AIL BALL VALVES

FLOATING BALL DESIGN

REDUCED BORE FULL BORE

BS 5351 BS 5159

AUDCO INDIA LIMITED

Introduction

AUDCO INDIA LIMITED (AIL) is a leading valve manufacturer, with a strong presence in India and overseas. AIL has three manufacturing facilities. The main plant is located in Manapakkam, Chennai. The t wo other plants are at MM Nagar, 40 kilometres south and at Kancheepuram, 70 kilometres west of the main plant. The plants are equipped with specialised production facilities with special purpose machines, automatic welding equipment, heat treatment furnaces and testing equipment for total control of all manufacturing operations. In-house metallurgical and NDE laboratories, and gauge calibration facilities with up-to-date equipment provide suppor t to ensur e the qualit y of products manufactured. AIL manufactures a wide variety of industrial valves with ISO 9001 cer tified Qualit y Management System in all three plants.

The AIL Ball Valve has established itself as the industr y standard for quality, integrity, reliability and long service. The valves are manufactured to the latest international designs, using advanced manufacturing techniques and stringent quality control checks.
Content Page No.

Introduction

03 - 05
03 04 05

Manufacturing Program ................................................... Salient Features ............................................................... Materials of Construction .................................................

Reduced Bore Valves

06 - 09

Three-piece Valves .......................................................... 06 & 07 Single-piece/Two-piece Valves ........................................ 08 &09

Full Bore Valves

10 - 13

Three-piece Valves .......................................................... 10 & 11 Single-piece/Two-piece Valves ........................................ 12 &13

Special Purpose Valves

14 & 15
14 14 14 15 15 15

Steam Ser vice .................................................................. Cr yogenic Ser vice ........................................................... Multipor t Valves ................................................................ High Pressure Ser vice .................................................... High Temperature Ser vice ............................................... Trunnion Mounted Ball Valves ...........................................

AIL Pneumatic Actuators Technical Information

16 & 17 18
18 18

Pressure-Temperature Graphs ......................................... Flow Coef ficients ..............................................................

Ordering Information International Clientele

19 19

Chennai plant

02

Introduction

Audco India Limited is committed to Total Customer Satisfaction. We achieve this by : Maintaining a high standard of quality consistent with the customer requirements Complying with the Codes, Standards, Customer Specifications, Statutory and Regulatory requirements as applicable to our Products Continually improving the effectiveness of Quality Management System to add value to our Products

Q
End Connection
8
G

Quality Policy

The floating ball design of Ball Valves is the universal choice for most process and utility applications. In this design, sealing takes place by allowing the ball under pressure to move towards the downstream seat to ef fect a tight seal. Other designs, such as the Trunnion Mounted design, are also maunfactured by AIL, details of which are available in a separate catalogue.
THREE-PIECE DESIGN Ball Valves featuring this design are the most easily on-line maintainable in their class. By removing thre e body connector bolts and loosening the four th, the body can be swung away using the fourth bolt as the fulcrum, to carry out any installation or maintenance operation on the valve. This feature reduces maintenance downtime to a bare minimum. SINGLE-PIECE / TWO-PIECE DESIGN Single-piece ball valves are high per formance valves, which come with a one-piece integrally flanged body, in sizes of up to 200mm reduced bore and 40mm full bore. This design of fers the unique advantage of eliminating the possibility of ex ternal leakage to the atmosphere through bolted body joints. These environment-friendly and high-integrity valves are preferred in critical applications where the media is expensive, volatile or toxic, and where ex ternal leakage or wastage is unacceptable. The t wo-piece design complements the single-piece design in sizes of 250mm and above reduced bore, and 50mm and above full bore.

Manufacturing Program
Valve Type Compliance Valve Size
10 15 20 25 32 40 50 80 100 150 200 250
G G G G G G G G G G G G G G G G G G G G G G G G G

Screwed/SW Standard BS 5159

REDUCED BORE

3-piece Fire-safe BS 5351

Flanged 150/ 300/600 Screwed/SW Flanged 150/ 300/600 Flanged 150 Flanged 300 Screwed SW Flanged 150 Flanged 300 Flanged 600 Flanged 150 Flanged 300

singlepiece 2-piece

Fire-safe

BS 5351

Standard

BS 5159 BS 5351

FULL BORE

3-piece Fire-safe singlepiece 2-piece

Fire-safe

BS 5351

SPECIAL PURPOSE VALVES

Valves for Steam Service Valves for Cr yogenic Service Multipor t Ball Valves Valves for High Pressure Service Valves for High Temperature Ser vice Trunnion Mounted Ball Valves

Refer pages 14 & 15

03

Introduction

A number of outstanding features in AIL Ball Valves of fer significant advantages to the user.
FIRE-SAFE FEATURE ANTISTATIC FEATURE Build-up of static electricit y can occur as a result of constant rubbing of the ball against the PTFE seats. This can be a potential fire hazard, especially while handling inflammable fluids. To provide electrical continuit y, spring-loaded plungers are provided bet ween the stem and the ball in single-piece and t wo-piece reduced bore (80mm and above) and full bore (40mm and above) valves. For smaller sizes, this is achieved through 35% Carbon-filled PTFE stem seals. Depending on the choice of seals, the designs also provide for additional spring-loaded plungers bet ween the stem and the body for full mechanical antistatic capability. AIL fire-safe design valves feature a secondar y metalto-metal seat which renders the valve fire-safe. An integral metal lip in the body and the configuration of the sof t seat are designed to prevent the sof tening downstream seat from being forced into the port in the event of a fire. When the seat is totally sublimated in a fire, the ball moves and rests against the lip, forming a metal-to-metal seat, thus ensuring leak-tightness. End connectors or inser ts have spigoted ends to ensur e concentricit y and correct alignment of the ball.

VALVE OPERATION As a standard, AIL Ball Valves are supplied with hand levers or gear units, depending on the valve size. The valves are also suitable for automation using either electric or pneumatic actuators. The AIL Series 90 Pneumatic Actuator is optimally designed for use with AIL Ball Valves, and is widely used to automate valves in diverse applications. Refer to page 17 for actuator selection data.

MOULDED PTFE SEATS WITH SLOTS PTFE seats are manufactured from moulded PTFE for a bet ter grain structure compared to other methods of manufacture. Slots are provided in the seats to relieve the pressure past the upstream seat and prevent it from being forced against the ball. These features help lower operating torques, permit higher dif ferential pressures and reduce wear, besides ex tending service life.

WIDE VARIET Y OF SEATS AND BODY SEALS AIL Ball Valves are available with a wide variet y of seat and seal material combinations to suit specific needs of customers. For details, refer to tables on page 5.

MIRROR-FINISHED SS BALLS The stainless steel balls are manufactured to ver y close sphericit y tolerances and are mirror-finished. This results in bubble-tight sealing and considerably reduced operating torque.

CAVITY PRESSURE RELIEF AIL range of two-piece full bore valves can be of fered with s built-in cavit y relief seat design on request. This feature prevents overpressure in the ball cavit y due to thermal expansion of the line fluid, and finds use in applications involving volatile line fluids. In principle, when cavit y pressure builds up and reaches a cer tain magnitude, it causes the seat lip to move away from the ball relieving the pressure. Once the pressure has relieved, the seat lip returns until the pressure builds up again. In the case of single-piece and three-piece valves, and in t wo-piece reduced bore valves, cavity relief can be provided on request by incorporating an upstream relief hole in the ball. All valves have a hole connecting the ball por t and the body cavit y to prevent build-up of trapped cavit y pressure when the valve is in open position.

BLOW-OUT PROOF STEM All AIL Ball Valves have a bot tom-entry stem design which features stem inser tion from inside the body. An integral shoulder on the stem sits against the shoulder in the body, giving it blow-out proof integrit y. The higher the line pressure, the tighter the seal. This design of fers safet y body gland features superior to topshoulder packing entr y stem design where the line pressure works to break the stem seating (see illustration for typical threepiece design). LEAK TIGHT STEM SEALING

ACTUATOR MOUNTING FLANGE All single-piece and t wo-piece valves are supplied with an integral actuator mounting flange with drilled and tapped holes suitable for mounting pneumatic actuators. The flange conforms to ISO 5211 for full bore valves and to AIL s manufacturing standard for reduced bore valves.

stem stem The stem seal package shoulder seal consists of one or t wo stem seals and one or a series of gland packing rings, depending on valve size. In smaller sizes of up to 50mm, a pair of Belleville washers acts as a spring to compensate for wear and thermal expansion.

04

Introduction

BODY AND BODY CONNECTOR Material

Carbon Steel Carbon Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Alloy 20 LCB

Specification
ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM A105 A216 A351 A351 A351 A351 A351 A352 Gr. Gr. Gr. Gr. Gr. Gr. Gr. WCB CF8M CF8 CF3M CF3 CN7M LCB

AIL Ball Valves can be supplied in a highly versatile range of body, seat and trim combinations to suit almost all types of services. Details of cer tain common materials of construction are furnished here. For a more exhaustive list of available materials and for guidance on body/ball/seat material combinations, refer to Ordering Information on page 19.
NOTE : Materials conforming to NACE standard, and for special ser vices like Ox ygen and Hydrogen can be supplied.

TRIMS (CONSISTING OF BALL / STEM) Material

Stainless Steel Stainless Steel Stainless Steel Stainless Steel 13% Cr. Steel Monel Hastelloy C Alloy 20

Specification (Ball / Stem)

ASTM ASTM ASTM ASTM ASTM ASTM ASTM ASTM A351 Gr. CF8M / AISI 316 A351 Gr. CF8 / AISI 304 A351 Gr. CF3M / AISI 316L A351 Gr. CF3 / AISI 304L A351 Gr. CA15 / AISI 410 A494 Gr. M35-1 / ASTM B164 Gr. N04400 A494 Gr. CW-12MW / ASTM B574 Gr. N10276 A351 Gr. CN7M

SEATS Material
PTFE 15% Glass-filled (reinforced) PTFE Special-filled PTFE PEEK Metal Acetal Resin

Description
The most common seating material, suitable for almost all media, as it possesses excellent corrosion resistance Stronger than PTFE seats and has higher temperature/pressure ratings Carbon, Glass and Graphite-filled PTFE - suited for steam and thermal resistance and has good abrasion resistance. Good for high-cycle applications PEEK (Poly Ether Ether Ketone) is a material that demonstrates outstanding pressure capabilities at elevated temperatures - has excellent chemical and abrasion resistance Made of SS 316 and impregnated with Graphite for sizes of up to 50mm and hard-faced with Stellite for larger sizes Capable of handling ex tremely high pressures - not suited for Oxygen service

BODY SEALS Material

PTFE 15% Glass-filled (reinforced) PTFE PEEK Graphite

Description
The most common body seal material, suitable for almost all media, as it possesses excellent corrosion resistance Stronger than PTFE seats and has higher temperature/pressure ratings PEEK (Poly Ether Ether Ketone) is a material that demonstrates outstanding pressure capabilities at elevated temperatures - has excellent chemical and abrasion resistance Used in fire-safe valves and in steam applications

05

AIL Series 3XR/3FXR

Reduced Bore Ball Valves

Three-piece design
3XR - Standard series
This 3-piece Ball Valve is the most easily on-line maintainable in its class. By removing three body connector bolts and loosening the fourth, the body can be swung away using the four th bolt as the fulcrum, to carry out any installation or maintenance operation on the valve, thus reducing downtime. This valve can be of fered in a wide variet y of body and seat combinations.

3FXR - Fire-safe series

This 3-piece fire-safe design Ball Valve features a secondary metal seat which renders the valve firesafe. When the seat is totally sublimated in a fire, the ball moves and rests against the lip, forming a metalto-metal seat, thus ensuring leak-tightness.

Dimensional Details
Screwed/Socket-weld end (in mm, unless specified) Valve Size 8 10 15 20 25 32 40 50 A C D E F
1

Approx. Weight (kg)

65 65 67 73 95

122 122 122 122 149

14.6 / 14.2 18.0 / 17.6 22.2 / 21.8 27.6 / 27.1 34.3 / 33.8 43.1 / 42.7 49.2 / 48.7 61.7 / 61.1

45 45 45

9.7 9.7 9.7

/4 /8 /2 /4

0.6 0.6 0.6 0.8 1.6 2.5 3.3 4.1

48 12.7 59 12.7

107 149 116 181 128 181

65 12.7 11/4 75 12.7 11/2 80 15.9 2

Dimensional Details - Flanged end (in mm, unless specified)

Valve Size 15 20 25 40 C D E Class 150 A 108 117 F G A Class 300 F 96 G 15 17 19 22 23 A 165 Class 600 F 96 G 22 24 26 30 33 Approx. Weight (kg)
Cl. 150 Cl. 300 Cl. 600

152 12.7 90 152 19.1 98

89 11.1 140

1.8 2.3 3.1 6.4 9.0

2.2 3.2 4.5 8.7 10.8

4.5 6.3 9.1 15.4 21.6

99 12.2 153 118

191 118 216 124 241 156 292 165

177 25.4 102 127 108 11.1 165 124 202 38.1 121 165 127 14.3 191 156 202 50.8 126 178 154 15.9 216 165

06

50

AIL Series 3XR/3FXR

Material Specification
Sl. No. 1 2 3 4 5 6 7 8 Par t Carbon Steel

3XR
Stainless Steel Carbon Steel ASTM A105

3FXR
Stainless Steel ASTM A351 Gr. CF8M

Body ASTM A105 or ASTM A351 Gr. CF8M Body Connector ASTM A216 Gr. WCB Ball Seat Stem Body Seal Gland Packing Stem Seal ASTM A351 Gr. CF 8M PTFE AISI 316 PTFE 35% Carbon-filled PTFE 35% Carbon-filled PTFE

ASTM A351 Gr. CF 8M PTFE AISI 316 Graphite Graphite 35% Carbon-filled PTFE

Specifications
Ma x. cold working pressure 69kg/cm2 for screwed/socketweld end valves with PTFE seat 103kg/cm2 for screwed/socketweld end valves with specialfilled PTFE seat As per flange rating for flanged valves Valve design Fire Test (for 3FXR) Testing Face-to-face dimensions BS 5159 for 3XR Series BS 5351 for 3FXR Series API 607 4th edition API 598 for flanged valves ASME B16.10 for flanged valves and AIL Standard for screwed/socket-weld end valves

Pressure Testing
Test pressures Ends kg/cm2 (psi) Shell Screwed/Socket weld (air) 5.6 (80) Flanged 150 (hydrostatic) 31.5 (450) Flanged 300 (hydrostatic) 79.0 (1125) Flanged 600 (hydrostatic) 154.0 (2225) Seat
NOTE

All valves (air)

5.6

(80)

Pressure testing as per BS 6755 available on request. Shell hydrostatic test can be done for screwed and socket-weld end valves on request. Shell hydrostatic test can be done as per Class 800 rating for both versions on request.

07

AIL Series XR1/XR3

Reduced Bore Ball Valves

Single-piece and two-piece design
XR - Fire-safe series
These single-piece Ball Valves are high per formance valves which come with a one-piece integrally flanged body, in sizes of up to 200mm. This design of fers the unique advantage of eliminating the possibility of ex ternal leakage to the atmosphere through bolted body joints. These environment-friendly and high-integrity valves are preferred in critical applications where the media is expensive, volatile or toxic, and where ex ternal leakage or wastage is unacceptable. The 2-piece design fire-safe design Ball Valves complement the single-piece design in 250mm size.

Dimensional Details - Flanged end (in mm, unless specified) Single-piece (Class 150)
Valve Size 15 20 25 40 50 80 100 150 200 A B C D E F G
Approx. Weight (kg)

Single-piece (Class 300)

Valve Size 15 20 25 40 50 80 100 150 200 A B C D E F G
Approx. Weight (kg)

108 117 127 165

62 68 70 78

152 12.7 89 152 19.1 91

89 11.5 99 11.5

1.5 2.0 3.0 5.0 8.1 17.0 27.8 47.0 115.0

140

94

152 12.7 89

96 118

15 16 18 21

2.2 3.2 4.5 8.7 10.8 24.1 37.5 67.0 167.0

152 103 152 19.1 91

177 25.4 103 108 11.5 202 38.1 118 127 14.5

165 108 177 25.4 103 124 190 116 202 38.1 118 156

178 107 202 50.8 131 154 16.0 203 120 546 76.2 169 191 19.5 229 130 546 102.0 182 229 24.0 267 138 762 150.8 275 280 25.4 292 148 203.0 343 28.4

216 145 202 50.8 131 165 22.5 283 199 546 76.2 169 210 305 206 546 102.0 182 254 403 274 762 150.8 275 318 419 275 203.0 381 29 32 37 41

Two-piece (Class 150)

Valve Size 250 A B C D E F G H
Approx. Weight (kg)

330 165 148 254 686 406 30.5 578

210

Two-piece (Class 300)

Valve Size A B C D E F G H
Approx. Weight (kg)

08

250

457 229 148 254 686 445

48

578

280

AIL Series XR1/XR3

Material Specification
Sl. No. 1 2 3 4 5 6 7 8 9 Par t Body Inser t Ball Seat Stem Body Seal Gland Packing Stem Seal Insert Seal Carbon Steel ASTM A216 Gr. WCB

XR Series
Stainless Steel ASTM A351 Gr. CF8M AISI 316 or ASTM A351 Gr. CF8M ASTM A351 Gr. CF8M PTFE AISI 316 PTFE Graphite 35% Carbon-filled PTFE 15mm - 40mm, 200mm : Metal-to-metal 50mm - 150mm : Graphite

ASTM A105 or ASTM A216 Gr. WCB ASTM A351 Gr. CF 8M PTFE AISI 316 PTFE Graphite 35% Carbon-filled PTFE 15mm - 40mm, 200mm : Metal-to-metal 50mm - 150mm : Graphite

Specifications
Valve design Fire test Pressure testing Face-to-face dimensions End flange dimensions BS 5351 API 607, 4th edition API 598 (testing as per BS 6755 Part I on request) ASME B16.10 ASME B16.5 Class 150 RF and Class 300 RF

Pressure Testing
Test pressures Ends Shell Class 150 (hydrostatic) Class 300 (hydrostatic) Seat Class 150 (air) Class 300 (air) kg/cm2 (psi) 31.5 (450) 79.0 (1125) 5.6 5.6 (80) (80)

09

AIL Series 3XF/3FXF

Full Bore Ball Valves

Three-piece design
3XF - Standard series
This 3-piece Ball Valve is the most easily on-line maintainable in its class. By removing three body connector bolts and loosening the fourth, the body can be swung away using the four th bolt as the fulcrum, to carry out any installation or maintenance operation on the valve, thus reducing downtime. This valve can be of fered in a wide variet y of body and seat combinations.

3FXF - Fire-safe series

This 3-piece fire-safe design Ball Valve features a secondary metal seat which renders the valve firesafe. When the seat is totally sublimated in a fire, the ball moves and rests against the lip, forming a metalto-metal seat, thus ensuring leak-tightness.

Dimensional Details
Screwed/Socket-weld end (in mm, unless specified) Valve Size 15 20 25 40 A C D E F
1

Approx. Weight (kg)

73 95

122 149

22.2 / 21.8 27.6 / 27.1 34.3 / 33.8 49.2 / 48.7

48

9.7

/ 2 / 4

0.8 1.6 3.3 4.1

59 12.7 75 12.7

116 181 128 181

80 12.7 11/ 2

Dimensional Details
Flanged end (in mm, unless specified) Valve Size 15 20 25 C D E Class 150 A 108 F G A Class 300 F 96 G 15 17 19 22 A 165 Class 600 F 96 G 22 24 26 30 Approx. Weight (kg)
Cl. 150 Cl. 300 Cl. 600

152 12.7 98

89 11.1 140

2.3 3.1 6.4 9.0

3.2 4.5 8.7 10.8

6.3 9.1 15.4 21.6

177 19.1 102 117

99 12.2 153 118

191 118 216 124 241 156

202 25.4 121 127 108 11.1 165 124 202 38.1 126 165 127 14.3 191 156

10

40

AIL Series 3XF/3FXF

Material Specification
Sl. No. 1 2 3 4 5 6 7 8 Par t Carbon Steel

3XF
Stainless Steel Carbon Steel ASTM A105

3FXF
Stainless Steel ASTM A351 Gr. CF8M

Body ASTM A105 or ASTM A351 Gr. CF8M Body Connector ASTM A216 Gr. WCB Ball Seat Stem Body Seal Gland Packing Stem Seal ASTM A351 Gr. CF8M PTFE AISI 316 PTFE 35% Carbon-filled PTFE 35% Carbon-filled PTFE

ASTM A351 Gr. CF8M PTFE AISI 316 Graphite Graphite 35% Carbon-filled PTFE

Specifications
Max. cold working pressure 69kg/cm2 for screwed/socket-weld end valves with PTFE seat 103kg/cm2 for screwed/socket-weld end valves with special-filled PTFE seat As per flange rating for flanged valves BS 5159 for 3XF Series BS 5351 for 3FXF Series API 607 4th edition API 598 for flanged valves ASME B16.10 for flanged valves and AIL Standard for screwed/socket-weld end valves

Pressure Testing
Test pressures Ends Shell Scr./Socket weld (air) Flanged 150 (hydrostatic) Flanged 300 (hydrostatic) Flanged 600 (hydrostatic) Seat
NOTE

Valve design Fire Test (for 3FXF) Testing Face-to-face dimensions

kg/cm2 (psi) 5.6 (80) 31.5 (450) 79.0 (1125) 154.0 (2225) 5.6 (80)

All valves (air)

Pressure testing as per BS 6755 available on request. Shell hydrostatic test can be done for screwed and socket-weld end valves on request. Shell hydrostatic test can be done as per Class 800 rating for both versions on request.

11

AIL Series XF1/XF3

Full Bore Ball Valves

Single-piece / Two-piece design
XF Fire-safe Series (Class 150 & Class 300)
These high performance full bore ball valves come in single-piece design (in sizes of 15 - 40mm) as well as in t wo-piece design (in sizes of 50 200mm). Advanced features such as fire safety, antistatic capability, cavity relief and blow-out proof stem are built into these valves. They are supplied with an integral actuator mounting flange with drilled and tapped holes conforming to ISO 5211.

15mm - 40mm

50mm - 200mm

Dimensional Details (in mm, unless specified) Class 150

Valve Size 15 20 25 40 50 65 80 100 150 A B C D E H
Approx. Weight (kg)

Class 300
Valve Size 15 20 25 40 50 65 80 100 150 200 A B C D E H
Approx. Weight (kg)

108 117 127 165 178 191 203

46 50 56 75 84 77 99

163 12.7 97 168 19.1 118 168 25.4 123 193 38.1 139 193 50.8 150 402 64.1 190 256 76.2 155

1.8 2.5 3.4 8.5 12.2 18.5 23.0 42.6 90.0 170.0

140 153 165

78 85 94

163 12.7 97 168 19.1 118 168 25.4 123

2.5 3.8 5.1 9.5 15.2 26.0 32.6 59.0 121.0 210.0

191 100 193 38.1 139 216 241 283 84 83 99 193 50.8 150 402 64.1 190 402 76.2 205

229 108 402 101.6 196 394 179 1004150.8 315 457 206 -

305 122 610 101.6 240 403 179 502 231 -

150.8 645 578 203.0 745 578

12

200

203.0 690 578

AIL Series XF1/XF3

Material Specification
Sl. No. 1 2 3 4 5 6 7 8 9 10 Par t Body Body Connector Ball Seat Stem Body Seal Gland Packing Stem Seal Inser t Insert gasket Carbon Steel ASTM A216 Gr. WCB ASTM A216 Gr. WCB ASTM A351 Gr. CF 8M PTFE AISI 316 Graphite Graphite 25% Glass-filled PTFE

XF Series
Stainless Steel ASTM A351 Gr. CF8M ASTM A351 Gr. CF8M ASTM A351 Gr. CF8M PTFE AISI 316 Graphite Graphite 25% Glass-filled PTFE AISI 316 or ASTM A351 Gr. CF8M Graphite

ASTM A105 / ASTM A216 Gr. WCB / IS1875 Cl2 Graphite

XF Series - single-piece valves up to 40mm ; t wo-piece valves from 50mm onwards.

Specifications
Valve design Fire test Pressure testing Face-to-face dimensions BS 5351 API 607, 4th edition API 598 (testing as per BS 6755 Part I on request) ASME B16.10 (compliance to BS 2080 can be of fered on request) End flange dimensions ASME B16.5 Class 150 RF and Class 300 RF

Pressure Testing
Test pressures Ends Shell Class 150 (hydrostatic) Class 300 (hydrostatic) Seat Class 150 (air) Class 300 (air) kg/cm2 (psi) 31.5 (450) 79.0 (1125) 5.6 5.6 (80) (80)

13

AIL Special-purpose Ball Valves

Special-purpose Ball Valves

VALVES FOR STEAM SERVICE
These three-piece ball valves, fit ted with special filled PTFE seats, are specially designed for on/of f steam applications.

Material Specification
Par t Body & Body Connector Ball Seat Stem Body Seal Gland Packing Stem Seal Carbon Steel version only ASTM A105 or ASTMA216Gr.WCB ASTM A351 Gr. CF8M Special filled PTFE AISI 316 Graphite 35% Carbon-filled PTFE 35% Carbon-filled PTFE

Specifications
Ma x. cold working pressure Valve design Testing Face-to-face dimensions 103kg/cm2 for scr. / sw end valves As per flange rating for flanged valves BS 5159 API 598 AIL Standard

Pressure Testing
Test pressures Ends Shell (hydrostatic) Seat (air) kg/cm2 (psi) 156.5 (2275) 5.6 (80)

The full range of reduced and full-bore valves are available with special designs for steam services. In general, these valves will have seats of special filled PTFE and body seals of graphite. Pressure ratings will be as per flange ratings in flanged valves and 103kg/cm2 for screwed/socket-weld end valves.

MULTIPORT BALL VALVES

3DTXR - T-Port Diverter Valve 3DLXR - L-Port Diverter Valve 3TT XR - T-Port Three-way Valve 3TLXR - L-Port Three-way Valve
The Diver ter Valve is designed to divert media from the bottom inlet port to either of the t wo outlet ports. The Three-way Valve, also known as a Mixer Valve, permits use of any port as inlet.
NOTE : Available in screwed and socket-weld designs. For material specifications and general dimensions, refer to table on 3XR series.

VALVES FOR CRYOGENIC SERVICE

3CXR
The 3CXR series Cryogenic Valve is designed for low temperature services down to -1960C. Typical applications are LNG storage/distribution, terminal unloading stations, liquid Nitrogen and liquid Oxygen lines.The valves incorporate exclusive features such as : Positive ball cavity relief - an upstream relief hole in the ball to prevent over pressure due to thermal expansion Effective stem ex tensions - conformance to standard international practices ; selection of wall thickness and lengths to keep heat transfer down, packing frost-free, operational torques low and actuators well supported Superior stem design - a one-piece stem with special stem seals to ensure a zero-leak stem and low operating torque High performance sealing - special seats and body seals to ensure bubbletight shutof f and zero body leakage Ease of installation - three-piece construction to facilitate easy installation and maintenance Flexibility - a variety of end connections such as screwed end, socket-weld end and ex tension nipples

14

NOTE : For general dimensions, refer to table on 3XR series. AIL single-piece valves are s also available for cryogenic service with and without stem ex tensions.

AIL Special-purpose Ball Valves

VALVES FOR HIGH PRESSURE SERVICE

3HXR
The AIL Series 3HXR Ball Valve has been specially developed to meet the industrys requirement of a safe and reliable shutof f valve for high-pressure applications. This valve incorporates a number of product features like high-pressure seals, thicker flanges on the body connectors, high-tensile bolting, special acetal resin seats, high-strength stem and highpressure integrity gland assembly.

Material Specification
Par t Body Body Connector Ball Seat Stem Body Seal Gland Packing Stem Seal

3HXR
Carbon Steel version only ASTM A105/A216 Gr. WCB ASTM A105/A216 Gr. WCB / IS 1875 Cl 2 ASTM A351 Gr. CF8M Acetal Resin ASTM A564 Type 630 Nitrile Rubber 15% glass-filled PTFE Nylon

Specifications
Ma x. cold 352kg/cm2 for liquids working pressure 210kg/cm2 for gases (15-25mm) 168kg/cm2 for gases (40-50mm) Valve design Testing Face-to-face dimensions BS 5159 API 598 AIL Standard

Dimensional Details (in mm, unless specified)

Valve Size 15 20 25 40 A
Scr. end S/W end Scr. end

C
S/W end

E
Scr. end S/W end

77.8 85 85

122 122 22.2 / 21.8

47 50 60 76 81

50 60 76 81 81

9.7 12.7 12.7 12.7 16.0

108 122 149 27.6 / 27.1

Pressure Testing
Test pressures Ends Shell (hydrostatic) Seat (air) kg/cm2 (psi) 527.0 (7500) 5.6 (80)

108 131 149 256 34.3 / 33.8 131 142 256 256 49.2 / 48.7 142 142 256 256 61.7 / 61.1

50

The standard 3HXR valve is a reduced bore valve.

VALVES FOR HIGH TEMPER ATURE SERVICE

These are high-durability ball valves for superheated steam and high temperature applications, with the following features : Ability to handle high presuure and temperature shock Ability to withstand high pressure drops Ability to resist abrasion and wear Services up to 3400C and 100kg/cm2 pressure
NOTE : Available in single-piece and three-piece designs. For general dimensions, refer to earlier tables.

The metal-seated versions have a graphite impregnated alloy stainless steel seat with integral graphite seat seal. These are suitable for conditions up to 3400C and 70kg/cm2. The stainless steel ball is ENP coated to make the surface harder. The resilient seated versions feature PEEK seats which handle conditions up to 2800C and 100kg/cm2.

TRUNNION MOUNTED BALL VALVES

The AIL Trunnion Mounted Ball Valve is the preferred choice of ball valve in higher sizes and pressure ratings, and is used in pipelines and critical process applications. In this design, sealing takes place by allowing the seat to move towards the ball along the flow a xis, which leads to lower operating torques over other types of valves. The valves have advanced design features such as a built-in cavit y relief mechanism, compact internal trunnion holder, and intrinsic double block and bleed facility. The valves are of two-piece design, bolted/welded at the body connection joint, with flanged/butt weld ends, in reduced and full bore designs and in ratings of ASME Class 150 - 2500. For details, refer to the Trunnion Mounted Ball Valve Catalogue.

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AIL Pneumatic Actuators

Pneumatic Actuators
Series 90 Double Acting and Spring Return types
AIL Pneumatic Actuators are among the widely used actuators today and are in service in diverse industries such as pharmaceutical, chemical, petrochemical, food and nuclear power. Compactness, reliability, low maintenance needs and ruggedness combine to make these actuators the best choice for use with ball valves. Spring Return (SR) type Actuator

Double Acting (DA) type Actuator

SERIES 90 ACTUATOR The AIL Series 90 Actuator is optimised for use with AIL ball valves for safe remote plant automation. Of fered in two options - Double Acting (DA) and Spring Return (SR) - this actuator incorporates a rack-and-pinnion mechanism to ensure positive engagement and a constant torque output throughout the entire cycle.

Material Specifications
Description Housing / Piston and End Cap Pinnion Seals Retention Spring Wire Pinnion Bush Springs Material Aluminium Alloy Steel Nitrile Elastomer Stainless Steel Nylon or filled PTFE Spring Steel

Features
Housing : Precision-ex truded or cast, to of fer a light weight, compact body with sound pressure por ting. Anodised to provide resistance to wear and corrosion. Piston : Rugged one-piece piston with integral rack to ensure positive engagement with the pinnion. Anodised to provide resistance to wear and corrosion. Pinnion : Surface-tested with low-friction coating for smooth operation. End Cover : Powder-coated for resistance to corrosion, with a single SS spring wire for positive clamping. Pinnion Bush : Self-lubricated for low friction and smooth operation.

Technical Specifications
Mounting standard Pinnion top Media ISO 5211 NAMUR Filtered and lubricated dry air or inert gas -100C to +800C Double Acting 2.1kg/cm2 to 8.4kg/cm2 (30psi to 120psi) Spring Return 2.1kg/cm2 to 7.0kg/cm2 (30psi to 100psi) Rotation Open - counterclockwise Close - clockwise

Ordering Information
Model number : Use the Actuator Selection Guide to select the required actuator model. Ser vice conditions : Line fluid, temperature, dif ferential pressure and frequency of operation. Actuator data : Double Acting or Spring Return ; operating media, operating pressure, media temperature (ma x) and operating time required. Solenoid Valve : Type, size, material, power supply ; enclosure (weather-pro of / flame-pro of) with relevant standards. Limit Switch : Nos., Switch t ype (1NO+1NC or 2NO+2NC), power supply (DC/AC), electrical rating (VA or wat ts), enclosure (weather-proof / flameproof) with relevant standards. Other accessories : Manual override, quick exhaust valve, accummulator, air filter regulator etc.

Temperature range Operating pressure range

16

AIL Pneumatic Actuators

Selection

Guide

Use the char ts below to select the appropriate model of actuator. The valve size (X-a xis), the valve operating pressure (Y-a xis) and the actuator air supply pressure (80psi or 60psi indicated in the chart title) together determine the actuator selection. For selection of actuators for TMBV, please contact AIL. DOUBLE ACTING R ANGE SPRING RETURN R ANGE

Reduced Bore Valves 5.6kg/cm2 (80psi)

Reduced Bore Valves 5.6kg/cm2 (80psi)

Full Bore Valves 5.6kg/cm2 (80psi) Full Bore Valves 5.6kg/cm2 (80psi)

Reduced Bore Valves 4.2kg/cm2 (60psi) Reduced Bore Valves 4.2kg/cm2 (60psi)

Full Bore Valves 4.2kg/cm2 (60psi)

Full Bore Valves 4.2kg/cm2 (60psi)

05SR50 05SR60 05SR80 10SR50 05DA 10DA 20DA 30DA 50DA 70DA 90DA 100DA 110DA 10SR80 20SR50

20SR60 20SR70 20SR80 30SR50 30SR60 30SR70

30SR80 50SR60 50SR70 50SR80 70SR50 70SR60

70SR70 70SR80 90SR60 90SR70 90SR80 100SR60

100SR70 100SR80 110SR60 110SR80 120SR70 120SR80

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Technical Information

Pressure-Temperature Graphs

The information contained in this section is to be used only as a guide to the ma ximum temperaturepressure combination that the seat material can withstand. Other factors such as process medium, material of construction of metal parts and design rating of the valve can also restrict overall valve per formance.

Flow Coef ficients (Kv values)

Valve Size
Reduced bore Full bore

15 7 33

20 10 61

25 28 95

32 39 199

40 71 303

50 104 433

65 208 675

80 303 1002

100 623 1832

150 882 4366

200 1557 8077

250 2569 16003

18

Kv = flow coef ficient in m3/hr

Global recognition

International Clientele
ADNOC ARCO BASF CHEVRONTEXACO CITGO CNOOC CSPC DAEGU PETROCHEM DSM ENGEN ENOC EQUILLON EXXONMOBIL FORMOSA PLASTICS GASCO KNPC KOC MOTIVA NOVACOR PDO PERTAMINA PDVSA PETROCANADA PETRONAS PNOC, PHILIPPINES QATAR PETROLEUM REPSOL SAPREF SASOL SAUDI ARAMCO SECCO SEPCO SHELL STAR SUNOCO SYNCRUDE TOTAL UNION CARBIDE UNOCAL ABB AMEC BECHTEL CHIYODA CMI CONTRINA FLUOR FOSTER WHEELER JACOBS JGC KELLOG, BROWN & ROOT KRUPP UHDE KVAERNER LINDE PARSONS PETROFAC SNAMPROGETTI SNC LAVALIN TECHNIP WUHAN BOILERS

Ordering Information
Familiarity with our catalogue numbering is not necessary when specifying or ordering our valves. A full description of the valve provided by you is translated into a catalogue number as per the system shown below : Three-piece Valves
SIZE (in mm)
8 10 15 20 25 32 50 65 3HXR 3CXR 3DT XR 3DLXR 3TT XR 3TLXR 3XF 3FXF

SERIES
3XR 3FXR

BODY & TRIM COMBINATIONS

Body & Connector Ball / Stem

SEAT
T Virgin PTFE R R-PTFE* X PEEK P Special filled PTFE A Acetal Resin C Seats for Cr yogenic Ser vice

OPERATOR
L Lever Operated P Pneumatic Actuated NPT

ENDS
- Screwed NPT

816 WCB/A105 813 WCB/A105 866 CF8M 833 CF8 817 WCB/A105 867 CF8M 8LL CF3M 8RR CF3

SS316 SS304 SS316 SS304 Monel Monel SS316L SS304L

BSPT - Screwed BSPT BSPL - Screwed BSPL SCT - Socket weld

FL150- Flanged CL150 FL300- Flanged CL300 FL600- Flanged CL600

Single-piece / Two-piece Valves

SIZE (in mm)
15 20 25 40 50 80 100 150 200 250

SERIES
XR1 XR3 XF1 XF3 16 13 66 33 17 67 LL RR AA

BODY & TRIM COMBINATIONS

Body & Connector Ball / Stem

SEAT
T Virgin PTFE R R-PTFE* X PEEK P Special filled PTFE

OPERATOR
L Lever Operated W Wrench G Gear Unit P Pneumatic Actuated E Electrically Actuated

NOTE * R-PTFE : 15% Glassfilled (reinforced) PTFE For any other special requirement, add SPL to the catalogue number and provide details. Special options such as ex tension spindles, ex tension nipples and locking arrangements are also available.

WCB/A105 WCB/A105 CF8M CF8 WCB/A105 CF8M CF3M CF3 Alloy 20

SS316 SS304 SS316 SS304 Monel Monel SS316L SS304L Alloy 20

19

Kancheepuram plant

Maraimalai Nagar plant

AUDCO INDIA LIMITED

Administrative Of fice

Mount-Poonamallee Road, Manapakkam, Post Bag 976, Chennai 600 089, INDIA. Tel : (044) 22492323. Fa x : (044) 22495055, 22494055. Website : w w w.ailvalves.com
Manufacturing Plants

Mount-Poonamallee Road, Manapakkam, Chennai 600 089, INDIA. Enathur, Kancheepuram 631 552, INDIA. B8, MMDA Industrial Area, Maraimalai Nagar 603 209, INDIA.
Marketed by

LARSEN & TOUBRO LIMITED

Valves Business Group Post Bag 5247, Chennai 600 002, INDIA. Tel : (044) 28462086, 28462090. Fax: (044) 28462145.

PB No. : C2022-1/09.05 (supersedes C2022-0) As we continuously endeavour to improve our products, the data given herein are subject to change without notice.