Ladish Critical & Severe Service Product Line (MEGA Seal & The “S” Series) – Steel, Chrome & Nickel Alloy Valves for Corrosive Chemical and High Temperature Service to 1500F
6″ Monel Metal Seated Ball Valve
MEGA Seal Metal Seated Ball Valves
- Dirty, Erosive and / or Mild Corrosive Service to 850F
- Graphite Energized Seats with Seat and Ball Coating based on Service Conditions. Class 150, 300 and 600
- Applications Include Ethylene, VCM, Catalyst / Powder Feed, Furnace Transfer Lines
- Generally Manual Valves or infrequent on/off where contaminants can “lock” more Severe Service Valves
MEGA Seal Graphite Seated Ball Valves
- “Clean” Service, 450F to 1000F
- Strong Acids and Oxidizers where Coatings of Metal Seated Valves will not Function (e.g. HF, Chlorine)
- 50% Torque Requirement vs. Metal Seated
- P/T Rating to ASME B16.34 Valve Body. Generally Class 300 and 600.
|GRAPHITE SEATED||METAL SEATED|
|Class 300 and 600||Class 150 – 600|
|Flanged Ends||SW/BW, RFF, RTJ End Connection Possible|
|¾” – 8”||.5” – 14”|
|Split Body or Unibody, Full or Reduced Port||Split Body or Unibody, Full or Reduced Port|
|Target Market: SPECIALTY CHEMICALS. Clean High Temperature and Acid Service with Temperatures above 450F (up to 1000F)||Target Market: Petrochemical and Chemical
•ETHYLENE and VCM
•Alloy Options include 316SS, Monel, Inconel, etc.
|API 598 Shutoff||API 598 Shutoff (HP Test Included)|
|Full Alloy Options (Hastelloy, Inconel, Incoloy, Monel, etc.)|
Monel Severe Service Ball Valve
“S” Series: Severe Service Ball Valves, our newest, upcoming product line, engineered for services up to 1500F
- Class 150 – Class 2500. Erosive, Abrasive and “High Energy” services such as high-pressure Steam,
BFW, Hydrogen, Oxygen, High Temperature Catalyst and Hot Hydrocarbons where tight shut-off is important.
- No measurable leakage in industry standard Testing. Spring Loaded Seat Design.
- Wide Variety of Ball and Seat Coatings Specified to individual applications.
|POWER VALVE||ENGINEERED METAL SEATED|
|Class 900/1500, 2500 (3100) & 4500||Class 150 – 2500|
|Welded – Ends (SW / BW)||SW/BW, RFF, RTJ End Connection Possible|
|.5” – 3”||Inserted Seats or Captured Flange (Repairable Design)|
|Forged (Machined from bar), 2-piece construction||.5” – 14”|
|Target Market: Co-Generation, High Pressure Steam / Hydrocarbons||Target Market: Petrochemical and Chemical
•Coking / Fouling Services
•Automated on/off & high cycle
|Tight Shut-Off Capability|
1. S1 Series
Compact & economical design with removable / replaceable trim, Low Emissions, and available in a wide range of material & coating options. Well suited for manual valve applications and those with bore sizes greater than 8″.
2. S2 Series
This “Second Generation” Metal Seated Ball Valve design improves on the S1 sealing by limiting possible leak paths to only one, while retaining the feature of fully removable / replaceable seats, stem and ball. The “Captured Flange Seat” allows exact thermal matching of all trim material for improved resistance to high temp and repid temp change, Designed for the most demanding automated applications and where tight shut-off on gases is required.
For more information on the Severe Service Ball Valve line, please email us at firstname.lastname@example.org. Catalog 431 is currently in progress.
What are “Metal Seats”?
- Dissimilar Metals (Old Technology no longer widely accepted)
- Base Metal Contact (Gate and Globe Valves – Not Sliding Wear)
- Coated or Modified Metal (Most Common)
- Stellite Weld Overlay (Usually Stellite VI – Cobalt Based)
- “Surface Modification” of Sealing Surfaces: Ex. Nitriding, Boronizing, etc.
- Plating: Ex. Chromium Plating or ENP (Electroless Nickel Plating)
- HVOF Coating: Tungsten and Chromium Carbide are the most common
- Fused or Vacuum Deposition of “Coating” typically Tungsten Carbide
- There is no “One size fits all” for “Metal-to-metal” sealing. Coatings are very application dependent.
Metal Seated Valve Coating – Metal seated valves represent the fastest growing (by %) segment of the valve industry. These seats can be found in ball valves, butterfly valves, plug valves and others.
1. HP-HVOF Process
- Chrome Carbide, Tungsten Carbide, Chrome Oxide and other specially formulated coatings.
- WC-Co / WC-Ni / WC-Co-Cr / WC-CrC-Ni
- Coating mechanically bonds to the Substrate Material.
- Mechanical bond – >12,000 psi bond strength for Carbides, 5,000 – 7,000 psi for Chrome Oxide Ceramic.
- Robotically positioned spray gun creates high kinetic energy allowing the coatings to be applied in a compressive state.
- Porosity – Poor Sealing on Gas
- Carbon Content makes these coatings vulnerable to Oxidation.
2. Spray & Fused Process
- Substrate material becomes annealed due to fusing temperatures; subsequent heat treatment required.
- Semi-molten coating “sags” or “sloughs” – gravity effect
- Coated Surface is “finish” machined using either CBN (cubic boron nitride) or PCD (polycrystalline diamond) tooling.
- Very Low Porosity – Best for small molecule gas and particles smaller than 1 micron.
Vacuum Testing of Valve Trim Sets Prior to Installation
Key Petrochemical Processes for Ladish MEGA Seal & “S” Series Ball Valves
- VCM (Vinyl Chloride Monomer) – Stainless, Monel and Inconel Valves for Acid from Chlorine. Nickel Alloys becoming more Prevalent at 600+ F
- Ethanol/Methanol – Stainless Steel for Acid Attack
- Propylene / Ethylene Oxide / PDH – Reactive Chemicals require High Alloy valves with little Corrosion. Oxygen Service Valves are common and use Stainless and Hastelloy
- Polyethylene / Polypropylene Production – Business is in Additive Handling and Ball Valves. Hastelloy and Stainless Steel are used so that Iron (from Carbon Steel) does not contaminate the process.
- Phenol, Cumene, Butadiene – These are Reactive Chemicals requiring Nickel Alloys due to ORGANIC Acids.
- Ammonia / Nitric Acid – Stainless (304) and Monel to Resist Attack
- Ethylene: Pyrolysis Oils and Start-Up Vent Valves
For more information on the Severe Service Ball Valve line, please contact email@example.com.
Once again, Ladish will continue To Mark Progress.