Professional Documents
Culture Documents
AIL
BALL
VALVES
FLOATING BALL DESIGN
Maraimalai Nagar plant
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
REDUCED BORE
FULL BORE
Manufacturing Plants
BS 5351
Marketed by
BS 5159
Introduction
ensur e
the
qualit y
of
products
manufactured.
Introduction
Page No.
03 - 05
06 - 09
10 - 13
14 & 15
14
14
14
15
15
15
16 & 17
Technical Information
AIL manufactures a wide variety of industrial
03
04
05
18
18
18
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
Global recognition
Ordering Information
19
International Clientele
19
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)
SERIES
3XR
3FXR
Chennai plant
32
50
65
OPERATOR
ENDS
Ball / Stem
T Virgin PTFE
L Lever Operated
NPT
- Screwed NPT
R R-PTFE*
P Pneumatic
816 WCB/A105
SS316
813 WCB/A105
SS304
X PEEK
866 CF8M
SS316
833 CF8
SS304
P Special filled
PTFE
SCT
3HXR
3CXR
3DT XR
3DLXR
3TT XR
3TLXR
817 WCB/A105
Monel
A Acetal Resin
867 CF8M
Monel
SS316L
8RR CF3
SS304L
C Seats for
Cr yogenic
Ser vice
8LL CF3M
20
25
SEAT
3XF
3FXF
10
15
Actuated
XR1
XR3
25
XF1
XF3
40
50
80
100
150
200
02
250
SERIES
16
13
66
33
17
67
LL
RR
AA
Ball / Stem
WCB/A105
WCB/A105
CF8M
CF8
WCB/A105
CF8M
CF3M
CF3
Alloy 20
SS316
SS304
SS316
SS304
Monel
Monel
SS316L
SS304L
Alloy 20
SEAT
OPERATOR
T Virgin PTFE
L Lever Operated
R R-PTFE*
W Wrench
X PEEK
G Gear Unit
P Special filled
PTFE
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.
19
Technical Information
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
Manufacturing Program
Valve Type
REDUCED BORE
Standard
20
25
32
40
50
65
80
100
150
200
250
Reduced bore
10
28
39
71
104
208
303
623
882
1557
2569
Full bore
33
61
95
199
303
433
675
1002
1832
4366
8077
16003
BS 5159
3-piece
singlepiece
Fire-safe
BS 5351
BS 5351
Screwed/SW
Flanged 150/
300/600
SPECIAL
PURPOSE
VALVES
Flanged 150/
300/600
Flanged 150
Flanged 300
Standard
BS 5159
Fire-safe
BS 5351
3-piece
singlepiece
Valve Size
End
Connection
Screwed/SW
Fire-safe
2-piece
Valve Size
Compliance
2-piece
FULL BORE
18
Introduction
Pressure-Temperature Graphs
Fire-safe
BS 5351
Screwed
SW
Flanged 150
Flanged 300
Flanged 600
Flanged 150
Flanged 300
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 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.
LEAK TIGHT
STEM SEALING
stem
shoulder
stem
seal
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).
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.
VALVE OPERATION
MIRROR-FINISHED SS BALLS
04
Guide
Selection
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 AILs
manufacturing standard for reduced bore valves.
05DA
20DA
50DA
90DA
10DA
30DA
70DA
100DA
110DA
05SR50
20SR60
30SR80
70SR70
100SR70
05SR60
20SR70
50SR60
70SR80
100SR80
05SR80
20SR80
50SR70
90SR60
110SR60
10SR50
30SR50
50SR80
90SR70
110SR80
10SR80
30SR60
70SR50
90SR80
120SR70
20SR50
30SR70
70SR60
100SR60
120SR80
17
Material
Specification
Carbon Steel
Carbon Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Alloy 20
LCB
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
Gr.
Gr.
Gr.
Gr.
Gr.
Gr.
Gr.
WCB
CF8M
CF8
CF3M
CF3
CN7M
LCB
Material Specifications
Material
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
13% Cr. Steel
Monel
Hastelloy C
Alloy 20
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
Features
Description
Material
Aluminium Alloy
Pinnion
Steel
Seals
Nitrile Elastomer
Stainless Steel
Pinnion Bush
Springs
Spring Steel
SEATS
Material
Description
PTFE
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
Technical Specifications
Mounting standard
Ordering Information
ISO 5211
Pinnion top
NAMUR
Media
Filtered and
lubricated dry air
or inert gas
Temperature range
-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
16
A105
A216
A351
A351
A351
A351
A351
A352
Introduction
Pneumatic Actuators
Open - counterclockwise
Close - clockwise
Metal
Acetal Resin
BODY SEALS
Material
Description
PTFE
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
Three-piece design
3XR - Standard series
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
3HXR
Par t
Body
Body Connector
Ball
Seat
Acetal Resin
Stem
Body Seal
Nitrile Rubber
Gland Packing
Stem Seal
Nylon
Specifications
Ma x. cold
352kg/cm2 for liquids
working pressure 210kg/cm2 for gases (15-25mm)
168kg/cm2 for gases (40-50mm)
Dimensional Details
Screwed/Socket-weld end (in mm, unless specified)
Valve
Size
65
122
14.6 / 14.2
45
9.7
/4
0.6
/8
0.6
Valve
Size
25
60
76
12.7
40
76
81
12.7
50
81
81
16.0
Test pressures
Ends
Shell
(hydrostatic)
Seat
(air)
kg/cm2 (psi)
527.0 (7500)
5.6
(80)
45
9.7
/2
0.6
/4
0.8
1.6
107 149
43.1 / 42.7
65 12.7 11/4
2.5
40
116 181
49.2 / 48.7
75 12.7 11/2
3.3
50
128 181
61.7 / 61.1
80 15.9
4.1
77.8 85
22.2 / 21.8
32
9.7
12.7
122
59 12.7
50
60
67
34.3 / 33.8
47
50
15
149
9.7
95
S/W
end
85
45
25
E
Scr.
end
20
18.0 / 17.6
48 12.7
AIL Standard
122
27.6 / 27.1
S/W
end
15
65
122
Scr.
end
Face-to-face
dimensions
10
73
C
S/W
end
BS 5159
API 598
20
A
Scr.
end
Valve design
Testing
Pressure Testing
Approx.
Weight
(kg)
06
Class 150
A
Class 300
G
Class 600
Cl. 600
15
152 12.7 90
108
89 11.1 140
96
15
165
96
22
1.8
2.2
4.5
20
152 19.1 98
117
17
191 118
24
2.3
3.2
6.3
25
19
216 124
26
3.1
4.5
9.1
40
22
241 156
30
6.4
8.7
15.4
50
23
292 165
33
9.0
10.8
21.6
15
Material Specification
Par t
Body &
Body Connector
ASTM A105 or
ASTMA216Gr.WCB
Ball
Seat
Stem
AISI 316
Body Seal
Graphite
Gland Packing
Stem Seal
Pressure Testing
Specifications
Ma x. cold working pressure
Valve design
Testing
BS 5159
API 598
Face-to-face dimensions
AIL Standard
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.
Material
Specification
Sl. No.
Par t
3XR
Carbon Steel
3FXR
Stainless Steel
Carbon Steel
Stainless Steel
ASTM A105
1
2
Body
ASTM A105 or
ASTM A351 Gr. CF8M
Body Connector ASTM A216 Gr. WCB
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
PTFE
Graphite
Gland Packing
Graphite
Stem Seal
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. AILs single-piece valves are
also available for cryogenic service with and without stem ex tensions.
Specifications
Pressure Testing
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
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)
Valve design
Testing
Face-to-face dimensions
Seat
5.6
(80)
NOTE
07
Valve
Size
94
Valve
Size
15
108
62
152 12.7 89
89 11.5
1.5
15
140
20
117
68
152 19.1 91
99 11.5
2.0
25
127
70
40
165
78
Approx.
Weight
(kg)
152 12.7 89
96
15
2.2
20
118
16
3.2
3.0
25
18
4.5
5.0
40
21
8.7
50
8.1
50
10.8
80
17.0
80
29
24.1
100
27.8
100
32
37.5
150
47.0
150
37
67.0
200
292 148
115.0
200
419 275
41
167.0
203.0
343 28.4
Approx.
Weight
(kg)
210
203.0
381
Material
Specification
Sl. No.
Par t
Carbon Steel
Stainless Steel
Body
Body Connector
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
Graphite
Graphite
Gland Packing
Graphite
Graphite
Stem Seal
Inser t
10
Insert gasket
Graphite
Graphite
Specifications
BS 5351
Fire test
Pressure testing
08
250
48
578
Approx.
Weight
(kg)
280
Test pressures
Ends
Shell
Class 150 (hydrostatic)
Class 300 (hydrostatic)
kg/cm2 (psi)
31.5 (450)
79.0 (1125)
Pressure Testing
Valve design
XF Series
Seat
5.6
5.6
(80)
(80)
be of fered on request)
End flange dimensions
13
50mm - 200mm
15mm - 40mm
Material
Specification
15
108
46
163 12.7 97
1.8
Class 300
Valve
Size
15
140
78
163 12.7 97
Approx.
Weight
(kg)
117
50
2.5
20
153
85
3.8
25
127
56
3.4
25
165
94
5.1
40
165
75
8.5
40
9.5
50
178
84
12.2
50
216
84
15.2
65
191
77
18.5
65
241
83
26.0
203
99
23.0
80
283
99
32.6
100
42.6
100
150
90.0
150
403 179
121.0
200
457 206
170.0
200
502 231
210.0
Sl. No.
Par t
Body
Inser t
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
PTFE
PTFE
Gland Packing
Graphite
Graphite
Stem Seal
Insert Seal
2.5
20
80
12
Approx.
Weight
(kg)
XR Series
Carbon Steel
Pressure Testing
Specifications
Valve design
BS 5351
Fire test
Pressure testing
Stainless Steel
Test pressures
Ends
Shell
Class 150 (hydrostatic)
Class 300 (hydrostatic)
kg/cm2 (psi)
31.5 (450)
79.0 (1125)
59.0
Face-to-face dimensions
ASME B16.10
Seat
5.6
5.6
(80)
(80)
09
Material
Specification
Sl. No.
Dimensional Details
Screwed/Socket-weld end (in mm, unless specified)
Valve
Size
15
73
122
22.2 / 21.8
48
20
95
149
27.6 / 27.1
59 12.7
25
116 181
34.3 / 33.8
75 12.7
40
128 181
49.2 / 48.7
80 12.7 11/ 2
9.7
Approx.
Weight
(kg)
/ 2
0.8
/ 4
1.6
3.3
Par t
3XF
Carbon Steel
3FXF
Stainless Steel
15
10
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
PTFE
Graphite
Gland Packing
Graphite
Stem Seal
152 12.7 98
Class 150
A
108
Class 300
G
89 11.1 140
F
96
Body
ASTM A105 or
ASTM A351 Gr. CF8M
Body Connector ASTM A216 Gr. WCB
ASTM A105
1
2
Specifications
Stainless Steel
4.1
Dimensional Details
Valve
Size
Carbon Steel
Class 600
G
15
A
165
F
96
G
22
2.3
3.2
Cl. 600
Valve design
Testing
Face-to-face dimensions
6.3
20
17
191 118
24
3.1
4.5
9.1
25
19
216 124
26
6.4
8.7
15.4
40
22
241 156
30
9.0
10.8
21.6
Pressure Testing
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
Test pressures
Ends
Shell
Scr./Socket weld (air)
Flanged 150 (hydrostatic)
Flanged 300 (hydrostatic)
Flanged 600 (hydrostatic)
kg/cm2 (psi)
5.6 (80)
31.5 (450)
79.0 (1125)
154.0 (2225)
Seat
5.6
(80)
NOTE
11
Material
Specification
Sl. No.
Dimensional Details
Screwed/Socket-weld end (in mm, unless specified)
Valve
Size
15
73
122
22.2 / 21.8
48
20
95
149
27.6 / 27.1
59 12.7
25
116 181
34.3 / 33.8
75 12.7
40
128 181
49.2 / 48.7
80 12.7 11/ 2
9.7
Approx.
Weight
(kg)
/ 2
0.8
/ 4
1.6
3.3
Par t
3XF
Carbon Steel
3FXF
Stainless Steel
15
10
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
PTFE
Graphite
Gland Packing
Graphite
Stem Seal
152 12.7 98
Class 150
A
108
Class 300
G
89 11.1 140
F
96
Body
ASTM A105 or
ASTM A351 Gr. CF8M
Body Connector ASTM A216 Gr. WCB
ASTM A105
1
2
Specifications
Stainless Steel
4.1
Dimensional Details
Valve
Size
Carbon Steel
Class 600
G
15
A
165
F
96
G
22
2.3
3.2
Cl. 600
Valve design
Testing
Face-to-face dimensions
6.3
20
17
191 118
24
3.1
4.5
9.1
25
19
216 124
26
6.4
8.7
15.4
40
22
241 156
30
9.0
10.8
21.6
Pressure Testing
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
Test pressures
Ends
Shell
Scr./Socket weld (air)
Flanged 150 (hydrostatic)
Flanged 300 (hydrostatic)
Flanged 600 (hydrostatic)
kg/cm2 (psi)
5.6 (80)
31.5 (450)
79.0 (1125)
154.0 (2225)
Seat
5.6
(80)
NOTE
11
50mm - 200mm
15mm - 40mm
Material
Specification
15
108
46
163 12.7 97
1.8
Class 300
Valve
Size
15
140
78
163 12.7 97
Approx.
Weight
(kg)
117
50
2.5
20
153
85
3.8
25
127
56
3.4
25
165
94
5.1
40
165
75
8.5
40
9.5
50
178
84
12.2
50
216
84
15.2
65
191
77
18.5
65
241
83
26.0
203
99
23.0
80
283
99
32.6
100
42.6
100
150
90.0
150
403 179
121.0
200
457 206
170.0
200
502 231
210.0
Sl. No.
Par t
Body
Inser t
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
PTFE
PTFE
Gland Packing
Graphite
Graphite
Stem Seal
Insert Seal
2.5
20
80
12
Approx.
Weight
(kg)
XR Series
Carbon Steel
Pressure Testing
Specifications
Valve design
BS 5351
Fire test
Pressure testing
Stainless Steel
Test pressures
Ends
Shell
Class 150 (hydrostatic)
Class 300 (hydrostatic)
kg/cm2 (psi)
31.5 (450)
79.0 (1125)
59.0
Face-to-face dimensions
ASME B16.10
Seat
5.6
5.6
(80)
(80)
09
Valve
Size
94
Valve
Size
15
108
62
152 12.7 89
89 11.5
1.5
15
140
20
117
68
152 19.1 91
99 11.5
2.0
25
127
70
40
165
78
Approx.
Weight
(kg)
152 12.7 89
96
15
2.2
20
118
16
3.2
3.0
25
18
4.5
5.0
40
21
8.7
50
8.1
50
10.8
80
17.0
80
29
24.1
100
27.8
100
32
37.5
150
47.0
150
37
67.0
200
292 148
115.0
200
419 275
41
167.0
203.0
343 28.4
Approx.
Weight
(kg)
210
203.0
381
Material
Specification
Sl. No.
Par t
Carbon Steel
Stainless Steel
Body
Body Connector
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
Graphite
Graphite
Gland Packing
Graphite
Graphite
Stem Seal
Inser t
10
Insert gasket
Graphite
Graphite
Specifications
BS 5351
Fire test
Pressure testing
08
250
48
578
Approx.
Weight
(kg)
280
Test pressures
Ends
Shell
Class 150 (hydrostatic)
Class 300 (hydrostatic)
kg/cm2 (psi)
31.5 (450)
79.0 (1125)
Pressure Testing
Valve design
XF Series
Seat
5.6
5.6
(80)
(80)
be of fered on request)
End flange dimensions
13
Material Specification
Par t
Body &
Body Connector
ASTM A105 or
ASTMA216Gr.WCB
Ball
Seat
Stem
AISI 316
Body Seal
Graphite
Gland Packing
Stem Seal
Pressure Testing
Specifications
Ma x. cold working pressure
Valve design
Testing
BS 5159
API 598
Face-to-face dimensions
AIL Standard
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.
Material
Specification
Sl. No.
Par t
3XR
Carbon Steel
3FXR
Stainless Steel
Carbon Steel
Stainless Steel
ASTM A105
1
2
Body
ASTM A105 or
ASTM A351 Gr. CF8M
Body Connector ASTM A216 Gr. WCB
Ball
Seat
PTFE
PTFE
Stem
AISI 316
AISI 316
Body Seal
PTFE
Graphite
Gland Packing
Graphite
Stem Seal
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. AILs single-piece valves are
also available for cryogenic service with and without stem ex tensions.
Specifications
Pressure Testing
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
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)
Valve design
Testing
Face-to-face dimensions
Seat
5.6
(80)
NOTE
07
Three-piece design
3XR - Standard series
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
3HXR
Par t
Body
Body Connector
Ball
Seat
Acetal Resin
Stem
Body Seal
Nitrile Rubber
Gland Packing
Stem Seal
Nylon
Specifications
Ma x. cold
352kg/cm2 for liquids
working pressure 210kg/cm2 for gases (15-25mm)
168kg/cm2 for gases (40-50mm)
Dimensional Details
Screwed/Socket-weld end (in mm, unless specified)
Valve
Size
65
122
14.6 / 14.2
45
9.7
/4
0.6
/8
0.6
Valve
Size
25
60
76
12.7
40
76
81
12.7
50
81
81
16.0
Test pressures
Ends
Shell
(hydrostatic)
Seat
(air)
kg/cm2 (psi)
527.0 (7500)
5.6
(80)
45
9.7
/2
0.6
/4
0.8
1.6
107 149
43.1 / 42.7
65 12.7 11/4
2.5
40
116 181
49.2 / 48.7
75 12.7 11/2
3.3
50
128 181
61.7 / 61.1
80 15.9
4.1
77.8 85
22.2 / 21.8
32
9.7
12.7
122
59 12.7
50
60
67
34.3 / 33.8
47
50
15
149
9.7
95
S/W
end
85
45
25
E
Scr.
end
20
18.0 / 17.6
48 12.7
AIL Standard
122
27.6 / 27.1
S/W
end
15
65
122
Scr.
end
Face-to-face
dimensions
10
73
C
S/W
end
BS 5159
API 598
20
A
Scr.
end
Valve design
Testing
Pressure Testing
Approx.
Weight
(kg)
06
Class 150
A
Class 300
G
Class 600
Cl. 600
15
152 12.7 90
108
89 11.1 140
96
15
165
96
22
1.8
2.2
4.5
20
152 19.1 98
117
17
191 118
24
2.3
3.2
6.3
25
19
216 124
26
3.1
4.5
9.1
40
22
241 156
30
6.4
8.7
15.4
50
23
292 165
33
9.0
10.8
21.6
15
Material
Specification
Carbon Steel
Carbon Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Alloy 20
LCB
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
Gr.
Gr.
Gr.
Gr.
Gr.
Gr.
Gr.
WCB
CF8M
CF8
CF3M
CF3
CN7M
LCB
Material Specifications
Material
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
13% Cr. Steel
Monel
Hastelloy C
Alloy 20
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
Features
Description
Material
Aluminium Alloy
Pinnion
Steel
Seals
Nitrile Elastomer
Stainless Steel
Pinnion Bush
Springs
Spring Steel
SEATS
Material
Description
PTFE
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
Technical Specifications
Mounting standard
Ordering Information
ISO 5211
Pinnion top
NAMUR
Media
Filtered and
lubricated dry air
or inert gas
Temperature range
-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
16
A105
A216
A351
A351
A351
A351
A351
A352
Introduction
Pneumatic Actuators
Open - counterclockwise
Close - clockwise
Metal
Acetal Resin
BODY SEALS
Material
Description
PTFE
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
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 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.
LEAK TIGHT
STEM SEALING
stem
shoulder
stem
seal
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).
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.
VALVE OPERATION
MIRROR-FINISHED SS BALLS
04
Guide
Selection
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 AILs
manufacturing standard for reduced bore valves.
05DA
20DA
50DA
90DA
10DA
30DA
70DA
100DA
110DA
05SR50
20SR60
30SR80
70SR70
100SR70
05SR60
20SR70
50SR60
70SR80
100SR80
05SR80
20SR80
50SR70
90SR60
110SR60
10SR50
30SR50
50SR80
90SR70
110SR80
10SR80
30SR60
70SR50
90SR80
120SR70
20SR50
30SR70
70SR60
100SR60
120SR80
17
Technical Information
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
Manufacturing Program
Valve Type
REDUCED BORE
Standard
20
25
32
40
50
65
80
100
150
200
250
Reduced bore
10
28
39
71
104
208
303
623
882
1557
2569
Full bore
33
61
95
199
303
433
675
1002
1832
4366
8077
16003
BS 5159
3-piece
singlepiece
Fire-safe
BS 5351
BS 5351
Screwed/SW
Flanged 150/
300/600
SPECIAL
PURPOSE
VALVES
Flanged 150/
300/600
Flanged 150
Flanged 300
Standard
BS 5159
Fire-safe
BS 5351
3-piece
singlepiece
Valve Size
End
Connection
Screwed/SW
Fire-safe
2-piece
Valve Size
Compliance
2-piece
FULL BORE
18
Introduction
Pressure-Temperature Graphs
Fire-safe
BS 5351
Screwed
SW
Flanged 150
Flanged 300
Flanged 600
Flanged 150
Flanged 300
03
Introduction
ensur e
the
qualit y
of
products
manufactured.
Introduction
Page No.
03 - 05
06 - 09
10 - 13
14 & 15
14
14
14
15
15
15
16 & 17
Technical Information
AIL manufactures a wide variety of industrial
03
04
05
18
18
18
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
Global recognition
Ordering Information
19
International Clientele
19
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)
SERIES
3XR
3FXR
Chennai plant
32
50
65
OPERATOR
ENDS
Ball / Stem
T Virgin PTFE
L Lever Operated
NPT
- Screwed NPT
R R-PTFE*
P Pneumatic
816 WCB/A105
SS316
813 WCB/A105
SS304
X PEEK
866 CF8M
SS316
833 CF8
SS304
P Special filled
PTFE
SCT
3HXR
3CXR
3DT XR
3DLXR
3TT XR
3TLXR
817 WCB/A105
Monel
A Acetal Resin
867 CF8M
Monel
SS316L
8RR CF3
SS304L
C Seats for
Cr yogenic
Ser vice
8LL CF3M
20
25
SEAT
3XF
3FXF
10
15
Actuated
XR1
XR3
25
XF1
XF3
40
50
80
100
150
200
02
250
SERIES
16
13
66
33
17
67
LL
RR
AA
Ball / Stem
WCB/A105
WCB/A105
CF8M
CF8
WCB/A105
CF8M
CF3M
CF3
Alloy 20
SS316
SS304
SS316
SS304
Monel
Monel
SS316L
SS304L
Alloy 20
SEAT
OPERATOR
T Virgin PTFE
L Lever Operated
R R-PTFE*
W Wrench
X PEEK
G Gear Unit
P Special filled
PTFE
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.
19
Kancheepuram plant
AIL
BALL
VALVES
FLOATING BALL DESIGN
Maraimalai Nagar plant
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
REDUCED BORE
FULL BORE
Manufacturing Plants
BS 5351
Marketed by
BS 5159