3-Piece Open Die Forged Cryogenic Ball Valve c/w SA Pneumatic Actuated
Description
TECHNICAL DATA SHEET
Cryogenic Floating Ball Valve (2-Piece, Flanged Ends, Stainless Steel)
Project: _______________________
Tag No.: _______________________
PO No.: _______________________
1. General Information
| Item | Specification |
|---|---|
| Valve Type | Floating Ball Valve, 2-Piece Split Body, Side-Entry, Anti-Static, Anti-Blowout Stem |
| Size Range | DN15 – DN300 (½” to 12″) [Specify size: _____] |
| Pressure Rating | Class 150 / 300 / 600 (PN16 – PN100) |
| End Connection | Flanged Ends (Raised Face / RTJ) per ASME B16.5 |
| Design Standard | BS 6364 / ISO 28921-1 / MSS SP-134 / ASME B16.34 / API 6D |
| Face to Face Standard | ASME B16.10 / ISO 5752 / BS 6364 Table 1 |
| Test Standard | API 598 / API 6D / BS 6364 |
| Service | LNG, LO2, LN2, LAr, Ethylene, Methane, Cryogenic Industrial Gases |
| Temperature Range | -196°C to +80°C (-320°F to +176°F) |
| Bore Type | Full Bore / Reduced Bore (Specify) |
2. Bill of Materials (Materials of Construction)
| Part Name | Qty. | Material | Material Specification / Notes |
|---|---|---|---|
| Body Halves | 2 | Stainless Steel | ASTM A182 F304/F304L (Forged) or ASTM A351 CF8/CF3 (Cast) |
| Ball | 1 | Stainless Steel | ASTM A182 F304/F316 (Forged), Chrome Plated / Surface Ra ≤ 0.4µm |
| Stem | 1 | Stainless Steel | ASTM A182 F304/F316, Anti-Blowout Design |
| Seat (Downstream) | 1 | PCTFE / RPTFE | Spring-Energized PCTFE (Preferred for -196℃) or Glass-Filled RPTFE |
| Seat (Upstream) | 1 | PCTFE / RPTFE | Optional Bidirectional Design |
| Stem Seals / Packing | Set | PTFE + Graphite | Live-Loaded Packing (Belleville Springs) at Ambient Zone |
| Body Gasket | 2 | PTFE / Spiral Wound | PTFE or SS+Graphite Spiral Wound |
| Body Bolts & Nuts | Set | Stainless Steel | ASTM A193 B8M (Bolts) / ASTM A194 8M (Nuts) |
| Thrust Washer / Bearing | 1 | PTFE / Reinforced PTFE | Reduces operating torque |
| Anti-Static Device | 1 | Stainless Steel | Ball-to-Stem / Stem-to-Body |
| Stop / Locking Device | 1 | Stainless Steel | Optional for safety |
| Name Plate | 1 | Stainless Steel | MSS SP-25 marking |
3. Material Specifications & Rationale
| Component | Material | Rationale |
|---|---|---|
| Body & Bonnet | A182 F304/F316 / A351 CF8/CF8M | Austenitic stainless steel retains ductility and impact toughness at -196°C. F304L/CF3 grades offer enhanced resistance to intergranular corrosion after welding. All components undergo cryogenic stabilization treatment per BS 6364 . |
| Ball | A182 F304/F316 | Hard chrome plating or electroless nickel coating improves surface hardness (Ra ≤ 0.4µm) and ensures low friction against PCTFE seat . |
| Seat | PCTFE (Spring-Energized) | PCTFE (Poly-chloro-tri-fluoro-ethylene) maintains dimensional stability and resilience at -196°C. Spring-energized design ensures bubble-tight shut-off even at low differential pressures . |
| Stem Seals | PTFE + Graphite | Extended bonnet positions packing away from cold zone; live-loading compensates for thermal cycles and prevents fugitive emissions . |
4. Cryogenic Design Features
| Feature | Description | Benefit |
|---|---|---|
| Extended Bonnet | Length per BS 6364 (e.g., 250mm for DN50) keeps stem packing at ambient temperature . | Prevents ice formation on packing; ensures reliable stem sealing and operation. |
| Pressure Relief Hole | Upstream-side hole in ball prevents cavity pressure buildup during warm-up . | Eliminates risk of cavity over-pressurization and seat damage. |
| Anti-Static Device | Springs/plungers ensure electrical continuity between ball, stem, and body . | Prevents static charge accumulation in flammable cryogenic services. |
| Blowout-Proof Stem | Stem retained internally by shoulder or retaining ring . | Safety critical: prevents stem ejection under pressure. |
| Cryogenic Treatment | All pressure-containing parts thermally cycled to -196°C . | Stabilizes microstructure; ensures dimensional stability in service. |
5. Dimensional Data (Reference – Flanged Type)
*Note: Dimensions vary by manufacturer, pressure class, and extension length. Below are typical values based on ASME B16.10 / BS 6364 .*
| Size | Face-to-Face (L) | Extension Length (E) | Height Open (H) | Handwheel Dia. (D) | Bolt Circle Dia. | No. of Holes |
|---|---|---|---|---|---|---|
| DN15 (½”) | 108 mm | 180 mm | 210 mm | 100 mm | 60.5 mm (2.38″) | 4 |
| DN25 (1″) | 127 mm | 200 mm | 240 mm | 125 mm | 79.4 mm (3.12″) | 4 |
| DN50 (2″) | 178 mm | 250 mm | 310 mm | 200 mm | 120.7 mm (4.75″) | 4 |
| DN80 (3″) | 203 mm | 280 mm | 370 mm | 250 mm | 152.4 mm (6.00″) | 4 |
| DN100 (4″) | 229 mm | 320 mm | 440 mm | 315 mm | 190.5 mm (7.50″) | 8 |
| DN150 (6″) | 394 mm | 400 mm | 570 mm | 400 mm | 241.3 mm (9.50″) | 8 |
| DN200 (8″) | 457 mm | 450 mm | 680 mm | 500 mm | 298.5 mm (11.75″) | 8 |
Flange Details: Raised Face (RF) per ASME B16.5. For RTJ (Ring Type Joint) or BW (Butt Weld) ends, specify separately .
6. Performance & Testing (Per API 598 / BS 6364)
| Test | Medium | Pressure / Condition | Acceptance Criteria |
|---|---|---|---|
| Shell (Body) Test | Water / Nitrogen | 1.5 x Rated Pressure @ Ambient | No visible leakage |
| Seat (Seal) Test | Air / Nitrogen | 1.1 x Rated Pressure @ Ambient | ISO 5208 Class VI (Bubble-tight) |
| Cryogenic Seat Test | Liquid Nitrogen | @ -196°C, 1.1 x Rated Pressure | ≤ 0.1 Nm³/hr (He) per BS 6364 Annex A |
| Low Pressure Seat Test | Air | 0.6 MPa (87 psi) | Bubble-tight |
| Stem Leakage Test | Helium | @ Ambient | ISO 15848-1 Class B (≤10⁻⁵ mbar·L/s) |
| Cavity Relief Test | – | Verify ball hole functions | Pressure relief to upstream side |
Typical Test Pressures (Class 300 Example):
-
Shell Test: 7.7 MPa (1,117 psi)
-
Seat Test: 5.6 MPa (812 psi)
7. Operating Torque & Actuation
| Size | Torque @ Ambient (Nm) | Torque @ -196°C (Nm) | Recommended Operator |
|---|---|---|---|
| DN15 (½”) | 8 | 12 | Lever |
| DN25 (1″) | 15 | 22 | Lever |
| DN50 (2″) | 45 | 68 | Lever / Gear |
| DN80 (3″) | 90 | 135 | Gear |
| DN100 (4″) | 160 | 240 | Gear |
| DN150 (6″) | 350 | 525 | Gear / Actuator |
| DN200 (8″) | 600 | 900 | Gear / Actuator |
Note: Torque values increase at cryogenic temperatures due to material contraction and seal compression . For actuated valves, specify pneumatic/electric/hydraulic actuator separately .
8. Flow Characteristics (Full Bore)
| Size | Flow Coefficient Cv (US gal/min) | Kv (m³/h) |
|---|---|---|
| DN15 (½”) | 8 – 12 | 7 – 10 |
| DN25 (1″) | 30 – 40 | 26 – 35 |
| DN50 (2″) | 120 – 150 | 104 – 130 |
| DN80 (3″) | 280 – 320 | 242 – 277 |
| DN100 (4″) | 480 – 550 | 415 – 476 |
| DN150 (6″) | 1,100 – 1,300 | 952 – 1,125 |
| DN200 (8″) | 2,000 – 2,300 | 1,730 – 1,990 |
*Note: Reduced bore valves have lower Cv values (typically 60-80% of full bore).*
9. Application Guidelines
-
Suitable Media:
-
LNG (Liquefied Natural Gas), Methane, Ethane, Ethylene
-
LO2 (Liquid Oxygen), LN2 (Liquid Nitrogen), LAr (Liquid Argon)
-
Liquid Hydrogen (with special material considerations)
-
-
Not Suitable For:
-
Media containing solid particles (may damage PCTFE seat)
-
High-temperature service >80°C (soft-seal degradation)
-
Fire-safe applications without special design (not API 607 compliant by default)
-
-
Installation Orientation: Any position (preferably stem vertical for extended bonnet applications)
-
Flow Direction: Bidirectional (with appropriate seat design)
10. Special Requirements for Cryogenic Service
| Requirement | Specification |
|---|---|
| Oxygen Service Cleaning | If service is LOX or oxygen-enriched, valve must be cleaned and packaged per CGA G-4.1 with special packaging to maintain cleanliness . |
| Material Traceability | Full traceability per EN 10204 Type 3.1 required for all pressure-containing parts . |
| Impact Testing | Charpy V-Notch impact tests at -196°C per ASTM A370 (minimum 41J average) . |
| PMI Testing | 100% Positive Material Identification verification for all alloy components . |
| Cryogenic Cycle Testing | Optional: 200+ thermal cycles between ambient and -196°C to validate long-term performance. |
| Vacuum Jacket Compatibility | Extended bonnet length must match insulation thickness for cold box applications. |
11. Marking & Documentation
-
Marking: Per MSS SP-25 (Size, Pressure Class, Material, Manufacturer’s Logo, Heat No., Cryogenic Rating, CE/PED if applicable)
-
Documents:
-
Material Test Certificates (EN 10204 3.1)
-
Pressure Test Report (Ambient + Cryogenic)
-
Certified Dimensional Drawing
-
Cleaning & Degreasing Certificate (if oxygen service)
-
NDE Reports (RT/PT/MT as required)
-
Procurement Notes
-
Pressure Class: Confirm required class (150LB / 300LB / 600LB) based on design pressure and temperature derating per ASME B16.34 .
-
Bore Type: Specify Full Bore (for minimum pressure drop) or Reduced Bore (for cost/weight savings) .
-
Seat Material: Confirm preference:
-
PCTFE: Better dimensional stability, preferred for cycling service at -196°C
-
RPTFE/PTFE: Lower cost, suitable for less demanding applications
-
-
Extension Length: Specify if valve will be installed in vacuum-jacketed or cold box applications (custom extension length may be required).
-
Actuation: If actuated (pneumatic/electric), provide torque requirements and control signal specifications .
-
Special Cleaning: Specify if oxygen service cleaning is required (CGA G-4.1) .
-
Fire-Safe Design: If fire-safe certification (API 607) is required, confirm with manufacturer as standard soft-seat designs are not fire-safe .
This technical data sheet complies with BS 6364, ASME B16.34, and API 6D requirements for cryogenic floating ball valves
