1″-800LB-Nipples 3 Piece Vacuum Ball Valve
Description
Technical Data Sheet
Product: 3-Piece Vacuum Ball Valve with Nipples
Model / Size: 1″ – 800LB – Nipples
Configuration: Three-piece body construction with integral nipples (socket weld or butt weld ends) for vacuum service
1. Product Description
This valve is a three-piece ball valve specifically designed for vacuum service, featuring integral nipples (short pipe extensions) welded or integrally formed on both ends. The three-piece construction allows for easy in-line maintenance without removing the entire valve from the piping system. The valve is rated for Class 800LB pressure, making it suitable for high-pressure vacuum applications, gas handling, and critical process systems where absolute leak integrity is required. It is ideal for vacuum systems, high-purity gas lines, and high-cycle applications where reliable shut-off is essential.
2. Basic Parameters
| Item | Parameter |
|---|---|
| Nominal Size | 1 inch (DN 25) |
| Pressure Class | Class 800LB (equivalent to PN 140 bar) |
| End Connections | Integral Nipples (Socket Weld or Butt Weld) – per ASME B16.11 or ASME B16.25 |
| Body Construction | 3-Piece (center body with two end caps) |
| Valve Type | Floating ball, full port or reduced port (as specified) |
| Stem Sealing | Live-loaded packing or PTFE/stainless steel bellows (for vacuum service) |
| Operation | Lever handle (standard), gear operator, or actuator (optional) |
| Vacuum Rating | Suitable for high vacuum (1×10⁻⁶ Torr and above) |
3. Design Standards
| Item | Standard |
|---|---|
| Design & Manufacture | ASME B16.34 / API 608 (or manufacturer’s standard) |
| End Connections (Nipples) | ASME B16.11 (Socket Weld) or ASME B16.25 (Butt Weld) |
| Face-to-Face Dimensions | Manufacturer’s standard (with nipples) |
| Inspection & Testing | API 598 / ISO 5208; vacuum leak test per ASME PVHO or helium mass spectrometry |
| Vacuum Testing | Helium leak test with leakage rate ≤ 1×10⁻⁶ Pa·m³/s (or better) |
| Material Traceability | EN 10204 3.1 (optional) |
4. Bill of Materials (Typical Configuration)
| Part Name | Material (Typical Options) | Remarks |
|---|---|---|
| Body (Center) | A105 / A182 F316 / A182 F304 | Forged steel or stainless steel |
| End Caps (x2) | A105 / A182 F316 / A182 F304 | Same material as body |
| Nipples (x2) | A106 Gr.B / A312 TP316 | Integral or welded extensions |
| Ball | A182 F316 / A182 F304 | Chrome plated or electropolished for vacuum service |
| Seats | PTFE / Reinforced PTFE / PEEK | Low outgassing materials for vacuum |
| Stem | A182 F316 / A182 F304 | Precision machined |
| Stem Packing / Seals | PTFE / Graphite / Bellows (optional) | Low leakage, vacuum-rated |
| Body Seals (End Caps) | PTFE / Spiral wound gasket | Vacuum-tight sealing |
| Handle / Operator | Stainless steel / Carbon steel | Locking handle option available |
5. Dimensions & Weight (Reference)
| Item | Value |
|---|---|
| Overall Length (End-to-End) | Approx. 200 ~ 250 mm (including nipples, manufacturer dependent) |
| Overall Height | Approx. 100 ~ 120 mm (lever type) |
| Nipple Length (each) | Approx. 50 ~ 75 mm (varies by manufacturer) |
| Nipple End Type | Socket Weld (per ASME B16.11) or Butt Weld (per ASME B16.25) |
| Approx. Weight | 4.5 ~ 7.5 kg (depending on material and nipple length) |
Note: Dimensions and weights are typical values and may vary by manufacturer.
6. Operating Conditions
| Item | Parameter |
|---|---|
| Suitable Media | Vacuum, gases, high-purity fluids, corrosive media, cryogenic liquids |
| Vacuum Rating | 1×10⁻⁶ Torr (higher vacuum achievable with bellows seal and metal seats) |
| Temperature Range (PTFE Seats) | -29°C ~ 180°C |
| Temperature Range (PEEK Seats) | -29°C ~ 250°C |
| Temperature Range (Graphite Packing) | -29°C ~ 425°C (with metal seats) |
| Max. Allowable Pressure | Approx. 13.8 MPa (138 bar) at ambient temperature (38°C) |
| Leakage Rate (Vacuum) | ≤ 1×10⁻⁶ Pa·m³/s (helium mass spectrometry) |
7. Testing & Inspection
| Test | Requirement |
|---|---|
| Shell Strength Test | 1.5 times rated pressure (hydrostatic); no leakage |
| High-Pressure Seat Test | 1.1 times rated pressure; zero visible leakage (tight shut-off) |
| Low-Pressure Pneumatic Test | 0.6 MPa compressed air; seat and stem leakage within allowable limits |
| Vacuum Leak Test | Helium mass spectrometry; leakage rate ≤ 1×10⁻⁶ Pa·m³/s (or as specified) |
| Operational Test | Full cycle test (opening/closing) under pressure and vacuum conditions |
| Material Verification | Positive Material Identification (PMI) on critical components |
| Cleanliness | Degreased and cleaned for oxygen or high-purity service (as required) |
8. Features & Benefits
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Vacuum Service Optimized: Low outgassing materials, helium leak-tested, and precision-machined components ensure high vacuum integrity.
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Three-Piece Construction: Allows for in-line maintenance – end caps can be removed to access ball and seats without disturbing pipe connections.
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Integral Nipples: Pre-welded or integrally formed nipples simplify field installation, reducing welding points and potential leak paths.
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High Pressure Capability: Class 800 rating suitable for high-pressure gas and liquid systems, including hydraulic and pneumatic applications.
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Tight Shut-Off: PTFE or PEEK seats provide zero-leakage sealing in both directions.
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Low Operating Torque: Smooth ball and seat surfaces ensure easy operation, even under differential pressure.
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Locking Handle (Optional): Prevents unauthorized operation – essential for safety-critical systems.
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Fugitive Emission Compliance: Stem sealing can be designed to meet ISO 15848 or TA-Luft standards.
9. Important Notes
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Vacuum Service: For ultra-high vacuum (UHV) applications, specify metal seats and bellows stem seal to achieve leakage rates below 1×10⁻⁹ Pa·m³/s.
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Installation: The valve may be installed in any orientation. Ensure proper support for piping to avoid stress on the valve body.
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Cleaning: For oxygen service or high-purity vacuum applications, the valve must be specified with degreasing and cleaning per ASTM G93 or CGA G-4.1.
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Nipple Ends: Confirm whether nipples are socket weld (SW) or butt weld (BW) to match piping specifications. Socket weld nipples require fillet welding; butt weld nipples require full penetration butt welds.
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Maintenance: When replacing seats or seals, use manufacturer-approved kits to maintain vacuum integrity.
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Material Compatibility: Verify seat and seal materials are compatible with the process media to prevent swelling, degradation, or outgassing.
If you require additional specifications such as NACE MR0175, oxygen cleaning, high-temperature bellows seal, or actuator mounting, please let me know and I can supplement the data sheet accordingly.
