Bellows seal
Mixing / Diverting
Option Mixing valves in DN 15 to 25 / NPS ½ to 1 can also be used for
Note:
flow-diverting service.
Electro-
pneumatic 3372-03xx
Actuator Type:
Pneumatic 3372-01xx
Actuator Type: 2780-2
Actuator area 120 cm2
Electric 5824-30
Actuator Type: 3374-xx
Valve pictures
For the valve sizes NPS 2½ to 3 / DN 65 to DN 80 you can choose between the following
actuator choices:
Type 3371 On-Off Service
Type 3372 (Size 120 cm2 and 350 cm2)
Type 3374 Electric Actuator
The valve of series V2001 is designed based on the modular principle and can be
combined with pneumatic as well as electric actuators as listed in Table 6.6.-8.
Pneumatic
120 cm2 1) 1)
Type 3372
350 cm2
Type 5824-xx
Electric
Type 3374-xx 2) 2) 2)
Table 6.6.-8: Actuators for Valves of series V2001
1) Actuator not in electropneumatic version
2) Only with Type 3374-10 and Type 3374-15
Technical data
Body Material: Cast Iron, Carbon
Sizes: NPS 1/2 to 4 / DN 15 to 100
ANSI Class 125 to 300 / PN 16 to 40
Travel: 0.6“ / 1.2“ for 4“ Cv 190
A minimum of two Cv values per valve size
Metal or soft sealing
Various pneumatic and electric actuators
With metal bellows stem seal only for Type 3531 and
Type 3535
Other versions
Explosion-protected version with electric actuators
Type 3321 according to ANSI standards · See T 8112
EN
Insulating section on request Figure 6.6.-9: Globe valve
Flow divider ST I for noise reduction on request Type 3321-IP
Choice of Accessories
The control valves can be optionally equipped with positioners, limit switches and
potentiometers.
The Type 3372, Size 350 cm2 pneumatic Actuator is used for control purposes and will be
supplied with the Type 3730-0 I/P Positioner as our standard.
It is possible to mount all the positioners from the Type 3730 family.
Type 4744
Type 3776
Figure 6.6.-10: The Type 3776 Limit Switch with integral solenoid valve or Type 4744 Limit Switch
Advantages
Standard type 3241 parts
Multiple Cv values readily available
Use all SAMSON Actuators
Versions
Type 3522-1 · Nominal sizes ½” to 2” with Type 3271
Pneumatic Actuator (see Data Sheet T 8310-1)
Type 3522-7 (Fig. 1) · Nominal sizes ½” to 2” with
Type 3277 Pneumatic Actuator for integral positioner
attachment (see Data Sheet T 8310-1)
Figure 6.6.1.-4: Type 3522 NPS ½ to 1 on the left side and Type 3522 NPS 1¼ to 2 on the right side
Series 250
Type 3251 Globe Control Valve
Nominal size: NPS ½ to 8
Nominal pressure: Class 150 to 2500
Temperature range: –325 to 930 °F
Series 240
Control valve for viscous, corrosive, and abrasive fluids conforming to
DIN, BS or ANSI standards.
Valve Type 3345-1 3345-7 3345-7 3345-1
Diaphragm valve
DIN
Standard version ANSI /
BS
Pharmaceutical / food industries - -
⋆Temperature See Table 6.7.-7
Characteristic Linear
DN 15 to 150 15 to 150 15 to 150 15 to 150
Nominal sizes
NPS ½ to 6 ½ to 6 ½ to 6 ½ to 6
PN 10 / 16 10 / 16 10 / 16 10 / 16
Nominal pressure
Class 125/150 125/150 125/150 125/150
Maximum pressure 10 bar / 150 psi 10 bar / 150 psi 10 bar / 150 psi 10 bar / 150 psi
Diaphragm ⋆See Table 6.7.-7
Leakage Class DIN EN 1349: Class VI / ANSI FCI 70-2
Flanges 10 / 16 10 / 16 - -
Ends Face-to-face
EN 558-1 Series 1 see the associated technical data sheet.
dimensions
Special Threaded DIN 11887 · ISO 2853 (IDF) · SMS 1146 · DIN 11864-1 Form A
connection Clamp DIN 32 676 · ISO 2852 · BS 4825 Part 3
version for For pipes acc. to: DIN 11 850 Series 2 · DIN EN ISO 1127
food industry Welding ends
ISO 2037 (NFA 49-249) · BS 4825 · ASTM A270 (O.D.) · SMS 3008
Valve pictures
Principle of operation
The valve diaphragm acts as a valve plug. The flow rate depends on the free cross-
section between the diaphragm and the bottom part of the valve body.
The actuator stem is fitted with stoppers which limit the force to protect the diaphragm.
Pressure-temperature diagram for
Elastomer diaphragms
DN 15 to DN 150 according to curve 1
Special version in PN 16:
DN 15 to DN 50 according to curve S
PTFE diaphragms
DN 15 to DN 125 according to curve 1 and DN 150 according to curve 2
bar
16 S
14
12
10 1
8
2
6
4
2
0 °C
-60 -40 -20 0 20 40 60 80 100 120 140 160 180
Figure 6.7.-4: Pressure-temperature diagram
Figure 6.7.-5: Type 3345 Valve, stainless steel with clamp connections
The FDA = Food and Drug Administration (FDA or USFDA) is an agency of the United
States Department of Health and Human Services and is responsible for regulating
and supervising the safety of foods, dietary supplements, drugs, vaccines, biological
medical products, blood products, medical devices, radiation-emitting devices, veterinary
products, and cosmetics.
Diaphragms
Ethylene propylene PTFE/Butyl
Lining Butyl (300) 1) FPM/FKM (226)
(425) 1) (214/425) 1)
°C °F °C °F °C °F °C °F
Without -10 to 130 14 to 266 –5 to 150 23 to 302 –10 to 130 14 to 266 –10 to 160 14 to 320
Butyl -10 to 110 14 to 230 –5 to 110 23 to 230 –10 to 110 14 to 230 –10 to 110 14 to 230
ETFE -10 to 130 14 to 266 –5 to 150 23 to 302 –10 to 130 14 to 266 –10 to 160 14 to 320
EBONITE -10 to 85 14 to 185 –5 to 85 23 to 185 –10 to 85 14 to 185 –10 to 85 14 to 185
Enamel -10 to 130 14 to 266 –5 to 150 23 to 302 –10 to 130 14 to 266 –10 to 160 14 to 320
1) Diaphragms with FDA/3-A conformity. Suitable for the food processing industry.
Table 6.7.-7: Temperature ranges for lining and diaphragm materials in °C and °F
Body lining
Lining material Valve body material Applications
Cast iron and cast carbon Mineral acids and acidic slurries,
BUTYL
steel corrosive and abrasive slurries
Solvents at medium temperature,
ETFE Speroidal graphite iron salts in water at higher
temperatures, strong acids
Portable water, salts in water,
Cast iron and cast carbon
EBONITE chlorine water, deionized water,
steel
dilute mineral acids.
For multi process chemical plant
on acids and solvents. Not suitable
for caustic alkalis or commercial
Enamel Cast iron mineral acids containing fluoride
salt impurities, also not suitable
where variations in temperature
occurs.
Table 6.7.1.-2: Body Lining
Type 3246-1
Type 3248-7
Type 3246-7
Series 240
Globe valve for cryogenic applications.
Globe Valve Type 3246-1/-7 3246-1/-7 3248-1/-7
Angle valve 3248-1/-7
Three-way valve 3246-1/-7
Valve with circulation
inhibitor
Standard DIN
version ANSI
–200 to 220 –200 to 220 –273 to 220 –273 to 220
–200 to 220 °C
⋆Temperature °C °C °C °C
–328 to 428 °F
–328 to 428 °F –328 to 428 °F –459 to 428 °F –459 to 428 °F
DN 15 to 250 15 to 150
Nominal sizes
NPS ½ to 10 ½ to 8 ½ to 6 1 to 6 1 to 6
Nominal PN 16 to 40 16 to 40
pressure Class 150, 300 600 150, 300 150 to 600 150 to 600
Linear
Quick
Characteristic
Equal
%
Seat -
Stellite facing
Plug
Metal sealing IV IV 0.05 % Cv IV IV
metal sealing
Leakage
meeting stricter V V
Class
requirements
Soft sealing VI VI
Insulating
Option section
Bellows seal
Flanges
Ends
Welding ends
Valve pictures
Technical data ⋆ For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.8.-1: Globe valve for cryogenic applications.
The word cryogenics stems from Greek and means "the production of freezing cold";
however the term is used today as a synonym for the low-temperature state. It is not well-
defined at what point on the temperature scale refrigeration ends and cryogenics begins.
In physics, cryogenics is the study of the production of very low temperature (below
−150 °C, −238 °F or 123 K) and the behavior of materials at those temperatures. Rather
than the familiar temperature scales of Fahrenheit and Celsius, cryogenic technicians use
the Kelvin scales.
The field of cryogenics as that involving temperatures below −180 °C (93.15 K). This is
a logical dividing line, since the normal boiling points of the so-called permanent gases
(such as helium, hydrogen, neon, nitrogen, oxygen, and normal air) lie below −180 °C
while the Freon refrigerants, hydrogen sulfide, and other common refrigerants have
boiling points above −180 °C. Helium is the coldest known liquid at -434.5 °F.
For years, SAMSON has been relying on state-of-the art technology and its know-how to
develop and constantly improve cryogenic valves. Thanks to the close cooperation with
its customers, SAMSON is capable of tailoring control valves for cryogenic applications
to the customer's individual requirements.
Huge requirements are placed on the Type 3246 and Type 3248 Valves, which were
developed for use in cryogenic air separation applications, concerning their material,
sealing ability and the protection used to prevent the valves from icing up. For example,
temperatures as low as –196 °C exist in cold boxes, where the valves are expected to
function safely.
All valves are subject to constant quality control, from the development stages through
production until final inspection. They are tested to match the specified operating
conditions, which guarantees absolute reliability also at such low temperatures.
The following SAMSON valves are suitable for the cryogenic application:
Type 3241
With Insulating or Bellows section
Material: Stainless steel
Pressure rating: Class 150/300
Short Insulating / Bellows : up to –50 °C
Long Insulating / Bellows : up to –198 °C
(See Table 6.3.-1)
Type 3246
Cold box valve – Bolted bonnet
Control Equipment for use in the field of cryogenics.
Designed to install in Insulated pipelines or cold boxes.
With long insulation section.
Circulation barrier to restrict the medium from getting in to insulating
section.
(See Table 6.8.-1)
Type 3248
Cold box valve – Top entry
Control Equipment for use in the field of cryogenics.
Designed to install in Vacuum-Insulated pipelines or cold boxes.
Metal bellow sealing.
Top Entry- Easy access to the seat, plug and bellow after removal of the
actuator.
Special versions as per customer requirement
(See Table 6.8.-1)
Type 3251
With Insulating or bellows section
Material: Stainless steel
Pressure rating: Class 600
Insulating / Bellows section
Temperature range : down to –200 °C
(See Table 6.9.-1)
2-Stage Trim
3-Stage Trim
$ 37.0
$ 30.4 Billion
Billion
$ 25.0
$ 13.9 Billion
Billion
The fastest growth will be in the emerging industrial economies of the Asia/Pacific region,
especially those of China and India. Those countries with advanced, highly developed
industrial economies will grow more slowly. Other developing regions (Latin America,
Eastern Europe and Africa/Middle east) will also experience above average growth.
Metal production, fabrication to dominate demand Metals production and fabricating will
be the largest market sector for industrial gases consumption, and will account for 35
percent of total demand value in 2011. In steel applications, growth will derive from the
increasing use of electric arc furnaces, more demand for stainless steel products and
more modern manufacturing methods, which consume greater amounts of industrial
gases.
Geographically, the best growth opportunities will exist in China and India, where steel
production continues to grow rapidly. The Japanese steel industry, the world’s second
largest after China, still remains a major industrial gas market, though not a high growth
one.
Strong gains are forecast for electronics markets, as demand for bulk and specialty gases
benefits from a projected rebound in global semiconductor shipments after a downturn
that began in late 2000, as well as on fabs2 (or chip making facilities) producing advanced
300 millimeter wafers.
The global industry is dominated by five multinational suppliers - Air Liquide (France),
BOC Group (UK), Praxair (US), Air Products and Chemicals (US) and Linde (Germany)
- which together accounted for two-thirds of total sales.
1 Publication: Research Studies - Freedonia Group
2 A semiconductor fabrication plant (commonly called a fab)
Figure 6.8.2.-2: Linde is the technological and market leader for air separation plants. An air separation
plant in Terni, Italy, is pictured.
Circulation Barrier
Industry, medicine, supply engineering or research, the fields of application and quantities
of industrial gases consumed vary immensely.
Consequently, the most important factor for a successful gas supplier is the location of the
production site, either as on-site gas generation or a central plant with a pipeline network.
This flexibility and the strict technical regulations require constructions that exceed the
limits of standard products. As a result, the SAMSON product range includes cryogenic
valves, pressure regulators and level meters developed specifically for these areas of
application.
For example, temperatures as low as
SAMSON coldbox
valve Type 3248
–196 °C are typical in cold boxes used for
cryogenic air separation. Huge demands are
placed on valve material, sealing ability and
the protection used to prevent the valve from
icing up.
Type 3252
Type 3253
Type 3254
Type 3251
Type 3256
Series 3250
Control valve for process engineering applications with high industrial requirements.
Globe Valve Type 3251-1/-7 3252-1/-7 3253-1/-7 3254-1/-7
Angle Valve
Three-way valve
Standard DIN
version ANSI
-200 to 500 °C -200 to 450 °C -200 to 500 °C -200 to 500 °C
⋆Temperature
-325 to 930 °F -328 to 842 °F -325 to 930 °F -325 to 930 °F
DN 15 to 200 15 and 25 15 to 500 80 to 500
Nominal sizes
NPS ½ to 8 ½ and 1 ½ to 20 3 to 16
Nominal PN 16 to 400 40 to 400 10 to 400 16 to 400
pressure Class 150 to 2500 300 to 2500 300 to 2500 150 to 2500
Linear
Characteristic: Equal %
On-Off
Metal sealing IV IV I IV
⋆ Metal sealing
meeting stricter V V V
Seat requirements
Plug
Soft sealing VI VI VI
Pressure-balanced IV / III IV / III
⋆Ceramic trim
Body ⋆Special material
Insulating section
Bellows seal
⋆Option Heating jacket
Flow divider
AC-Trim
Flanges
Ends
Welding ends
⋆Special end connections
Valve pictures
Technical data ⋆For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.9.-1: Overview of series 3250
Series 3250
Control valve for process engineering applications with high industrial requirements.
3259-1
Globe Valve Type 3256-1 3258-1/-7 RVG RVG Flange
IG standard
Angle Valve Split body
Standard DIN Split body
version ANSI
≤ 260 °C ≤ 260 °C
-200 to 500 °C -10 to 220 °C > 260 °C > 260 °C
⋆Temperature -200 to 450 °C
-325 to 930 °F -10 to 450 °C ≤ 500 °C ≤ 500 °C
> 500 °F > 500 °F
25, 50, 80, 16, 24, 30,
DN 15 to 200 100, 150, 45, 58, 70, 25 to 150 50 to 150
Nominal sizes and (⋆200) and 90
NPS ½ to 8 1 to 6 2 to 6
16 to 40
Nominal PN 16 to 400 325 16 to 400 40 to 400
(⋆160)
pressure
Class 150 to 2500 150 to 2500 300 to 2500
Linear
Characteristic:
Equal %
Metal sealing IV IV IV V V
metal sealing
meeting stricter V V V
Seat requirements
Plug Soft sealing VI VI
Pressure-balanced IV / III IV IV
⋆Ceramic trim
Body ⋆Special material
Insulating section
Bellows seal
Option
Heating jacket
Flow divider
⋆Flanges Form B1
Ends
Welding ends
⋆Special end connections
Valve pictures
Technical data ⋆For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.9.-2: Continuation of the overview the valve series 3250
Control valve Series 3250 for processes with high industrial requirements.
Series 250 Control Valves are used when large nominal sizes and/or high pressures are
involved in process engineering, power plant or supply engineering.
In addition to globe, three-way and angle valves, four-flanged valve bodies with bottom
plug stem guides, and valves with axial multi-stage throttling plugs, customized valve
constructions to meet customer specifications can be engineered as well.
The valves are manufactured in nominal sizes from DN 15 to DN 500 (NPS ½ to 16) and
for nominal pressures between PN 16 and PN 400 (Class 150 to 2500).
The standard versions of these control valves are suitable for temperatures ranges
between –10 and +220 °C (15 and 430 °F). This temperature range can, however, be
extended by using an adjustable high-temperature packing to a temperature range
between –10 and +350 °C (15 and 660 °F) and by using a bellows seal or an insulating
section to a temperature range between –200 and +500 °C (–325 and +930 °F).
Some pictures of different SAMSON valve of larger sizes and ANSI Class ≥ 900
SAMSON stuffing box uniform for highest Sand protection bellows opened for the
pressure classes picture
Figure 6.9.3.-1: Some pictures of different SAMSON valve of larger sizes and ANSI Class ≥ 900
Type
Control valve used to control very low flow rates in process
Application
engineering
Nominal size Nominal pressure Cv value Body material
G ½ to G 1,
PN 40 to 400
½ NPT to 1 1.4404
ANSI Class 0.12 to 5
NPS ½ to 1 A 316 L
300 to 2500
Valve data DN 15 to 25
Trim material: 1.4404 / A 316 L
All valve parts are manufactured from standard industrial products.
That makes it possible to use a diverse assortment of materials in
order to match the customer’s requirements.
Welding ends · DN 15, 20, 25 or NPS ½, ¾, 1
Flanges · DN 15, 20, 25 or NPS ½, ¾, 1
Male thread · On request
Extension bonnet
Special features For temperatures from –200 to 450 °C (–328 to 842 °F)
Bellows seal · For PN 40 to PN 400 or Class 150 to 2500
Special valve body materials · On request
Adjustable packing
Heating jacket · Details on request
Figure 6.9.1.-1: High Pressure Valve Type 3252-1 / -7
AB A AB A
B B
Figure 6.10.1.-1: Three-way valves Type 3244 for mixing service (left) and diverting service (right)
With a three-way diverting valve the fluid enters the unit at the connecting flange at the left
and distributes the fluid - depending on the plug position - either to the right or the lower
exit. Stability is in this case also ensured, because the differential pressure of the fluid is
tending by both flow directions to open the valve. The reconfiguration of a mixing valve -
as shown in the example above - into a diverting type is quite simple.
Type 3244 Three-way Valve with (Figure 6.10.1.-2):
Type 3271 Pneumatic Actuator (left) or
Type 3277 Pneumatic Actuator (right) for integral positioner attachment
Valve body made of:
Cast iron (DIN version only)
Cast steel or
Cast stainless steel
Undivided bonnet
These control valves in modular design can be equipped with various accessories:
Positioners, solenoid valves, limit switches and other accessories according to IEC 60534-
6 and NAMUR recommendation.
Optional integral positioner attachment with Type 3277 Pneumatic Actuator.
Standard version designed for temperatures from –10 °C to +220 °C (15 °F to 430 °F).
Figure 6.10.1.-2: Three-way valves Type 3244-1 with 3271 actuator (left) and Type 3244-7 with 3277
actuator (right)
Fail-safe position
Depending on the arrangement of the compression springs in the actuator, the control
valve has two different fail-safe positions:
Direction of flow
Closing direction
AB A
Direction of flow
Closing direction
Direction of flow
B
Figure 6.10.2.-1: Diverting valve
Note:
In linear motion valves, the direction of flow is usually against the closing direction of the
plug.
If the direction of flow is the same as the closing direction of the plug, instabilities are
caused when controlling around the closing point.
A suction forms at the plug trying to pull it into the seat.
AB A
AB A AB A
B B
Figure 6.10.3.-2: Three-way Valve Type 3253-1 with actuator Type 3271 and additional handwheel, Body
version for DN 50 to DN 500, Plug arrangement for mixing service (left). Three-way valve Type 3253-7
with actuator Type 3277 (only up to DN 100), Plug arrangement for diverting services (right)
Principle of operation
Depending on plug arrangement, the three-way
valve can be used for mixing or diverting service.
When used as a mixing valve, the process media
to be mixed enter through valve ports A and B.
The combined stream leaves at port AB (Figure
6.10.3.-2). The flow rate from valve ports A and B
to port AB depends on the cross-sectional area of
flow between the seats and the valve plugs.
When used as a diverting valve, the process
medium enters at port AB and the partial streams
leave at valve ports A and B.
Fail-safe action
Depending on how the compression springs are
arranged in the pneumatic actuator (see T 8310-
1 EN and T 8310-2 EN for further details), the
control valve has two different fail-safe actions
which become effective upon a supply air failure:
Actuator stern extends:
Whenever the air supply fails, either valve port B
(mixing valve) or valve port A (diverting valve) is
closed.
Actuator stern retracts:
Whenever the air supply fails, either valve port A
(mixing valve) or valve port B (diverting valve) is
closed.
Piping design
To allow the control valve to work properly, the pipeline upstream and downstream of the
valve should be straight and free of obstructions for a length of at least 6 times the pipe
diameter (DN).
Contact SAMSON if this length cannot be met during installation.
Clean out the pipeline thoroughly prior to installing the valve.
Strainer, bypass
We recommend to install a SAMSON Type 2 Strainer upstream of the valve body. We
also recommend to install a shut-off valve both upstream of the strainer and downstream
of the valve, as well as a bypass, so that you do not need to shut down the plant for
maintenance.
Test connection
If there is a test connection (G 1/8) at the upper flange of a valve version with metal
bellows seal (Figure 6.10.4.-1), you can check the tightness of the bellows there.
Particularly for liquids and vapors, we recommend you to install a suitable leak indicator
at the test connection, such as a contact pressure gauge, an outlet into an open vessel
or an inspection window.
Test connection
Metal bellows
Actuator
Fail-safe action: ATC
Pump
Flow A AB Q = constant
A AB
Consumer
B B
Return flow
Figure 6.10.5.-1: Mixing service, installation in the flow pipe; Fail-safe action: ATC
Actuator:
Fail-safe action: ATO
Pump
Flow A AB Q = constant
A AB
Consumer
B B
Return flow
Figure 6.10.5.-2: Mixing service, installation in the flow pipe; Fail-safe action: ATO
Actuator:
Fail-safe action: ATC
Pump
Consumer
Return flow AB A
AB A
B
B
Figure 6.10.6.-1: Mixing service, installation in the return flow pipe; Fail-safe action: ATC
Actuator:
Fail-safe action: ATO
Pump
Consumer
Return flow AB A
AB A
B
B
Figure 6.10.6.-2: Mixing service, installation in the return flow pipe; Fail-safe action: ATO
Actuator
Fail-safe action: ATC
Pump
Flow AB A
AB A
Consumer
B B
Return flow Q = constant
Figure 6.10.7.-1: Flow-diverting service, installation in the flow pipe; Fail-safe action: ATC
Pump
Flow AB A
AB A
Consumer
B
B
Return flow Q = constant
Figure 6.10.7.-2: Flow-diverting service, installation in the flow pipe; Fail-safe action: ATO
Actuator
Fail-safe action: ATC
Consumer
A AB
B
B
Figure 6.10.8.-1: Flow-diverting service, installation in the return flow pipe; Fail-safe action: ATC
Actuator
Fail-safe action: ATO
Consumer
A AB
B
B
Figure 6.10.8.-2: Flow-diverting service, installation in the return flow pipe; Fail-safe action: ATO
Type
Control valve for process engineering applications with high
Application industrial requirements, especially for high pressures and
temperatures
–200 to 500 °C (–320 to 930 °F)
Nominal size
Nominal pressure Cv value Body material
PN 16 to 400
DN 80 to 500
Valve data ANSI Class
NPS 3 to 20
150 to 2500
Trim material:
The modular design of the control valves allows them to be
equipped with various accessories:
Positioners, solenoid valves and other accessories according to IEC
Technical data 60534-6 and NAMUR recommendation.
and accessories See Information Sheet T 8350 EN for details.
For all further data and industry codes see the associated technical
data sheet
Figure 6.10.9.-1: Control Valve Type 3254-1 and Type 3254-7
Pneumatic Control Valves Series 3240 and 3250 with AC-1 or AC-2 Trim
Application
Optimized trim for low-noise and low-wear pressure reduction for liquids with differential
pressures up to 40 bar (580 psi).
The AC-1 Trim includes the following One to four attenuation plates are
special features: integrated into seat of the AC-2 Trim
Raised seat upstream of the parabolic plug and the
Parabolic plug with integrated guide in plug guide.
the seat. Optimized trim with one to four attenuation
Optimized trim for valve sizes plates for valve sizes
DN 50 to DN 300 (NPS 2 to NPS 12). DN 80 to DN 250 (NPS 3 to NPS 10)
Figure 6.10.9.-2: AC-1 and AC-2 Trim special features for Control valves Series 3240 and 3250.
Application
Optimized trim for low-noise and low-wear pressure reduction for liquids with
differential pressures
AC-3 Trim up to 100 bar (1450 psi) and for AC-5 Trim up to 180 bar (2610 psi).
AC-3 Trim AC-5 Trim
Figure 6.10.9.-4: Control Valve Type 3254-1 NPS 20, ANSI Class 900
with Positioner Type 3731-3
Control valves with ceramic trims (see data sheet T 8071 EN)
Control valves with extremely resistant ceramic trims are used when the valve body and
the trim are subject to considerable erosion and abrasion.
The following valves can be fitted with ceramic trims Figure 6.10.10.-2:
Type 3251 Globe Valve,
Type 3256 Angle Valve.
The Type 3256 Angle Valve can be fitted with a ceramic wear-resistant pipe. When the
process medium flows in the flow-to-close (FTC) direction, this version is suitable for
extreme erosive and abrasive conditions caused by process medium containing solids.
Details on ceramic materials and their properties are available on request.
In industrial plants, pneumatic and electric control valves control different media, often
under unfavorable flow conditions. In flashing service and with aggressive fluids containing
solid matter, the valve trim, i.e. seat and plug, as well as the valve body are subject to
erosive and abrasive wear.
In some applications, valve trims made of cast iron or PTFE are worn out within only a few
days and valve trims of stellited or forged titanium within a few weeks. Valve trims made
of low-wear ceramic, however, shows almost no signs of wear after one year in service.
Depending on the valve design and the particular properties of the ceramic material
used, the following advantages can be attained:
Seat and plug made of hot-pressed silicon nitride (HPSN)1
Constant high flexural strength and resistance to abrasive wear
Corrosion resistance
Service life 200 times longer compared to valve trims made of austenitic steel used
under highly erosive and abrasive conditions
Longer service life of angle valve bodies thanks to the flow¬to-close direction of flow
and an additional anti-wear sleeve of silicon carbide (SiC)
Figure 6.10.11.-2: SAMSON CONTROL VALVE Type 3256-1 NPS 10, ANSI CLASS 1500, Cv 1150,
Body material DUPLEX®, WN 1.4462, Plug material: SAFUREX®
Urea project: KARNAPHULI FERTILIZER COMPANY Ltd, KAFCO, Dhaka, Bangladesh,
(KAFCO a partner to Stamicarbon)
The medium Urea and Carbamate are very corrosive, crystallization may occur. This
material SAFUREX® (a super Duplex) is designed by Sandvik Sweden together with
Stamicarbon for corrosive applications. This material is very new and exclusive, and can
only be purchased after signing an agreement with Stamicarbon.
Safurex® materials
Safurex® is a duplex stainless steel grade exclusively
developed by Sandvik for the Stamicarbon Urea and
Melamine process. Safurex® is a high alloy ferrite-
austenite stainless steel, combining the good (stress)
corrosion properties of the ferrite steel with the good
ductility and weld-ability of austenitic steel.
The duplex structure results in high mechanical
properties and, in combination with the low thermal
expansion coefficient, results in great benefits with
respect to the design and construction of the HP urea
equipment. Not only savings in equipment weight but
consequently also in costs are evident. Safurex®
is the standard material for Stamicarbon HP urea
equipment, allowing the Stamicarbon urea plants, in
case all wetted parts in the HP synthesis section are
made in Safurex®, to run with very low oxygen in the
carbamate solution.
The good corrosion resistant properties of Safurex
®, also in oxygen free carbamate solutions, have
been demonstrated in elaborate laboratory testing
and field experiences with Safurex® equipment in
service for more that five years now (HP Carbamate
Condensers and HP Strippers). All material forms
(plates, forgings, heat exchanger tubes, piping)
and welding consumable needed to fabricate HP
equipment in Safurex® are available and proven. Al
so delivery time of these materials is comparable to
other stainless steels grades.
SBN to date has fabricated more that 10 HP Urea
equipment in Safurex® a nd the handling as well as
the welding is not more difficult compared to the fully
austenitic stainless steels grades traditionally used.
Figure 6.10.11.-3: Pneumatic Globe
Since Safurex® is supplied by a single source
Control Valve Type 3251-1 Size 4”, ANSI
supplier and Stamicarbon and Sandvik have a
Class 2500, with Actuator 2 x 2800 =
5600 cm2 p1 = 180 bar, p2 = 177 bar,
mutual agreement with respect to the quality control
225°C
and quality assurance on the Safurex® materials,
counter testing on Safurex® base materials is not necessary.
All Safurex® materials will be delivered fully tested according to the Stamicarbon
specifications (A4-18005, BE.06/MS50). To check the quality Stamicarbon performs
doping tests on Safurex ® base materials under production at Sandvik. Furthermore
for each project Stamicarbon must qualify the welding procedures. Since Safurex® is a
proprietary material, the Stamicarbon involvement in inspections during the fabrication of
HP equipment is therefore mandatory.
Bellows seal
Figure 6.10.12.-2: Gas expansion and flashing valve which could be mounted directly to a large vessel or
pipe volume
Plant BASF
Control valve for industrial high pressure plants according to the
Application
IG standard
Nominal size Nominal pressure Kvs value Body material
Valve data Forged
DN 16 to 90 PN 325 0.1 to 100
stainless steel
Trim material: WN 1.4571 stellited
Adjustable high-temperature packing ▪ For temperatures from −10 to 350 °C
Insulating section ▪ For temperatures from −200 to 450 °C (see pressure-
temperature diagram for pressures and temperatures)
Heating jacket▪ Available on request
Special features Metal bellows seal ▪ Material 2.4819 with additional backup packing and test
connection
Nominal size DN 120 ▪ Available on request
Nominal sizes DN 6 and DN 10 ▪ As Type 3510 Micro-flow Valve version
Technical data For all further data and industry codes see the associated technical
and accessories data sheet T 8059 EN.
Figure 6.10.13.-1: Control Angle Valve Type 3259-1 and 3259-7
SAMSON and VETEC have delivered around 100 standard valves as well as a large
number of IG high-pressure valves with nominal pressure PN 325 in valve sizes DN 16
to DN 120 for this plant. The SAMSON Type 3259 Valve was used for nominal sizes up
to DN 70. Valves from the Series 71.13 M for nominal sizes DN 90 and DN 120 were
supplied by VETEC.
The order was handled by the Technical Sales (V42 Dept.) and VETEC working in close
cooperation. A particular challenge was posed by the large nominal valve sizes DN 90
and DN 120 for the pressure letdown of liquid butadiene at a pressure drop of up to 300
bar and a closing pressure of 330 bar.
The quality assurance measures required, starting with the forging right up to the final
inspection and approval, were accordingly complex.
An actuator with four diaphragm chambers and a positioning force of 300,000 N was
developed by VETEC to achieve the high actuator forces. A similar double actuator has
successfully been in use at BASF for a long time.
The valves were delivered on time.
Figure 6.10.13.-2: Type 3259 of IG high-pressure valves with nominal pressure PN 325
Figure 6.10.14.-2: Globe Valve Type 3251 on the left side and Angle Valve Type 3256 on the right side
both with perforated plug.
Figure 6.10.14.-3: Globe Valve Type 3251 on the left side - FTO and
Angle Valve Type 3256 on the right side - FTC, both with perforated plug.
6.10.15. Control Globe and Angle Valve Type RVG with Multi-stage plug
6.10.16. For natural gas and offshore applications Valve Type VNG
Choke valve design and gas cavern storage control.
Characteristics:
Excellent device for highest pressure and pressure
reducing of gas
Especially for natural gas
Qualified for erosive stress
For operation of high pressure compressors
Optionally for sour gas
Simple and non-complicated internal parts (decisive in
case of soiling, erosion)
Patented jet extruder decreases vibrations and effects
sound - deadening.
Figure 6.10.-18: Example: Stainless carbon steel · A 351 CF8M (ANSI Class 150, 300)
Figure 6.10.-19: Example: Stainless carbon steel · A 351 CF8M (ANSI Class 600, 900)
(See Information Sheet T 8000-2 EN)
Figure 6.10.19.-1: Vinyl Chloride Malaysia Figure 6.10.19.-2: Offshore, Anti Surge Valves
Type 3284
Series 3280
Final control element with either globe or angle valve for use in
process engineering applications and thermal plants.
Valve pictures
Superheated steam
Steam converting
Water bath Condensate spray
valve control loop:
desuperheaters control nozzles control loop:
Pressure and
loop: Level Temperature
Temperature
Reduced pressure
Saturated steam
min. 5 to 15 °C Saturated steam
Saturated steam min. 5 to 15 °C
above saturation
temperature above saturation
temperature
Applications in which the products have to be heated through heat exchanger surfaces
where overheating of the product must be surely avoided are for example:
Heat exchangers for pasteurizers and sterilizers in the food industry
Heating systems for dry rolls in the paper industry
Heating systems for reaction vessels and pipelines in the chemical industry
Operation
2.7.3 E
P
3.1
T
Overflow Process
1.7.4
P
1.7.2 1.7.1 1.7.3
P
E A
Auxiliary energy
Pressure regulation
Saturated steam pressure and saturated steam temperature are associated with one
another physically. In the version with pressure regulation, the saturated steam pressure
is converted into a measurement signal which is conducted to a pressure controller [2.3]
through a pressure transmitter [2.2]. The output signal of the pressure controller [2.3]
operates the steam pressure control valve [2.5] through a positioner [2.4]. Thus the
pressure of the superheated steam can be reduced and cooled to desuperheated steam
temperature.
Safety equipment
The operating pressure in the pressure vessel [1.1] of the water bath desuperheater is
limited to the permissible value by means of a safety valve [2.6.3]. A safety pressure limiter
[2.7.1] and a safety temperature limiter [2.7.2] ensure that the pressure and temperature at
the saturated steam outlet do not exceed the permissible values. Whenever the pressure
and temperature reach the respective limit values, the steam pressure control valve [2.5]
is closed via a solenoid valve [2.7.3].
Figure 6.11.1.-2: Example: Steam heating of an autoclave vessel complete mounted system
The Type 994 - 0001 water bath desuperheater has the following features:
Desuperheating superheated steam to saturated steam temperature
Pressure reduction of superheated steam
Control range 0 to 100 %
Operating overpressure max. 11 bar, higher pressure on request
Saturated steam pressure max. 11 bar, higher pressure on request
Saturated steam temperature max. 187 °C
Steam throughput max. 40 t/h, depending on the saturated steam pressure
Pressure vessel made from H II (Material no. 1.0425) or CrNiTi (Material no. 1.4541)
Pressure vessel with German Technical Inspectorate Certificate, other certificates on
request
Version with fastening supports
Version with liquid level control
Version with liquid level control and pressure control
Version with liquid level control, pressure control and process temperature control
Version as complete system, ready for connection assembled in a frame
6.11.2. Spray Water Nozzle for steam temperature reduction with continuous
control
6.11.3. Spray Water Nozzle for steam temperature reduction with continuous
control
Introduction
Desuperheating (cooling) the steam can simply be achieved
by inject water into the steam flow. When injected, the water is
evaporated by means of the desuperheater nozzles. Thereby the
water absorbs heat and consequently the temperature of steam
is reduced.
The desuperheater is designed so, the at even at low injection
water quantities an efficient spray of very fine droplets (mist) is
obtained. When increasing the stroke, the water injection will
increase with a modified parabolic flow characteristic.
The nozzles in the sprayhead are designed to give the injection
water a high velocity and a radial rotating movement under
all conditions. The result is a fine atomization and very quick
evaporation. Figure 6.11.2.-2
Features of the DKV Desuperheater:
3 types of control characteristics, for accurate temperature
control
Large ∆p Water / steam pressure difference of 100 bar
(1450 psi) can be applied without an external control valve
Figure 6.11.3.-1: Excellent atomizing characteristics at a ∆p Water / steam of
Spray water nozzle min. 10 bar (145 psi) and at min. steam velocity of 10 m/s.
Tight shut-off. No leakage in closed position
No additional control valve required
High reliability due to simple party, minimal wear
Excellent control accuracy for the whole control range
Principal of Operation
The temperature sensor (Fig 5) transmits a signal through the control system to the
actuator (positioner) and positions the control piston according to the valve characteristic
(Figure 6.11.3.-2).
The cooling fluid is now admitted to the injection nozzle, and is accelerated by the nozzle
insert.
The cooling fluid is injected as a very fine water spray cone; the small droplets are
quickly evaporated and absorbed by the independent steam (hot gas). Our high quality
atomization of the cooling liquid is the basis of a good mixing from cooling fluid and steam
at all load conditions.
The position of the valve seat, just before the spray head, provides a tight shut-off in the
closed position, so that dripping is prevented (the piston is lapped into the seat!).
The small number of moving parts results in a reliable operation of the valve.
Materials
Standard housing materials 15 Mo 3 (DIN 1.5415) eq. to ASTM A 182 F1 13 CrMo44
(DIN 1.7335)eq. to ASTM A 182 F12
The body material is selected according to temperature and pressure conditions of steam
and water.
Internal parts are various stainless steel (min 13 % chrome).
DKV Details
The desuperheater is available in a standard body size with a max. pressure rating of
PN 160. Higher pressure ratings upon request.
Connections
Inlet flanges
DN 25 (NPS 1), DN 40 (NPS 1½) or DN 50 (NPS 2); up to PN 160 (ANSI Class 900)
Mounting flanges:
DN 80 (NPS 3) or DN 100 (NPS 4); up to PN 160 (ANSI Class 900) Flanges acc. DIN and
ANSI. The min. required internal pipe-diameter of the mounting flange is 76 mm.
% Cv
100
90
80
70
0
1:1
60
lic
25 bo
50 r
ea
1: ara
n
Li
P
40
30 ol
ic
ab
Par
20
10
Stroke
0
0 10 20 30 40 50 60 70 80 90 100 %
Figure 6.11.3.-2: Characteristics
Capacities
The desuperheater can be installed on a stub (min 150 mm or 6" height) on the steam pipe
(see fig. 10). Water is injected in the same direction as the steam flow. The desuperheater
can be installed in any position. The spray nozzle orientation, in regard to the water flange
position, can be selected according Figure 6.11.3.-4.
At a stroke of 32 mm the minimum pipe size is DN 150 (NPS 6). At a stroke of 55 or 80
mm, minimum pipe size is DN 200 (NPS 8). The minimum distance − Ls − (see Figure
6.11.3.-3) required between the desuperheater and the sensing element depends on
service conditions.
Instrumentation
A temperature sensing element, fitted on the steam piping (downstream of the
desuperheater) transmits changes of the steam temperature to a temperature controller.
This controller sends a signal (electric or pneumatic) to the actuator, which results in an
upward or downward repositioning of the desuperheater stem and control piston. Thus
the injection water quantity and subsequently the steam temperature are controlled.
Actuator
The desuperheater can be fitted with all electric, pneumatic or electric / hydraulic actuators.
For manual operations the valve can be fitted with a handwheel.
Ls
Figure 6.11.3.-3: Distance to the temperature measurement
A B C D
e
75 mm
150 mm
Diameter D
Cooling Water
Superheated Steam
Steam-converting Reduced Steam Pressure
Valve Type 3284 and Temperature
③
Figure 6.11.4.-1: Principle of steam conversion using two valves
Another proven construction which also has a noise reducing effect is represented in
Figure 6.11.4.-2. The cooling water is kept away from the hot walls of the conversion
valve and meets firstly a wire gauze of stainless steel which is an excellent mixing device
and improves the homogeneity of the steam on the low pressure side over the entire load
range.
BR 8a
BR 1d
BR 1a
BR 6a
BR 1a
BR 1c BR 1b
Standard DIN
version ANSI
-40 to 200 °C -40 to 200 °C -10 to 140 °C -40 to 200 °C
Temperature
-40 to 392 °F -40 to 392 °F 14 to 284 °F -40 to 392 °F
DN 25 to 150 25 to 100 50 to 150 25 to 150
Nominal sizes
NPS 1 to 6 1 to 4 2 to 6 1 to 6
Nominal PN 10/16 10/16 10/16 10/16
pressure Class 150 150 150 150
Linear Linear Linear Linear
Characteristic Equal Equal Equal
-
percentage percentage percentage
⋆ Lining PTFE PFA PFA PTFE
Material EN-JS 1049 EN-JS 1049 EN-JS 1049 EN-JS 1049
⋆ Body
(GGG 40.3) (ASTM A 395) (ASTM A 395) (GGG 40.3)
⋆ Valve plug / seat
PTFE PTFE PTFE-TFM PTFE
and Bellows
Packing PTFE-graphite PTFE V-ring PTFE V-ring PTFE-graphite
Leakage rate A acc. to DIN
EN 12266-1, P12
(Leakage rate 1 BO acc. to
DIN 3230 Part 3)
⋆ Conductivity for EX-Zone 0 Possible Possible Possible Possible
⋆Pneumatic actuator or hand
operated actuator
Valve pictures
Technical data ⋆ For all further data, accessories, and industry codes see the associ-
and accessories ated technical data sheet.
Standard DIN
version ANSI
-10 to 150 °C -10 to 150 °C -10 to 150 °C
Temperature
14 to 302 °F 14 to 302 °F 14 to 302 °F
DN 20 to 100 6 to 15 15 to 100
Nominal sizes
NPS
Nominal PN 10/16 10/16 10/16
pressure Class
Linear Linear Linear
Characteristic Equal Equal Equal
percentage percentage percentage
⋆ Lining PTFE PTFE PTFE
Material GGG 40.3 GGG 40.3 GGG 40.3
⋆ Body
- PTFE - PTFE - PTFE
⋆ Valve plug / seat
PTFE PTFE PTFE
and Bellows
Valve pictures
Technical data ⋆ For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Diameter
Curve DN NPS
25 1
a 40 1½
50 2
80 3
b
100 4
c 150 6
PFA Lining
The operating range is determined by the Pressure - Temperature - Diagram.
Process data and media can influence the values of the diagram. For process data above
the limits of application please consult company Pfeiffer Chemie Armaturenbau GmbH1.
Diameter
Curve DN NPS
25 1
a 40 1½
50 2
80 3
b
100 4
Figure 6.13.-1: On the left the Gate valve () is closed and on the right open.1
A gate valve with multiple orifices is shown in Figure 6.14.-2. It is perceived as a control
valve and considered as an alternative to the classic globe valve. A sandwich-like valve
body contains a fixed plate with narrow, horizontal slots. A moveable plate, with a similar
slot profile as the fixed plate, is pressed by means of the differential pressure, against
the fixed plate and is driven by a short stroke linear actuator. Depending on the stroke
position of the valve the free cross-sectional area changes and enables thus a continuous
control of the fluid. A high contact pressure and a flat and smooth gliding surface help to
achieve a low seat leakage.
1 http://www.valve.asia
Sleeve
The operating principle of a Pinch valve is simple. In the open position (left), the valve is
at full bore with no flow restrictions thus making the valve an integral part of the pipeline.
During closing (right), two pinch bars squeeze the sleeve shut AUTOMATIC on the center
line.
Opening tags
Reinforcing cords
The standard sleeve design consists of three sets of layers: the inner layer, the
reinforcement layer and the outer layer.
Sleeve design
The inner layer, which is the only part in
contact with the medium, is resistant to
wear and chemicals.
The reinforcement layer gives the
sleeve its pressure retaining capability.
The operating pressure of the sleeve
determines the reinforcement fabric to
be used in this layer.
The outer layer protects the sleeve from
the external process environment.
Technical Features:
Size range: 25 mm – 1000 mm
Operating temperature: -50°C – +160°C
Operating pressure: Vacuum to 100 bar
The valves provide a 100 % tight shut-off
Only the sleeve is in contact with the
Medium
Linear Control Curve
Flexible Sleeve
Figure 6.15.1.-2: Pinch valve
Valve Typical
Advantages Disadvantages
style availability
Valve Typical
Advantages Disadvantages
style availability
Limited application range
Sandwich type, very compact
No typical options available as
DN 15-100 Independent from flange
Gate valve for standard easy type
PN 25-40 standards (DIN or ANSI)
type Poor rangeability and high
ANSI 150-300 Economical solution for ON/ pres-sure recovery (short
OFF services
stroke)
Table 6.16.-1: Advantages and disadvantages of commonly used linear control valves
This trend is further supported by a number of pre-requisites which did not have
the same importance in earlier days as they do now:
Strong cost-control by the users and planners requires the best economic solution in
the selection of a suitable control valve.
Service and maintenance always attain a greater importance and are taken early into
account in the planning procedure.
The almost obligatory use of computers in the specifying of control valves permits, today,
a much more specific selection of the most suitable type. The occurrence of cavitation
can be, for example, precisely predicted. This leads either to countermeasures, in
order to achieve the required service life span or to a check of the operating conditions,
to see if the pressure differential can be reduced. Frequently a reduction of the pump
pressure head is possible and this provides a number of advantages:
Avoidance of cavitation by means of lower differential pressures across the
control valve often allows the use of standard valves instead of expensive special
versions.
Reduction of the differential pressure to the absolutely necessary minimum yields a
lower noise level and frequently avoids the need for expensive low noise valves.
Lower differential pressures which might be obtained by the selection of pumps
with a lower head pressure means, naturally, a lower energy consumption for the
motor driving the pump.
Lined Metallic
PTFE PFA
Standard Special
BR 20a BR 20b
Figure 6.17.1.-2: Ball valve with PTFE lining Figure 6.17.1.-3: Ball valve with special metal
There are ball valves with swimming ball (floating ball) or with a guided ball (trunnion ball).
A trunnion ball valve has a mechanical means of anchoring the ball at the top and the
bottom, this design is usually applied on larger and higher pressure valves.
Figure 6.17.2.-2: Ball valve with „floating“ ball Figure 6.17.2.-3: Trunnion type ball valve
The process medium can flow through the Ball Valve in both directions when the valve is
completely open.
The ball with its cylindrical passage rotates around the middle axis. Over the trunnion
which is located underneath the ball, the ball is double-guided. The rotary angle of the ball
determines the flow rate over the free area between the body and the ball channel. When
the valve is fully open, the entire cross-section is released.
The top end of the stem is fitted with a lever. It can optionally fitted with a pneumatic rotary
actuator or manual gear.
Note: The ball valve can also be used for throttling service. Please refer to the Data Sheet
for further instructions in this case.
Note: Before using the ball valve in hazardous areas, check whether this is possible acc.
to ATEX 94/9/EC. See Operating Instructions.
Cup spring life-loaded PTFE packing: Single side cup spring loaded and covered:
* For low pressure and low temperatures. * For low pressure and increased temperature and
(„bubble-thight version) differential pressure and extended life time.
Cup spring life-loaded PTFE packing: Single side cup spring loaded:
* For low pressure and low temperature by low dif- * For low pressure and increased temperature and
ferential pressure. differential pressure.
Not cup spring loaded but covered: Double side cup spring loaded and covered:
* For low pressure and increased temperature and * For high pressure and increased
differential pressure and extended life time. Temperature and extended life time.
Figure 6.17.3.-3: Ball Valve seat rings; * see P-T - Diagram and Figure 6.17.3.-7
Control shaft
Locking plate
Spring washer
Spacer
Series 20a
Pressure ring
V-ring packing
These qualities make full bore ball valves - when used in a straight flow path - particularly
suitable for tough, sticky media or fluids loaded with hard particles like slurries or
suspensions. The design principles and body styles are numerous.
For simple ON-OFF applications, the ball normally carries a slit or another form-locking
connection with the drive shaft. A small backlash is, for those services, usually acceptable
Figure 6.17.2.-3.
Hardened surface for metal sealing systems
Low tear and wear approx. 70 HRC1
High abrasion resistance
Extended temperature resistance
-10 °C to 550 °C, 14 to 1022 °F
Low leakage due to lapped surfaces
DN 15 to DN 300, NPS ½ to 12
PN 10 to PN 160 , Class 150 to 900
Thickness approx. 0,2 mm
Special hardening available
Figure 6.17.3.-5: Hardened surface for metal sealing systems
The body of ball valves is usually split in the direction of the main axis and closed by
a bonnet flange through which the ball, including the shaft, can be assembled Figure
6.17.3.-5. One can distinguish between ball valves with a “floating” ball and a ball guided
by two trunnions, the so-called trunnion type ball valve. A disadvantage of the “floating”
ball valve is the high friction at large nominal sizes and high pressure differentials. These
require very high drive torques.
With trunnion type ball valves, the friction radius and the required torque is reduced, but
this is achieved at the expense of the maximum permitted differential pressure Figure
6.17.3.-6.
Trunnion
NPS ½ to 1
580 psi
DN 15 to 25
40 bar
NPS 1½ to 2
DN 40 to 50
NPS 6 to 20
440 psi
30 bar
DN 150 to 500
NPS 2½ to 4
DN 65 to 100
290 psi
20 bar
NPS 6 to 8
DN 150 to 200
145 psi
10 bar
0 psi
0 bar
- 4 °F 32 °F 104 °C 176 °C 248 °C 320 °C 392 °C T
- 20 °C 0 °C 40 °C 80 °C 120 °C 160 °C 200 °C
Black curves:
Tight-closing ball valve of stainless steel for aggressive media, especially with high
process demand in chemical plants.
Red curve:
Tight-closing ball valve produced from anti-corrosive material for heavy duty service,
especially for high process demand in chemical plants.
Figure 6.17.3.-7: Pressure -Temperature diagram for stainless steel or precious metal
DN PN 10 PN 16 PN 25 PN 40 PN 63 PN 100 PN 160
15
20 BR 26a
32
40
50
65
BR 26e
80
100
150
200
250
300
350 BR 26s; BR 26e Special
400
450
500
NPS 150 lbs 300 lbs 600 lbs 900 lbs 1500 lbs
½
¾
1
1¼
1½ BR 26a
2
2½ BR 26e
3
4
6
8
10
12
BR 26s; BR 26e
14 Special
16
18
20
Versions:
Ball valve Series 26d alternatively in the following
designs:
Ball valve with hand-lever (DN 150 with gear
operator).
Ball valve with gear-operated actuator.
Ball valve with pneumatic quarter-turn actuator.
Special designs:
Safety stem seal.
Fire-safe version with test certificate according to
British Standard B.S. 6755 Part 2.
Heating jacket, stainless steel with various
connection.
Flange versions acc. to DIN EN 1092. Figure 6.17.4.-2: Ball valve
Series 26d with heating jacket
Control ball valve due to characteristic seatring
(For details see respective data sheet).
Thanks to high quality standard and important supplies an the largest worldwide projects,
Starline year by year has grown his qualification into the leading companies in the Oil &
Gas field, Shipyards, LNG, and Energy.
This process is in continuing update and development.
Certificates
Customer Approvals
PDO ENI ACHILLES EIL NIGC
Many other approvals and certificates such as but not limited to PED, ATEX, FUGITIVE
EMISSION NAVAL TYPE APPROVAL, DNV, CRYOGENIC are available an their latest
issue on our WEB PAGE http://www.starline.it "news and quality & Certification" area.
Super STAR N. 1
Three pieces floating ball valves "FIRE SAFE", ISO 5211,
TA-LUFT
Size range: NPS ¼ to 3 full bore, NPS ½ to 4 reduced bore
Carbon steel ASTM A105/LF2 dual certified
Stainless steel ASTM A182 F316 and special materials
CLASS 150 to 900 Lbs - PN 16 to PN 160,
1000 to 2200 WOG
Split STAR N. 7
Split body floating ball valves
"FIRE SAFE", ISO 5211, TA-LUFT
Size range: NPS ½ to 6 full bore, NPS 6, 8 reduced bore
Carbon steel ASTM A105/LF2 dual certified
Stainless steel ASTM A182 F316 and special materials
CLASS 150 to 300 Lbs, PN 10 to PN 40
Cryostar TRUNNION
Three pieces bolted construction trunnion mounted
Size range: NPS ½ to 10 full bore, NPS ¾ to 12 reduced bore
Stainless Steel ASTM A182 F316 and other special materials
CLASS 150 to 2500 LBS, PN16 to PN420,
1000 to 6000 WOG
6.17.5.5 Floating
There are many different Starline models to cover the range of floating valves:
STANDARD, MASTERSTAR, SUPERSTAR, SPLITSTAR, MEGASTAR,
THREADEDSTAR
With this large selection of models we shall cover range between NPS ¼ - 8 and pressure
ratings from 150 to 2500 lbs** (**class 900/1500 up to NPS 2 class 2500 up to NPS 1).
Within this range we shall offer any kind of end connection (screwed, welded - long and
short - flanged ASME or DIN) and soft seat/seals material (Virgin or Reinforced PTFE,
Nylon, Delrin, Peek, Kel’f, Vespel, UHMWPE - O-rings in VITON (Aed,Glt) - Elast-o-lion,
Chemraz, Kalrez, Aflas etc.).
We have also a special line of Metal seated valves for abrasive and high temperature
applications and one line of Cryogenic valves.
Description:
Three pieces bolted floating construction
Size range from NPS ¼ to 2
Pressure classes up to 800 Lbs - PN100
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation
Material CS A105-LF2 and SS 316.
Flanged Connection:
Description:
Three pieces bolted floating construction
Size range from NPS ¼ to 2
Pressure classes up to 800 Lbs - PN100
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
Flanged to ASME B16.5 class 150
Flanged to ASME B16.5 class 300
Flanged to DIN PN16-25-40-63
Description:
Three pieces bolted floating construction
Size range from NPS ¼ to 4
Pressure classes up to 900 Lbs - PN 150
Full or reduced bore
Anti blow out proof stem design
Encapsulated soft seats
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Description:
Three pieces bolted floating construction
Size range from NPS ¼ to 2
Pressure classes up to 2500 Lbs - 415 bar
Full bore
Anti blow out proof stem design
Encapsulated soft seats
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS LF2 and SS 316
All SPECIAL MATERIAL available.
Flanged Connection:
Flanged to ASME B16.5 class 2500 up to NPS 1 RB
Flanged to ASME B16.5 class 1500 up to NPS 2 RB
Flanged to DIN PN250 - 420 up to NPS 1 RB
Flanged to DINPN250 up to NPS 2 RB
Description:
Three pieces screwed floating construction, seal welded on request.
Size range from NPS ¼ to 4
Pressure classes up to 2500 Lbs - 5000 PSI
Full or reduced bore
Anti blow out proof stem design
Encapsulated soft seats
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
FLOATING - Multiport
THREE & FOUR WAY
Description:
Mutiport bolted floating construction
Size range from ¼" to 3"
Pressure classes up to 600 Lbs - PN 100
Full or reduced bore
Anti blow out proof stem design
4 Encapsulated soft seats that support the ball
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
Flanged to ASME B16.5 class 150 up to NPS 3 RB
Flanged to ASME B16.5 class 300 up to NPS 3 RB
Flanged to ASME B16.5 class 600 up to NPS 1¼ RB
Flanged to DIN PN16-25-40 up to NPS 3 RB
Description:
Two pieces bolted floating construction
Size range from NPS ½ to 8
Pressure classes up to 300 Lbs - PN 40
Full or reduced bore
Anti blow out proof stem design
Encapsulated soft seats
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
Flanged to ASME B16.5 class 150 up to NPS 8 RB
Flanged to ASME B16.5 class 300 up to NPS 6 RB
Flanged to DIN PN16-25-40 up to NPS 6 RB
Flanged to DIN PN16-25 up to NPS 8 RB
Description:
Two pieces bolted floating construction
Size range from NPS ½ to 6
Pressure classes up to 800 Lbs - PN 100
Full or reduced bore
Anti blow out proof stem design
Soft seats spring energized
Antistatic device
One piece solid extended bonnet
Top ISO 5211 for easy automation.
Standard Material SS 304 and 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 - ASME B31.1 – API6D
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR 0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Flanged Connection:
Flanged to ASME B16.5 class 150-300-600
Flanged to DIN PN16-25-40-63-100
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-13: FLOATING - Cryogenic service Type CRYOSTAR
Description:
Two pieces bolted floating construction
Size range from NPS ½ to 3
Pressure classes up to 800 Lbs - PN 100
Full or reduced bore
Anti blow out proof stem design
Metal to metal Construction
No O-ring (metal + graphite design)
Seats spring energized
Ball/Seats hardened with Tungsten Carbide or Chrome Carbide (HVOF Process)
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
Flanged to ASME B16.5 class 150-300-600
Flanged to DIN PN16-25-40-63-100
Description:
Two/Three pieces bolted floating construction
Size range from NPS ½ to 4
Pressure classes up to 2500 Lbs - PN 420
Full or reduced bore
Anti blow out proof stem design
Soft Seated - Encapsulated seats
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Design & Certification:
This model is designed with special long body including two balls and one needle
valve (Double Block and Bleed - DBB) or one ball and one needle valve (single block
and bleed - SBB)
The needle valve on request shall be replaced by another ball valve used as drain
(multiport style).
End caps shall be used in different executions and sizes (for example one side flanged
NPS 2 and one side NPS ½ screwed)
Flanged Connection:
Flanged to ASME B16.5 class 150-300-600
Flanged to DIN PN16-25-40
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-15: FLOATING - Double block and bleed Single block and bleed
Type TWINSTAR
6.17.5.16 Trunnion
Description:
Three pieces bolted construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs – PN 420
Soft Seated (PTFE-NYLON-PEEK-KEL’F)
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-17: TRUNNION - Bolted costruction Type ULTRASTAR
Description:
Three pieces screwed construction - seal welded
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - 420 bar
Soft Seated (PTFE-NYLON-PEEK-KEL’F)
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500Lbs
DIN PN 16-25-40-63-100-250-420
Description:
Three pieces bolted or screwed (seal welded) construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Ball/Seats Hardened with Tungsten Carbide or Chrome Carbide (HVOF Process)
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 - ASME B31.1
API6D - API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Leakage Rate ANSI/FCI 70-2 CLASS VI
Flanged Connection:
ASME B16.5 CLASS 150 to 2500Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available
Figure 6.17.5.-19: Metal seated - Abrasive service Type ULTRASTAR - TRUNNION
Description:
Three pieces bolted or screwed (seal welded) construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Ball/Seats Hardened with Chrome Carbide (HVOF Process)
- Special construction with metal and Graphite packing - No o-rings.
Service up to 700°C
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available (Including F9, F11, Inconel 625 for very high
temperature). Material selection depending on service and temperature.
Design & Certification:
ASME B16.34 – ASME B31.1
API6D – API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Leakage Rate ANSI/FCI 70-2 CLASS VI
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500 Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-20: TRUNNION - Metal seated - High temperature service Type ULTRASTAR
Description:
Three pieces bolted or screwed construction
Trunnion Mounted construction
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Metal Seats + Soft insert (PTFE-PEEK-KEL’F)
Special o-ring Design with Low temp materials and/or Lip Seal
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material S.S. 304 and 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 - ASME B31.1
API6D - API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Lloyd’s Register Testing to BS 6364
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500 Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS 21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-21: TRUNNION - Metal seated - Cryogenic design Type ULTRASTAR
Description:
Three pieces bolted construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Soft Seated (PTFE-NYLON-PEEK-KEL’F)
Metal Seated - Ball/Seats hardened with Tungsten Carbide or Chrome Carbide
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material C.S. A105-LF2 and S.S. 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 – ASME B31.1
API6D - API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-22: Type TWIN ULTRASTAR - TRUNNION
Double block and bleed twin valve
In the course of the latest years Starline has developed several products intended for use
on very critical applications, such as low temperature (till -196°C) abrasive applications and
very high temperature (till +700°C) applications. These special valves, like CRYOSTAR,
METALSTAR and TWINSTAR, are available in all possible existing materials and
configurations and they cover the complete Starline Range, both as regards sizes and
pressure. Due to the importance and critical services which they are meant for, we have
carried out several tests on these valves in order to check their performance under severe
conditions.
We have also at disposal in-house instruments for repeating such tests on the Customer’s
demand.
For example, we carried out Cryogenic tests as certified by Lloyd’s Register, according
to BS6364, Fugitive emission tests according to Shell and TUV standard, Cycling tests in
temperature and long cycle performance tests according to EN161-264.
SPECIAL VALVES - Double block and bleed single block and bleed
TWINSTAR
Description:
Two/Three pieces bolted floating construction
Size range from NPS ½ to 4
Pressure classes up to 2500 Lbs - PN 420
Full or reduced bore
Anti blow out proof stem design
Soft Seated - Encapsulated seats
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Flanged Connection:
Flanged to ASME B16.5 class 150 to 2500 Lbs
Flanged to DIN PN16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
SW-BW-PE to ASME B16.11/B16.25 (Different schedules available)..
Figure 6.17.5.-24: Type TWINSTAR - SPECIAL VALVES
Double block and bleed single block and bleed
SPECIAL VALVES - Double block and bleed single block and bleed
TWIN ULTRASTAR
Description:
Three pieces bolted construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Soft Seated (PTFE-NYLON-PEEK-KEL’F)
Metal Seated - Ball/Seats hardened with Tungsten Carbide or Chrome Carbide
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 – ASME B31.1
API6D - API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500 Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
Description:
Two pieces bolted floating construction
Size range from NPS ½ to 3
Pressure classes up to 800 Lbs - PN 100
Full or reduced bore
Anti blow out proof stem design
Metal to metal Construction
No O-ring (metal + graphite design)
Seats spring energized
Ball/Seats hardened with Tungsten Carbide or Chrome Carbide (HVOF Process)
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 - ASME B31.1 - API6D
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR 0175 Latest Edition
Fire Safe API 607- API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Flanged Connection:
Flanged to ASME B16.5 class 150-300-600 Lbs
Flanged to DIN PN16-25-40-63-100
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
SW-BW-PE to ASME B16.11/B16.25 (Different schedules available)
Figure 6.17.5.-26: SPECIAL VALVES - Metal seated Type METALSTAR
Description:
Three pieces bolted or screwed (seal welded) construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Ball/Seats Hardened with Tungsten Carbide or Chrome Carbide (HVOF Process)
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available.
Design & Certification:
ASME B16.34 - ASME B31.1
API6D - API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Leakage Rate ANSI/FCI 70-2 CLASS VI
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500 Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-27: SPECIAL VALVES - Metal seated Type ULTRASTAR - ABRASIVE SERVICE
Description:
Three pieces bolted or screwed (seal welded) construction
Trunnion Mounted
Size range from NPS ½ to 12
Pressure classes up to 2500 Lbs - PN 420
Ball/Seats Hardened with Chrome Carbide (HVOF Process) -
Special construction with metal and Graphite packing - No O-rings.
Service up to 700°C
Full or reduced bore
Anti blow out proof stem design
Antistatic device
Top ISO 5211 for easy automation.
Standard Material CS A105-LF2 and SS 316
All SPECIAL MATERIALS available (Including F9. F11, Inconel 625 for very high
temperature).
Material selection depending on service and temperature.
Design & Certification:
ASME B16.34 - ASME B31.1
API6D - API6A
P.E.D. 97/23/EC - ATEX 94/9 CE
NACE MR0175 Latest Edition
Fire Safe API 607 - API 6FA - BS 6755 Part.2
Standard certification UNI EN 10204 type 3.1, 3.2 available on request.
Leakage Rate ANSI/FCI 70-2 CLASS VI
Flanged Connection:
ASME B16.5 CLASS 150 TO 2500Lbs
DIN PN 16-25-40-63-100-250-420
Welded or Screwed Connections:
NPT to ASME B1 20.1
BSPP or BSPT to BS21
Integral Nipples SW-BW-PE to ASME B16.11/B16.25 (Different schedules available).
Figure 6.17.5.-28: SPECIAL VALVES - Metal seated - Type ULTRASTAR - HIGH TEMPERATURE
Description:
One piece seal welded body
Floating ball double block
Primary seal METAL TO METAL
Secondary seal Vulcanized Viton or Nbr
Pressure safe cover for the stem to prevent any leakage.
Antistatic device
Available on three typical sizes ½" - 1" - 2"
Class ASME 600 and 1500Lbs (PN100 – PN250)
Standard Material C.S. A105-LF2
All SPECIAL MATERIAL available.
Flanged Connection:
ASME B16.5 CLASS 600 and 1500Lbs
DIN PN 100 and 250
BR 20a
PTFE-lined
BR 20z
PTFE-lined
BR 20b
PFA-lined
BR 20c
PTFE-lined
Valve pictures
PTFE = Polytetrafluorethylen
PFA = Perfluoralkoxy
Carbon
Fluor
Oxygen
Finishing
Stage 1 Internal machining with corresponding
Computerized Numerical Control (CNC)
tools.
PTFE Filling
Stage 2 Flexible tubes keep the PTFE-powder,
carefully hand filled, between body and
Membrane.
PTFE
Isostatic pressing at approx. 275 bar
Stage 3 gives the PTFE-powder a proper shape.
Flexible Membrane
PTFE
Stage 4 After isostatic pressing the lining has
to be pre-machined to be prepared for
sintering.
PTFE
Stage 5 Sintering at approx. 390°C for a period
of almost 15 hours.
Finalization
Stage 6 Finishing to realize required dimensions,
after sintering.
Finishing
Stage 1 Internal machining with corresponding
Computerized Numerical Control (CNC)
tools.
PFA
Stage 2 PFA-granulate will be heated up and
melted in a cylinder.
PFA
Melted PFA will be pressed with approx.
Stage 3
280 bar between tool and body
(Lining thickness 3 mm).
Cooling
To achieve a homogenous bubble free
cast lining, the unit will be cooled parallel
Stage 4
with air and water, still hold under
pressure.
Period: approx. 15 Minutes.
Finalization
The result is a completely finished unit
Stage 5
without any request for further finishing
steps..
Figure 6.17.8.-3: Cup spring live-loaded packing for PFA-lined ball valve
Advantage
Protected DIN-ISO Top-Flange
The fluid will never get in contact with Graphite
Double shaft sealing PTFE & Graphite
Low emission packing acc. TA-Luft
PTFE V-Ring Packing, spring loaded, self-adjustable
Two shaft bearings
More than 7500 Ball Valves in using at company BASF AG world-wide.
Figure 6.17.9.-2: Pressure -Temperature diagram for PTFE - lining above and PFA - lining below
1 2 4 6 5 3 1
Figure 6.17.10.-1: Ball Valve Series 20a (schematic)
The ball (2) with its cylindrical passage rotates around the middle axis. The opening angle
of the ball determines the flow through the free area between the body (1) and passage.
When the ball valve is opened, the entire profile is available.
The stem is externally equipped with a hand-lever (13). Optionally, a pneumatic quarter-
turn actuator can be fitted.
The sealing of the ball (2) inside the PTFE lined body is provided by exchangeable
seatrings (3).
The ball stem is sealed by a maintenance-free live-loaded PTFE - V-ring packing (4). The
live-loading is carried out by cup springs positioned above the packing.
Pos. Description Pos. Description
1 Body and lining 8 Thrust washer
2 Ball with coating 9 Set of spring washers
3 Set of seatrings 10 Bearing bushing
4 Screw 11 Stuffing box
5 Nut 12 Screw
6 Spring washer 13 Hand-lever
7 V-ring packing
Table 6.17.10.-2: Parts list
Application
For control tasks with small pressure drops and high flow rates. Optional calibrated sealing
ring versions are available for the following Pfeiffer ball valves:
Series 20a PTFE-lined Ball Valves
Series 20b PFA-lined Ball Valves
Series 26a Precious Metal Ball Valves
Series 26d Stainless Steel Ball Valves
Calibrated sealing rings for other valves are available on request.
Equal-percentage
Square characteristic
characteristic
V-Ball Valves
Pro Contra
Very high Cv-Value High friction ≧ high wear
Almost free of dead corner Not suitable for abrasive media
Free flow path No noise attenuation
Tight shut off Only for low delta p
Low profile Limited temperature range
Linear or equal-percentage characteristic
Suitable for fibrous materials
Table 6.17.12.-2: V-Ball Pro and Contra
Flow characteristics
Modified
Modified Equal
Style On-Off Linear Equal
Linear percentage
percentage
Globe valve Yes Yes Yes Yes Yes
Rotary plug
Function Yes Yes No No
valve
V-Ball valve Function Yes Yes Yes Yes
Butterfly
Function Yes No
valve
Ball valve Function No No Yes Yes
100
90
i c
e r ist
80 ract
tic a
ris ch
70 e e ar
lin
ct
d
ra
fie
tic
ha
60 di
ris
c
o
Cv / Cv100 %
ff
M
te
-O
ac
On
ar
50
ch
age
40 e nt
rc t
ic
tic e r is
ris lp te
30 acte q ua r a c
ar de c ha
ch difie e
ar Mo tag
20 Lin
e cen
al-per
Equ
10
0
0 10 20 30 40 50 60 70 80 90 100
Globe and rotary valve opening %
Ball Valves
Pro Contra
Suitable for control only with reduced
Very high Cv - values
Cv100; reduced bore
Free flow path ≧ suitable for
Fixed inherent characteristic
PIC-cleaning systems
Expensive design for large diameters
Tight shut-off
and high ∆p ≧ double guided balls
Low profile Expensive noise attenuation
Table 6.17.12.-4: Ball Valve - Pro and Contra
Price comparison
100
Globe Valve
80
Rotary Plug
Flange
60
%
Rotary Plug
40 Sandwich
20
Butterfly Valve
0
25 40 50 80 100 150 200 250 300 400
Diameter mm
Pressure ratings
Type Type Type Type Type Type Type Type Type
26d, 26d, 26l,
Class PN
Type Type 20a 20b 26a 26e 26s 26u t, x, v,
C A and w
DN 15 DN 15 DN 15 DN 15 DN 15 DN 15 DN 15 DN 15
to 150 to 100 to 150 to 100 to 150 to 150 to 500 to 200
125 10
NPS NPS NPS NPS NPS NPS NPS NPS
½ to 6 ½ to 4 ½ to 6 ½ to 4 ½ to 6 ½ to 6 ½ to 6 ½ to 8
DN 15 DN 15 DN 15 DN 15 DN 15 DN 15 DN 15 DN 15
to 150 to 100 to 150 to 100 to 150 to 150 to 500 to 200
150 16
NPS NPS NPS NPS NPS NPS NPS NPS
½ to 6 ½ to 4 ½ to 6 ½ to 4 ½ to 6 ½ to 6 ½ to 20 ½ to 8
DN 15 DN 15 DN 15 DN 80 DN 15 DN 15
to 100 to 100 to 150 to 150 to 500 to 200
250 25
NPS NPS NPS NPS NPS NPS
½ to 4 ½ to 4 ½ to 6 3 to 6 ½ to 20 ½ to 8
DN 15 DN 15 DN 15 DN 80 DN 15 DN 15
to 100 to 100 to 150 to 150 to 500 to 200
300 40
NPS NPS NPS NPS NPS NPS
½ to 4 ½ to 4 ½ to 6 3 to 6 ½ to 20 ½ to 8
DN 15 DN 40 DN 125
to 50 to 150 to 300
400 63
NPS NPS NPS
½ to 2 1½ to 6 5 to 12
DN 15 DN 40 DN 150
to 25 to 100 to 300
600 100
NPS NPS NPS
½ to 1 1½ to 4 6 to 12
DN 15 DN 40 DN 150
to 25 to 100 to 300
900 160
NPS NPS NPS
½ to 1 1½ to 4 6 to 12
DN 15 DN 10 DN 150
to 25 to 25 to 300
1500 250
NPS NPS NPS
½ to 1 ⅜ to 1 6 to 12
DN 15 DN 10
to 25 to 25
2500 320
NPS NPS
½ to 1 ⅜ to 1
DN 15 DN 10
to 25 to 25
2500 400
NPS NPS
½ to 1 ⅜ to 1
Table 6.17.12.-7: Pressure rating of ball valves
Type BR 21a
Tight-closing PTFE-lined drain ball valve for corrosive media, especially with high
process demand in chemical plants. The ball valves fitted with a pneumatic actuator
can be equipped with positioner, solenoid valve and other devices in accordance with
VDI/VDE 3845. Please contact http://www.pfeiffer-armaturen.com for more details.
General technical data Options
Inlet DN 50 up to DN 150 as well as 2“ up to 6“
Special materials
Outlet 50, 80, and 100
PN 10/16 and ANSI Class 150 Double bearing assembly
Valve body made of spheroidal graphite iron with
Heating jacket version
isostatic lining made of white PTFE
Ball material Stainless steel encapsulated in Lining with special PTFE
PTFE compounds
Temperatures -10 to 200 °C
High temperature version
(See Pressure-Temperature diagram)
Two-piece body Metallic sealing system
Exchangeable PTFE seat rings With hand-lever
Ball shaft sealed by a spring-loaded PTFE V-ring
With gear-operated actuator
packing
TA-Luft (German clean air act) equivalent With pneumatic quarter-turn
certification actuator,
Figure 6.18.-3: Bottom Drain Ball Valve Type BR 21a with PTFE-lined
Type BR 22a
Non-clogging, tight-closing bottom drain ball valve of stainless steel for corrosive
media, especially suitable for vessels. The ball valves fitted with a pneumatic actuator
can be equipped with positioner, solenoid valve and other devices in accordance with
VDI/VDE 3845. Please contact http://www.pfeiffer-armaturen.com for more details.
General technical data Options
Inlet DN 50 up to DN 200, NPS 2 to 8 Nominal size DN 25, DN 40 and up
Outlet 50, 80, 100, and 150 to DN 300 (NPS 12) available.
PN 10 to PN 40 and ANSI Class 150/300 Pressure rating > PN 160 on request
Body, Ball and Stem in stainless
Two-piece body
steel or special materials
Inclined stem Double bearing assembly
Temperatures up to 200°C High temperature version
Sealing rings in PTFE / TFM
Metallic sealing system
Exchangeable seat rings
Materials: WN 1.4408 / WN 1.4462 / WN
Heating jacket version
1.4571
Materials: WN 1.4408 / WN 1.4462 / WN With sampling device in stainless
1.4571 steel.
Connecting flanges acc. to ANSI
PTFE - packing
Class 150/300 on request
Figure 6.18.-4: Bottom Drain Ball Valve Type BR 22a of stainless steel
Type BR 22a
Tight-closing stainless steel ball valve for corrosive media, especially designed for
demanding applications in chemical plants. The ball valves fitted with a pneumatic
actuator can be equipped with positioner, solenoid valve and other devices in
accordance with VDI/VDE 3845. Please contact http://www.pfeiffer-armaturen.com for
more details.
General technical data Options
Inlet DN 50 up to DN 200, NPS 2 to 8 Nominal size DN 25, DN 40 and up
Outlet 50, 80, 100, and 150 to DN 300 (NPS 12) available.
PN 10 to PN 40 and ANSI Class 150/300 Pressure rating > PN 160 on request
Body, Ball and Stem in stainless
Two-piece body
steel or special materials
Inclined stem Double bearing assembly
Temperatures up to 200°C High temperature version
Sealing rings in PTFE / TFM
Metallic sealing system
Exchangeable seat rings
Materials: WN 1.4408 / WN 1.4462 / WN
Heating jacket version
1.4571
Materials: WN 1.4408 / WN 1.4462 / WN With sampling device in stainless
1.4571 steel.
Connecting flanges acc. to ANSI
PTFE - packing
Class 150/300 on request
Figure 6.18.-5: Tank valve Type BR 27h to be placed at the bottom of a container or tank
Table 6.18.-6: Functional description of Bottom Drain Ball Valve Type BR 27h
In comparison with a full bore ball valve the segmented type offers the required expansion
volume within the valve body Figure 6.19.-1. Instead of a solid ball this type contains a
double guided and , trunnion like, shell-shaped ball segment with a V-shaped slit
which is connected to the valve stem by a form-locking connection . This design
enables, in association with a resilient seat that deposits are removed and long fibers
carried along with the fluid are cut-off by the scissors-like plug/seat construction. Depending
on the free cross-sectional area of the V-shaped slit, the desired characteristics (linear
Gasket
V-ring packing
Type LTR 43
Type BR 10a
Butterfly Valves
Butterfly valves of stainless steel or special material on inquiry.
A acc. to
Leakage ≤ 0.5 to 1 % 0.05 to ≤ 0.5 %
EN 12266-1, Test P12
Handwheel or Pneumatic or
electric actuators
Butterfly Valves
Butterfly valves of stainless steel or special material on inquiry.
Flange Double-flanged
Wafer
Connection
Lug-type
Welding ends On request
Safe position with pneumatic or electric actuators see the associated
Fail-safe position
technical data sheet.
Accessories Accessories are available on request for customer specifications.
Technical data ∗For all further data, accessories, and industry codes see the associated
and accessories technical data sheet.
Table 6.20.-2: Butterfly Valve Type BR 10a, BR 10e, BR 14b, BR 14c and LTR 43
Disc
Stem
Sealing face
As for other control valve styles, for butterfly valves there are numerous body constructions,
disk designs and seating technologies. The housing or valve body can be flange less,
flanged or with welded ends for connection to the piping system.
There is also a large variety in the manner of the disc movement (concentric, single
or double eccentric, and triple eccentric) and also in the disk orientation in the closed
position. Most common is the flange less, wafer type valve body with an aligned disc.
This type is used mainly for simple control tasks where a certain level of leakage is
acceptable. The seat leakage is naturally determined by the gap width between the disc
or disc and the wafer body, which is necessary for faultless operation at low and high
temperatures. Since standard butterfly valves with an aligned disk do not touch any seat
in the valve body, a travel stop within the actuator is required to avoid over-stroking of the
disc.
A somewhat lower leakage can be achieved with a canted disc or by means of two centric
sealing ridges which are welded into the wafer body. Five of the many variations available
are schematically illustrated in Figure 6.20.1.-3. Some disks are equipped with metallic or
elastic piston rings to achieve lower leakage rates.
Some have EPDM (Ethylene Propylene Diene Monomer), or PTFE (Polytetrafluoroethylene)
rings - either in the valve body or at the disc - to achieve tight shut-off at temperatures
below 200 °C. The valve body is also frequently lined completely with synthetic rubber
or PTFE, and thus the sealing surface to both counter flanges is thereby achieved. The
outer stainless steel disc surface is rounded in such cases and is pressed, at the closed
position, into the soft lining material causing a small radial deformation Figure 6.20.1.-1.
Another design relies on a profile ring of synthetic rubber as the sealing element.
This is fastened to the disc with the help of a metallic clamping ring. The additional closing
(or opening) torque is in both cases exceptionally high. This is caused by the relatively
high friction between the steel vane and the synthetic rubber sealing element when the
disk is opening or closing.
Therefore special butterfly valves have been developed enabling low friction and
hysteresis. One of these special butterfly valves uses, for example, a synthetic rubber
tube as the sealing element. This tube can be inflated by low air pressure when the disk
has reached the closed position. One disadvantage of butterfly valves with tight shut-off
capabilities by means of elastic rubber sealing elements, is the limited applicability with
respect to pressure, temperature and resistance of most elastomers to aggressive fluids.
Centric
Centric between the shaft centre line and the disc centre line.
Single eccentric
OS = Offset
OS
The first eccentric is the offset between the shaft centre line and the disc trunnion
centre line.
Figure 6.20.1.-4: Centric and eccentric bearing of the butterfly disc (schematic)
OS
OS = Offset
OS
First eccentric is the offset between the shaft centre line and the disc trunnion
centre line. Second eccentric is the offset (OS) between the body centre line and
the disc centre line.
Triple eccentric
OS
OS
OS = Offset
OS
First eccentric is the offset between the shaft centre line and the disc trunnion centre
line. Second eccentric is the offset between the body centre line and the disc centre
line. The third and the most important is the eccentric in the sealing (multiple) itself
such that if you draw a imaginary contour line between the sealing shape versus the
body centre.
Figure 6.20.1.-5: Double and Triple eccentric (schematic)
Butterfly valves have been steadily improved within the last decades and many new
designs have been developed. There are available, for example, butterfly valves with
considerably reduced torques under dynamic conditions. This is achieved by a special
design of the disk profile. Other versions use vanes with „teeth“ which work at low openings
like a flow distributor and thereby reduce the generated noise. The greatest progress,
however, has been achieved in the development of the so-called “high-performance”
butterfly valves. These constructions utilize, as a rule, the double eccentric and triple
eccentric design principle and are fitted with a metallic sealing element, which make them
also therefore suitable for high pressures and temperatures. A typical example of a high
performance butterfly valve of the new generation is shown in Figure 6.20.1.-8 as a triple
eccentric, high performance butterfly valve with metallic sealing element suitable for high
static pressures and temperatures.
Closing
Torque
FLOW
Particularly advantageous are the high rangeability and the metal to metal leak rate
class V at the closed position which competes favorably with the single seated standard
valve in case of larger sizes and/or high shut down pressures. The geometry of the disk
movement is quite complicated. These valves require therefore a sealing element that
provides a minimum of elasticity, and beyond this, it must allow small movements in
the radial direction without allowing any leakage between the disk and the sealing ring.
Through these features the sealing ring can adapt itself to the seat during closing and thus
makes tight shut-off possible. The sealing ring consists usually of an exotic material with
a high strength at elevated temperatures and an excellent corrosion resistance against
common industrial fluids.
A typical dynamic torque curve of a concentric butterfly valve is shown in Figure 6.20.1.-7.
This behavior should be considered, particularly in connection with a pneumatic actuator.
Ms0 Md100
0.965
1.0 0.9
(+ -) Ms direction of torque always against (-)
Static "Break off" torque Ms/Ms0
0.8 0.7
0.7
0.6 0.5
0.5
0.4 0.306
0.3 0.192
0.2 0.106
0.05
(-) Tends to close the obturator
0.1 0
Md100 = f(∆pqmax at 60 to 75 % opening)
0
0 10 20 30 40 50 60 70 80 90
Aperture angle in degrees Not for control
▪ On-off Only ▪
Figure 6.20.1.-7: Typical torque requirements for a centric butterfly valve under dynamic operating
conditions
The dynamic torque in contradiction to the static "break off" torque is in the closed position
almost, zero and increases steadily up to an opening angle of approx. 75 degrees and
reaches a maximum at this point. At higher aperture angles the torque decreases rapidly
and can even reach negative values. This might give bistable control with a trend to either
close or open the valve depending on its current position. This undesirable behavior must
be taken into account at the actuator selection to avoid instability problems. To overcome
this disadvantage, special low torque constructions have been developed. These types
use specially shaped vanes to reduce the dynamic torque and to permit opening angles
above 75 degrees, in order to increase valve capacity and to allow the use of smaller
valve actuators.
Actuator sizing must take care of both kind of torques. In most of applications the static
"break off" torque is dominating the actuator size, because the differential pressure
decrease in direction of maximum flow.
In case of applications with moderate constant differential pressure like level controls,
pump recycling, pressure let down and anti-surge control the dynamic torque will demand
to a larger actuator size than the static torque. In this case actuator sizing becomes
sophisticated and need special care to size for the closed - and for the open position at
the highest dynamic torque. Parameters are: actuator size, spring range and air supply
and the safe position air to close or air to open.
Figure 6.20.1.-8: Leusch Control Butterfly Valve Type LTR 43, triple eccentric,
NPS 24 ANSI Class 900 with return actuator
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Figure 6.20.2.-1: Butterfly Type LTR 43 with Darmatt fire protection system
air flow etc. Darchem’s Lloyds approved Thermal Transient Programme addresses each
of these variables to determine the optimum solution.
Darmatt’s exterior layer is usually either vinyl-coated polyester of a coated fibre glass cloth,
in a fire this sacrificial fabric cover burns off, the nylon pins melt and release, allowing
the composite to expand, increasing the insulating effect of the fibre. Darmatt has a high
resistance to corrosion, vibration, acoustics and shows no deterioration of performance
throughout intended life span. Darmatt is lightweight enough for ease of handling and is
totally removable to facilitate access to the protected equipment or fittings.
Figure 6.20.2.-2: Butterfly Type LTR 43 with Darmatt fire protection system
Application (Control)
triple eccentric
optional low noise design
Medium
double eccentric
Single eccentric,
Swing through,
Step seated
Low
6.21 Ball Valve “Trunnion mounted” for On/Off and Control Service
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
Triple Eccentric Control and Shut-off Butterfly Valve LTR 43, Standard
6.21.1. PTFE coated Ball and Butterfly Valves sizing and application limits.
Sizing of flow coefficients of this high flow capacity valves as well as sound and reliability
check are integrated in the SAMSON group software SAMSON Sizing or CONVAL which
following the international standard IEC 60534 2.1 for flow calculation see chapter 5 and
IEC 60534 8-3 and 60534 8-4 see chapter 8 for sound prediction.
For standard metallic Ball and Butterfly valves there are some limitations regarding critical
cavitation, maximum sound level and critical outlet velocities as well as regulations about
using hardened trim material and downstream baffles in liquid applications. See also the
general selection flowchart Chapter 20.
This guideline lean on approved factors used for metallic valve products for control
applications in SAMSON group sizing software.
PTFE / PFA inline coated Ball, Butterfly or Globe Valves may have some more restrictions
regarding cavitation, and critical pressure differentials and outlet velocities. If the pressure
differential Δp and the pressure ratio xF; x is non negligible in case of throttling or control
processes. Table 6.20.-1 and Table 6.20.-2 include some rules of thumb replacing a lack
of measurements for this special valves used mainly for on-off applications.
Table 6.21.-2: PTFE coated Ball, Butterfly Valves sizing and application limits.
In case of exceeding the limitation above contact the company R&D department.
If Cv100 ∙100 / DN2 >> 2.5 the influence of reducers should be taken into account.
Figure 6.21.2.-1: Approximation of the xFzp1 characteristic for a BR 20 / BR 26 Ball Valve with calibrated
sealing ring : Cv 174, DN 100, p1 = 5 bar
This valve consists of a body with a straight flow path, a bonnet which gives access to the
tapered plug which contains normally a round or rectangular opening. If the plug opening
is positioned crossways to the flow direction, the valve is closed. Full opening is reached
by a turn of 90 degrees by means of a manually actuated lever or by a pneumatic or
electric actuator. In the full open position the pressure loss is correspondingly low; this
is always desired for a pure ON-OFF service. Tight shut-off can be reached by an exact
fit between the tapered plug and the conical bore hole of the valve body and by a high
surface finish of these parts.
The tapered plug has, in addition, the advantage that adjustment is possible by pressing
the tapered socket, with the help of the bonnet, further into the conical bore hole. Most
cock valves used today have a PTFE or PFA lining, which enable a high tight shut-off
quality at comparatively low torques. This also avoids seizing between plug and body, if
the medium does not provide self lubrication. A special PTFE disk mounted on the top
surface of the plug reduces the friction force and provides, at the same time, an excellent
sealing at the plug shaft Figure 6.22.-1.
A cock valve for pure control tasks is not the best choice although some of these rotary
plug valves have a triangular hole or a special profile instead of a simple bore to achieve
a better rangeability.
Cock valves with a PTFE/PFA bushing or lining have
natural application limits. Without the application
of modern synthetic fluorine materials high friction
and above all the unwanted „stick-slip“ effect in
combination with pneumatic diaphragm actuators
might occur. Under these circumstances a fine
control is almost impossible.
There is, in addition, another disadvantage of cock
valves with metal to metal contact: the valve can be
stuck in the same way as a ball valve, especially if it
has not been moved for a long time.
Often corrosion or a sticking fluid are the causes of
this malfunction. Another problem is caused by the
often differing expansion coefficients of valve body
and plug.
This limits the temperature range at which a high
tight shut-off quality can be guaranteed. The
manufacturing of this construction is simpler than for
ball valves and this reflects lower costs and/or lower
retail prices.
They are used in a wide range of severe and highly
demanding services - ideal for corrosive, scaling,
adhering, inflammable, or erosive flow media. These
valves show excellent performance in traditional ball
and gate valve applications, and they offer a cost-
efficient solution for tight shutoff and throttling of
gases, vapors, slurries, etc.
1 http://www.az-armaturen.de
Type 82.7
Type 72.3
Type 73.7
Type 72.4
Valve pictures
Valve pictures
Flange style Flange style Wafer or Lug type Flange or Wafer type
Low pressure High pressure Type 72.4 For neutral gases
Type 72.3 Type 73.3 DVGW 72.3 AT / 72.4 AT
Type 82.7 Type 73.7 DVGW 72.3 MN / 72.4 MN
This valve construction has gained great approvals since the eighties. The forerunner of
this development was Masoneilan’s “Camflex”-valve. In the meantime almost all important
manufacturers of control valves have introduced a similar valve type and extended thereby
their product range. Of advantage are: high rangeability, good controllability at low friction
and an tight shut-off feature at a comparatively low actuator thrust.
The eccentric rotary plug valve is an attempt to combine the advantages of standard valves
(low friction, good rangeability) with ball valves (high Cv-values, compact dimensions).
The original idea was a flange less valve which could be installed into any piping system
regardless of the very many flange standards. In the meantime, however, also short
comings have come to light in spite of the advantages of a flange less version: there are
dangers of leakages at high pressures and temperatures. This led, for example, to the
recommendation in refineries and petrochemical plants to use preferably control valves
with flanges for combustible liquids and gases, in order to reduce the risk of a fire.
Since flange less rotary valves are clamped between the pipe flanges by means of 4 to
12 long overhung bolts, these would be directly exposed to the flames, in case of a fire.
The highly stressed bolts would, under this circumstance, expand and increase thereby
the leakage. Although the same problem exists for all flange less valves, the danger of
a leakage is diminished for a short sandwich style body, due to a great number of short
bolts as in, for example, a butterfly valve with wafer type body.
6.22.1. What is a rotary plug valve and what are its advantages?
The VETEC rotary plug valve is an outstanding combination of a segmented ball valve,
butterfly valve, and the classic control valve and unifies all their advantages such as free
passage, no dead space, high gland nut insularity, control over high pressure difference,
compact design and very good control properties. Rotary plug valves have a variety of
critical applications that can only be covered by conventional control valves with difficulty.
The advantage
One of the main advantages of the rotary plug valve is its free passage. Due to the
flow restrictor which moves crossways to the flow, the media current does not have to
be diverted through the housing wall. This confers a special advantage on abrasive or
adhesive media.
The bearing
The axle’s bearing in connection with the plug and the housing is arranged double
eccentric and causes the plug to lift up immediately and smoothly from the seat when
rotating the plug shaft. The valve does not fire open and therefore displays stable control
action even for small opening angles.
Figure 6.22.1.-2: Sectional diagram: Plug movement with double eccentric bearing
90
80
70
% Cv100 - Value
60 c
r isti
50 cte istic
ra er
ha t
arc r ac
40
Line ch
a
t ural ic
30 Na ist
ter
20 harac
ge c
rcenta
10 Equal-pe
0
0 10 20 30 40 50 60 70 80 90 100
% Opening angle (100%= 75°)and % signal for the red linear and blue signal characteristic
Figure 6.22.2.-1: Rotary plug valves characteristic by using cam disk or positioner
The rangeability defines the ratio of the nominal Cv100-value to the smallest controllable
flow value where the curve is still within the permitted tolerances. Rotary plug valves attain
typical values of 1:200 in comparison with globe valves with range abilities of 1:30 to 1:50.
The rotary plug’s valves are pre-determined by the design, because the plug does not
dip into the seat through the double eccenter, but releases a traceable transverse section
for the smallest opening angle. Therefore, in the case of a rotary plug valve, it can be
adjusted to zero.
In contrast with the globe valves, rotary plug valves produce a torque through the
actuator’s linear transmission via a lever which favours the use of smaller actuators with
shorter manipulation. This can be seen, most notably, in the case of large nominal sizes.
Compared to globe valves, rotary plug valves have a more compact design.
Seat Ring
Keyed or squared Bearing
shaft connection Anti-blow out (stellited)
Shaft
Shaft
Seat Holder
Seat Ring
If one considers this valve philosophy, then one can only be fascinated that this valve,
which only has a few options, can be used ways that are similar to a universal valve.
A rotary valve with eccentric plug consists of a body with a straight flow path, a seat ring
which is usually adjustable in the radial direction, a fastening ring, and a specially shaped,
eccentrically pivoted plug.
This plug can be rotated, by a shaft which sticks radially out of the body, to an angle of
rotation of 50 to 75 degrees Table 6.21.1.-1. As a result of the eccentrically positioned
valve shaft, the plug with the spherical cup, touches the seat ring only in the closed
position. This reduces the friction forces to a minimum and designates this valve type
particularly for control services. The size of eccentricity (approx. 10% of nominal size)
plays a important part in the closing thrust of the pneumatic or electric actuator. The
smaller the eccentricity is, the smaller the actuator thrust be-comes and the higher the
differential pressure in the closed position can be.
Ceramic inserts
Seat Holder
Thread Ring
Seat Ring
Figure 6.22.3.-3: Three-part seat system
Plug Solid Stellite 6 without ceramic Plug Solid Stellite 6 with ceramic
after 4 months after 3 years
Features
Valve equipment for HPI1 industries like upstream oil-and gas exploring and downstream
refinery and petrochemical processing are subjected to one of the heaviest duties of all
industries. Rough and dirty media, high service temperatures, high velocities and hard
differential pressures demand heavy valve designs and solid components. Corrosive and
abrasive dirt media may cause malfunctions of ESD-Ball valves = Safety Risk VETEC
rotary plug valves are proved for ESD and work faultless.
Materials:
CS 1.0619 / A216 WCC
SS 1.4408 /1.4308 /1.4931 ; A351 CF8M ;
Low temperature and high temperature Steels, eg. 1.4308, 1.7357,
Hastelloy C4, Monel®, Duplex®, SuperDuplex®
Titanium, Zirconium
Bronze, Brass
Flushing parts: Solid Stellite 6 or 20, Ceramic Si3N4 inserts, hardened metal
1 HPI = Hydrocarbon Processing Industry
2 Detailed service conditions, operation times and customers from VETEC publications available.
Photo Unknown
Steam 32 pieces DN 100 + 150
Air 24 pieces DN 150
Product contents of Naphtha 25 pieces DN 50 + 100
VETEC Rotary Plug Quench oil 41 pieces DN 100 to 250
Valves Ethane 21 pieces DN 150 + 200
LPG 8 pieces DN 150 + 200
Heating Gas (DVGW) 280 pieces DN 25 to 200
Contractor Linde AG, Germany
Commissioning 2007
Order 431 VETEC Maxifluss Rotary Plug Valves were installed in this plant.
Typical
Valve style Advantages Disadvantages
availability
High friction and hysteresis
Low-priced ON-OFF valve for
Cock valves DN 25-300 Not very suitable for fine
low duty applications
(cylindrical PN 10-40 control
High Cv-values
plug version) up to ANSI 300 Restricted applicability for
Low leakage rates valve with PTFE or PFA lining
Hydraulic actuating
system Type NBF 400
Control valves are used in power plants, power stations and industrial facilities as actuators
in temperature, pressure, and level control circuits as well as in volume control systems.
Welland & Tuxhorn is your reliable partner for comprehensive solutions in the fields of
liquid and gas media control. Solutions which function better in the long run!
For over 100 years, our work in production and development has been distinguished
by precision, first-class processing quality and life-long stability. The tough, robust, and
solid construction of our fittings, from the smallest to the largest, assures you of optimal
performance and availability. This is the result of our years-long quality assurance system,
certified according to DIN ISO 9001 and other international standards. All the valves which
we supply are manufactured exclusively on our centrally- net worked CNC machinery.
Process safety guarantees process quality!
Figure 6.24.-1: Combined Cycle Power Plant (CCPP), Lingen, Germany (Model)
Welland & Tuxhorn AG1 offers as a world-wide active technology partner customized
special control-valves for power plants, for:
Conventional power stations
Combined Cycle Power Plants (CCPP)
Nuclear power plants
District heating power plants (CHP)
Industrial power stations
Other applications
1 http://www.welland-tuxhorn.de
Graphic W&T
Valve-No. Description
1 Minimum Load - Control Valve
2 Feed Water Control Valve
3 Condensate Level Control Valve
4 Control Valves / Shut-off Valves
5 Injection Control Valves
6 Injection Control Valves
7 HP - Bypass Valves
8 Reheater Safety Relief Valves
9 IP/LP-Bypass
10 Condensate Control Valve
11 Combined emergency stop and control valve
Figure 6.24.-2: Conventional power stations
Design:
Forged bodies: Angled or z-shaped valves, for welding
connections according to DIN, ANSI or other standards.
Advantages:
No cavitations
No erosion
No oscillations or vibrations
Long service life
Noise levels <75 dB (A)
Precise characteristic
Quick maintenance and servicing due to easily-
Figure 6.24.-3: Minimum flow - replaced internal parts
Control Valve with hydraulic actuator
Fail-safe technology: valves open in case of energy
blackouts or malfunctions
Versions:
Forged Valves in Angle- or Z-Form
With Welding supports according to DIN, ANSI or other Standards
For conventional and nuclear power stations, or for industrial facilities: Welland & Tuxhorn
delivers suitable control fittings – from level control to injection and safety valves.
Versions:
Size NPS 5 to 20 / DN 125 to 500
Pressure Rating up to Class 300 to 2500
and greater / PN 40 to 640
Differential Pressures up to 435 psi / 30 bar
Perforated Plug
Capacity up to Q = 2000 m3/h
Materials: GS-C25. GS17CrMo55,
Figure 6.24.-5: Feed Water Control Valve with C22.8, 15Mo3, 13CrMo44
electric actuator Body Style: Z- or Straight
For conventional and nuclear power stations, or for industrial facilities: Welland & Tuxhorn
delivers suitable control fittings – from level control to injection and safety valves.
No cavitations
No oscillations or vibrations
Advantages Long service life
Quick maintenance and servicing due to easily-replaced internal
parts
Advantages:
Steam pressure and steam temperature achieved just beyond point of injection in the
superheater
Optimal steam conversion throughout the entire load area through pressurized-steam
nozzles
Quick maintenance and servicing due to easily-replaced internal parts
Advantages:
Optimal steam conversion throughout the entire
load area due to integrated pressurized-steam
nozzles
Individual adjustment of all governing levels to
operational parameters
Low retardation levels of steam cooling, especially
with partial loads
Low noise and vibration operations due to built-in
mufflers
Low cooling water pressure
Figure 6.24.-10: Steam converting Quick maintenance and servicing due to easily-
valve Type DUV-C replaced internal parts
Inlet: DN 80 to 500, NPS 3 to 20; PN 16 to 630, ANSI Class 150 to 2500 (4500)
Outlet: DN 100 to 1600, NPS 4 to 64; PN 16 to 100, ANSI Class 150 to 900
Construction:
Forged bodies: Angled valve
Advantages:
Simple, reliable design and construction
Safety function with cup spring packet in control cylinder
Cup spring packet and steam pressure act in direction of open position to guarantee
opening of the valve.
Functions:
The IP/LP-Bypass station connects the hot reheater in
the bypass to the IP/LP turbine via the condenser.
Should the turbine not be running during start-up and
shut-down of the power plant unit, any steam which
collects in the reheater must be redirected from the IP/
LP-Bypass Station to the turbine condenser, avoiding
the medium and low-pressure turbines.
This secondary injection spray cools down the steam
from the hot reheating enough so that the condenser is
not damaged.
Design:
Forged body angled
Advantages:
Optimum cooling along the entire load area, due to sequential opening of the
pressure-regulated nozzles
Optimum spray angle and minimum droplet size
Compact construction form, due to reduced steam pressure by means of control
pistons
Worn parts can be easily replaced on location
Noise and vibration-reduced operation, due to built-in mufflers
Suitable for high-temperature applications
Can be delivered in combination with a dump tube, constructed to your specific
application needs
Definite answers If you should have any question to this product, please feel free to
contact us: contact/inquiry
Nozzles
Functions:
The cooling water is injected by pressure-regulated nozzles, in accordance with the
amount of steam.
Firstly, the centrally-arranged nozzles are opened, then dependant on the amount of
cooling water the others are opened.
As the amount of cooling water increases, further nozzles are opened. The axially
arranged nozzles in the steam guarantee an even temperature distribution in the exhaust
steam pipe.
Design:
Forged bodies: straight, angled
or Z-shaped valves for welding
connections, manufactured
according to DIN, ANSI or other
standards.
Advantages:
No cavitation
No erosion
No oscillation or vibration
Long service life
Precise characteristic
Quick maintenance and
servicing due to easily-replaced
internal parts
Figure 6.24.-16: Drainage Control valves for water and steam Type RVG
In Power Stations:
At the boiler as injection valves together with the injection unit
(HP and cold reheat line side)
At HP- Bypass- Stations as cooling water control valves
At LP- Bypass- Stations as cooling water control valves
As level control valves for tanks and vessels
In the Industry:
At steam converting stations and atomizing steam coolers as cooling water control
valves
As pressure and mass flow control valves in the chemical and petrochemical industry
As level control valves for tanks and vessels
Figure 6.24.16.-1: Control valves for water and steam Type RVG: 3-stage
function
Figure 6.24.-20:
Highest availability
Optimum steam conversion over the whole
Load range through multi stage controlled
Pressure reduction
Minimum delay steam condition reduction
Temperature reduction without excess water through linked control water spray
Low noise and vibration steam conversion through internals and downstream noise
attenuation
All wearing parts exchangeable in-situ
Figure 6.24.-21: Combined emergency stop and control valve with hydraulic actuators
Functions:
Control part:
This part of the inlet combination valve controls the steam inlet into the steam turbine.
Within the range of small flows of steam, in which turbines are run up to speed from turn
rotation speed to synchronized rotation, stable regulating action must be guaranteed by
a good rangeability.
Trip part:
The trip part protects the turbine, and must be able to completely stop the entire steam
mass flow in under 1 second.
Design:
Seal-off and regulatory functions are mounted in contra-flow forged valve bodies.
Horizontal or vertical assembly is possible.
Advantages:
Use of only one body means compact construction!
Stable control behavior
Can be equipped according to TRD 421
Graphic W&T
Combined Cycle Power Plants (CCPP) gas and steam turbine power plants in
Applications longhand, serve the purposes of power generation. These types of power stations
combine the use of gas and steam turbine processes.
Valve-No. Description
Graphic W&T
Valve-No. Description
Advantages:
Austenitic materials
Simple, fail-safe design and construction
Bellows seals
Graphic W&T
District heating power plants (CHP) are industrial facilities for the
production of electrical current and heat within a dome process; this
process is named "heat and power coupling". Combined heat and power
Applications
stations are located in the proximity of urban high-density population
areas, or nearby industrial plants with high heat requirements, as the heat
produced is fed into the district heating grid.
Valve-No. Description
Graphic W&T
Industrial power stations are industrially-owned plants, primarily serving
to provide coverage of on-site power requirements.
This energy is electrical and thermal in the main, but mechanical energy,
above all in the form of rotational kinetic energy, is also used.
Applications Most of the power stations are back-pressure plants, as process steam
is often needed in addition to electrical energy.
Combined Heat and Power is an ideal solution whether working with
thermal energy in the form of process energy -steam, for example or
only heating factories and commercial premises by utilizing the industrial
waste heat.
Valve-No. Description
1 Minimum flow - Control Valve
2 Feed Water Control Valve
3 Condensate Level Control Valve
4 Control Valves / Shut-off Valves
5 Injection Control Valves
6 Injection Control Valves
7 HP - Bypass Valves
8 Reheater Safety Valves
Figure 6.24.-25: Industrial power station
Injection cooler
Functions:
Steam cooling in thermal power stations
Design:
Pressure spraying with twist nozzle regulation via spindle
stroke.
With flanges or for welding connections, suitable for all
types of actuators
Advantages:
Fine misting even in partial load areas
Precise setting of prescribed temperatures through
exact dosage of injection flow.
High rangeability through sealing of nozzles not in use
by means of piston rings
Pre-throttling in 1 to maximum 3 regulation levels, and
therefore low wear even with large pressure drops.
Drip-proof in closed position.
Fitted with upstream strainer as standard equipment.
All replaceable parts can be easily replaced without
mechanical work.
Description of functions; basic principles:
Injection coolers are pressure sprayers. They use the
pressure drop occurring in the nozzle for spraying water.
The water film which develops at first on the nozzle opening
breaks up into many tiny droplets, with increasingly smaller
diameters, depending on the flow velocity. Adjustable W &
T injection coolers are cooling water control valves and
nozzle heads combined into one unit.
The upper part functions as a one-level or multi-level
cooling water control valve.
It regulates flow masses and pressure at the nozzle head.
The elongated valve spindle controls a host of nozzles
with various port openings. A drop in pressure is thus
sustained at the nozzles along the entire work load area
which assures a good, even misting of the film of water.
The extremely fine water mist thus produced evaporates in
a very short time, and so optimal cooling is achieved. The
use of protective pipe in the steam pipe is not required.
References extract
Lünen / Germany
Customer: STEAG AG
Application: HP- Turbines bypass
Product: Steam converting valve C3
Termoli / Italy
Customer: Technip ITALY S.p.A.
Application: HP turbines by-pass with security
function, boiler protection
Product: Steam converting valve C3
Pemex / Mexico
Customer: Samson Mexico
Application: Steam conditioning
Product: Steam converting valve E34
Zhangshan / China
Customer: Siemens Power Plant Automotion
Application: HP / LP Bypass
Product: Steam converting valve S30 / E20
Other applications:
Photo W&T
In order to operate many production facilities, process steam is required in addition to
electrical power.
One example of this is aluminium smelters: The production of a ton of aluminium
requires approximately 20,000 kWh of electrical current, while the treatment of bauxite
in autoclaves requires process steam.
A special example for the use of process steam is a paper factory, where variable
amounts of steam are required at various times. The steam is created in steam
boilers, which are fired by primary energy sources such as oil or gas, or in which the
exhaust heat of the production process is used.
Different steam pressure networks as well as an intermittent use of electricity,
especially when taking process optimization into account, require an increased
degree of complexity, not only for steam production, but for electricity production and
distribution as well.
Figure 6.24.-26: Other applications
Service
After receiving delivery of your control valves, an experienced service team is at your
disposal, from the first start-up to conducting routine check-ups later.
Reliability which pays off in the long run!
Our company service organization team, trained and highly specialized, enables
worldwide inspections and check-ups, maintenance and servicing, and thus the most
optimal customer support.
flow and pressure level measurement and, the improvements in control valve technology
are - in spite of an apparent low innovation potential - considerable:
Standard valves are now, fundamentally, more compact. There is undoubtedly a
close relationship between the weight of the control valve and its production costs.
Therefore most manufacturers have managed to reduce unnecessary weight to stay
competitive. Considering the average rate of the yearly price in-creases in the two last
decades, the standard control valve is today certainly less costly than 20 years ago!
Numerous rules and regulations with regard to environment protection have forced
manufactures to address many problems in detail. This has led to a quality standard
for control valves which is even higher than 20 years ago. Worthy of mentioning are,
for example:
More attention is given to noise behavior today. This has led particularly to the
development of low noise control valves.
The harmful events with the appearance of cavitation are today, not only better
understood and mastered, but are also precisely foreseeable so that correct
measures can be taken.
Furthermore predicting or classifying on one hand long term reliability and at other
hand controllability of control valves initiated by major end users, test institutes and
manufacturers is an ongoing challenge to get a better balance between the lowest
cost of investment and the total cost of ownership (TCO).
Asbestos for gaskets and packing has been replaced by substitute mate-rials which
have no harmful consequences for human beings and nature.
To comply with the tough requirements of the European TA-Luft (clean air act)
essential progress has been made with regard to the valve stem sealing and
flange joint gaskets. Also the inner tight shut-off level in the valve seat has been
considerably improved so that in many cases an additional block valve is no longer
necessary.
New materials and a better knowledge of corrosion patterns permit today a better
selection of suitable materials.
Last but not least the introduction and implementation of the international quality
standard ISO 9000 gives the user today, the assurance that he gets the product he
ordered.
The trend towards low pressure differentials at the control valve continues, in order to
(1) apply standard valves instead of expensive low noise types,
(2) reduce or avoid cavitation and its too high sound- and sometimes damaging
consequences and
(3) enable the use of pumps with a lower power consumption. This trend has
promoted the application of rotary type control valves enormously because of their
greater flow capacity and lower initial costs.
The preferred application of a definitive control valve type has to be seen also under
statistical considerations. Various investigations in Europe, in the USA and Japan have
shown an astonishing agreement with regard to valve materials, nominal sizes and pressure
ratings. This surprising fact must, however, be rationalized after careful consideration,
since the technical processes are world-wide, normally the same or at least very similar.
The "know-how" in the petrochemical sector, for example, is still mastered by the USA
and there is hardly a refinery which doesn't use a license of the "Seven Sisters" which is
the large group of worldwide operating companies like Exxon, Royal Dutch Shell, British
Petroleum, Chevron Oil etc. A harmonization in the use of certain control valve styles
also results from this source. A further essential factor is the necessity of international
standardization to save costs, to reduce inventories and spare parts supply and to simplify
service and maintenance of control valves.
Other Valves
Diaphragm Valves
3%
2%
Figure 6.25.-1: Fig. 6-33: Statistical distribution of various valve styles
The following pie-charts show the random distribution of common control valve types
used most frequently in industry, as well as the nominal sizes, pressure ratings and body
materials. To avoid misunderstandings the term control valve shall be again defined.
According to an international definition a control valve is a „power actuated device“,
i.e. a control valve with a power unit. This might be a pneumatic an electric or electro-
hydraulic actuator. The distinction between "regulating“ and "ON-OFF“ service seems to
be outdated, since more and more processes are no longer continuous but discontinuous
today.
Continuous processes are found mainly in refineries, raw material production plants and
power stations where the same product is continuously being produced. This method is
ideal from a production point of view. Large quantities can be produced fully automatically
with a minimum number of workers.
These plants were originally designed for a definite purpose. They run usually 20 years
or more and are replaced from time to time by more modern plants which correspond to
the latest advances in technology.
DN 40, 50
NPS 1½, 2
30 %
DN 15, 20, 25
NPS ½, ¾, 1 DN 65, 80, 100
37 % NPS 2½, 3, 4
22 %
DN 150
NPS 6
≥ DN 150 6%
NPS 6
5%
Figure 6.25.-2 illustrates that about 2/3 of the required control valves today fall into the
range of nominal sizes up to and including DN 50. The share of the larger nominal sizes
above DN 50 is continuing to shrink. This applies particular to very large valve sizes of DN
150 and above. The statistics are influenced of course, by the most important and largest
user segment of industrial control valves the chemical industry.
A still more dramatic picture demonstrates the statistics of the applied nominal pressure
ratings. One usually distinguishes between the so-called low pressure range (up to and
including PN 40 or ANSI Class 300), the middle or medium pressure range of PN 64, PN
100 and PN 160 (and/or ANSI Class 400, 600 and 900) and the high pressure range of
PN 250 (ANSI Class 1500) and higher. The most important low pressure range covers
more than 90 % of all control valves installed world-wide, while the remainder is reserved
for higher pressure ratings (Figure 6.25.-3).
Carbon Steel
65 %
Stainless Steel
30 %
Exotic Steel
5%
The random distribution of body materials is shown in Figure 6.25.-4. The so-called
carbon steel materials, including the minor share of high temperature steels, hold a share
of approximately 2/3 of all industrial valves. The share of standard stain-less steel alloys
(austenitic materials) is about 30%. The rest falls to high alloy exotic materials for special
applications.