Copeland s 2007 Training Series Dry Abrasive Applications The

Copeland’s 2007 Training Series Dry Abrasive Applications The BV Series: An Introduction Applications Features Benefits Marketing Literature

Applications Silica Sand Hydrogen Gold and Nickel Mining Coal Mining and Coal Gasification Ti. O 2 Plants Catalyst High Velocity Particulates High Temperatures Corrosives Coal Liquefactions

Copeland’s BV Series: Features Forged Bodies Made to Order 150# to 4500# ANSI A Variety of Trim Packages and Options Available Extra Strong Body Metal Seats with Carbide and Ceramic Coatings

Additional Features Forged vs. Cast Body In-house Coatings Fine Lapping Relief Cut Full Bore Protective Loaded Stem Packing Load Spring Fixed Downstream Seat Close Tolerances Experience Purge Options MSS-SP 61 & Zero Leakage Testing Lined vs. Coated Beveled Upstream Seat Pocket Optimal Cv Values Made in the USA

Bodies: Forged vs. Cast Forged Bodies are stronger and thicker than Cast Provides thick body flanges for higher torque values Allows flexibility in choosing body materials and valve features Cast bodies are available in 316 ss and Carbon Steel Sizes range from 1” to 10” Very Economical Trunnion Designs are available for applications involving only small amounts of impurities

In-House Coatings History Copeland introduced thermal sprayed coatings in the 1950’s and pioneered its development During the 1960’s and 1970’s coating applications were quickly adopted by the drilling tool and oil industries. Experimentation with coatings on valves, pumps and compressors led to many new applications Late 1980’s saw coatings expand to ball valve sealing components: balls and seats. Today: Development continues Copeland is one of the few companies that maintain inhouse coating capabilities Copeland has provided coatings for a majority of companies manufacturing severe service valves.

HVOF Coatings Better Wear Resistance Hardness exceeds 70 Rc vs. 40 -60 Rc for Fused Applied at 250 F with no heat effected zones or thermal distortion. Porosity less than 0. 25% Applied by a miniature rocket engine Four times more chrome carbide particles than spray and fuse HVOF coatings applied in-house at Copeland for over 20 years. Excellent coatings available for ALL pressure classes.

Liners Features Copeland has a wealth of experience with liners and coatings for abrasive applications. Please ask you Copeland Specialist for his advice for dry abrasives. Explanation

Ball & Seat Lapping Each seat is mate lapped to one side of the ball. Copeland laps in BOTH seats for longer life and polishes each seat to a high degree to reduce the risk of small particulates eroding the sealing surface and to provide tight sealing for gases Features Lapping Extra strong load springs are used for these valves to provide extra tight shut-off Load springs are normally made of Inconel 718 ss for long life at elevated temperatures Load Springs

The Double Relief Cut It’s purpose is to allow the initial flow to be spread out over a larger area of the ball’s edge reducing wire draw and wear to this critical part of the sealing surface. The ball and coating lasts longer under high pressure and abrasive conditions. This modification provides a blunt, leading edge against flow. The coating is thickest at this point and the elimination of a sharp edge minimizes coating fracture. Explanation Features For high pressure or highly abrasive applications, a relief cut may be made in the leading edge of the ball on the sides that first see flow when the valve is opened. Relief Cut is also called an Arcuate Cut

Relief Cut Flow Diagram As the ball first starts to open, the velocity is at its greatest through the opening. By allowing the flow to be spread across a greater area, erosion to the leading edge of the ball can be reduced. Explanation Features RELIEF CUT ALLOWS FOR FASTER PRESSURE RELIEF

Cross Sectional Views Explanation Full Bore: Standard Features Full bore valves are generally chosen for dry abrasives to avoid wear and possible plugging. However, regular, standard and reduced port valves are also available. The above diagrams show some of the standard features Copeland uses in building these valves. Liners, coated bores, purge ports are some of the many options used to customize the product to the particular application.

Stem Packing Features Explanation Live Loaded Standard Packing Up to 850°F - Oxygen Present Up to 1200°F - Reducing Atmospheres Special Features Stainless steel studs and nuts, torqued to meet pressure requirements Heavy duty gland flange Braided carbon fiber anti-extrusion rings surround two to three die-formed Grafoil packing rings Double 431 stainless (typical) rings with chrome carbide coating or single peek filled Teflon¨ make up the inner stem seal bearings Options Dual Stem Packing: 316 stainless steel molycoated lantern ring situated between the two packing sets High Temperature Packing 850°F-1300°F - Oxygen Present 850°F-1652°F - Reducing Atmospheres Top - two reinforced composite fiber braided ropes surround two oxygen resistant, corrosion inhibited, Grafoil packing rings Center - two ceramic fiber gasket insulators and two ceramic fiber braided rope insulators split up to form an oxygen and heat barrier Bottom - Grafoil impregnated, Inconel 718 anti-extrusion and sealing ring, also includes inner stem seal bearings

Coated with Carbide or Ceramic 17 -4 PH, 400 SS, 329 SS, 316 SS, Stellite 6, Inconels, Hastelloys, Monel, Alloy 20, Titanium, Zirconium Features Seats The leading edges of the seat ring wipe the sealing surface clean, A wide sealing surface on each seat ring minimizes the possibility of nicks and scratches, Each seat is mate-lapped front and back (to ball and body) to ensure the integrity of the seals All metal to metal seals - no Grafoil or Teflon behind the seat Explanation

Fixed Downstream Seat The downstream seat is fixed with bolting, tabs or a metal ring. All methods of locking-in the seat provide sealed seat protection and easy seat removal for repair. By trapping the seat into its proper place, debris cannot get behind the seat and cause leakage. Leakage can ultimately lead to severe erosion. Repairable seats offer significant advantages for larger or high alloy valves. Explanation Features

24” Mining Valve Leakage Behind a Non-Fixed Seat. Competitor No. 2 Example 7. 843

Copeland allows for a variety of testing options to meet or exceed customer requirements. Our standard test MSS-SP 61 includes a liquid seat test For gases, we can include a Zero Leakage test and proprietary options to ensure the longest life and lowest maintainable leakage rate. Zero Leakage Features Testing Zero Leakage Option Zero Leakage has been defined as “ 50 psi of air for 3 minutes with the minimum acceptable passing criteria being zero bubbles during the 3 -minute test. Additionally a 1000 psi nitrogen seat test is performed for 3 minutes with zero bubbles. Furthermore, 3500/4500 ASME/ANSI valves are seat leak tested at 4000 psi of nitrogen for 3 minutes with zero bubbles. ” Note, that this test does not include the lengthy test requirements and definitions required by most specifications. It is also a bench test and not a guaranty against future leakage. It can be, in fact, a much less exacting testing criteria than those generally accepted by the valve industry such as MSS-SP 61 and ANSI B 16. 104/FCI 70. 2 Class IV, V or VI leakage requirements. Copeland tests its valve against MSS-SP 61 and performs the zero leakage test IN ADDITION to this generally accepted test criteria.

BV Series Valves Warranty Features All products manufactured by Copeland are warranted against defects of material or workmanship for a period of one and one half years from the date of shipment when these products are used within the service and pressure for which they are manufactured. This warranty is limited to replacement, without charge, of parts found by Copeland to be defective in material or workmanship and does not extend to claims for labor, expense or other loss or damage occasioned by such defect. This warranty does not cover deterioration by corrosion, erosion or any cause of failure other than defect of material or workmanship. Purchasers are expected to determine the suitability of Copeland products for the particular purposes. This warranty is in place and in lieu of all warranties of merchantability and fitness.

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