Information

 

 

 

 

I. Applications

Ball valves, produced by GAZOMET, are dedicated mainly to the gas and oil industry.

Their application includes:

• gas distribution
• gas transmission,
• processing lines,
• natural gas mines
• underground gas stores.

Ball valves from GAZOMET are also applied in other industry sectors, where resistance to aggressive media is required,fuels.

 

The actual production programme includes ball valve diameters, ranging from DN6 to DN500 and  pressures from PN16 to PN420. GAZOMET ball valves in their standard version can be used in temperatures from -30°C to +60°C.

 

II. Materials

•  properties of applied materials
• material specification for ball valves
• material specification for ball valves (continued)

III.Flanges

• table 1

 

IV. External anti-corrosion protection coating

Ground version

Surface preparation

abrasive blast treatment - Sa21/2 Class, meeting the Polish PN-ISO 8501-1 Standard washing and phosphate treatment with SUR-TEC fluid

• flushing in IZOPROPANOL alcoholPrime coat
• epoxy paint - SEEVENAX Grundierung 144 (white colour), coat thickness 40 ÷ 80 μm

 Top coat

• polyurethane paint - ALEXIT Decklack 460-80 (yellow colour RAL 1023), coat thickness 80 ÷ 120 μm

 

Underground version - Set I

Surface preparation

• abrasive blast treatment - Sa21/2 Class in conformity with the Polish PN-ISO 8501-1 Standard

Insulation coating

• polyurethane coat - PROTEGOL 32-55(black colour), coat in Class B (coat thickness above 1.5 mm), following EN 10290 andDIN 30677 part 5

 

Underground version - set II

Surface preparation

• abrasive blast treatment - Sa21/2 Class in conformity with the Polish PN-ISO 8501-1 Standard
• flushing in IZOPROPANOL alcohol Prime coat
• epoxy paint - SEEVENAX Grundierung 144 (white colour), coat thickness 40 ÷ 80 μm

 Top coat

• polyurethane paint - ALEXIT Decklack 460-80 (yellow colour RAL 1023), coat thickness 170 ÷ 210 μm

Optional anti-corrosion protection systems are available with different paint sets and colours.

 

V. Tests

Ball valve testing is performed in conformity with General Specifications (GS), defined on the basis of current regulations and standards. Tests of ball valves may also be performed, according to the American API6D Standard, German DIN 3230 Standard, part 5 or following individual criteria.

The scope of production series tests, as defined in GS, includes:

pressure test - hydraulic test with pressure of 1,5 x PS*

external leak-proof test – pneumatic test with pressure of 1.1 x PS

valve closure test – pneumatic test with pressure of 0.6 MPa and 1.1 x PS for each side performance test

Ball valves are made in leakproof class A, meeting the Polish PN-EN 12266-1 Standard.

 

VI. Pipeline tests

Mechanical strength and leakproof tests of mounted ball valves

Ball valve in opened position

hydraulic test - max. pressure 1.5 x PS

pneumatic test - max. pressure 1.25 x PS

Note: When a pipeline is filled with test medium, close slightly the ball valve (10° ÷ 20°) in order to allow the transfer of test medium into the space between the ball and the body (Fig. 1). Leave the ball valve in this position during the entire test.

  

Ball valve in closed position

• hydraulic or pneumatic test -max. rated pressure

 

VII. Documents at delivery

Ball valves are delivered with the following documents:

• Technical acceptance certificate 3.1 acc. to PN-EN 10204 Polish Standard
• Declaration of Conformity, acc. to 97/23/EC Directive(CE symbol)
• Assembly and operation manuals
• Warranty certificate

 VIII. Special version

Ball valve with metal-metal sealing  fileadmin/_rmg/applications/ball-valves/kdk/metal-metal-przekroj.jpg(KDKa, KDSa)

TOP ENTRY ball valve  fileadmin/_rmg/applications/ball-valves/kkk/KKS-TE-10.JPG(KKK,  KKS)

Ball valve with staged opening fileadmin/_rmg/applications/ball-valves/kurki1/kpk-1.jpg<//a>(KPK)

 

IX. Engineering solutions

Cross-coupling

GAZOMET has introduced a new solution to ball valve design, linking the ball with the stem with a cross coupling. This allows for the ideal adjustment of the ball position to the seals in the full rotation range (90°). Such a configuration eliminates unfavourable stress in the valve, which makes the rigid stem mounting and the cross coupling more stable. Reduced torque provides uniform distribution of ball pressure on the seals around the entire circumference, which improves leakproof performance of the whole sealing system.

  

Independent retaining ring

Serially manufactured, the KSK ball valves have got a special (not found in products of other manufacturers) “independent retaining ring” to eliminate stresses, transferred from gas pipeline, which can be detrimental to ball valve performance. This solution provides stable torque and long-term leakproof properties.

 

Sealing compensation

Ball valves manufactured by GAZOMET are provided with elastic compensation of the main sealing. This compensation is ensured by the special corrosion-resistant spring packages. This solution allows for a uniform and controlled pressure of the sealing package to be applied to the ball surface, eliminating mounting stresses and improving the performance of the ball valve under a wide range of temperatures and pressures. All this provides a reliable ball valve performance in the long run. GAZOMET always uses

the double, independent sealing compensation, while maintaining the “Double Block and Bleed (DBD) function, which guarantees some leakproof properties of the valve in its inlet and outlet sections while completely closed (Fig.2) or opened (Fig. 3). This feature enables leakproof tests to be performed via the plug or the drain valve.

  

X. New technologies

Electron beam welding

In the GAZOMET valves that have a uniform, non-disassamblable body, a new welding technology, electron beam welding, has been implemented. This method melts the area of adherence of the connected objects with the heat obtained from an electron beam emiting heat energy that is directed onto a welding surface. The main characteristic feature of this process is the welding of the adhering surfaces by melting parent material of the two objects without adding any welding flux.

 The process reveals high manufacturing efficiency, minimal heat spread and provides aesthetic welding shapes. It introduces only slight stresses to the engineering structure and allows for fusing different materials of considerable thickness.

  

Numerically controlled machine tools

GAZOMET is a manufacturing organisation, where the stock of machine tools is subject to continuous upgrading. A consequent investment process allows for systematic replacement of conventional machine tools with new, more precise and efficient machine tools that are numerically controlled.

The Boehringer turning centre is one of the latest CNC machines, used by GAZOMET. This machine provides high rigidity of machining, high efficiency and manufacturing precision. It allows the machining of parts that are up to 550 mm in diameter, with length of up to 1000 mm and max weight of 800 kg. This machine is equipped with an additional “C” axle, which, with the use of driven tools, enables drilling operations and milling around the perimeter.

 

Supfina superfinisher

Extensive manufacturing experience of GAZOMET combined with application experience of the end-user leads to conclusion that the high quality of ball valves, i.e., their tightness, depends on the performance and matching of the two main elements: the ball and the sealing. In the dynamic sealing provided by the sealing component, the quality of the ball manufacturing, especially its perfectly smooth surface, miniscule deviations in shape and the radial run-out are the key important features. In order to meet these requirements, GAZOMET possesses a special ball superfinisher. The SUPFINA superfinisher is the only new generation machine tool in Europe, which provides high quality surface finish (Ra parameter< 0,16 μm) and roundness deviations < 0.02 mm.

 

XI. Drives

All ball valves, depending on the torque required to open a valve, are equipped with a wrench or a worm gear. Optionally, ball valves may have their own drive system: electric, pneumatic or electro-hydraulic.