3-Piece Trunnion Ball Valve— 12″ 600LB RF
Description
3-Piece Trunnion Ball Valve – 12″ 600LB RF, WCB Body, F316 Trim, Devlon Seat
Model: TBV-3PC-WCB-12-600-DEV
Product Description: Three-piece bolted-body, side-entry, trunnion-mounted ball valve with raised face flanges. The cast carbon steel body (ASTM A216 WCB) combined with ASTM A182 F316 stainless steel internals and high-performance Devlon (polyamide-imide based) seats provides a robust, high-pressure valve suitable for demanding pipeline and process applications.
1. Main Design Codes and Standards
| Item | Standard / Code |
|---|---|
| Valve Design & Manufacturing | API 6D / ISO 14313 |
| Face-to-Face | ASME B16.10 (Long Pattern for Trunnion Ball Valve) |
| Flanged Ends | ASME B16.5, Class 600, Raised Face (RF) |
| Pressure-Temperature Ratings | ASME B16.34, Material Group 1.1 (Body) |
| Testing & Inspection | API 6D / API 598, ISO 5208 |
| Fire-Safe Testing (Optional) | API 607 / API 6FA / ISO 10497 |
| Fugitive Emissions (Optional) | ISO 15848-1 |
| Anti-Static Design | Per API 6D (≤10 Ω) |
| Blow-out Proof Stem | Integral stem shoulder, retained by body |
2. Main Technical Parameters
| Parameter | Specification |
|---|---|
| Nominal Size | 12″ (DN300) |
| Pressure Class | Class 600 (PN100) |
| End Connection | Flanged RF, ASME B16.5 Class 600 |
| Body Construction | 3-Piece bolted body, side-entry (two end connectors + center body) |
| Ball Type | Trunnion-mounted (Upper & Lower trunnion bearings) |
| Seat Type | Double-seat, spring-loaded, Devlon insert (bi-directional bubble-tight) |
| Operation | Bare stem for gearbox/actuator; manual gearbox standard for this size |
| Flow Direction | Bi-directional, self-relieving seats (single-direction relief or double-piston optional) |
| Design Life | ≥ 25 years with proper maintenance |
3. Pressure-Temperature Ratings
Based on ASME B16.34 Group 1.1 (A216 WCB body). The practical operating limit is further restricted by the Devlon seat material.
Body Pressure-Temperature (Non-shock, Class 600)
| Temperature (°C) | Max. Working Pressure (bar) | Approx. psi |
|---|---|---|
| -29 to 38 | 102.1 | 1480 |
| 50 | 101.4 | 1470 |
| 100 | 93.1 | 1350 |
| 150 | 90.7 | 1315 |
| 200 | 87.2 | 1265 |
| 250 | 84.5 | 1225 |
| 300 | 81.7 | 1185 |
Seat (Devlon) Temperature Limits: Devlon is recommended for continuous service from -50 °C to +120 °C, with intermittent excursions up to +150 °C. For operation above 120 °C, the pressure rating may need further derating based on the seat material’s mechanical properties. Consult the manufacturer for seat-specific P-T curves.
4. Materials of Main Parts
| No. | Part Name | Material | Remarks |
|---|---|---|---|
| 1 | Body (Center Section) | ASTM A216 WCB | Carbon steel casting, normalized and tempered |
| 2 | End Connectors (2 pcs) | ASTM A216 WCB | |
| 3 | Ball | ASTM A182 F316 | Solid F316, polished, electroless nickel plating (ENP) optional |
| 4 | Stem | ASTM A182 F316 | One-piece, anti-blowout, ground and polished |
| 5 | Seat Ring Body / Insert | ASTM A276 316 / Devlon | Devlon insert molded or snapped onto a metallic retainer; spring-energized behind seats |
| 6 | Trunnion Bearings (Upper/Lower) | PTFE/PEEK composite bushings / F316 sleeve | Self-lubricating, low friction |
| 7 | Body Seals (O-rings / Gaskets) | Graphite with SS316 spiral wound / Viton® (FKM) / HNBR | For class 600, graphite gaskets standard |
| 8 | Stem Packing | Graphite with SS316 wire-reinforced, or PTFE | Live-loaded gland optional |
| 9 | Stem Thrust Washer | PTFE or graphite composite | |
| 10 | Bolting (Body & Bonnet) | ASTM A193 B7 / A194 2H (or B8M/8M for corrosion) | Standard high-strength steel, or SS316 for corrosion |
| 11 | Gearbox (Standard for 12″) | Cast iron with ductile iron gear train, epoxy coated | IP67, adjustable stop bolts for open/close position |
| 12 | Handwheel | Ductile Iron / Carbon Steel | Rim blow-out resistant |
Note: The term “F316 Trims” includes Ball, Stem, Seat Ring body, and all metallic internal components exposed to the process fluid. Devlon is a high-performance modified polyamide-imide (PAI) specifically developed for valve seats, offering exceptional wear resistance, low friction, and high strength.
5. Dimensions & Weight – 12″ Class 600 RF (Typical with Gearbox)
| Parameter | Dimension (mm) | Remarks |
|---|---|---|
| Face-to-Face (L) | 838 | ASME B16.10 Long Pattern for Trunnion Ball Valve |
| Flange Outside Diameter (D) | 521 | ASME B16.5 Class 600, Raised Face height 7 mm |
| Centerline to Gearbox Top (H) | Approx. 1050 | With standard manual worm gearbox |
| Handwheel Diameter (W) | Approx. 760 | |
| Stem Center Height (H1) | Approx. 280 | Centerline to top of ISO mounting pad (for actuator removal and fit) |
| ISO 5211 Top Flange | F35 / F40 | Pilot spigot and bolt circle for actuator mounting (if gearbox removed) |
| Weight (Body Only) | Approx. 1150 kg | Without gearbox |
| Weight (With Gearbox) | Approx. 1220 kg |
Exact dimensions and weights will be provided on certified outline drawings. The 3-piece bolted design allows for maintenance without removing the entire valve body from the pipe, though the two end connectors remain bolted to the flanges.
6. Performance Testing
| Test Item | Test Medium | Test Pressure | Acceptance Criteria |
|---|---|---|---|
| Shell Hydrostatic (Body) | Water | 153.2 bar (1.5 × max. rated at 38 °C) | No visible leakage or deformation |
| Seat Tightness – High Pressure | Water | 112.3 bar (1.1 × max. rated at 38 °C) | API 6D / API 598 Rate A (zero leakage for soft seats) |
| Seat Tightness – Low Pressure | Air / Nitrogen | 6 bar (87 psi) | Zero bubble leakage |
| Stem Seal (Backseat) | Water | 112.3 bar | No visible leakage at gland |
| Anti-Static Test | Dry circuit | ≤ 10 Ω (Stem-to-ball, ball-to-body) | API 6D / ISO 17292 |
| Fire-Safe Test (If ordered) | – | Per API 607 / 6FA | External and internal leakage within limits after burn and cool down |
7. Design Features
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3-Piece Bolted Construction: Simplifies in-line maintenance. The center body can be unbolted and swung out after loosening the end connectors, providing access to seats and ball without needing to cut the pipe.
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Trunnion-Mounted Ball: The ball is rigidly supported by upper and lower trunnion shafts running in self-lubricating bearings. This absorbs line pressure thrust, drastically reducing operating torque compared to a floating ball of the same size, and prevents seat crushing even at high differential pressures.
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Devlon Seat Inserts: Devlon (PAI-based) offers a unique combination of high mechanical strength (up to 300 MPa compressive), excellent wear and abrasion resistance, low coefficient of friction (similar to PTFE), and very low moisture absorption. It operates effectively over a wide temperature range and is resistant to chemical attack, making it ideal for high-cycle and dirty services where PTFE would cold-flow or abrade.
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Spring-Loaded Seats: Two independently spring-energized seat rings provide constant contact with the ball, ensuring low-pressure sealing capability and compensating for wear and temperature fluctuations.
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Self-Relieving Cavity: The seats are designed to relieve excessive cavity pressure automatically into the pipeline (single piston effect upstream seat), preventing body cavity over-pressurization due to thermal expansion of trapped media. (Double-piston effect seats available for double block and bleed applications.)
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Anti-Blowout Stem & Anti-Static: The stem incorporates an integral shoulder that bears against the body/bonnet, preventing ejection. A spring-loaded conductive ball/stem contact ensures electrical continuity, preventing static charge buildup during operation.
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Actuator Ready: The gearbox can be removed and a direct-mount actuator (pneumatic, electric, hydraulic) can be installed using the ISO 5211 top pad, with a matched stem coupling. The gearbox itself can also accept an actuator via its own mounting interface.
8. Application Scope
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Suitable Media: Crude oil, natural gas, produced water, refined petroleum products, lubricants, condensate, hydrocarbon gas, various industrial chemicals (check Devlon compatibility with aromatics and strong oxidizers), steam (limited by Devlon temperature), hydraulic fluids.
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Temperature Range: -50 °C to +120 °C (continuous), +150 °C intermittent. Body rated for -29 °C to +300 °C (seat is the limiting factor).
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Industries: Oil & gas production, pipelines, gas processing plants, refineries, petrochemicals, mining, power generation, marine and offshore topside.
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Key Advantages:
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Devlon seats extend service life dramatically compared to soft PTFE in abrasive or high-pressure-drop throttling duties.
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Trunnion design with 3-piece body makes the valve easy to maintain without re-welding or special tooling.
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Carbon steel WCB body with F316 trim provides an excellent balance of cost, strength, and corrosion resistance.
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Full-bore design (standard) minimizes pressure drop and allows in-line pigging.
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9. Optional Configurations & Accessories
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Seat Material Alternatives: RPTFE (up to 150 °C), PEEK (up to 260 °C body permitting), Nylon, metal/graphite (for fire-safe and high-temp), Devlon V (PTFE-filled), Devlon XL (solid lubricant-filled).
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Body/Trim Material Upgrades: Full stainless steel body (CF8M), F51 Duplex, Inconel overlays, etc.
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Double Block & Bleed (DBB): Double-piston effect seats with body cavity bleed valve.
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Fire-Safe Package: API 607 certified, with graphite secondary seats and stem seals.
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Sour Service (NACE): Conforming to NACE MR0175 / ISO 15156 for H₂S environments (special body and bolting materials).
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Low-Temperature / Cryogenic: Extended bonnet, special trim materials.
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Actuation: Complete automation packages with pneumatic (rack & pinion, scotch yoke), electric, hydraulic, or gas-over-oil actuators. Including limit switches, solenoid valves, positioners, and manual override.
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Gearbox Locking Device: Key-locked or padlockable handwheel in open/closed position.
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Bypass and Drain Lines: Custom connections.
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Coatings: Offshore-grade paint systems (NORSOK M-501, etc.), 3-layer polyurethane.
Disclaimer: This technical data sheet presents typical information for engineering reference based on API 6D / ASME B16.34 design philosophy and standard industry practice. Exact performance characteristics, dimensions, trim details, and certifications must be verified against the manufacturer’s official certified documentation, material test certificates, and approved outline drawings before selection or installation.
