Ball Valves

Health And Safety

Containment

Background

Industry is making major contributions towards improving our global environment by reducing hazardous emissions. Reducing product losses and addressing environmental concerns.

Since the advent of the ‘Clean Air Act Amendments of 1990 (CAM), introduced by the U.S. Environmental Protection Agency (EPA), industrial plants have revised their specifications regarding fugitive emissions.

The Challenge

Eliminating product emmission is one of the most serious challenges for process industry and consequently can be most costly to control. As part of its Health & Safety initiative campaign Habonim has introduced additional security to the valve stem design for critical applications.

Design Features

• Modular design uses a double defence sealing concept. The first defence line is based on the valve stem seal

arrangement, while the second line is integral with the FE bonnet.

• A machined lip on the bonnet bottom plane will ensure a safe fit over the valve ISO pad. A static seal will provide security to the atmosphere.

• The bonnet design allows a sensing device to be fitted between the two sealing arrangements. In case of first

defence line failure an alert can be immediately identified.

• Any media is contained within the FE bonnet until valve maintenance can be safely carried out.

• Double blowout proof stems.

• Linear alignment between valve stem, extension and actuator to reduce side load.

• Rigid construction.

• Precision stem and packing bore finish.

• Fire-safe valve stem packing and valve connection to bonnet (upon request)

• Stainless steel cast CF8M housing material as standard.

• Exotic materials Alloy-20, Hasteloy-C22. Monel and more (upon request).

• Various solutions are offered by Habonim when sizing FE bonnets to customer applications: HC (high cycle),

N (Control valves), KG (fire-safe and thermal applications), and the HermetiX Habonim patented stem packing.

Valve Construction and ISO 5211 Pad

The rigid valve body construction is designed in accordance with ANSI B16.34 and BS 5351. The 47P series valve bodies have a top mounting flange conforming to ISO 5211 with centering ring for direct mounting of actuators, limit switches, fugitive emission bonnets or extended handles.

The 3-piece body construction enables valve in-line maintenance and replacement of intenal parts. Standaid 47P valve bodies have through body bolts. Firesafe valves have threaded body screws. With the ISO mounting flange there is no need to loosen body bolts when fitting actuators.

The 47P/46 series ball, seats and seals are interchangeable with HABONIM flanged 31/32 series reduced bore valves and with HABONIMflanged 73/74/78 series full bore valves up to and including 2". Stem assemblies are interchangeable through out.

Body and Trim Materials

Standard HABONIM body and end materials are Carbon Steel or Stainless Steel. Carbon Steel bodies and ends are forgings to ASTM A105 or castings to ASTM A216 WCB. Stainless Steel  bodies are casting to ASTM A351 CF8M. The ends are castings  to ASTM A351 CF3M, which have a lower carbon content and  are therefore more suitable for welding.

The standard ball and stem material is stainless steel 316. All high torque valve stems are in high tensile 17-4PH stainless steel. Balls in 17-4PH stainless steel are also available. Other valve and trim materials such as Alloy-20, Hastelloy-C22, Duplex or Monel for specified applications are available on request.

All valve pressure containing parts such as bodies and ends  are heat numbered and can be traced by their work number which is stamped on the valve tag. Documentation will be supplied on request.

Stainless steel valves have stainless steel bolts and nuts. Carbon steel valves have plated carbon steel bolts and nuts. Special alloy valves carry stainless steel bolts and nuts unless otherwise specified.

Stem Sealing

What is HermetiX™?

Named after its distinctive X-shaped design, the patent-pending HermetiX™ seal is designed to eliminate stem leakage.

Even as fluid pressure or side load increases, the HermetiX™ seal dynamically adjusts to prevent fugitive emission.


Advantages

• Environment - friendly

• Safe - Meets ISO 15848-1** for eliminating fugitive emissions

• Patent - pending Hermetix™ gland packing and seal

• ZERO-Stem-Leak Hermetix™ valves are now Habonim standard, putting Habonim at the industry forefront in
saving our environment

• Anti-static as standard

• 4-Year guarantee against stem leakage!

Additional Features of the ZERO-Stem-Leak HermetiX™ Valve

• As standard, the HermetiX™ seal is comprised of an NRG (carbon-filled PTFE) and carbon-filled PEEK thrust bearing. For FDA and other clean applications (where carbon particles are prohibited), a TFM HermetiX™ gland packing and Virgin PEEK thrust bearing is available.

End Connections

Many types of end connections are made to suit most customer requirements. The standard types are screwed, welded or flanged connections.

Screwed Ends

Screwed ends are identified by a marking on the end face:

BSPT - no identification
NPT - concentric groove
BSPP DIN 2999 - external chamfer
DIN 3852 - external step

Other screwed ends identification will be advised on request.

Pipe weld Ends

Welded ends are available according to the pipe type and schedule in buttweld or socket weld. The standard pipe schedule is 4O. Buttweld ends are available from Sch 5 to Sch 180 and socket weld ends are available up to Sch 40 in reduce bore and up to Sch 80 in full bore.

 

Tube weld ends

Tube ends are available in imperial or metric sizes. The ends are short stubs or one piece extended stubs suitable for AOW (automatic orbital welding). Weld end valves can be installed in-line without dismantling the valve or changing internal parts, as long as the proper welding procedures are kept. Please refer to Habonim Welng Instructions for more information.

 

Flanged Ends

Flanged ends complying to class 150 ANSI B16.5 and DIN 3202 F1 face-to-face dimensions are available in reduce or full bore. In some cases ANSI flange end valves will comply to class 300 face-to-face dimensions only.

 

Other Ends

Other available ends are Clamp ends for the Biopharm and Food industry, Compression Fitting ends for Instrumentation and the Semiconductor industry, Extended Pipe ends for the Chemical industry. Other ends are available on request.

Seat Seals

A flexible seat design provides tight shutoff at high and low pressures, reduces wear and valve torque. The seat perimeter has equalizing pressure slots to alow penetration of pressure to the body cavity for better sealing capability.

Other available seat designs are Cavity Filler seats for reducing dead volume in the ball cavity, One-piece Seat/Seal for diverter valves or Double-Block and Bleed seats with O-ring.

Habonim has a line of metal seated valves for severe service applications where high temperature, abrasion and/or corrosion restrict the use of soft seats.


T PTFE

PTFE is the material of choice where the characteristics of low friction, high durability, excellent thermal resistance or chemical inertness are required. Recommended for use with water foodstuff or corrosive chemicals.

Identification: Colour white.


   A TFM^TM (Modified PTFE)

TFM^TM is a chemically modified PTFE that offers enhanced properties while retaining all the proven advantages of conventional PTFE.
 

Identification: Colour white with brown stripe.


J R Glass Filled PTFE

Glass filed PTFE has virtually the same chemical compatibility as virgin PTFE but extends the pressure/temperature rating of the valve. Its superior compression and heat resistance provide the seat good wear resistance at high loads and is particularly good for steam application.

Available with glass fibre content of 15% (R) or 25% (J).

Identification 15% GF: Color off-white with blue stripe.

Identification 25% GF: Color off-white with red stripe.


P Carbon Filled PTFE (NRG)

NRG seats are suitable for elevated temperatures, resistance under high pressure loads, low coefficient of friction and are suitable for many corrosive applications. They are available in two different profiles to suit both steam or thermal fluid at high temperature and cryogenic applications.

ldentification: Colour charcoal black with white stripe.


H Glass & Metal Oxide Filled PTFE

This seat withstands higher temperatures and pressures than glass filled PTFE, has good resistance under load, not recommended for foodstuff.

Identification: Colour blue.


U UHMWPE (Ultra High Molecular Weight Polyethylene)

UHMWPE is mainly used where PTFE is not acceptable. It has high radioactive resistance of 2 x 10 rads. Other typical applications are the tobacco industry, H2SO4 and the handling of highiy abrasive media.

Identification: Colour pale white with green stripe.


Y Delrin^®(Acetal Resin)

Delrin^® is used for high pressure applications where resistance to wear and deformation under load is essential. It is mainly used in the Petroleum industry. Its maximum temperature is limited to 80°C (176°F) under full load.

Delrin^® must not be used in presence of OXYGEN.

Identification: Colour creamy white with black stripe.


K Carbon Filled PEEK^®

PEEK^® (Polyetheretherketone) is a tough, high temperature, semicrystalline thermoplastic offering excellent characteristics such as high tensile strength and elongation properties, excellent shear strength and creep resistance, outstanding fatigue and chemical resistance, no susceptibilty to hydrolysis (Steam/Hot Water).

Identification: Colour black with yellow stripe.


L Virgin PEEK^®

Virgin PEEK^® has no fillers and comprises similar physical characteristics as filled PEEK^®. It has higher radiation resistance and is suitable for food, tobacco and pharmaceutical applications.

Identification: Colour beige.


S Vespel^®
Vespel^® is a polyimide material that has high temperature capabilities under load and is mainly used for heat transfer applications, hot gases and oils.

Vespel must not be used in with STEAM or media containing WATER or WATER VAPOR.

Identification: Colour brown.

 

C PCTFE (Kel-F^®)

PCTFE material, better known as Kel-F^® (Chloro Tri Floro Ethylene) is used extensively for cryogenic services for temperatures down to -196°C (-320F°) to 121°C (250°F). Its main applications are for gas production, transportation and storage.

Identification: Colour see through white.

Pressure/Temperature Rating (Seat Material)

The solid lines in the Pressure/Temperature (PT) graphs are the maximum seat rating for each material*, and are not the valve body rating. Valves above 2” have a limiting body rating of #300 for all seat matenal. The PT lines are based on differential pressure with the valve in the closed position. Data is given  from field applications and laboratory tests.

Blowout Proof Stem

Stem

A precision machined blowout-proof stem is inserted into the valve body from within. Available as standard, antistatic or firesafe. The firesafe stem has a special contour for metal to metal contact in the event of fire. Stems ½” to 2½” output shaft are double “D”. Stems 3” and above have square shaft as standard and double D can be provided upon request by mentioning “WR” Stem.

Antistatic Device

Antistatic stem device to discharge static electricity buildup on the ball are optional. This conforms to BS 5351 for continual  electrical contact between ball/stem and stem/body.

Contact is made by a spring loaded stainless steel element inserted in the stem or a conductive PTFE stem seal. Valve sizes up to 2 require a stern/body contact, while larger size valves also need a ball/stem contact.

Stem Assemblies

All valves have blowout-proof stems. The stem assembly incorporates live loaded springs to compensate for pressure and temperature surges and wear. A tab washer ensures that the stem nut will not loosen during cyclic operations. The stem is machined with a high surface finish for better sealing capability. Optional stem seal materials and shapes are available. Special High Cycle stem arrangements are available for specific applications.

 

Standard Stem Assembly Sizes 1/2” to 21/2”

A blowout-proof stem and thrust washer are inserted in the valve body from its cavity. A set of one or two stem packings followed by a stem-centering gland are spring loaded and fastened by a nut and tab washer from the outside. A rigid handle is fastened above it by a second nut and serrated washer.


 

Standard Stem Assembly Sizes 3” to 8”

A blowout-proof stem and thrust washer are inserted in the valve body from its cavity. A set of three stem packings followed by a stem centering gland and stop plate are fastened by a slotted gland nut from the outside. A pipe wrench is inserted into a “TEE” head and fastened by a screw to the stem.


 

O-Ring Stem Assembly

 
O-ring stem assemblies for searching gas, high vacuum and other special applications such as ammonia or high cycle applications are standard options. The O-ring, followed by backup rings, is secured in place by a metal washer and bearing.

 

V-Ring Stem Assembly
V-ring or sandwich style stem seals are some times more efficient for applications such as high cycle or where it is essential to have low emissions. These seals can be fitted into the standard valve body.

 

High Cycle Stem Assembly
In high cycle applications where the valves may pass through many operational cycles per year, an upgrade to the stem assembly is done according to the working conditions. Thrust seal with better wear resistant material, hardened polished stems and special stem seals are suggested. A unique gland with an O-ring groove securred by a live-loading spring-pack give the valve long service life.

Case Studies                                                       

Pharmaceutical Industry

Bar Stock Fire-Safe Valves

Habonim redesigned a range of valves for a leading international pharmaceutical company to meet aesthetic and technical specifications. Habonim supplied over 200 actuated Fire-Safe 48T Bar Stock valves (with a special dome actuator), and 400 manual valves for solvents, gases and liquids. Both the valves and actuators were specially designed to match existing site specifications. The Bar Stock design was adopted to create a clean exterior finish.

Low Ferrite and Sulfur Valves

Habonim designed a range of 48T series valves with low ferrite and sulphur content to meet site specifications of a new contact lens manufacturing facility in Europe. Habonim supplied 200 manual and 80 actuated packages to the site for use in a clean steam application.

Habonim Dedicated Petrochemical Solutions

Oil field skid utilizes Habonim valves

A consortium of small oil field developers is employing a new technology to recover oil reserves previously deemed to be unrecoverable. Habonim valves were selected for this critical new project due to the quality and proven reliability of its specialty valves.

The engineers specified 316L for the entire ball valve assembly and Habonim recommended its TuBore 48 Series valves, with schedule 80 weld ends. To control the flow of oxygen and carbon Habonim V-Ball Control valves were selected and automated with Habonim’s actuators, as well as block valves using on/off electric actuators with battery packs.

New petrochemical installations in Poland choose Habonim’s MTM valves

Special sampling units for different media operating at temperatures of 300°C - 500°C were designed for Lurgi and Fluor by Ecozam, Habonim’s distributor in Poland. Habonim MTM valves made from special alloys were mounted in the insulated box.

Customized DBB Dual-Safe valves developed for ORL oil refineries

Habonim developed a Double Block and Bleed valve with total shutoff to ensure the safe flow of gas at ORL refineries in Israel. The Dual- Safe unit incorporates two main isolation valves and one bleed valve in a single body, effectively eliminating the danger of combustion.

LNG Dedicated Solution

Leading LNG safety

Working with REPSOL Spain, an internationally recognized leader in LNG production, Habonim developed a special double block and bleed (DBB) cryogenic valve to improve the company’s safety practices when transferring gases in liquid form at very low temperatures in the most severe applications.

Part of Habonim’s ‘Dual Safe’ series, the DBB cryogenic valve is employed at key stages of LNG processing with a focus on safety and efficiency. The DBB technology ensures that upon completion of specific processes, there is no pressure remaining in the body between the valves. The DBB valve contains a bleeding port to release pressure buildup in the body and a special indicator to show if there is any remaining pressure once a process is complete. Habonim’s DBB solution also features a single body construction, thereby reducing the number of body seals, and the potential for leakage, while at the same time saving space, and provid¬ing maximum safety at the most critical stages of LNG processing. Habonim’s DBB cryogenic valve can be operated manually or actuated.

Innovation for efficient LNG operations

In cooperation with Enric, a leading producer of LNG storage, transport, and processing equipment, Habonim developed a solution that addresses the company’s operational efficiency. Instead of the four units in their previous LNG transportation equipment, Habonim developed the Enric Valve Commutator which effectively condensed the old system into one unit. The result was operational improvements in a number of key areas:

• Eliminated 95% of required piping
• Reduced costs – lower equipment costs and simplified maintenance
• Reduced space – system consolidated into one unit
• Improved safety – less piping and sealing rings minimize the leakage path
• Flexible ‘plug and play’ system – allows for quick and easy expansion
• Reduced energy usage

Chemical Industry

Innovation for Enhanced Isolation

EKA Chemicals (Akzo Nobel) required an enhanced Double Block & Bleed solution for its Chromasil production. The media used in the process were: ethanol, industrial water, nitrogen, stabilizer solution, desalinated water & acetone. The design required two of each component (including actuators and valves), making the standard DBB too costly, heavy and space-consuming, while creating many possible sources of leakage.

Habonim’s innovative Dual-Safe™ DBB offered the customer a compact, tailor-made package, operated by a single actuator, which increased safety and strict isolation as well as meeting the need for cost and space savings.

Cost Effective Flow Control Solution

In a headbox profile of a dewatering machine designed by Andritz AG in Graz, the main requirement was for a large number of control valves to be fitted in a limited space application. The demand for a flow rate of “5.000 - 12.000 l/min”, for 54 valves in one machine had to be maintained. Habonim’s engineered solution offered the customer a hand-operated control valve, using V- Port 60 with oval hand wheels and position indicators to allow precise control of media flow.

Video