DA Pneumatic Trunnion Ball Valve for High Temperature Service
Description
TECHNICAL DATA SHEET
Automated Trunnion Ball Valve Assembly – High Temperature
DN200 PN40 | C5 Body | Double-Acting Pneumatic with Manual Gear Override
Series ATBV-HT-200
1. PRODUCT DESCRIPTION
This automated valve assembly combines a heavy-duty, trunnion-mounted ball valve in high-temperature ASTM A217 C5 alloy steel with a fully integrated pneumatic actuation system. A double-acting scotch-yoke or rack-and-pinion actuator provides the primary mode of operation, while a direct-mounted manual worm gear override allows local handwheel operation for commissioning, maintenance, or emergency shutdown without removing the actuator.
Designed for continuous high-temperature isolation of superheated steam, thermal oil, and refinery process fluids up to +500 °C (seat) and +550 °C (body rating).
2. SYSTEM KEY FEATURES
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Complete Engineered Assembly: Valve, extended stem with cooling fins, manual gearbox, mounting bracket, and pneumatic actuator supplied as a single unit and tested.
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Reliable Automation: Double-acting pneumatic actuator delivers high torque output for on/off or modulating service; fails in last position on loss of air.
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Safe Manual Override: Declutchable worm gear gearbox allows easy handwheel operation in the event of air supply failure or during setup.
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High Temperature Integrity: Stellite® hardfaced metal seats and live-loaded pure graphite stem packing withstand severe thermal cycling.
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Trunnion Design: Ball is mechanically fixed; line pressure thrust is absorbed by bearings, allowing low operating torque and prolonged seat life.
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Extended Stem & Cooling Fins: Protect the gearbox and actuator seals from radiated process heat.
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Optional Controls: Full range of limit switch boxes, solenoid valves, and positioners can be factory mounted.
3. VALVE SPECIFICATIONS (ATBV-HT-200)
| Parameter | Specification |
|---|---|
| Valve Model | TBV-HT, Trunnion Mounted, Side or Top Entry |
| Nominal Size | DN200 (8 inch) |
| Pressure Rating | PN40 (EN 1092-1) / Class 300 (ASME B16.34) |
| Body Material | ASTM A217 Grade C5 (5Cr – 0.5Mo) |
| Ball | ASTM A182 F5 + Stellite 6 overlay |
| Seat Rings | A182 F5 + Stellite 6, spring-loaded self-relieving |
| Stem | A182 F5, blow-out proof |
| Packing | Live-loaded pure graphite rings |
| Connection | Flanged RF, EN 1092-1 Type 11 PN40 |
| Face-to-Face (L) | 630 mm (EN 558 Series 26) |
| Bore | Full bore |
| Seat Leakage | Class V (metal seated) to ANSI FCI 70-2 |
| Temperature Range | -29 °C to +500 °C (seat), +550 °C (body) |
| Design Standards | API 6D / ASME B16.34 |
4. PNEUMATIC ACTUATOR SPECIFICATIONS
| Parameter | Specification |
|---|---|
| Actuator Type | Double-acting, scotch-yoke (recommended for high torque) or heavy-duty rack & pinion |
| Operating Pressure | 4 – 7 bar (standard), up to 10 bar (max) |
| Output Torque at 5.5 bar | Typically 4,500 – 6,000 Nm (sized to provide 1.3x safety factor on valve max torque) |
| Rotation | 90° ±5° (with external travel stops) |
| Body Material | ASTM 316 stainless steel or carbon steel with corrosion-resistant coating |
| Seals | Viton (FKM) standard; FFKM or graphite-filled options for high ambient |
| Ambient Temperature | -20 °C to +80 °C |
| Enclosure Protection | IP67M (standard) |
| Manual Override | Integrated declutchable worm gearbox with handwheel (see Section 5) |
| Visual Indicator | Dome-type position indicator, red/green |
| Actuator Mounting | ISO 5211 flange (matched to actuator base) |
| Solenoid Valve | Namur mount, 5/2 way, single or dual coil (to be specified) |
| Accessories | Limit switch box (2 x SPDT), positioner (4-20 mA) – optional |
5. MANUAL GEAR OVERRIDE SPECIFICATIONS
| Parameter | Specification |
|---|---|
| Gearbox Type | Worm gear, declutchable, flange mounted directly to actuator or valve ISO pad |
| Reduction Ratio | 60:1 to 80:1 (typical for DN200 PN40 trunnion) |
| Handwheel Diameter | Approx. 500 mm |
| Input Turns | Approx. 100 – 140 turns for 90° stroke |
| Locking | Pad-lockable handwheel in open/closed positions |
| Engagement | Manual clutch lever to disengage actuator drive and engage handwheel |
| Safety | Mechanical interlock prevents simultaneous pneumatic and manual operation |
| Housing | Cast iron GJS-400-15, fully enclosed, weatherproof IP65 |
| Finish | Epoxy powder coated, high-temperature silver or blue |
6. OVERALL ASSEMBLY DIMENSIONS
| Dimension | Value (approx.) |
|---|---|
| Face-to-Face (Valve L) | 630 mm |
| Overall Height (from pipe centre) | ~1,600 mm (valve + extended stem + gearbox + actuator) |
| Width across Actuator | ~750 mm |
| Handwheel Diameter | ~500 mm |
| Total Assembly Weight | Approx. 700 – 850 kg (valve + gear + actuator) |
Exact dimensions and weights depend on final actuator and gearbox model selected; a certified dimensional drawing will be provided at order.
7. ORDERING CODE
ATBV-HT-C5-200-40-FB-MT-DA-MO
| Field | Description |
|---|---|
| ATBV-HT | Automated Trunnion Ball Valve, High Temp |
| C5 | Body Material: ASTM A217 C5 |
| 200 | Size: DN200 |
| 40 | Pressure Class: PN40 |
| FB | Bore: Full Bore |
| MT | Trim: Metal-to-Metal (Stellite) |
| DA | Actuator Type: Double-Acting Pneumatic |
| MO | Manual Override: Declutchable Gearbox with Handwheel |
Example: ATBV-HT-C5-200-40-FB-MT-DA-MO
8. TYPICAL SCOPE OF SUPPLY
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1 x DN200 PN40 Trunnion Ball Valve, C5 body, metal seated, extended stem
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1 x Double-acting pneumatic actuator, sized and tested
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1 x Declutchable manual worm gear override with handwheel
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1 x Mounting bracket and coupling set
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Factory-mounted limit switch box (optional)
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5/2 Solenoid valve, NAMUR (optional)
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Shell and seat pressure test certificate (API 598)
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Material certificates to EN 10204 3.1 for body, ball, and stem
DISCLAIMER: This technical data sheet is for preliminary engineering guidance. Final design, actuation torque, and P/T limits will be confirmed by our engineering department based on full service conditions. Specifications subject to change without notice. For certified and stamped submittal drawings, please contact the factory.
