PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 40 SERIES BALL CONTROL VALVES PRODUCT BULLETIN HIGH PERFORMANCE BALL CONTROL VALVE: intelligent field devices for efficient field based architecture HEAVY TRUNNION DESIGN SEVERE SERVICE CAPABILITY HIGH VERSATILITY LOW NOISE AND CAVITATION CONTROL WITH RMT TRIMS CUSTOMIZABLE SOLUTIONS 1 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES RMT CONTROLS a division of RMT VALVOMECCANICA – GIVA GROUP Via dei Patrioti • 21058 Solbiate Olona (VA) Italy Ph: +39 0331 375441 • Fax: +39 0331 376847 [email protected] www.rmtvalvomeccanica.com 2 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES INDEX 1. GENERAL FEATURES .............................................................................................................................................................. 5 2. TECHNICAL DESCRIPTION ..................................................................................................................................................... 9 2.1 BODY/CLOSURE ............................................................................................................................................................... 11 2.2 BONNET ............................................................................................................................................................................ 11 2.3 PACKING........................................................................................................................................................................... 11 2.3.1 STANDARD LOW EMISSION PACKING .................................................................................................................. 11 2.3.2 LIVE LOADING LOW EMISSION PACKING............................................................................................................. 12 2.4 TRIM COMPONENTS ........................................................................................................................................................ 13 2.4.1 TRUNNION/STEM AND BEARINGS ........................................................................................................................ 13 2.4.2 SEAT RING AND BALL ELEMENT .......................................................................................................................... 14 2.4.2.1 SEAT RING CONFIGURATION ...................................................................................................................... 14 2.4.2.2 SEAT RING SEALING CONSTRUCTION ....................................................................................................... 14 2.4.2.3 BALL .............................................................................................................................................................. 15 2.4.2.4 MATERIAL OF CONSTRUCTION ................................................................................................................... 15 2.4.3 SEALING COMPONENTS (STATIC AND DYNAMIC)............................................................................................... 16 2.4.3.1 O RING SEALS ............................................................................................................................................... 16 2.4.3.2 LIPSEALS....................................................................................................................................................... 16 2.4.3.3 GRAPHITE PACKING AND SPIRAL WOUNDS .............................................................................................. 16 2.4.3.4 FIRE SAFE DESIGN ....................................................................................................................................... 16 2.5 RMT CONTROL TRIMS FOR 40 SERIES ........................................................................................................................... 17 2.5.1 45 SERIES: V CUT BALL CONTROL VALVE .......................................................................................................... 17 2.5.1.1 2.5.2 43 SERIES: MULTISTAGE BALL CONTROL VALVE............................................................................................... 19 2.5.2.1 : NOISE ABATEMENT .................................................................................................................................... 19 2.5.2.2 CAVITATION CONTROL ................................................................................................................................ 20 2.5.2.3 RMT 43 SERIES BALL CONTROL VALVES FOR CAVITATION AND NOISE CONTROL .............................. 21 2.5.3 2.6 3. 45 SERIES FOR EXTREME EROSIVE APPLICATIONS: 45SS....................................................................... 18 42 SERIES: BALL CONTROL FOR EXTREME NOISE CONTROL ........................................................................... 22 40 SERIES FLEX DESIGN FOR QUICK CHANGE AND EASY MAINTENANCE ................................................................ 23 ACTUATORS AND CONTROLLING DEVICES ....................................................................................................................... 24 3.1 ACTUATORS ..................................................................................................................................................................... 24 3.2 POSITIONERS AND PANELS ............................................................................................................................................ 24 4. PRODUCT QUICK SPECIFICATION ...................................................................................................................................... 25 5. 40 SERIES RATING/CONNECTION TABLES ......................................................................................................................... 26 6. MATERIAL SELECTION GUIDE ............................................................................................................................................. 27 7. FLOW CHARACHTERISTICS ................................................................................................................................................. 29 REVISION DESCRIPTION PREPARED APPROVED DATE A FIRST ISSUE MARCO FUSCA MATTEO ROSSI 01/07/2015 3 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 4 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 1. GENERAL FEATURES The 40 series is the RMT product line of trunnion mounted ball valve for control application. 40 series control valve couple: the advantages of a ball valve design, typically applied for on/off service: excellent tightness high flow capability heavy duty construction, suitable for extreme severe pressure/temperature combination the advantages of an engineered control trim: extremely high rangeability cavitation control capabilities noise abatement and sound emission control capabilities anti-clogging design for dirty and viscous fluid applications Moreover 40 series ball control valve are designed to offer: quick change trim for easier maintenance operations even if they have a side entry construction low torque design, for compact actuation with higher performance both in terms of smooth control and quick positioning compact design with short end-to end dimensions of our flex® design. You can use it in Oil & Gas as Upstream: onshore and offshore Midstream: transportation, filtering, reduction, metering, storage … Downstream: petrochemical, refineries, LNG … Distribution networks … and also in many other industrial applications: Chemical applications Power Water: potable and desalination plants … Everywhere you need a process control. 5 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 40 SERIES HAS THE AIM TO OFFER: HIGH PERFORMANCE SOLUTIONS TO SUIT CUSTOMER REQUIREMENTS: high tightness capabilities and high flow capacities; design flexibility thanks to the wide range of trim option, actuation and instrumentations solutions; the goal to suit customer request at every process condition, even the most severe ones; HIGH RELIABILITY: solid design and attention to materials selection to provide wear resistance and long life even in severe conditions; COMPACT DESIGN: design attention to reduce overall costs and offer easy handling and installation. HIGH PERFORMANCE SOLUTIONS TO SUIT CUSTOMER REQUIREMENTS HIGH TIGHTNESS CAPABILITIES WIDE RANGE OF PACKING SOLUTIONS 40 series make possible to reach the higher classes In order to satisfy any special requirement in of tightness according to ISA standard, up to a zero term of low emission, different suitable leakage design typical of an on/off ball valve. packing solutions are provided: HIGH CAPACITY DESIGN Ball design make possible to maximize flow capacity. Low emission packing (LEM) Live loading low emission packing (LL-LEM) Have a look to packing section. TRIM CONSTRUCTION ACTUATION AND ADVANCED DIGITAL Trim is engineered to offer a smooth behavior even POSITIONING CONTROL under the most severe conditions, making possible reduction in thrust requirements and actuator Pneumatic piston are typically used in actuation of sizing 40 series valves: typically rack & pinion for size up high pressure drop capabilities to 3’’ (DN80) and scotch yoke pneumatic piston facing up of cavitation matters actuators noise abatement applications. dealing with dirty, sticking or slightly abrasive actuators are available on request too. fluids quality machining control to ensure parts; all this also the low and high hydraulic shut or off electric industrial group that holds RMT Valvomeccanica) or other main manufacturer. operating costs size addition, construction (a well known sister company inside precision of means bigger In Pneumatic actuator may be of DVG automation very smooth valve operations thanks to design and for excellent flow control through different design Actuator selection is always performed carefully to of match the valve design features and offer excellent the ball and seating elements: precise valve positioning for the best process control. contouring of the V profiles offer modified equal percentage flow characteristics suited to Advanced valve diagnostic is available. specific application. Smart provide communication real-time hardware preventive and and software predictive diagnostic data. Best brands are available and skilled technicians at complete disposal. 6 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES DIFFERENT CONSTRUCTION TYPES AND WIDE RANGE OF TRIM SOLUTIONS FOR EFFICIENT VALVE OPERATION RMT has engineered three design types in order to be able to suit every kind of applications of ball control valves, even the most severe ones: - 45 Series: is the V cut series of RMT ball control valves. A V cut design is performed to make possible have a perfect equal percent characteristic. V cut shape allow high rangeability, up to 150:1: in this way is possible to optimize control both during high turndown processes (low flow requirements) and during normal operational phases when maximum CV shall be provided (high flow rate required). Moreover the intrinsically V cut shapes self-cleaning and assures an non-clogging design. - 43 Series: is the multistage series of ball control valve. A multistage labyrintic trim is built inside the ball element, thus making possible to realize a multistage approach to pressure reduction across the valve. A multistage approach make possible to control noise matters and especially cavitation phenomenon. In this way we are able to couple the advantages of a ball design with those of a multistage approach customized on the particular process. - Cavitation control trims CCT43 42 Series: is the low noise series of RMT ball control valves. The concept design is to realize a multipath approach for noise abatement. These valves are therefore provided with special diffusers for noise control. Noise control trims NCT42 Trim and constructive tips combined with suitable material selection make 40 series suitable for a wide range of applications, even the most severe one in terms of pressure/temperature combination and type of fluid: No Erosion / corrosion applications (sour liquids or gases) High Temperature operations Low Temperature operations: CRYO service. 7 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES HIGH RELIABILITY MATERIAL SELECTION We put a great attention into material selection, especially with reference to the trim ones. In order to offer the best wear resistance and a We can guide you through the best choice at the long best cost even under the most severe conditions of working life, following key feature characterize the 40 series control valves. fluid temperature/pressure combination. WIDE RANGE OF MATERIAL Materials are available for application involving sour The 40 series control valves have been developed to liquids or gases. Design can be in compliance with cover a wide range of applications with practically NACE MR0175-2003. no limit in pressure and temperature. Great attention is put into material selection, Forged raw materials are the standard of especially in severe service applications where construction, thus assuring an higher quality rather erosion or corrosion problems may be present. than casted components. Sour service material class possibilities and Exotic materials, solid tungsten carbide and ceramic materials can be provided for trim components. DESIGN CONSTRUCTION AND TRIM SELECTION As a brand of GIVA Group, RMT is perfectly The variety of design construction types and the integrated with the still mills, forges, foundries and different trim solutions let us to develop a valve that machining shops of the company. is able to suit the customer process conditions. RMT has the full support of an own advance metal 40 series are able to face up and control the effects testing laboratory located next to the factory. of flashing, cavitation and noise matters, even in the most severe service conditions: high or low temperature applications, corrosive atmospheres, erosion matters,… SEAT TIGHTNESS Seat leak class IV of ISA reference is our standard, but we can also achieve class V, class VI up to a zero leakage design, depending on the customer request. COMPACT DESIGN 40 series ball control valve up have been engineered with a compact assembly up to NPS 12’’ (DN 300) and rating #600: upper and lower trunnion construction for 2 pieces body-closure design. For above mentioned size/rating combination short face to face dimensions make possible - global cost reduction - simplified handling and installation - quick change for easier maintenance, that means also lower maintenance costs. Valve packing offers a easy maintenance “top entry” design and the possibility of a quick change. There is no need of any special components during assembly or disassembling operations. 8 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2. 1. 2. 3. 4. 5. 6. 9. 10. 12. 13. 14. 15. 16. 18. 19. 23. 24. 27. 28. 30. 61. 62. 71. 72. 81. 82. 83. 84. 85. 86. 87. 88. TECHNICAL DESCRIPTION BODY CLOSURE BODY STUD BODY NUT STEM/UPPER TRUNNION LOWER TRUNNION BALL SEAT RING BONNET PACKING FLANGE PACKING STUD PACKING NUT PACKING FOLLOWER YOKE/ISO FLANGE PACKING GLAND BOLT LOWER FLANGE LOWER FLANGE BOLT YOKE STUD YOKE NUT SPRINGS AXIAL BEARING RADIAL BEARING PACKING RINGS PACKING END RINGS PACKING GLAND FIRE SAFE GASKET PACKING GLAND O RING LOWER TRUNNION O RING LOWER TRUNNION FIRE SAFE GASKET BODY-CLOSURE O RING BODY-CLOSURE FIRE SAFE GASKET SEAT O RING SEAT FIRE SAFE GASKET 45 SERIES STANDARD CROSS DRAWING: TWO PIECES CONSTRUCTION UP TO NPS 12’’ (DN 300) AND RATING #600. 9 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 45 SERIES API 6D CROSS DRAWING: THREE PIECES CONSTRUCTION FROM NPS 12’’ (DN 300) UP TO NPS 48’’ (DN 1200) UP TO RATING #2500. 10 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.1 BODY/CLOSURE 2.2 Design. BONNET Forged or rolled steels are used for bonnet raw material. Bodies of 40 series valves have a side entry design as Bolted design with valve body is provided as standard. standard. Standard Pressure/temperature ratings and mechanical design temperature of the controlled fluid is between -30 ˚C are according to ASME B16.34. and 600 °C making use of different packing type Materials of constructions. execution solutions. As standard, forged raw materials are used. Refer cover to applications packing section where for the detailed explanation. The choice depends on the combination of fluid type, NON STANDARD EXECUTION ARE AVAILABLE: pressure rating and design temperature. - extension for high temperature application, in order Carbon Steel and stainless steel, Duplex, Nickel alloys to lower packing and operator temperature: in this and cases graphite based solutions are available for other exotic material (DIN, ASME or ASTM specification) can be provided. packing; RMT Valvomeccanica have the full support of the steel - mills forges and of the holding (GIVA) group for high extension in order to increase packing and operator temperature for low temperature application, down to quality standards. -196°C ( cryogenic); - Weld overlay (SS 316 or Inconel 625 as standard) of special constructions with grease injection points for emergency sealing may be provided; the wetted parts is possible for the best corrosion - resistance at the lower cost. customizable solutions. As a standard of construction, bonnet material is the same of body. Weld overlay (SS 316 or Inconel 625 as Size and rating. standard) of the wetted parts is possible for the best Dimensions up to NPS 12’’ (DN 300) and rating #600 corrosion resistance at the lower cost. are provided with a “two-pieces” bolted execution For material choice, refer to material selection guide. (body & closure). 2.3 Out of this size/rating combination standard design is according API 6D, with “three pieces” bolted 40 series have been developed with different suitable execution (body & upstream/downstream closure). packing solutions that make possible to control fugitive emissions levels. End to end connections. Due to the modulating service of a control valve packing Flanged body-closure is the standard construction. has been designed to allow adjustment over the service- Short face-to-face dimensions are provided for the life of the valve. compact design, that is up to NPS 12’’ (DN 300) and Packing is designed to offer: rating #600. Out of this size/rating combination standard end-to-end Flow direction. Standard flow design is unidirectional. top entry design - fully welded design - casting bodies - flangeless construction - bi-directional flow type reduction in environment contamination; respect of the criteria of most restrictive legislations, avoiding connected sanctions Fire Safe design is allowable on request. NON STANDARD EXECUTION POSSIBILITIES: - limitation in the loss of process fluid, thus increasing efficiency; dimensions are according API 6D. PACKING 2.3.1 STANDARD LOW EMISSION PACKING Low Emission (LEM) packing meets the criteria of ISO 15848-1: CC3 class. It is made by a series of pre-formed braided rings PTFE or GRAPHOIL based with two anti-extrusion terminal solid rings. For rating tables, refer to product spec. section. For material choice, refer to material selection guide. PTFE based rings can be adopted from -30 °C up to 200°C with a plain bonnet and from -30°C up to 300 °C with an extended one; max allowable pressure is 250 Barg. 11 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES GRAPHOIL based can be adopted from -30 °C up to 600°C with a plain bonnet and from -100°C up to 600 °C with an extended one; there are no practical limitation in max allowable pressure. Furtherly it’s possible to introduce to standard design: leak-off in order to provide the possibility of measuring the emission level; packing follower with a dual O-ring design that allows very high performances with extremely volatile gas LOW EMISSION PACKING (LEM) WITH LEAK OFF AND DUAL OPTIONAL O RING 2.3.2 LIVE LOADING LOW EMISSION PACKING Live Loading maintain to Low Emission optimal levels packing the (LL-LEM) leak can performance practically during all life service of the valve. This is possible by the use of bellows springs that maintain a constant sealing force within the packing box. STANDARD LOW EMISSION PACKING (LEM): PTFE BASED 13. 14. 15. 16. 71. 72. The results is constant low leakage performance with minimal field adjustment. PACKING FLANGE PACKING STUD PACKING NUT PACKING FOLLOWER PACKING RINGS (PTFE BASED - CRANE 285K) PACKING END RINGS (PTFE @25% GLASS LOADED) LIVE LOADING LOW EMISSION PACKING (LL-LEM) STANDARD LOW EMISSION PACKING (LEM): GRAPHITE BASED 13. 14. 15. 16. 71. 72. PACKING FLANGE PACKING STUD PACKING NUT PACKING FOLLOWER PACKING RINGS (GRAFOIL BASED) PACKING END RING (SOLID GRAPHITE) 12 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.4 TRIM COMPONENTS Different constructive tips make 40 series of ball control valves capable to suit a wide range of applications, even the most severe. Different trims solutions have been applied to 40 series in order to be able to couple the advantages of a ball control valve solution with the capability to face also up: - applications where risk of flashing/ cavitation could occur: RMT Controls have developed 43 series of multistage ball control valves; - applications affected by noise matters UPPER AND LOWER TRUNNION CONSTRUCTION and, consequently, its abatement: RMT Controls have developed 42 series of ball control valves for a multipath approach to noise abatement and, eventually, a multistage approach too where necessary; - applications characterized by the presence of dirty, sticking or slightly abrasive fluids: 45 series of V Cut Ball Control offers not only an effective way for customized characterization of valve flow characteristic, but also a self-cleaning and anticlogging design in case of “dirty” applications; - applications where corrosive or high abrasive STEM AND BEARING RETAINER DESIGN fluids are involved: for these application special solutions with unconventional ceramic materials Stainless steel materials are used for trunnions while have been developed. The main goal is to obtain a smooth control and a precise positioning from one side, and guarantee high performances and reliability along the all service life of the valve. 2.4.1 Two - reference to upper trunnions/stem execution. TRUNNION/STEM AND BEARINGS different Anti-blow out design is a standard of construction with Antistatic device is possible on request according to API 6D and ISO 17292: constructions are provided stem/trunnion: - carbon steel ones for bearing retainers. for throw a small spring loaded ball electrical continuity between the stem and the valve body is ensured. Two kind of bearing are used: (standard radial bearing to allow components rotations with low execution in case of 2 pieces body-closure design) characterize by short face to face dimension; axial: to hold the thrust due to internal pressure, using upper trunnion and lower trunnion stem and bearing retainer in compliance with API 6D face to face dimensions. friction; antifriction washers. Special bearing materials are used to lower friction, thus obtaining a smoother control, and reduce wear, Heavy duty trunnions make possible longer service life with reduction in terms of maintenance. Torque for ball positioning is transmitted by the upper trunnion / stem that can be a spline shaft (with DIN grooved profile) for enhanced precision into positioning. 13 for lower maintenance costs and enhanced reliability. RMT Controls works continuously in partnership with well-known bearing manufacturers to select the best choice for the required application. Refer to material section guide for standard materials of construction. PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.4.2 SEAT RING AND BALL ELEMENT 2.4.2.1 SEAT RING CONFIGURATION Since the modulating type of service, RMT 40 series are single seated as a standard of construction Standard design of seat configuration is single piston effect and the flow is therefore with a preferred direction. SINGLE PISTON AND DOUBLE PISTON EFFECT Independent floating spring loaded seat is in COMPARISON contact with the ball when the pressure comes from the upstream line, thus providing an effective seal even at low differential pressure. 2.4.2.2 SEAT RING SEALING In case of reverse flow direction standard single piston seat configuration is no more capable of sealing, since the seat would release the pressure (self relief). CONSTRUCTION Depending on pressure/temperature combination, and considering the type of fluid and application, two main construction are possible: This METAL TO METAL SEAT design make possible to offer high performances in terms of leakage capability: - in applications where dirty and/or abrasive fluid are involved; - in applications where high design temperature are required. A metal to metal seat offers also lower maintenance SINGLE PISTON EFFECT STANDARD CONFIGURATION Customizable standard solutions execution: are double available seat as costs and longer field life. non- configuration and/or double piston effect configuration may be provided. In double piston effect, configuration independent floating spring loaded seat is always in contact with the ball to provide an effective sealing, even at low differential pressure. METAL TO METAL SEAT CONSTRUCTION In case of n on standard double seat construction, a combination of single piston effect on upstream seat ring and a double piston execution on the downstream ring are possible, as an alternative to a relief valve for avoiding overpressure at the body Leakage class. Leakage class up to class V according to ANSI/FCI 70-2 and IEC 60534-4 is possible. cavity. SOFT SEAT This design make use of relisient insert that make possible to reach higher leakage classes. This design is mainly limited by - the service temperature: max 250 °C; - the type of fluid: not suitable in case of abrasive applications. DOUBLE PISTON EFFECT: NON STANDARD CONFIGURATION 14 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES Cladding with highly corrosion resistance material is possible (SS 316 or Inconel 625 as standard) for the best corrosion resistance at the lower cost: both for wetted parts and especially for dynamic seals areas. Carbide coating on sealing area may be performed on metal to metal construction, thus SOFT SEAT CONSTRUCTION enhancing valve reliability against wear. - Special execution may be provided with injection tungsten carbide coating TCC for service temperature up to 350 °C (120µm and points for emergency sealing in case of any failure over); up to seat replacement. - chromium carbide coating for service temperatures higher than 350 °C(120µm and over). Stellite overlay is possible as a non standard execution that couple an high wear capability with greater corrosion resistance than carbide coating. Since LUBRIFICATED SOFT SEAT CONSTRUCTION stellite is a welding overlay it’s characterized by cracking risks: therefore this operation has technologies Leakage class. Leakage class better than class VI according to ANSI/FCI 70-2 and IEC 60534-4 is possible. to and be performed procedures with by such skilled personnel that highly affect the valve cost. Special materials and technological way of constructions are possible for application where highly abrasive fluids are involved: for instance fully tungsten carbide obtained by 2.4.2.3 BALL tungsten sintered powders or similar. Ball is the plugging element of the 40 series. RMT Valvomeccanica have the full support of the Mechanical design is according to ASME B16.34. steel mills, forges and metal testing laboratories of Materials of constructions. the As standard material of constructions are the same of the seating ring. Forged materials construction but are also used ball as from holding group GIVA, for higher quality standards. standard casting is possible. Antistatic device is possible on request according to API 6D and ISO 17292: throw a small spring loaded ball electrical continuity between the ball and the valve body is . ensured. Finite element analysis are performed to offer 2.4.2.4 MATERIAL OF CONSTRUCTION customized and effective solution for the specific The choice depends on the combination of fluid type, application. pressure rating and design temperature. Carbon Steel and stainless steel, Duplex, Nickel alloys and other exotic material (DIN, ASME or ASTM specification) can be provided. 15 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.4.3 SEALING COMPONENTS (STATIC AND DYNAMIC) The choice for sealing components is mainly based on the combination of pressure/temperature from one side and fluid type from the other. 2.4.3.1 O RING SEALS O ring are the standard seals (both dynamic and static) for temperature between -46°C and +250 °C. Standard sizes from the market (section/ID) are LIPSEALS used for an easy replacement all around the world. As a standard decompression of construction (AED)compound anti explosion are 2.4.3.3 GRAPHITE PACKING AND SPIRAL chosen. WOUNDS For high pressure applications back up rings are Standard seals for high temperature applications used. are: The choice of the compound is performed by technical department considering both the operating conditions and the type of fluid, in order to ensure performance and reliability for lower maintenance costs: Fluoroelastomers Hidrogenated nitrile HNBR, – - graphite rings, self energized by fluid pressure, for dynamic seals (seat & packing) - spiral wounds for static seals: they ae made of graphite & SS316 rings, energized at assembly Viton, by a pre-compression. Perflouroelastomers (Kalrez), etc O RING SEALS 2.4.3.2 LIPSEALS Lipseals are the standard seals (both dynamic and static)for low temperature application, between - 196°C and +250 °C. GRAPHITE RINGS & SPIRAL WOUND They are made of an elastomeric jacket pre- 2.4.3.4 FIRE SAFE DESIGN energized by an helicoidal spring that works being Together self energized by the pressure of the fluid. with the basic pressure/temperature/fluid For high pressure applications back up rings are design used. API6FA,API 607 and ISO 10497. is seals for applications, possible, upon request, different fire safe according to The choice of the compound is performed by A fire safe design is characterized by the use of technical the graphite based sealing. They can be used as a operating conditions and the type of fluid, in order primary sealing elements and/or as a secondary to ensure performance and reliability for lower sealing elements, which can prevent for uncontrolled maintenance pressure relief in case of failure of the primary seals, department costs: considering Reinforced jacket + Elgiloy spring,etc both PTFE (RPTFE) due to excessive high temperatures. 16 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.5 RMT CONTROL TRIMS FOR 40 SERIES 2.5.1 45 SERIES: V CUT BALL CONTROL VALVE The 45 series is the V Cut series of ball control valve. The V Cut is the shape of the discovered downstream area. Through the good design of the V is possible to perfectly customize the valve behavior both from a flow capacity point of view (CV) and with reference to the flow characteristic: - V cut may be tailor-suited to process flow requirements: high rangeability, high flow capacity V CUT SEAT RING or dealing with low flow conditions is possible (micro V cut); - a near equal percentage behavior is possible; - precise positioning through a low friction design of the whole trim; - capability to deal with dirty fluids, with a nonclogging design; - through the proper selection of materials, treatments and the good engineering of the whole trim, is possible; - dealing with highly erosive applications; - dealing with sour service process conditions: high corrosion resistance materials may be chosen, in V CUT ELEMENT ON BALL: INTEGRAL AND SEGMENTED compliance with NACE MR0175 requirements. Moreover, the V cut may be performed on the following components depending on the design: - obtained on the seat ring: this is our standard design of construction. Seat ring can be easily replaced with a different V cut design for valve adapting to different process conditions; - obtained on the ball element; - obtained on a V-cut diffuser placed downstream to the valve: DOWNSTREAM V CUT DIFFUSER 17 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.5.1.1 45 SERIES FOR EXTREME EROSIVE APPLICATIONS: 45SS For applications were severe conditions occurs from an erosive point of view, a special valve design with two seating rings is possible. 45 SERIES FOR EROSIVE APPLICATIONS: 45SS The upstream seat ring (blue marked) is the sealing element. The downstream seat ring is the modulating V This design make possible to obtain: - a great rangeability: we are able to keep the ability of regulate a small Cv (high pressure drop and valve Cutted element: it performs the pressure reduction. near to closed position) and a high Cv (low pressure Immediately downstream this modulating element drop and valve nearly completely opened). The there will be the minimum passage area, that is the valve can pass from one condition to another vena without the need of changing internal trim; contracta, where the fluid reaches the maximum velocities: in this zone there are no this high rangeability is very difficult to be reached internal trim components but only a straight line with a traditional globe style choke valve; pipe, so that all the internal parts of the valve are - high tightness performance: since the type of service, high leakage class is required, generally preserved from any erosion problem. better then class V. Through this special design we are The two seat are engineered in such a way that - same material is located downstream to - ball valve is 45SS has been engineered to offer a low torque for the no erosion design makes this ball control valve of erosion due to high velocities related to gas expansion. suitable for severe and able to deal with two phase flow without problems the modulating seat ring. This performance a smooth control action; characterized by extreme hardness (for instance In order to protect valve body a bushing made in the leakage sealing element; occurring during initial modulating phase. fully tungsten carbide with 1200 HV). ensure trim in the globe solutions) to protect from wear the discovered, thus being protected from high velocities advanced technique of sintering ceramic powders, to don’t need particular trim solutions (such as bi-tight ring, when the upstream seat ring has already being Downstream V Cutted seat ring is built with an able reliability for all the service life of the valve; we pressure drop occurs only at downstream seating service conditions typical of a choke service, for instance flashing conditions. 18 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.5.2 43 SERIES: MULTISTAGE BALL CONTROL VALVE It’s undoubtable that when extremely high differential pressure occurs into the process, a globe valve solution offer the possibility to control the whole pressure drop with extremely precision. This is the reason why globe valve solution is often the preferred choice in extremely critical operations, such as pump recirculation services, turbine by-pass control valves, etc.… Our 43 series has the following purpose: extend the concept of the multi stage design, typical of a globe valve for low noise application or high DP cavitation control, to a ball valve solution. In this way, we are able to extend the typical high Cv of a rotary control valve with axial flow, to moderate severe service applications, in which a standard segmented ball or butterfly control valve can’t be used. 2.5.2.1 : NOISE ABATEMENT MULTIPATH APPROACH Noise attenuation is obtained by breaking the flow into a As a regulating device, a control valve is a noise great number of multiple jets. source. In fact pressure waves produced by flow Physically a multipath trim make possible to decrease the turbulences are responsible of the aerodynamic geometrical factor (Fd) of the valve and this permit to noise, and it’s impossible to control the flow of a shift to higher values the peak frequencies (fp) of the fluid without introducing turbulences. generated Mechanical vibrations are too potential noise sources, but they can be easily avoided for a ball valve through a good design. In fact, comparing to a globe, a ball solution has much less problems of vibrations due to the rotary design of the stem and the consequent lower friction and damage of the noise. The higher will be noise peak frequencies respect to piping ring frequencies (fr),the higher will be the noise attenuation obtainable by the pipe itself (fp>fr). The purpose is to maximize the flow breaking into multiple independent jets. The independence of the flow jets is the greatest limitation of this kind of approach. packing. MULTISTAGE APPROACH Aerodynamic noise is generally a problem to be Noise reduction can be achieved also with a different faced with gases and vapors rather than liquids. technique: Liquids noise matters depends on another more critical phenomenon: the cavitation. For liquids avoiding cavitation means basically to control also the generated noise. Furthermore, noise power is related to the stream power of mass fluid that depends on the square of fluid velocity. And gas/vapors velocities are much more higher than liquids. There are two approach for noise abatement in a ball control valve. the multi-stage approach. If the whole pressure drop is divided into multiple stages of pressure reduction, it will be possible to change in favor of a noise reduction the acoustic efficiency of the valve. Small pressure drops p1/p2 make possible to control fluid expansions and velocities keeping always the last stage in sub-critical conditions. This is mandatory for the noise abatement. Multistage approach is very effective from a theoretical point of view. Unfortunately, it has some practical limitation, related to the number of feasible stages. Furthermore, there are limitations to the obtainable expansion section ratios to proper control the fluid velocities. 19 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.5.2.2 CAVITATION CONTROL Cavitation is a phenomenon that characterizes liquid Pressure recover, quantified by the parameter FL in IEC flow behavior when pressure value becomes lower than standards, cause the bubble to implode when the valve the saturation Pv point. outlet pressure becomes again higher than the vapor When cavitation occurs the liquid begins to flash and tension. Bubbles collapse can seriously damage solid steam bubbles are generated. This condition is obtained surfaces because of the high amount of energy released in the so called “vena contracta” -where the pressure with this phenomenon. reach the lowest value and the velocity reach the peak Cavitation highly affects both performances (vibrations, values- before the recovery of pressure that occurs noise, etc.) and reliability: metal surfaces undergo an downstream to the reduce passage. inevitable pitting damage if this process is not controlled. In order to face up this problem is necessary to break the pressure drop into a convenient amount of smaller pressure stages inside the ball valve. This is shown in the following. VALVE INLET STANDARD CONTROL TRIM inlet pressure vena contracta area outlet velocity inlet velocity outlet pressure flashpoint velocity VALVE INLET VALVE OUTLET pressure vapour pressure MULTI STAGE CAVITATION CONTROL TRIM inlet pressure vena contracta area VALVE OUTLET outlet velocity inlet velocity outlet pressure flashpoint velocity pressure 20 vapour pressure PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES break the flow into multiple jets thus coupling the 2.5.2.3 RMT 43 SERIES BALL CONTROL VALVES advantages of a multistage approach with those of a multipath one in the noise abatement, as well described FOR CAVITATION AND NOISE CONTROL 43 Series has been engineered to offers a strong ball previously. valve solution to face efficiently up both cavitation and noise matters, on the basis of the physical greatness involved in this two phenomena. With reference to cavitation matter, 43 Series make possible to break the whole pressure drop into multiples stages. The adoption of a multiple stage design allow to avoid the cavitation beginning since the pressure is kept always higher than the flashpoint limit, by an engineered control of the fluid velocities. This is obtained by the insertion of parallel perforated plates inside the ball that realize the multiple breaking of the entire pressure drop. In order to make the plates work properly it’s necessary to control the grade of opening for the valve: an optimal opening would be lower than 40-45 degrees. This is necessary to avoid the fluid to by-pass the plate and reach the downstream side vanishing their effect. The good design of the plates offer our 43 series the possibility to suit the particular process conditions, for a customized design and improved performances. Detailed calculation is always performed and made available to the customer as a guarantee of the good engineering of the valve. During valve moving 43 Series trim act as a variable resistant trim. This make possible to greatly increase valve rangeability. Great attention is put into material selection, procurement and quality control. As a brand of GIVA Group, RMT is perfectly integrated with the still mills, forges and foundries of the company. RMT has the full support of an own advance metal testing laboratory located next to the factory. We can guide you through the best choice at the best cost with reference to fluid temperature/pressure combination. 43 SERIES BALL CONCEPT The parallel plates are offset by an optimally designed angle and allow to control fluid velocities thus obtaining an improvement in terms of: - fluid stability, that means better performances and lower and more balanced torques (with consequently gains in term of smaller safety factors and overall cost); - noise emission. Furthermore the engineered design of the 43 SERIES BEHAVIOUR holes (disposition, diameter, number, etc) make possible to 21 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.5.3 42 SERIES: BALL CONTROL FOR EXTREME NOISE CONTROL For extreme noise control, 42 series of ball control valve make use of a downstream attenuator. The goal is a great noise abatement through a multipath approach. Together with the noise reduction the attenuator, that consists in construction, a spherical make cage possible as a vibration standard of control for increased flow and therefore process stability. Downstream spherical cages (one or more) represent fixed stages for pressure reduction. The 42 series cannot face only up noise matters, but it can also be used for liquids. In this last application, attenuator acts as a flow diffuser with stabilizing capability and may help in case of cavitation problems. The variety of orifices in the cage allows to achieve a precise control even with high pressure drop and small flow rate. Shape and number of the openings can be customized to get optimal results in every condition. Noise abatement up to 20 Db is possible with a single cage construction and up to 25 Db with a double cage execution. Standard construction is full bore (to maximize drilled available area of passage) with single seat and single downstream attenuator. Optional constructions are possible to suit customer requirements: - two or more attenuator for extreme control requirements; - reduced passages; - double seat construction; - double block and bleed execution; - bidirectional attenuation capability. Drilled spherical cage can be also located inside the ball element, thus coupling of 43 series variable multistage approach with the attenuation capabilities of the 42 series. Moreover combination of multiple and fixed stages approaches is possible, for suited solution with the goal of an optimal process control. 22 42 SERIES PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 2.6 40 SERIES FLEX DESIGN FOR QUICK CHANGE AND EASY MAINTENANCE In order to make possible NPS size up to 12’’ (DN 300) and rating up to #600 are the quick change of the valve trim standard of construction. easy maintenance where necessary Customize size/class combinations may be engineered. without losing the constructive features and the control Ball valve may be placed and removed from the upstream capabilities of 40 series, a special flex designed has been side of the valve, while the seat ring is kept in position by a designed for the different types of RMT ball control valves: retainer ring. During installation, retaining screws and 45,43 and 42 series. washer are removed and the retainer ring is kept in This design is characterized by a single seat design and an position through a wafer design between valve body integral body construction with flange connections. upstream flange and pipeline flange. End to end dimensions are according to ASME B16.10 with All the constructive tips of RMT 40 series and all the trim reference to short pattern design. combinations of 45,43 and 42 series may be adopted in this Flex design. 1. 2. 3. 4. 5. 6. 9. 10. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 71. 72. 81. 82. 85. 86. 87. BODY RETAINER RING STEM STUD NUT O RING BALL SEAT RING B. SPRING O RING PACKING GLAND PACKING FLANGE STUD NUT PACKING FOLLOWER PIN (NOT SHOWN) COUNTERFLANGE BOLT (NOT SHOWN) LOWER TRUNNION O RING O RING BOLT LOWER FLANGE PIN PACKING PACKING END RING AXIAL BEARING RADIAL BEARING RETAINING WASHER RETAINING SCREWS WASHER 45 SERIES FLEX CROSS DRAWING: INTEGRAL BODY CONSTRUCTION: UP TO NPS 12’’ (DN 300) AND RATING #600. 23 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 3. 3.1 ACTUATORS AND CONTROLLING DEVICES ACTUATORS a working package suitable for customer requirements with Pneumatic piston are the standard in actuation of 40 series valves: the goal of a precise positioning for stable process control, even in the most severe service conditions. Advanced valve diagnostic is available. rack & pinion for size up to 3’’ (DN80); Smart communication hardware and software provide realtime preventive and predictive diagnostic data. Best brands are available and skilled technicians at complete disposal. 3.2 POSITIONERS AND PANELS Advanced digital positioner and controller are available for enhanced performance and control. This make possible improved process yields and real time diagnostic features to offer real-time preventive and predictive diagnostic data. scotch yoke pneumatic piston actuators for bigger size and high shut off applications. Both HART and Fieldbus communication protocol are available making reference to the best positioner brands on the market. In addition, hydraulic or electric actuators are available on request too. Dedicated positioner’s manufacturer software is provided. Great variety of control panel configurations and wide range of available accessories to offer you the best equipment for your 40 Series operation: Pneumatic actuator may be of DVG automation construction (a well known sister company inside the industrial group that holds RMT Valvomeccanica) or other main manufacturer. The coupling of correct actuator choice and valve high quality in design and manufacturing make possible to obtain filter regulators (standard), gauges, solenoid valves, boosters, limit switches, …… Our technical department is at you complete disposal and skilled technicians are available positioners/control panels trainings. 24 for service and PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 4. PRODUCT QUICK SPECIFICATION RMT BALL SERIES RATING TABLE SIZES* up to 48’’ [up to DN1200] PRESSURE RATINGS* ASME B16.5 up to #2500 [up to PN 420] DESIGN TEMPERATURES* -196°C up to 565°C [-320°F up to 1049 °F] *Standard codes of reference: IEC60534 general design code ASME B16.34 - EN 12516 strength design code ISA75.19 - ANSI/FCI 70-2 – IEC60534 tests and inspections RMT BALL CONNECTION TABLE END CONNECTIONS: ASME B16.5 * RAISED FACE RF RING JOINT RJ BUTT WELD SOCKET WELD X X X (not for Flex design) *special on request (not for Flex design) * Standard codes of reference: IEC60534-3 end to end dimensions MSS SP-6 surface finishing RMT BALL PERFORMANCE TABLE FLOW COEFFICIENT CV RANGEABILITY Up to 87420 according to ISA 75 series IEC 60534-2 SEAT LEAKAGE Up to class VI according to ANSI/FCI 70-2 and IEC 60534-4 NOISE AND CAVITATION CONTROL according to ISA 75 series and IEC 60534-8 FUGITIVE EMISSION CONTROL Up to class A according to ISO 15848-1 OPERATING PERFORMANCES according to ANSI/ISA 75-25 and IEC 60534-4 25 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 5. 40 SERIES RATING/CONNECTION TABLES STANDARD 40 SERIES STANDARD 40 SERIES SIZE 1’’ up to 2’’ 3’’ up to 12’’ ASME 150 CLASS [PN 20] ASME 300 CLASS [PN 50] ASME 600 CLASS [PN 100] DN RF RJ THD SW BW RF RJ THD SW BW RF RJ THD SW BW DN25 up to DN50 DN80 up to DN 300 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● STANDARD 40 SERIES ● ASME 900 CLASS [PN 150] ASME 1500 CLASS [PN 250] ASME 2500 CLASS [PN 420] BW RF RJ BW RF RJ ● ● ● ● ● ● SIZE DN RF RJ 1’’ up to 48’’ DN25 up to DN 1200 ● ● THD SW THD SW THD SW BW ● 40 SERIES FLEX DESIGN 40 SERIES FLEX DESIGN ASME 150 CLASS [PN 20] SIZE DN RF RJ 1’’ up to 48’’ DN25 up to DN1200 ● ● 40 SERIES FLEX DESIGN THD SW BW ASME 300 CLASS [PN 50] RF RJ ● ● THD SW BW ASME 600 CLASS [PN 100] RF RJ ● ● THD SW BW ASME 900 CLASS [PN 150] ASME 1500 CLASS [PN 250] ASME 2500 CLASS [PN 420] RF RJ RF RJ ● ● ● ● SIZE DN RF RJ 1’’ up to 48’’ DN25 up to DN 1200 ● ● THD SW BW THD SW BW THD * Standard Flange Finish is Ra between 3.2 and 6.3 micrometers [125 and 250 micro inches] * Customized flange faces and surface finish are available on request 26 SW BW PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 6. MATERIAL SELECTION GUIDE 27 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES As a brand of GIVA Group, RMT is perfectly integrated with the still mills, forges and foundries of the company. RMT has the full support of an own advance metal testing laboratory located next to the factory. Throw the combination of following material tables is possible to suit every condition with reference to fluid/pressure/temperature application. PART DESCRIPTION 1-2 BODY/ CLOSURE BODY/ CLOSURES/ BONNET 3-4 STUD AND NUTS 5-6 STEM 9-10 BALL & SEAT CARBON STEEL A105 A350 LF2 A350 LF3 *1 *2 A193 B7 / A194 2H A193 B7M / A194 2HM A193 L7 / A194 GR4 A193 L7M / A194 GR4M MARTENSITIC STAINLESS STEEL AUSTENITIC STAINLESS STEEL DUPLEX STAINLES S STEEL A182 F6a (AISI 410) AISI 316 AISI 321 A182 F44 A182 F51 A182 F53 A183 F55 - A193 B8 / A194 GR8 A193 B8M/A194 GR8M A182 F51 A182 F53 A183 F55 AISI 410 + ENP 75 µM A105 + ENP 75 µM A350 LF2+ ENP 75 µM A350 LF3+ ENP 75 µM *3 A182 F6a (AISI 410) *4 A182 F6a (AISI 410) *3 *4 12 BONNET 13 PACKING FLANGE - - 16 PACKING FOLLOWER - - 18 YOKE/ISO FLANGE 23 LOWER FLANGE 27-29 YOKE STUD AND NUTS 30 SPRINGS A105 A350 LF2 (Fe based Zinc Plated) A105 A350 LF2 A350 LF3 *5 *6 A193 B7 / A194 2H A193 B7M / A194 2HM A193 L7 / A194 GR4 A193 L7M / A194 GR4M *5 *6 *7 - A182 F6a (AISI 410) AXIAL BEARING RADIAL BEARING PACKING RING SEALS MONEL 400 INCONEL 625 A453 GR 660 - AISI 316 A182 F XM 19 *4 A182 F51 A182 F53 A183 F55 *4 17-4PH *4 MONEL K500 INCONEL 718 AISI 316 A182 F XM 19 *4 A182 F51 A182 F53 A183 F55 *3 *4 17-4PH *3 *4 MONEL 400 MONEL K500 INCONEL 625 AISI 316 AISI 321 A182 F44 A182 F51 A182 F53 A183 F55 AISI 316 AISI 316 AISI 316 - - MONEL 400 INCONEL 625 - - - - - - - - - A182 F51 - - - - - INCONEL 750 INCONEL 718 - AISI 316 - A193 B8 / A194 GR8 A193 B8M/A194 GR8M - - - - overlay on dynamic seal areas *2 overlay on wetted areas *3 hard coating (tungsten carbide or chrome carbide) on seating contact surfaces (120 µm and above) 61 62 71-72 8x - NICKEL ALLOYS *5 *6 *7 A105 A350 LF2 A350 LF3 *1 *2 *1 OTHER STAINLESS STEEL *4 electro nickel plating (25 µm and above) *5 zinc plating (25 µm and above) *6 hot dip galvanized HDG (ASTM A153 or ISO 1461) *7 Fluorocarbon coated PTFE BASEDAISI 316 + LOW FRICTION REFER TO PACKING SECTION REFER TO SEALING SECTION Combination of the above material is possible. Sour service materials and related certifications are possible. Exotic materials, solid tungsten carbide and ceramic materials can be provided for customized trim solutions. 28 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES 7. FLOW CHARACHTERISTICS 45 SERIES 43 SERIES Max CV DN 42 SERIES Max CV DN 1'' 2'' 3'' 4'' 6'' 8'' 32 113 306 499 1316 2270 1'' 2'' 3'' 4'' 6'' 8'' DN 1'' 2'' 3'' 4'' 6'' 8'' Max CV 45 164 374 683 1536 2731 10'' 12'' 14'' 16'' 18'' 20'' 4336 6268 7617 10120 12979 16193 10'' 12'' 14'' 16'' 18'' 20'' 3675 5311 6862 9170 11375 14195 10'' 12'' 14'' 16'' 18'' 20'' 22'' 24'' 26'' 28'' 30'' 32'' 19763 23687 27358 31944 36885 41434 22'' 24'' 26'' 28'' 30'' 32'' 17180 21855 25670 29760 34170 38890 22'' 24'' 26'' 28'' 30'' 32'' 36'' 40'' 48'' 52156 65039 92827 36'' 40'' 48'' 49210 60760 87420 36'' 40'' 48'' Flow characteristic is equal percentage. Customized solution on specific process condition. 29 58 139 269 636 1188 1885 2726 3312 4715 6047 7544 9207 11035 12745 14882 17184 19303 24298 30300 43246 PRODUCT BULLETIN RMTC-PB-40S-001 REV A 40 SERIES RMT CONTROLS a division of RMT VALVOMECCANICA – GIVA GROUP Via dei Patrioti • 21058 Solbiate Olona (VA) Italy Ph: +39 0331 375441 • Fax: +39 0331 376847 [email protected] www.rmtvalvomeccanica.com 30
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