Forged Ball Valves for Severe Service Applications
- Sizes 1/2″ – 20″
- 150-4500# ANSI
- Boiler Feed Pump
- Bottom Ash
- Cold Reheat D rain
- Control Valve
- Feed Water Heater
- Isolation Steam to Pulverizer
- Main Steam Reheat
- Spray Soot Blower
- Steam Drum Instrument
- FCCU Catalyst Isolation
- Hydrogen Isolation
- Heavy Oil
- Catalyst Slurry
Perfect Ball Valves for Heavy Abrasives, Refining, Chemicals & More
Balls, Seats and Stems
We only make metal seated products at Copeland and coatings are the heart of the valve: the sealing surface. Copeland has applied wear resistant, thermal sprayed coatings for over 60 years. We never trust this important process to outside vendors, quality audits and random samplings. We apply these coatings ourselves. We test them ourselves and we make sure that only the best materials and processes are used. This is no place to cut corners.
The seat rings have sharp leading edges that help scrape away tenacious solids and the coatings are hard and polished so that the impurities have difficulty sticking to the surface.
Our standard material for the ball, seats and stem is 410ss with CFS131, chrome carbide applied in-house with one of several types of HVOF thermal spray units. Optional materials include 17-4 ph, 316ss, Inconels, Ferralium 255 (autoclaves), Hastelloys, Monel, Alloy 20, Titanium and Zirconium. A chemical engineer will match the coating to the service when corrosion is an issue.
The sealing surface is machined and lapped to a tight tolerance. Balls and seats are checked for cracks prior to installation. Coating hardnesses vary with the coating selected. Our balls are oversized to allow the ball to seal even when there is some actuator misalignment and to provide a method for us to round the edges of our balls to increase coating life.
Stem Seal Bearings
Typically, these act as thrust bearings and side load bearings. Copeland uses a variety of materials and configurations for these items, depending upon the design. But, they are important to proper stem alignment, especially in high cycle valves. A stem bushing located on the actuator mounting plate provides a second bearing that helps keep the stem perfectly aligned.
Copeland pays close attention to the packing chamber. We don’t just depend on the old die formed ribbon and carbon anti-extrusion rings anymore. Our packing boxes are always live loaded and carefully constructed to exceed the tight fugitive emissions in the petrochemical industry and high pressure steam in power plants.
Actuator Mounting Flanges
Side loading prevention and accurate stem alignment are always concerns. We take every precaution to ensure that the mounting flange is stable and accurately machined for heavy torques, sideloading issues and high cycle conditions.
Locked-in Down Stream Seat
For larger valves, Copeland locks in the downstream seat to make it an integral part of the end connection and to prevent leakage and build-up between the body and seat. We are not a big fan of carving a seat out of the body material. Sure, it’s cheaper. But the coefficient of expansion is normally different than that of the ball. So, will you have a seal when they both get hot? We would rather not risk it.
Typically, for classes up to 900# ANSI, Copeland uses a spiral wound Graphoil gasket to provide a non-pressure energized seal for excellent high and low pressure sealing. For higher pressures, either a metal pressure ring or a unibody construction is chosen.
A Variety of Bore Sizes A straight through bore (full port) is preferable in heavy abrasives and minimizes turbulance and high pressure erosion. But reduced sizes such as Standard Bores, Regular Bores or Reduced Bores may be used to save money in both the valve and the actuator when a full bore is unnecessary.
End Connections include RF, RTJ, BWE, SW and hub connectiors. Let us know if you have a special requirement.