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AIL CAST STEEL GATE, GLOBE & CHECK

VALVES

ASME Class 150 - 2500


50mm - 1500mm (2 - 60)

API 600 BS 1873 BS 1868 API 603 ASME B16.34 API 6D

AUDCO INDIA LIMITED

Introduction

AIL Cast Steel Gate, Globe and Check Valves have established themselves the world over for their quality, reliability and long service. The valves are manufactured to the latest international designs, using advanced manufacturing techniques and stringent quality control checks. The valves are regularly supplied to major Indian and international clients including oil refining companies and EPC contractors. A wide network of distributors ensures the availability of AIL valves anywhere in the world.

Table of Contents
AUDCO INDIA LIMITED (AIL) is a leading valve manufacturer, with a strong presence in India and overseas.
Content Page No.

Introduction

02 - 05
03 04 04 05 05

AIL has three manufacturing facilities located in Southern India. The main plant is located in Manapakkam, Chennai. The two other plants are at Maraimalai Nagar, 40 kilometres south and at Kancheepuram, 70 kilometres west of the main plant. The plants are equipped with modern manufacturing 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 calibration facilities with modern equipment provide support to ensure the quality of products manufactured.

Manufacturing Programme ................................................ Common Test / Inspection methods ................................. Test Pressures for standard Carbon Steel Valves ............ Compliance Standards ..................................................... Body / Bonnet Materials ...................................................

API 600 / BS 1873 / BS 1868 AIL Gate, Globe & Swing Check Valves

06 - 15

Salient Features ............................................................... 06, 07 Bonnet Gaskets ................................................................ 08 Trim Material ..................................................................... 09 Stem Packing .................................................................... 09 Ordering Information ......................................................... 09 Gate Valves (Cl 150, 300 & 600) ....................................... 10 Gate Valves (Cl 900 & 1500) ............................................. 11 Globe Valves (Cl 150, 300 & 600) ..................................... 12 Globe Valves (Cl 900 & 1500) ........................................... 13 Swing Check Valves (Cl 150, 300 & 600) .......................... 14 Swing Check Valves (Cl 900 & 1500) ................................ 15

API 603 AIL Stainless Steel Gate Valves

16 & 17
16 17

Salient Features ................................................................ Stainless Steel Gate Valves (Cl 150 & 300) ......................

ASME B16.34 AIL Gate, Y-Globe & Swing Check Valves

18 - 21

AIL manufactures a wide variety of industrial valves. The Quality Management System in all three plants is certified to ISO 9001:2000 System.

Salient Features ............................................................... 18, 19 Pr. Seal Bonnet Gate Valves (Cl 900, 1500 & 2500) ........ 20 Pr. Seal Bonnet Y-Globe Valves (Cl 1500) ....................... 21 Pr. Seal Bonnet Swing Check Valves (Cl 900, 1500 & 2500) 21

AIL Cryogenic Valves AIL Angle Globe Valves AIL Special Valves Technical Information

22 & 23 24 25 26 - 29

Pressure-Temperature Ratings ........................................ 26, 27 End Flange Dimensions-Cl 150 & 300 - RF ..................... 28 Large-sized End Flange Dimensions - Cl 150 & 300 - RF 28 End Flange Dimensions-Cl 600 - RF / RTJ ...................... 28 End Flange Dimensions-Cl 900 - RF / RTJ ...................... 28 End Flange Dimensions-Cl 1500 - RF / RTJ .................... 28 Butt-weld end Details and Dimensions ............................. 29 Cast Steel - Material Characteristics ................................ 29

AIL Valve Accessories Reputed Clientele

30 31

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 Conn. Flanged Buttweld ends Flanged Buttweld ends Flanged Buttweld ends Buttweld ends Buttweld ends 150 300 600 900 1500 150 300 600 900 1500 150 300 600 900 1500 150 300 600 900 1500 150 300 600 900 1500 150 300 600 900 1500 150 300 900 1500 2500 900 1500 2500 900 1500 2500 150 300 600 150 300 600 150 300 150 300 600 150 300 600 900 1500 150-900 1500
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Quality Policy

AIL Manufacturing Programme

Valve type

ASME 1 Class 2 2 /2 3 4 5 6 8 10 12 14 16 18 20 24 28 30 34 36 42 48 60
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API 600 & BS 1414

T H I C K N E S S

Gate Valves Bolted Bonnet Flex Wedge

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W A L L

Globe Valves Bolted Bonnet Plug/Ball type Disc

BS 1873

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D E S I G N S T A N D A R D API BS 1868 ASME B16.34 603

&

Check Valves Bolted Cover Swing type Disc

Gate Valves Bolted Bonnet Flanged Gate Valves Buttweld Pr. Seal Bonnet ends Parallel Slide Disc Globe Valves Pr. Seal Bonnet Plug type Disc Check Valves Pr. Seal Bonnet Swing type Cryogenic Gate Valves Cryogenic GlobeValves Angle Globe Valves Soft-seated Gate Valves

l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

CRYOGENIC

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V A L V E S

l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

O T H E R

SPECIALS

Live Loaded Gate / Globe Valves API 6D Gate Valves

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03

Introduction

Common Test / Inspection methods


Test / Inspection
Visual Inspection Chemical Analysis Mechanical Properties Radiographic Inspection Magnetic Particle Inspection Liquid Penetrant Inspection Ultrasonic Inspection Positive Material Identification (PMI) Pressure Testing* Dimensional Inspection ASTM E350 ASTM A370 ASME B16.34 ASTM E709 ASTM E165 ASTM A388 Vacuum emission spectrometer API 600/API 598/ BS 6755 Part I

Method

Acceptance Criteria
MSS SP55 Relevant ASTM Relevant ASTM ASME B16.34 ASME B16.34 ASME B16.34 ASME B16.34 Customer specification API 600/API 598/ BS 6755 Part I Valve Standard

AIL valves undergo a range of destructive and nondestructive tests according to the requirements of the Standard, service conditions and specific customer requirements.

* Performed on all valves. The pressure containing parts of all valves are marked with the foundry identification and heat numbers.

Test Pressures for standard Carbon Steel Valves


Every individual valve manufactured at AIL is inspected and pressure-tested to API 598 / BS 6755 Part I requirements, for which test certificates are provided. ASME Class Shell 150 300 600 900 1500 2500 32 (450) 79 (1125) 156 (2225) 236 (3350) 392 (5575) 652 (9275) Hydrostatic Test Pressure in kg/cm2 (psig) Back Seat 22 (315) 57 (815) 115 (1630) 172 (2445) 287 (4080) 477 (6790) Closure 22 (315) 57 (815) 115 (1630) 172 (2445) 287 (4080) 477 (6790) Pneumatic low pressure closure test pressure in kg/cm2 (psig) 7 (100) 7 (100) 7 (100) 7 (100) 7 (100)

7 (100)

Low Pressure Test for Swing Check Vlaves In addition to the high pressure closure test, Swing Check Valves are subjected to low pressure hydrostatic closure test at a pressure of 25% of the high pressure closure test. The duration of the test is the same as that of the high pressure closure test.

04

Introduction

Compliance Standards
Parameter
API 600 Gate Valve Globe Valve Check Valve API 603 Gate Valve ASME B16.34 Gate, Globe, Check Valves Pressure-Temperature rating Face-to-face / End-to-end dimension End Flange dimensions Butt-weld End dimensions Valve Inspection & Testing

Compliance
API 600 BS 1873* BS 1868* API 603 ASME B16.34 ASME B16.34 ASME B16.10 ASME B16.5** ASME B16.25 API 600, API 598, BS 6755 Part I

AIL has the distinction of having obtained a number of national and international approvals. Notable among these are :

ISO 9001:2000 certified Quality Management System Certified to use CE marking for supply to the European Union Specific company approvals from national and international oil majors and EPC contractors Indian Boiler Regulation (IBR) certification for all three plants.

The valves also comply with applicable BS specifications. * Shell wall thickness as per API 600 ** For valves larger than 24 (600mm), the flange drilling shall be as per ASME B16.47 Series A (MSS SP 44) or Series B (API 605). RTJ flanges are offered as optional for Class 600 and above.

Body / Bonnet Materials


AIL Cast Steel Gate, Globe and Check Valves are offered in a variety of body and bonnet materials to suit different requirements. These materials include Carbon Steel (standard), Alloy Steels and Stainless Steels. For other materials of construction, refer to AIL.

Material Classification
Carbon Steel 11/4 Cr - 1/2 Mo 2 /4 Cr - 1 Mo 5 Cr - /2 Mo 9 Cr - 1 Mo 9 Cr - 1 Mo - /4 V Low-temperature Steel Austenitic Stainless Steel 18-8 (Type 304) Austenitic Stainless Steel 16Cr - 12Ni - 2 Mo (Type 316)
1 1 1

ASTM Specification
ASTM A216 Gr. WCB ASTM A217 Gr. WC6 ASTM A217 Gr. WC9 ASTM A217 Gr. C5 ASTM A217 Gr. C12 ASTM A217 Gr. C12A ASTM A352 Gr. LCB/LCC ASTM A351 Gr. CF8 ASTM A351 Gr. CF8M

Working temperature*
-290C to 4270C (-200F to 8000F) -290C to 5930C (-200F to 11000F) -290C to 5930C (-200F to 11000F) -290C to 6490C (-200F to 12000F) -290C to 6490C (-200F to 12000F) -290C to 6490C (-200F to 12000F) -460C to 3430C (-500F to 6500F) -1960C to 6490C (-3200F to 12000F) -1960C to 6490C (-3200F to 12000F)

Other materials such as ASTM A351 Gr. CF3, ASTM A351 Gr. CF3M and Duplex SS are also offered.

* ASME pressure-temperature ratings on pages 26 & 27. Bolting & trim materials will influence the working temperature.

05

AIL Valves to API 600 / BS 1873 / BS 1868

AIL Gate, Globe & Check Valves


Bolted Bonnet / Cover design
The API 600 / BS 1873 / BS 1868 family of AIL Gate, Globe and Swing Check Valves is exceptionally sturdy, rugged and durable, with a reputation for quality, integrity and long service. They are designed for tight sealing and ease of operation. The valves are available with flanged ends or butt-weld ends, in pressure ratings from ASME Class 150 to Class 1500, and in a variety of materials of construction. Gate Valves are of flexible wedge, outside screwand-yoke and bolted-bonnet construction. The valves conform to API 600. Globe Valves feature a ball-type disc, outside screwand-yoke and bolted-bonnet construction. They conform to BS 1873 and also meet the general requirements of API 600, including shell wall thickness and stuffing box dimensions. Check Valves are of swing-type and bolted-cover construction. They conform to BS 1868 and also meet the general requirements of API 600, including shell wall thickness.
Body-Bonnet Joint The body-bonnet joint for Class 150 gate valves is oval in shape, while for Class 300 and for globe valves, this joint is circular in shape. In 2 (50mm) valves, the bodybonnet joint has a square configuration. Gate valves of Class 150 rating have a flatface joint with a graphite gasket having metallic inserts. Those of Class 300 rating have a male-female type joint with a spirallywound gasket. Gate valves of Class 600 rating and above have a Ring Type Joint (RTJ). Globe and Check valves in Class 150 and 300 ratings have a male-female type joint with a spirally-wound gasket. Those of Class 600 rating and above have an RTJ.

Square Joint

Body and Bonnet The body and bonnet are cast with uniform section and generous radius fillets to prevent stress concentration. The castings are precision-machined for high performance.

Circular Joint

The gate valve body has a straight through port without recesses except at the seat area. This ensures minimum turbulence, erosion and resistance to flow. Long integral guide ribs in the body match with guide slots in the wedge for accurate alignment and guidance. Bonnet castings are of one-piece design, where the yoke is integral with the bonnet for gate valves of sizes up to 12 (300mm). This ensures accurate alignment of stem and a smooth operation.

Back Seat In AIL gate and globe valves, a precisionmachined back-seat bush is threaded in the bonnet and is secured by a tab-weld.
tab tab weld

In globe valves of larger sizes and for higher pressure classes of ASME Class 900 and above, the internal part of the body is machined to provide continuous guiding of the disc from the open to the closed position.

Flexible Wedge AIL gate valves feature a one-piece cast flexible wedge that minimises stress concentration. Wedge flexibility ensures tight seating over a wide range of differential pressures and temperatures. It also adjusts to slight misalignments caused by pipeline deflections and thermal deformation. The stem-to-wedge thrust is applied close to the wedge centre. This reduces lateral stem loading and provides for more accurate wedge movement.

The check valve body provides a full port without pockets from inlet to the valve seat. On the downstream side, the body has generous proportions to facilitate full swing of the disc to reduce disc erosion and flow resistance.

06

Ball-type Disc AIL globe valves feature a ball-type disc that provides a fine grain surface on the taper seat. For severe services that demand hard-faced seats, a plug-type disc is provided.

Yoke Sleeve and Yoke Bush Cast in austenitic, copper-free ductile iron alloy to provide resistance to heat, corrosion and wear, the Yoke Sleeve in gate valves features a long thread engagement that assures accurate alignment of the stem. Moreover, it can be removed without replacing the bonnet. In gate valves of sizes 150mm and higher in Class 600 rating and above, the yoke sleeve is mounted on thrust bearings to facilitate easy operation. The Yoke Bush of globe valves is also made from ductile iron alloy, and has a long thread engagement for accurate stem alignment. In Class 900 and 1500 ratings, the valves have a yoke sleeve to facilitate smooth operation.

AIL Valves to API 600 / BS 1873 / BS 1868

Swing-type Disc Assembly The one-piece construction is securely fastened to the hinge by means of a lock nut and pin. The disc is free to rotate to avoid localized wear. The hinge pin offers excellent wear resistance properties.

Seat Ring AIL gate valves and check valves feature a seal-welded seat ring that offers a leakproof design as it eliminates the leakage path between the seat ring and the body. This design is superior to threaded seats which can loosen up due to temperature fluctuations, corrosion or vibration and result in leakage. Threaded seat rings are optional. For 50mm gate valves, the seat ring is flared into the body, while seal welding is optional. AIL globe valves feature a shoulder type, threaded body seat ring which has a wide taper area that provides for ample seating. Slots on the seat ring allow easy in-situ removal for servicing. Threaded seat rings are additionally secured by a tab-weld. Welded seat rings are also availble in AIL Globe Valves.

Stuffing Box The machined stuffing box chamber with a flat bottom allows correct sealing of the gland packing. Surface finish is controlled to required limits, to ensure low-emission performance. Stuffing boxes are provided with five numbers of gland packing to achieve correct compression of all packings and to ensure tight sealing. Valves in Class 300 rating and above feature a provision for a lantern ring arrangement for conditions that demand that there be no leakage of service fluid to the atmosphere. The lantern ring has a leakoff plug which allows connection for liquid or grease seal. See page 30 for more details on the lantern ring.

Stem AIL gate and globe valves feature a stem of one-piece construction, ACME threaded and precision-machined with polished surfaces to reduce friction, minimise leakage and extend stem life. In gate valves, the heavy forged T-head engages with the T-slot in the wedge. The stem also has an integral self-adjusting radial back-seat shoulder that matches with the back-seat bush in the bonnet. In globe valves, the stem is held to the disc by a stem nut that permits the disc to swivel. This free-floating design ensures uniform seating.

Flange Drilling and Facing finish The standard range of AIL flanged valves in sizes of up to 24 (600mm) is finished with end-flanges faced, drilled and spot-faced (or backfaced) to ASME B16.5 Raised Face (RF). Flanges in valves of sizes larger than 24 (600mm) are drilled as per ASME B16.47 Series A (MSS SP 44) or Series B (API 605). Valves in ASME Class 600 and above are offered with RTJ end flanges on request. The standard finish offered on the raised faces is 125-250 microns in Ra (AARH) Spiral Serration. Other finishes can be offered on request.

07

AIL Valves to API 600 / BS 1873 / BS 1868

Bonnet Gaskets
Valve ASME Type Class
150

Typical
Graphite Gasket with SS 316 insert

Optional
Spirally-wound SS 304 / SS 316 with Graphite or PTFE filler

300

Spirally-wound SS 316 with Spirally-wound SS 304 with Graphite filler Graphite filler Spirally-wound SS 304 / SS 316 with PTFE filler

Gate
600

Octagonal Ring Type (RTJ) Spirally-wound SS 304 with metal gasket in Soft Iron Octagonal Ring Type (RTJ) Graphite filler metal gasket in SS 304 / SS 316 Octagonal Ring Type (RTJ) metal gasket in Soft Iron Octagonal Ring Type (RTJ) metal gasket in Soft Iron Octagonal Ring Type (RTJ) metal gasket in SS 304 / SS 316 Octagonal Ring Type (RTJ) metal gasket in SS 304 / SS 316

900 1500 150 300

Spirally-wound SS 316 with Spirally-wound SS 304 with Graphite filler Spirally-wound SS 304 / Graphite filler SS 316 with PTFE filler Octagonal Ring Type (RTJ) Spirally-wound SS 304 with metal gasket in Soft Iron Graphite filler Octagonal Ring Type (RTJ) metal gasket in SS 304 / SS 316

Globe

600

900 1500 150 300

Octagonal Ring Type (RTJ) Octagonal Ring Type (RTJ) metal gasket in Soft Iron metal gasket in SS 304 / SS 316 Octagonal Ring Type (RTJ) Octagonal Ring Type (RTJ) metal gasket in Soft Iron metal gasket in SS 304 / SS 316 Spirally-wound SS 316 with Spirally-wound SS 304 with Graphite filler Graphite filler Spirally-wound SS 304 / SS 316 with PTFE filler

Check

600

900 1500

Octagonal Ring Type (RTJ) Spirally-wound SS 304 with metal gasket in Soft Iron Graphite filler Octagonal Ring Type (RTJ) metal gasket in SS 304 / SS 316 Octagonal Ring Type (RTJ) Octagonal Ring Type (RTJ) metal gasket in Soft Iron metal gasket in SS 304 / SS 316 Octagonal Ring Type (RTJ) Octagonal Ring Type (RTJ) metal gasket in Soft Iron metal gasket in SS 304 / SS 316

48-inch Class 150 Gate Valve

08

AIL Valves to API 600 / BS 1873 / BS 1868

Ordering Information
Valve Size mm (in)
50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24) 700 (28) 750 (30) 850 (34) 900 (36) 1050 (42) 1200 (48)
As a standard, AIL Valves are made in Carbon Steel to ASTM A216 Gr. WCB. For valves in other materials and for accessories like gear operation and electrical actuators, suffix suitable abbreviations to the above ordering code such as : WC6 for ASTM A217 Gr. WC6 WC9 for ASTM A217 Gr. WC9 LCB for ASTM A352 Gr. LCB LCC for ASTM A352 Gr. LCC C5 C12 for ASTM A217 Gr. C5 for ASTM A217 Gr. C12 GO for Gear Operation LA for Locking Arrangement E for Electrical Actuator EB for Extended Bonnet (Cryogenic valves) ES for Extension Spindle IBR for IBR Certification FSJ for Full Steam Jacket PSJ for Partial Steam Jacket

Valve Type

ASME Pr. Class


1 Class 150 3 Class 300 6 Class 600 9 Class 900 A Class 1500

End Connection
3 Flanged RF 5 Flanged RTJ 6 Butt-weld 1 2 5 8 9

Trim Number

1 Gate 4 Globe 7 Check

Refer table below on Trim Materials

10 12 16

Trim Materials
AIL Trim #
1 2 5 8 9 10 12 16

API 600 Trim #


1 2 5 8 9 10 12 16

Stem
13% Cr. SS 316 13% Cr. 13% Cr. Monel SS 316 SS 316 SS 316

Material of Construction Seat Wedge / Disc Seating Surface Surface


13% Cr. SS 304 HF* HF* Monel SS 316 HF* HF* 13% Cr. SS 304 HF* 13% Cr. Monel SS 316 SS 316 HF*

Back Seat
13% Cr. SS 316 13% Cr. 13% Cr. Monel SS 316 SS 316 SS 316@

@AIL Trim No. 16 will feature a back-seat of either SS 316 or SS 316 + HF* * HF : Hard-faced with Stellite #6 (Co-Cr-W alloy) or equivalent. Trim 12 valves comply with NACE MR 01 75 for hardness and heat treatment requirements of wetted components. Trim 8 valves can also be offered for NACE service on request.

Stem Packing
Construction
Die-formed flexible Graphite rings with braided Graphite top & bottom rings* Braided PTFE * AIL standard For other materials, refer to AIL.

Max. temp.

6490C (12000F)

2040C (4000F)

09

AIL Valves to API 600 / BS 1873 / BS 1868

Gate Valves - ASME Classes 150, 300 & 600


Figure Numbers 113-8, 133-8 & 163-8
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 BUTT-WELD END FLANGED END 13 14 15 16 17 18 19 20

Description
Body Body Seat Ring Wedge Stem Gasket - Cl.150 Gasket - Cl.300 & 600 Bonnet Stud Stud Nut Back-seat Bush Packing Gland Gland Flange Eye Bolt Eye Bolt Nut Groove Pin Yoke Sleeve (Stem Nut) Grease Fitting Retainer Nut Handwheel Handwheel Nut Nameplate

Material
ASTM A216 Gr. WCB ASTM A105 + HF* ASTM A216 Gr. WCB + 13% Cr. Steel ASTM A182 Gr. F6a ASTM A308 Spirally-wound SS 304 with graphite filler ASTM A216 Gr. WCB ASTM A193 Gr. B7 ASTM A194 Gr. 2H 13% Cr. Steel Graphite with braided end rings Steel ASTM A105 / ASTM A216 Gr. WCB Cr. - Mo Steel ASTM A194 Gr. 2H Steel ASTM A439 Type D2 Steel Steel / Ductile Iron / Malleable Iron SS 304

Dimensions (in mm, unless specified) & Weights (in kg)


Valve Size Fl.
50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24) 700 (28) 750 (30) 850 (34) 900 (36) 1050 (42) 1200 (48) 1500 (60) 178 191 203 229 254 267 292 330 356 381 406 432 457 508 610 610 711 711 813 864 1143

* HF - Hard-Faced with Stellite #6 or equivalent For other body / bonnet materials, refer page 5

Class 150 A B/W


216 241 283 305 381 403 419 457 502 572 610 660 711 813 991 914 1118 1118 -

Class 300 Approx.Wt. A Fl.


216 241 283 305 381 403 419 457 502 762 838 914 991 1143 1397 1727 -

Class 600 Approx.Wt. A Fl.


292 356 432 559 660 787 838 889 991 1092 1194 1397 2438 -

Approx.Wt. B/W
292 356 432 559 660 787 838 889 991 1092 1194 1397 -

B
376 480 480 584 750 790 996 1205 1410 1539 1752 1956 2159 2565 3160 3429 3650 3734 4200 4990 6175

C
203 229 229 254 254 305 356 406 457 508 508 610 610 686 762 762 762 762 -

Fl.
21 32 35 53 75 87 139 210 302 410 520 690 900 1410 2060 3100 3350 3980 * * *

B/W
19 27 27 43 64 77 118 198 271 365 490 665 865 1375 1750 2850 2950 3000 4500 6000 -

B/W
216 241 283 305 381 403 419 457 502 762 838 914 991 1143 1397 -

B
399 505 505 604 850 850 1039 1265 1460 1590 1791 2126 2261 2654 4267 3975 -

C
203 229 229 254 356 356 406 457 508 508 610 686 686 762 1016 -

Fl.
25 48 53 78 135 158 234 355 495 750 958 1310 1640 2460 4750 -

B/W
23 34 41 55 105 111 186 284 400 620 850 1075 1525 2075 -

B
399 541 635 874 1044 1285 1476 1565 2062 2062 3048 3150 4420 -

C
203 254 305 457 457 508 610 610 762 762 762 762 -

Fl.
42 67 119 252 418 652 1100 1600 1955 2075 2150 3620 -

B/W
36

63 112 225 365 554 984 1465 1760 1840 1960 3180 -

Fl. - Flanged ; B/W - Butt-weld. * Depends on flange dimensions. Intermediate sizes 22, 26, 32, 38, 40, 44, 46 in Class 150 are also offered. Class 600 gate valves can also be given in pressure seal bonnet design, in sizes from 80mm (3) up to 300mm (12). For details of pressure seal bonnet arrangement, see page 18.

10

AIL Valves to API 600 / BS 1873 / BS 1868

Gate Valves - ASME Classes 900 & 1500


Figure Numbers 193-8 & 1A3-8
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20

Description
Body Body Seat Ring Wedge Stem Gasket RTJ Bonnet Stud Stud Nut Back-seat Bush Packing Gland Gland Flange Eye Bolt Eye Bolt Nut Yoke Sleeve (Stem Nut) Bearing Yoke Cap Screw Handwheel Handwheel Nut Nameplate

Material
ASTM A216 Gr. WCB ASTM A105 + HF* ASTM A216 Gr. WCB + 13% Cr. Steel ASTM A182 Gr. F6a Soft Iron ASTM A216 Gr. WCB ASTM A193 Gr. B7 ASTM A194 Gr. 2H 13% Cr. Steel Graphite with braided end rings 13% Cr. Steel ASTM A105 / ASTM A216 Gr. WCB 13% Cr. Steel ASTM A194 Gr. 2H ASTM A439 Type D2 Steel Ductile Iron Steel Steel / Ductile Iron / Malleable Iron SS 304

FLANGED END

* HF - Hard-Faced with Stellite #6 or equivalent For other body / bonnet materials, refer page 5

GEAR UNIT ASSEMBLY

BUTT-WELD END

Dimensions (in mm, unless specified) & Weights (in kg)


Valve Size Fl.
50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 400 (16) 381 457 610 737 838 965 1130

Class 900 A B/W


381 457 610 737 838 965 700 800 1100 1500 1800 2000 2000 305 356 508 508 762 762 762

Class 1500 Approx.Wt. Fl.


138 216 426 723

A Fl.
368 470 546 705 832 991 1130 -

B B/W
368 470 546 705 832 991 1130 570 720 850 1200 1600 1950 2150 -

C
229 305 356 508 508 762 762 -

Approx.Wt. Fl.
128 255 315 643 1258 2008 2963 -

B/W
126 196 375 625

B/W
115 245 285 570 1120 1760 2580 -

1173 1040 1792 1610 2535 -

Fl. - Flanged ; B/W - Butt-weld. Sizes 18, 20 and 24 are also offered.

11

AIL Valves to API 600 / BS 1873 / BS 1868

Globe Valves - ASME Class 150, 300 & 600


Figure Numbers 413-8, 433-8 & 463-8
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

Description
Body Body Seat Ring Disc Disc Washer Stem Disc Stem Nut Gasket Bonnet Stud Stud Nut Back-seat Bush Packing Gland Gland Flange Eye Bolt Eye Bolt Nut Groove Pin Yoke Bush Handwheel Washer Handwheel Nut Nameplate

Material
ASTM A216 Gr. WCB ASTM A182 Gr. F6a+HF ASTM A216 Gr. WCB + 13% Cr. Steel 13% Cr. Steel ASTM A182 Gr. F6a 13% Cr. Steel ASTM A308 ASTM A216 Gr. WCB ASTM A193 Gr. B7 ASTM A194 Gr. 2H 13% Cr. Steel Graphite with braided end rings 13% Cr. Steel ASTM A105 / ASTM A216 Gr. WCB Cr. - Mo Steel ASTM A194 Gr. 2H Steel ASTM A439 Type D2 Steel / Ductile Iron / Malleable Iron Steel ASTM A563 Gr. B SS 304

FLANGED END

* HF - Hard-Faced with Stellite #6 or equivalent For other body / bonnet materials, refer page 5

BUTT-WELD END

Dimensions (in mm, unless specified) & Weights (in kg)


Class 150 Valve Size Fl.
50 (2) 65 (2 /2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12)
1

Class 300 Approx.Wt. A Fl. B/W


267 292 317 356 445 559 623 711 267 317 356 445 559

Class 600 Approx.Wt. A Fl.


292 356 432 559 661 787 838

A B/W
203 242 292 406 495 623

Approx.Wt. B
400 560 593 837 947 1285 1560

B
335 355 421 477 575 680 895

C
203 203 254 254 356 457 356 610

Fl.
23 35 41 66 118 207 335 495

B/W
20 38 62 110 195 320 470

B
355 410 457 556 668 830

C
203 203 254 356 457 610 610 762

Fl.
33 46 58 97 186 329 520 705

B/W
28 50 84 164 296 471 634

B/W
292 356 432 559 661 787 838

C
254 356 406 610 610 762 762

Fl.
42 75 136 245 546 756 1086

B/W
38 60 116 195 466 656 896

203 216 242 292 406 495 623 699

623 1206 711 1160

699 1215

Fl. - Flanged ; B/W - Butt-weld.

12

AIL Valves to API 600 / BS 1873 / BS 1868

Globe Valves - ASME Class 900 & 1500


Figure Numbers 493-8 & 4A3-8
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

Description
Body Body Seat Disc Disc Washer Stem Disc Stem Nut Gasket RTJ Bonnet Stud Stud Nut Back-seat Bush Spacer Packing Eye Bolt Eye Bolt Nut Gland Handwheel Handwheel Nut Retainer Nut Yoke Sleeve Bearing Nameplate

Material
ASTM A216 Gr. WCB Integral Stellite #6 or eq. ASTM A216 Gr. WCB + 13% Cr. Steel 13% Cr. Steel ASTM A182 Gr. F6a 13% Cr. Steel SS 316 ASTM A216 Gr. WCB ASTM A193 Gr. B7 ASTM A194 Gr. 2H 13% Cr. Steel 13% Cr. Steel Graphite with braided end rings ASTM A193 Gr. B7 ASTM A194 Gr. 2H 13% Cr. Steel Steel / Ductile Iron / Malleable Iron ASTM A439 Type D2 Steel SS 304

* HF - Hard-Faced with Stellite #6 or equivalent For other body / bonnet materials, refer page 5

FLANGED END

Dimensions (in mm, unless specified) & Weights (in kg)


Class 900 Valve Size Fl.
50 (2) 80 (3) 100 (4) 150 (6) 381 457 610

Class 1500 Approx.Wt. Fl. B/W


138 216 426 120 180 395

A B/W
381 467 610

B
700 800 1100

C
305 356 508

A Fl.
368 470 546 -

B B/W
368 470 546 590 720 850 -

C
305 305 356 -

Approx.Wt. Fl.
110 255 315 -

B/W
85 195 265 -

Fl. - Flanged ; B/W - Butt-weld.

13

AIL Valves to API 600 / BS 1873 / BS 1868

Swing Check Valves - ASME Class 150, 300 & 600


Figure Numbers 713-8, 733-8 & 763-8
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12

Description
Body Body Seat Ring Disc Hinge Disc Washer Disc Nut Disc Nut Pin Hinge Pin Gasket Cover Stud Stud Nut Hinge Pin Cover Hinge Pin Cover Bolt Nameplate

Material
ASTM A216 Gr. WCB ASTM A105 + HF* ASTM A216 Gr. WCB + 13% Cr. Steel ASTM A216 Gr. WCB 13% Cr. Steel SS 304 13% Cr. Steel 13% Cr. Steel ASTM A308 ASTM A216 Gr. WCB ASTM A193 Gr. B7 ASTM A194 Gr. 2H ASTM A105 ASTM A193 Gr. B7 SS 304

* HF - Hard-Faced with Stellite #6 or equivalent For other body / cover materials, refer page 5 FLANGED END

COVER FOR 3 VALVE (CLASS 600)

COVER & EYEBOLT ARRANGEMENT FOR 12 VALVE (CLASS 150)

COVER & EYEBOLT ARRANGEMENT FOR VALVES 14 & ABOVE (CLASS 150), VALVES 10 & ABOVE (CLASS 300) & VALVES 4 & ABOVE (CLASS 600)
A

BUTT-WELD END

Dimensions (in mm, unless specified) & Weights (in kg)


Class 150 Valve Size Fl.
50 (2) 65 (21/2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24) 203 216 241 292 356 495 622 698 788 864 978 978 1295

Class 300 A Fl.


267 317 356 444 533 622 711 839 864 978 1016 1346

Class 600 Approx.Wt. A Fl.


292 356 432 559 661 787 838 -

A B/W
203 216 241 292 356 495 622 698 788 864 978 978 1295

Approx.Wt. B
165 175 181 213 273 335 406 483 515 455 500 675 780

Approx.Wt. B/W
292 356 432 559 661 787 838 -

Fl.
21 24 34 49 88 168 280 413 509 580 635 925

B/W
19 20 30 42 79 154 260 382 466 524 583 855

B/W
267 317 356 444 533 622 711 839 864 978 1016 1346

B
165 190 229 279 343 368 412 559 636 562 675 790

Fl.
24 45 70 151 242 333 450 659 873 1090

B/W
19 36 56 129 210 284 378 556 747 900

B
178 203 229 365 442 450 590 -

Fl.
35 55 92 204 323 550 790 -

B/W
30 46 70 161 260 455 680 -

1360 1176 1850 1573

1500 1403

Fl. - Flanged ; B/W - Butt-weld.

14

AIL Valves to API 600 / BS 1873 / BS 1868

Swing Check Valves - ASME Class 900 & 1500


Figure Numbers 793-8 & 7A3-8
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 FLANGED END

Description
Body Body Seat Ring Disc Hinge Hinge Pin Disc Washer Disc Nut Disc Nut Pin Gasket RTJ Cover Stud Stud Nut Nameplate

Material
ASTM A216 Gr. WCB ASTM A105 + HF* ASTM A216 Gr. WCB + 13% Cr. Steel ASTM A216 Gr. WCB 13% Cr. Steel 13% Cr. Steel SS 304 SS 304 Soft Iron ASTM A216 Gr. WCB ASTM A193 Gr. B7 ASTM A194 Gr. 2H SS 304

* HF - Hard-Faced with Stellite #6 or equivalent For other body / cover materials, refer page 5

BUTT-WELD END

Dimensions (in mm, unless specified) & Weights (in kg)


Valve A Size
50 (2) 65 (2 /2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12)
1

Class 900 B B/W


381 457 610 737 838 965 381 457 610 737 838 965 250 280 350 420 510 610

Class 1500 Approx.Wt. Fl.


88 162 336 673 938 1480

A Fl.
368 470 546 705 832 991 1130

B B/W
368 470 546 705 832 991 1130 250 285 340 400 465 570 680

Approx.Wt. Fl.
69 118 177 566 892

Fl.

B/W
70 131 275 569 789 1280

B/W
53 89 134 467 728

1730 1447 2580 2157

Fl. - Flanged ; B/W - Butt-weld

15

AIL Valves to API 603

API 603 AIL Stainless Steel Gate Valves


Bolted Bonnet design
The API 603 family of AIL Stainless Steel Gate Valves is an economic alternative to API 600 Stainless Steel Gate Valves. They are available in flanged

construction and in pressure ratings of ASME Class 150 and Class 300. Gate Valves are of flexible wedge,outside screw-andyoke and bolted-bonnet construction.

Body and Bonnet The body and bonnet are cast with uniform section and generous radius fillets to prevent stress concentration. The castings are precision-machined for high performance.

Flexible Wedge The valves feature a one-piece cast flexible wedge that minimises stress concentration. Wedge flexibility ensures tight seating over a wide range

The gate valve body has a straight through port without recesses except at the seat area. This ensures minimum turbulence, erosion and resistance to flow. Long integral guide ribs in the body match with full-length guide slots in the wedge fo accurate alignment and guidance.

of

differential

pressures

and

temperatures. It also adjusts to slight misalignments caused by pipeline deflections and thermal deformation. The stem-to-wedge thrust is applied close to the wedge centre. This reduces lateral stem loading and provides for more accurate wedge movement.

Ordering Information
Valve Size mm (in)
50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12)
GO for Gear Operation LA for Locking Arrangement E for Electrical Actuator As a standard, API 603 Gate Valves are made of Stainless Steel ASTM A351 Grade CF8M. For accesories like gear operation and electrical actuators, suffix suitable abbreviations to the above ordering code such as :

Valve Type

ASME Pr. Class


1 Class 150 3 Class 300

End Connection
3 Flanged RF 10 12 16

Trim

3 Gate - API 603

Refer table on Trim Materials on page 9

16

AIL Valves to API 603

Stainless Steel Gate Valves - ASME Class 150 & 300


Figure Numbers 313-10 & 333-10
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

Description
Body Wedge Stem Gasket - Cl.150 Gasket - Cl.300 Bonnet Stud Stud Nut Spacer Packing Eye Bolt Eye Bolt Nut Gland Gland Flange Yoke Sleeve (Stem Nut) Grease Fitting Retainer Nut Handwheel Handwheel Nut Nameplate

Material
ASTM A351 Gr. CF8M ASTM A351 Gr. CF8M ASTM A182 Gr. F316 Graphite with SS 316 insert Spirally-wound SS 304 with graphite filler ASTM A351 Gr. CF8M ASTM A193 Gr. B8 Cl.2 ASTM A194 Gr. 8 SS 316 Graphite with braided end rings SS 316 ASTM A194 Gr. 8 SS 316 SS 316 ASTM A439 Type D2 SS 304 SS 304 ASTM A536 Gr. 60-40-18 / ASTM A602 Gr. M3210 SS 304 SS 304

* HF - Hard-Faced with Stellite #6 or equivalent

Dimensions (in mm, unless specified) & Weights (in kg)


Valve Size
50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12)

Class 150 A
178 203 229 267 292 330 356

Class 300 Approx.Wt.


18 26 44 66 110 158 225

B
385 495 610 820 1025 1250 1655

C
160 204 229 254 305 356 406

A
216 283 305 403 419 457 502

B
400 505 630 860 1060 1280 1780

C
204 229 254 356 406 457 508

Approx.Wt.
24 45 67 121 184 295 416

Fl. - Flanged ; B/W - Butt-weld

17

AIL Valves to ASME B16.34

ASME B16.34 AIL Gate, Y-Globe & Swing Check Valves


Pressure Seal Bonnet design
The ASME B16.34 family of AIL Gate, Y-Globe and Swing Check Valves features a pressure seal bonnet design for high pressure services. These valves are extensively used in high pressure and high temperature steam, oil, gas, chemical and water applications in thermal power plants, fertiliser plants, petrochemical plants and refineries. The valves are available with butt-weld ends in pressure ratings of Classes 900, 1500 and 2500, and come in carbon steel and alloy steel construction. Gate valves also meet the requirements of API 600 Style A.

GATE VALVES
Parallel Slide Disc Mechanism This mechanism consists of two independent discs held by a disc carrier. An alloy steel spring between the discs provides the initial loading to keep the discs pressed against the body seats. The disc faces are parallel to each other and seal on parallel seat rings in the body. Sealing takes place by utilizing the line pressure to provide tight seal on the downstream seat. As the two discs are independent and parallel, opening / closing torques are significantly lower than comparable wedge disc designs, thereby minimizing the possibility of jamming at high temperatures or pressures. When the valve is operated, the discs are allowed to slide and rotate over the body seats. This helps wipe out foreign particles from the seat faces. Yoke Sleeve and Thrust Bearings The yoke sleeve is made of nodular Niresist Iron, supported by a set of bearings to reduce friction and the consequent torque required to operate the valves. Nodular Niresist Iron also withstands high temperatures. Weather seals, provided in the yoke sleeve, protect the bearing area against ingress of dirt and water.

body seat ring spring discs

disc carrier

Pressure Seal arrangement for body-bonnet joint This pressure seal body-bonnet joint utilizes the line pressure to create a tight body-bonnet seal. Sealing is achieved by compressing a high-purity graphite gasket between the bonnet and the body retainer ring. Preloaded fasteners provide an initial tight seal at low line pressures. At higher pressures, the line pressure pushes up the bonnet against the gasket, compressing it further and providing a much tighter seal.

Seat Rings Body seat rings are welded to the body to offer a leakproof design as they eliminate the leakage path betwen the seat ring and the body. This design is superior to screwed seats which can loosen up due to temperature fluctuations, corrosion or vibration and result in leakage.

bonnet high-purity graphite gasket

Trim Both the disc and the seat ring faces are hard-faced with Stellite #6 or equivalent.

Back-seat The back-seat is in-situ hard-faced with Stellite #6 or equivalent.

Stem and Gland Packing The valves feature a stem, made of 13% Cr. Steel - ACME threaded, precision-machined and ground to a high finish to ensure a smooth operation. The high-purity graphite gland packings, used for stem sealing, provide capability to withstand high temperatures and pressures, and also to resist many chemicals. The smooth-finish stuffing box ensures longer life for the packings. Accessories AIL Valves can be supplied with accessories such as bypass arrangement, drain plugs, live-loading and mountings like extension spindles, floor stands and chain wheel. The valves can also be supplied with gear units and electrical actuators.

18

AIL Valves to ASME B16.34

Y-GLOBE VALVES
By virtue of their Y-type configuration, AIL Y-Globe Valves have a relatively straight flow and a lower pressure drop compared to conventional globe valves. The valves are suitable for tight shutoff and throttling in high pressure and high temperature lines. Some of the unique features of AIL Y-Globe Valves are :

Pressure Seal Bonnet Low operating torque due to use of thrust bearings Non-rotating stem Integrally-stellited body seats Fully-guided disc with Stellite seating and guiding surface Impactor handwheel in sizes of 6 (150mm) and above

SWING CHECK VALVES


AIL Swing Check Valves feature a pressure-seal body-cover joint and seal-welded seat rings. The seating surfaces are hard-faced with Stellite #6 or equivalent.

Swing-type Disc The disc is of swing-type design and is opened by line velocity and the resultant pressure. When the flow stops, the disc is closed by gravity. Seating load and the resultant tightness are dependent on the back pressure. As the disc is internally hinged, there is no opening in the body of the valve. This ensures high integrity. Installation AIL Swing Check Valves are used to prevent the reversal of flow in vertical, horizontal or inclined pipelines. These valves are to be used only for upward or horizontal flow. Pulsating flows, as obtained at the outlet of a reciprocating pump, would cause disc chatter and hence ought to be avoided. End Connection AIL Valves with butt-weld ends comply with ANSI B16.25 Fig. 2a or 3a, as applicable. For ANSI pipes, pipe schedule ought to be specified. For non-ANSI pipes, OD (or ID) and wall thickness ought to be furnished for end preparation.

Ordering Information
Valve Size mm (in)
50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24)

Valve Type

ASME Pr. Class


Gate Valve 81 Class 900 86 Class 1500 91 Class 2500 Globe Valve 66 Class 1500 Check Valve 80 Class 900 85 Class 1500 90 Class 2500
1

End Connection
/2 Butt-weld

Trim

Disc

3 Pressure Seal Bonnet / Cap

U Hard-faced

P Gate Valve Parallel Slide Disc S Globe Valve Standard

None for Check Valve


As a standard, AIL Valves are made in Carbon Steel to ASTM A216 Gr. WCB. For valves in other materials and for accesories like gear operation and electrical actuators, suffix suitable abbreviations to the above ordering code such as : GO for Gear Operation LA for Locking Arrangement WC6 for ASTM A217 Gr. WC6 ACT for Actuator WC9 for ASTM A217 Gr. WC9 BP for Bypass C12 for ASTM A217 Gr. C12 IBR for IBR-certified

19

AIL Valves to ASME B16.34

Pr. Seal Bonnet Gate Valves - ASME Class 900, 1500 & 2500
Figure Numbers 3811/2UP, 3861/2UP & 3911/2UP

Standard Materials of Construction


Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

Description
Body Body Seat Ring Disc Bonnet Stem Yoke Yoke Sleeve Packing Spring Gasket Stud Stud Nut Gland Stud Gland Nut Thrust Ball Bearing Handwheel Nameplate ASTM A216 Gr. WCB

Material
ASTM A217 Gr. WC6 ASTM A217 Gr. WC9

ASTM A216 ASTM A217 ASTM A217 Gr. WCB+HF* Gr. WC6+HF* Gr. WC9+HF* ASTM A216 ASTM A217 ASTM A217 Gr. WCB+HF* Gr. WC6+HF* Gr. WC9+HF* ASTM A216 Gr. WCB ASTM A217 Gr. WC6 ASTM A217 Gr. WC9

13% Cr. Steel ASTM A216 Gr. WCB ASTM A439 Type D2 Graphite with braided end rings Inconel X750 / Nimonic 90 Graphite ASTM A193 Gr. B7 ASTM A194 Gr. 2H ASTM A193 Gr. B7 ASTM A194 Gr. 2H Steel Steel / Malleable Iron / SG Iron SS 304

* HF - Hard-Faced with Stellite #6 or equivalent Class 900 and Class 1500 gate valves can also be offered in flexible wedge design for the full range. For details of flexible wedge arrangement, refer Page 6.

Dimensions (in mm, unless specified) & Weights (in kg)


Valve A
216 305 356 508 660 787 914 991 1092 * * *

Class 900 B
470 580 730 890 1040 1540 1785 1825 2050 * * *

Class 1500 Approx.Wt.


45 55 95 190 350 710 1000 1145 * * * *

Class 2500 Approx.Wt.


45 60 105 230 440 850 1045 * * * * *

Size
50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24)

C
229 305 356 508 686 762 762 762 762 * * *

A
216 305 406 559 711 864 991 1067 1194 1346 1473 *

B
470 580 730 890 1375 1540 1720 1730 2100 2150 2500 *

C
229 305 356 508 508 762 762 762 762 762 762 *

A
279 368 457 610 762 914 1041 1118 1245 1397 *

B
450 710 720 925 1370 1490 1690 1850 2050 2300 *

C
229 457 457 610 762 762 762 762 762 762 *

Approx.Wt.
50 120 140 305 685 1270 1895 * * * *

* Refer to AIL 2 valves are in flexible wedge design. Valves in sizes of 10 and above in Class 900 and, 8 and above in Classes 1500 and 2500 are supplied with gear unit.

20

AIL Valves to ASME B16.34

Pr. Seal Bonnet Y-Globe Valves - ASME Class 1500


Figure No. 3661/2US
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08 09

Description
Body Bonnet Disc Stem Packing Yoke Gasket Stud Stud Nut Nameplate

Material
ASTM A216 ASTM A217 ASTM A217 Gr. WCB+HF* Gr. WC6+HF* Gr. WC9+HF* ASTM A216 ASTM A217 ASTM A217 Gr. WCB Gr. WC6 Gr. WC9 SS 410 Hard-Faced with Stellite #6 or equiv. ASTM A479 Type 410 Graphite with braided end rings ASTM A216 Gr. WCB Graphite ASTM A193 Gr. B7 ASTM A194 Gr. 2H SS 304

B - OPEN (Max.)

* HF - Seat Hard-Faced with Stellite #6 or equivalent

Dimensions (in mm, unless specified)


Valve Size
80 (3) 100 (4) 150 (6) 200 (8)

Class 1500** A
470 546 705 832

B
650 875 1210 2000

C
508 508 762 762

Approx.Wt.
? ? ? ?
A

** Refer to AIL for dimensions of 10 and 12 sizes and of Class 2500 valves.

Pr. Seal Cover Swing Check Valves - ASME Class 900, 1500 & 2500
Figure Nos. 3801/2U, 3851/2U & 3901/2U
Standard Materials of Construction
Sl. No.
01 02 03 04 05 06 07 08

Description
Body Cover Disc Seat Ring Hinge Pin Gasket Stud Stud Nut Nameplate

Material
ASTM A216 ASTM A217 ASTM A217 Gr. WCB Gr. WC6 Gr. WC9 ASTM A216 ASTM A217 ASTM A217 Gr. WCB+HF* Gr. WC6+HF* Gr. WC9+HF* 13% Cr. Steel Graphite ASTM A193 Gr. B7 ASTM A194 Gr. 2H SS 304

* HF - Seat Hard-Faced with Stellite #6 or equivalent

Dimensions (in mm, unless specified) & Weights (in kg)


Class 900 Valve Size
50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 500 (20) * Refer to AIL

Class 1500 A
216 305 406 559 711 864 991 1067 1194 *

Class 2500 A
279 368 457 610 762 914 1041 * * -

A
991 -

B
630 -

Approx.Wt.
780 -

B
240 275 275 310 415 500 605 630 750 *

Approx.Wt.
35 45 62 110 250 435 600 875 * *

B
240 240 300 360 485 615 665 * * -

Approx.Wt.
40 55 80 180 320 945 1135 * * -

21

AIL Cryogenic Valves


22

AIL Cryogenic Gate & Globe Valves


Services that handle fluids at sub-zero temperatures present several technical challenges. AILs specially-adopted, extended-bonnet gate and globe valves provide the right solution for such low-temperature and cryogenic services. AIL offers a range of gate and globe valves (as well as check valves) for low temperature and cryogenic services, used in processing, storage and transportation of liquefied gases such as Ethylene, LPG, LNG, Hydrogen, Helium, Oxygen, Nitrogen and Argon. Low temperature services of up to -460C are covered by low-temperature carbon steels like LCB and LCC materials. Cryogenic services at -1960C are covered by stainless steel grades like CF8M and CF8. AIL Cryogenic Gate and Globe Valves are available in ASME Class 150, Class 300 and Class 600 ratings. Refer page 3 for detailed manufacturing programme.
Extended Bonnet Optional extended bonnet with vapour column length according to BS 6364 and / or customer specifications is furnished. The vapour column allows the stem packing to be functional by keeping it away from the cryogenic fluid. Testing and Standards AIL Cryogenic Valves are type-tested as per valve standards and specifications of leading oil companies as part of the design verification process.

Test facilities
AIL has Cryogenic test facilities for testing valves of temperatures as low as -1960 in sizes from 50mm (2) to 1500mm (60). This ranks one among the largest facilities in the worldwide.

Cryogenic Gate Valves - ASME Classes 150, 300 & 600


Parts List
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

AIL Cryogenic Valves

Description
Body Body Seat Ring Wedge Stem Gasket Bonnet Stud Stud Nut Back Seat Packing Gland Yoke Sleeve Grease Fitting Retainer Nut Handwheel Handwheel Nut Nameplate

Materials of construction are selected, based on the service fluid, temperature and customer specifications.

For dimensions of A and C, refer page 10 for corresponding tables under API 600 range of valves. Dimension B will be as per customer requirement.

Cryogenic Globe Valves - ASME Classes 150, 300 & 600


Parts List
Sl. No.
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

Description
Body Body Seat Ring Disc Disc washer Stem Disc Stem Nut Gasket Bonnet Stud Stud Nut Back Seat Packing Gland Handwheel Handwheel Yoke Bush Nameplate

For dimensions of A and C, refer page 12 for corresponding tables under API 600 range of valves. Dimension B will be as per customer requirement.

Materials of construction are selected, based on the service fluid, temperature and customer specifications.

23

AIL Angle Globe Valves to BS 1873

Angle Globe Valves - ASME Class 150 & 300


AIL Cast Steel Angle Globe Valves are tight sealing, easy-to-operate regulation valves for liquid and gaseous fluids over a wide range of line pressures and temperatures. Angle Globe Valves operate in a manner similar to that of a globe valve. However, the 900 angle between the inlet and outlet pipes greatly reduces the pressure drop across the valve as compared to a conventional globe valve. These valves are used for flow control especially in systems where valve geometry or pressure drop is a concern.
Body and Bonnet The flow to the body outlet is streamlined by the smooth curvature of the inner surface which minimises the pressure drop across the flow path. The bonnet is fitted with a bonnet bush to guide the stem and provide for back seating when the valve is open and under pressure. Disc and Stem The disc provides a fine bearing on a taper seal for tight sealing over a wide range of differential pressures. As the seating between disc and body seat ring is a narrow line contact, tight sealing can be achieved even if any foreign particle gets stuck to the seating area. The disc and stem are held together by a disc nut with allowance for the disc to swivel. The disc has internal threads to receive the disc nut which retains the stem with the disc. A stem thrust plate is provided between the stem and the disc. Body Seat Ring A forged shoulder type body seat ring has threaded engagement with the body and a widetapered seating area. The body seat ring is tack welded to the body to prevent loosening. The seating surfaces are ground and lapped.

Test Pressures
Class 150 Class 300 Hydrostatic
Body Seat (Closure) Back Seat

bar psig
31 22 22 450 315 315

bar
78 56 56

psig
1125 815 815

Materials of Construction
Sl. No.
01. 02. 03. 04.

Description
Body Bonnet Stem Disc

Material
ASTM A216 Gr. WCB ASTM A216 Gr. WCB ASTM A182 Gr. F6A/SS316/ AISI 410 AISI 410 / ASTM A 217 Gr. CA15 / ASTM A216 Gr. WCB with Stellite AISI 410 / ASTM A 217 Gr. CA15 / ASTM A182 Gr.F6a / ASTM A182 Gr. F6a + Stellite / ASTM A105 + Stellite ASTM A439 Type D2 Graphite
C TACK WELD A

05. 06. 07. 08. 09. 10. 11. 12.

Seat Ring Yoke Bush Stem Packing Handwheel Gasket Back Seat Bush Studs Stud Nuts

SG Iron or Malleable Iron or Steel SWG with Graphite filler only AISI 410 / 420 ASTM A193 Gr. B7 ASTM A194 Gr. 2H

Dimensional Details (in mm, unless specified)


Valve Size
mm
50 80 100 150 200 250 300

Class 150
A
102 121 146 203 248 311 349

Class 300
A B C

inches
2 3 4 6 8 10 12

End Connection Offered with flanged and butt weld ends to the following standards : Flanged : ASME / ANSI B16.5 Raised Face (RF) Serrated spiral to 125 to 250 Ra (AARH) : ASME / ANSI B16.25 to suit the corresponding pipe schedule

339.0 203.0 133 346.6 203.0 423.9 254.0 159 465.5 254.0 493.7 254.0 178 568.5 254.0 560.5 356.0 222 680.5 457.0 663.8 457.0 279 821.6 610.0 790.7 610.0 311 917.5 762.0 934.5 610.0 356 1200.2 762.0

Butt Weld

Standards Valve Design : BS 1873 Shell Wall thickness : BS 1873 Face to Face : ASME/ANSI B16.10 Pressure temperature Ratings : ASME/ANSI B16.34 Pressure testing : API 598

Valves can also be offered with IBR Certification.

* Gear-operated

24

AIL Special Valves

AIL Special Valves


Live-loaded Valves
The stem packing system in a valve prevents leakage of line fluid to the atmosphere. The effectiveness of the sealing performance of the stem / gland packing depends on several factors such as dimensional tolerance and surface finish of the stem and packing chamber, packing material and its resilience, and packing pressure. In a conventional valve, packing consolidation takes place and the packing pressure gets reduced in service, resulting in the possibility of leakage. Tightening of the gland nut restores the packing pressure and arrests possible leakage. This adjustment restores the effectiveness of the packing sealing. In a live-loaded arrangement, the packing pressure or the load is maintained at a relatively constant level as the packing consolidates during service. Achieved by means of a set of Disc Springs or Belleville Springs that is installed between the gland flange and the gland stud, this creates additional elasticity in the gland loading system. The precompression load applied on the Disc Springs ensures that the load required for leak-tight sealing is exerted on the packing, even after relaxation or consolidation of packing. This continuous in-service self-adjustment results in superior stem sealing performance, particularly in services where pressure / temperature fluctuation or cycling is frequent.

Soft-seated Valves
In applications that require positive shut-off such as in chemical and petrochemical services, the AIL Soft-seated Gate Valve is a suitable solution. PTFE seat inserts provide the necessary soft-seating to ensure positive shut-off.

Salient features of these valves are :

PTFE seat inserts for positive shut-off Block-and-Bleed capability Dual seating (metallic and soft seats) Intrinsically fire-safe Bubble-tight performance
All API 600 AIL gate valves can be offered with the option of soft-seating for sizes up to 10 (250mm).

Low-emission Service Valves


To comply with the requirements for Clean Air Act, AIL Cast Steel Valves have undergone extensive in-house testing, using Compressed Natural Gas (CNG) at the full-rated pressure as a test medium, as well as Helium in accordance with ISA standards. Based on proven experience over the years, AIL has established appropriate design parameters and manufacturing methods to offer valves that meet stringent fugitive emission norms as per industry practices.

API 6D Through-Conduit Gate Valves


AIL offers a special range of API 6D Through-Conduit Gate Valves for applications such as flow lines, manifolds, pipeline transmission and distribution, pressure regulation and metering runs, underground storage and general pipeline service. These valves are available in the following ranges : 2 (50mm) - 30 (750mm) in ASME Class 150 to Class 900 2 (50mm) - 16 (400mm) in ASME Class 1500

Salient features of these valves are :

Gland Packing of high-purity, flexible graphite, sandwiched


between braided graphite end-rings with Inconel wire mesh reinforcement. On request, gland packing with conical / wedgeshaped configuration can also be offered.

Bonnet gasket in valves of ASME Class 150 is made of graphiteSS 316 insert. Valves of ASME Class 300 feature gaskets of spirally-wound stainless steel with graphite filler. In valves of ASME Class 600 and higher, metallic ring gaskets are offered.

Important features of these valves are :

Through conduit, full-bore (piggable) or


reduced-bore

The stem finish is 16-32 RMS, with a straightness of 0.001 0.005 over the length of the plain shank. Cylindricity is controlled as per AIL standards.

Valve seat with PTFE inserts for bubbletight seal

The Stuffing Box surface finish is 180 RMS max., and its
straightness is controlled as per AIL standards.

Self-relieving seat ring Different options available for stem


packing system

The diametrical clearances between the stem, gland and the


stuffing box are controlled to close tolerances to ensure compliance with emission norms.

Valves for special services


AIL offers a wide variety of valves for special applications that call for additional design features and special testing.

Valves for Hydrogen service which are pressure tested with Helium Valves for Dowtherm service Valves for sour gas services, conforming to NACE specifications of different Indian and overseas customers
and consultants

Valves for Chlorine service, having special trims like Monel or Hastelloy C Valves for nuclear applications requiring designs to withstand seismic disturbances, quick operation and special
features to avoid external leakage to atmosphere

Bellow Seal Gate and Globe valves Y-type Stop Check Valves

25

Technical Information

Pressure-Temperature Ratings - ASME B16.34, 1996


Temp in 0F Temp. in 0C ASTM A216 Gr. WCB** (Standard Class) #150
285 260 230 200 170 140 125 110 95 80 65 50 35 20 -

ASTM A217 Gr. WC6 (Standard Class) #2500


6170 5625 5470 5280 4990 4560 4475 4440 4200 3430 2230 1430 860 430 -

#300
740 675 655 635 600 550 535 535 505 410 270 170 105 50 -

#600
1480 1350 1315 1270 1200 1095 1075 1065 1010 825 535 345 205 105 -

#900
2220 2025 1970 1900 1795 1640 1610 1600 1510 1235 805 515 310 155 -

#1500
3705 3375 3280 3170 2995 2735 2685 2665 2520 2060 1340 880 515 260 -

#150
290 260 230 200 170 140 125 110 95 80 65 50 35 20 *20 *20 *20 *15

#300
750 750 720 695 665 605 590 570 530 510 485 450 320 215 145 95 60 40

#600
1500 1500 1445 1385 1330 1210 1175 1135 1065 1015 975 900 640 430 290 190 125 75

#900
2250 2250 2165 2080 1995 1815 1765 1705 1595 1525 1460 1350 955 650 430 290 185 115

#1500
3750 3750 3610 3465 3325 3025 2940 2840 2660 2540 2435 2245 1595 1080 720 480 310 190

#2500
6250 6250 6015 5775 5540 5040 4905 4730 4430 4230 4060 3745 2655 1800 1200 800 515 315

-20 to 100 -28.9 to 37.7 200 93.3 300 148.9 400 204.4 500 260.0 600 315.5 650 343.3 700 371.7 750 398.9 800 426.6 850 454.4 900 482.2 950 510.0 1000 537.8 1050 565.5 1100 593.3 1150 621.1 1200 648.9

Working Pressure in psig Temp in 0F Temp. in 0C ASTM A216 Gr. WC9 (Standard Class) #150
290 260 230 200 170 140 125 110 95 80 65 50 35 20 *20 *20 *20 *20

ASTM A216 Gr. C5 (Standard Class) #2500


6250 6250 6070 5880 5540 5040 4905 4730 4430 4230 4060 3745 3145 2170 1455 915 570 345

#300
750 750 730 705 665 605 590 570 530 510 485 450 375 260 175 110 70 40

#600
1500 1500 1455 1410 1330 1210 1175 1135 1065 1015 975 900 755 520 350 220 135 80

#900
2250 2250 2185 2115 1995 1815 1765 1705 1595 1525 1460 1350 1130 780 525 330 205 125

#1500
3750 3750 3640 3530 3325 3025 2940 2840 2660 2540 2435 2245 1885 1305 875 550 345 205

#150
290 260 230 200 170 140 125 110 95 80 65 50 35 20 *20 *20 *20 *20

#300
750 745 715 705 665 605 590 570 530 510 485 370 275 200 145 100 60 35

#600
1500 1490 1430 1410 1330 1210 1175 1135 1055 1015 965 740 550 400 290 200 125 70

#900
2250 2235 2150 2115 1995 1815 1765 1705 1585 1525 1450 1110 825 595 430 300 185 105

#1500
3750 3725 3580 3530 3325 3025 2940 2840 2640 2540 2415 1850 1370 995 720 495 310 170

#2500
6250 6205 5965 5880 5540 5040 4905 4730 4400 4230 4030 3085 2285 1665 1200 830 515 285

Working Pressure in psig Temp in 0F Temp. in 0C ASTM A352 Gr. LCB (Standard Class) #150
265 250 230 200 170 140 125 110 95 80 65 50 35 20

ASTM A352 Gr. LCC (Standard Class) #2500


5785 5470 5315 5145 4850 4440 4355 4320 3945 3260 2230 1430 860 430

#300
695 655 640 620 585 535 525 520 475 390 270 170 105 50

#600
1390 1315 1275 1235 1165 1065 1045 1035 945 780 535 345 205 105

#900
2085 1970 1915 1850 1745 1600 1570 1555 1420 1175 805 515 310 155

#1500
3470 3280 3190 3085 2910 2665 2615 2590 2365 1955 1340 860 515 260

#150
290 260 230 200 170 140 125 110 95 80 65 50 35 20

#300
750 750 730 705 665 605 590 570 505 410 270 170 105 50

#600
1500 1500 1455 1410 1330 1210 1175 1135 1010 825 535 345 205 105

#900
2250 2250 2185 2115 1995 1815 1765 1705 1510 1235 805 515 310 155

#1500
3750 3750 3640 3530 3325 3025 2940 2840 2520 2060 1340 860 515 260

#2500
6250 6250 6070 5880 5540 5040 4905 4730 4200 3430 2230 1430 860 430

Working Pressure in psig Temp in 0F Temp. in 0C ASTM A351 Gr. CF8 (Standard Class) #150
275 230 205 180 170 140 125 110 95 80 65 50 35 20 *20 *20 *20 *20 *20 *20 *20 *20 *15 *10

ASTM A351 Gr. CF8M (Standard Class) #2500


6000 5000 4500 4140 3880 3640 3580 3540 3460 3360 3300 3240 3180 2675 2570 2145 1655 1285 945 715 515 400 285 230

#300
720 600 540 495 465 435 430 425 415 405 395 390 380 320 255 200 155 115 85 60 50 35 25

#600
1440 1200 1080 995 930 875 860 850 830 805 790 780 765 640 615 515 400 310 225 170 125 95 70 55

#900
2160 1800 1620 1490 1395 1310 1290 1275 1245 1210 1190 1165 1145 965 925 770 595 465 340 255 185 145 105 80

#1500
3600 3000 2700 2485 2330 2185 2150 2125 2075 2015 1980 1945 1910 1605 1545 1285 995 770 565 430 310 240 170 135

#150
275 235 215 195 170 140 125 110 95 80 65 50 35 20 *20 *20 *20 *20 *20 *20 *20 *20 *20 *20

#300
720 620 560 515 480 450 445 430 425 420 420 415 385 350 345 305 235 185 145 115 95 75 60 40

#600
1440 1240 1120 1025 955 900 890 870 855 845 835 830 775 700 685 610 475 370 295 235 190 150 115 85

#900
2160 1860 1680 1540 1435 1355 1330 1305 1280 1265 1255 1245 1160 1050 1030 915 710 555 440 350 290 225 175 125

#1500
3600 3095 2795 2570 2390 2255 2220 2170 2135 2110 2090 2075 1930 1750 1720 1525 1185 925 735 585 480 380 290 205

#2500
6000 5160 4660 4280 3980 3760 3700 3620 3560 3520 3480 3460 3220 2915 2865 2545 1970 1545 1230 970 800 630 485 345

26

* For weld-end valves only. Flanged-end ratings terminate at 10000F.

-20 to 100 -28.9 to 37.7 93.3 200 148.9 300 204.4 400 260.0 500 315.5 600 343.3 650 371.7 700 398.9 750 426.6 800 454.4 850 482.2 900 510.0 950 537.8 1000 565.5 1050 593.3 1100 621.1 1150 648.9 1200 676.7 1250 704.4 1300 732.2 1350 780.0 1400 787.8 1450 815.6 1500

Not to be used over 6500F.

-20 to 100 -28.9 to 37.7 93.3 200 148.9 300 204.4 400 260.0 500 315.5 600 343.3 650 371.7 700 398.9 750 426.6 800 454.4 850 482.2 900 510.0 950 537.8 1000

* For weld-end valves only. Flanged-end ratings terminate at 10000F.

-20 to 100 -28.9 to 37.7 93.3 200 148.9 300 204.4 400 260.0 500 315.5 600 650 343.3 371.7 700 398.9 750 426.6 800 454.4 850 482.2 900 510.0 950 537.8 1000 565.5 1050 593.3 1100 621.1 1150 648.9 1200

* For weld-end valves only. Flanged-end ratings terminate at 10000F. ** Not recommended for prolonged use above 8000F (4250C).

Working Pressure in psig

Technical Information

Pressure-Temperature Ratings - ASME B16.34, 1996


Working Pressure in psig Temp in 0F Temp. in 0C ASTM A217 Gr. C12 (Standard Class) #150
290 260 230 200 170 140 125 110 95 80 65 50 35 20 *20 *20 *20 *20

#300
750 750 730 705 665 605 590 570 530 510 485 450 375 255 170 115 75 50

#600
1500 1500 1455 1410 1330 1210 1175 1135 1065 1015 975 900 755 505 345 225 150 105

#900
2250 2250 2185 2115 1995 1815 1765 1705 1595 1525 1460 1350 1130 760 515 340 225 155

#1500
3750 3750 3640 3530 3325 3025 2940 2840 2660 2540 2435 2245 1885 1270 855 565 375 255

#2500
6250 6250 6070 5880 5540 5040 4905 4730 4430 4230 4060 3745 3145 2115 1430 945 630 430

Temp in 0F

Temp. in 0C

ASTM A216 Gr. WCB** (Special Class) #150


290 290 290 290 290 275 270 265 240 200 130 85 50 25 -

ASTM A217 Gr. WC6 (Special Class) #2500


6250 6250 6250 6250 6250 5940 5825 5780 5250 4285 2785 1785 1070 535 -

#300
750 750 750 750 750 715 700 695 630 515 335 215 130 65 -

#600
1500 1500 1500 1500 1500 1425 1400 1390 1260 1030 670 430 260 130 -

#900
2250 2250 2250 2250 2250 2140 2100 2080 1890 1545 1005 645 385 195 -

#1500
3750 3750 3750 3750 3750 3565 3495 3470 3150 2570 1670 1070 645 320 -

#150
290 290 290 290 290 290 290 280 280 275 260 225 155 105 70 45 30 20

#300
750 750 750 750 750 750 750 735 730 720 680 585 400 270 180 120 75 45

#600
1500 1500 1500 1500 1500 1500 1500 1465 1460 1440 1355 1175 795 540 360 240 155 95

#900
2250 2250 2250 2250 2250 2250 2250 2200 2185 2160 2030 1760 1195 810 540 360 230 140

#1500
3750 3750 3750 3750 3750 3750 3750 3665 3645 3600 3385 2935 1995 1350 900 600 385 235

#2500
6250 6250 6250 6250 6250 6250 6250 6110 6070 6000 5645 4895 3320 2250 1500 1000 645 395

-20 to 100 -28.9 to 37.7 200 93.3 300 148.9 400 204.4 500 260.0 600 315.5 650 343.3 700 371.7 750 398.9 800 426.6 850 454.4 900 482.2 510.0 950 1000 537.8 565.5 1050 1100 593.3 1150 621.1 1200 648.9

Working Pressure in psig Temp in 0F Temp. in 0C ASTM A217 Gr. WC9 (Special Class) #150
290 290 285 280 275 275 275 275 265 260 245 230 180 125 85 55 35 25

ASTM A352 Gr. LCB@ (Special Class) #2500


6250 6250 6180 6035 6000 6000 5965 5930 5750 5605 5355 5000 3930 2715 1820 1145 715 430

#300
750 750 740 725 720 720 715 710 690 675 645 600 470 325 220 135 85 50

#600
1500 1500 1485 1450 1440 1440 1430 1425 1380 1345 1285 1200 945 650 435 275 170 105

#900
2250 2250 2225 2175 2160 2160 2145 2135 2070 2020 1930 1800 1415 975 655 410 255 155

#1500
3750 3750 3705 3620 3600 3600 3580 3555 3450 3365 3215 3000 2355 1630 1095 685 430 255

#150
265 265 265 265 265 265 260 255 190 130 85 50 25 -

#300
695 695 695 695 695 695 680 665 490 335 215 130 65 -

#600
1390 1390 1390 1390 1390 1390 1360 1185 980 670 430 260 130 -

#900
2085 2085 2085 2085 2085 2085 2040 1775 1465 1005 645 385 195 -

#1500
3470 3470 3470 3470 3470 3470 3400 2960 2445 1670 1070 645 320 -

#2500
5785 5785 5785 5785 5785 5780 5670 4930 4070 2785 1785 1070 535 -

* For weld-end valves only. Flanged-end ratings terminate at 10000F. @ Not to be used over 6500F.

-20 to 100 -28.9 to 37.7 200 93.3 300 148.9 400 204.4 500 260.0 600 315.5 650 343.3 700 371.7 750 398.9 426.6 800 850 454.4 900 482.2 950 510.0 1000 537.8 1050 565.5 593.3 1100 1150 621.1 1200 648.9

* For weld-end valves only. Flanged-end ratings terminate at 10000F. ** Not recommended for prolonged use above 8000F (4250C).

Working Pressure in psig

* For weld-end valves only. Flanged-end ratings terminate at 10000F.

-20 to 100 -28.9 to 37.7 200 93.3 300 148.9 400 204.4 500 260.0 600 315.5 650 343.3 700 371.7 750 398.9 800 426.6 850 454.4 900 482.2 950 510.0 1000 537.8 1050 565.5 1100 593.3 1150 621.1 1200 648.9

27

Technical Information

End Flange Dimensions - ASME 16.5, 1996


ASME Class 150 Raised Face (in mm) Valve Size
50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24)

E D

ASME Class 300 Raised Face (in mm) Bolt No. Dia
/8 /8 5 /8 5 /8 3 /4 3 /4 3 /4 7 /8 7 /8 1 1 11/8 11/8 11/4
5 5

A
152 178 190 229 254 279 343 406 483 533 597 635 698 813

B
120 139 152 190 216 241 298 362 432 476 539 578 635 749

C
92 105 127 157 186 216 270 324 381 413 470 533 584 692

D*
19.1 (15.9) 22.3 (17.5) 23.9 (19.1) 23.9 23.9 25.4 28.6 30.2 31.8 35.0 36.6 39.7 42.9 47.7

E
19 19 19 19 22 22 22 25 25 29 29 32 32 35 4 4 4 8 8 8 8 12 12 12 16 16 20 20

A
165 190 210 254 279 318 381 444 521 584 648 711 775 914

B
127 149 168 200 235 270 330 387 451 514 571 628 686 813

C
92 105 127 157 186 216 270 324 381 413 470 533 584 692

D*
22.3 25.4 28.6 31.8 35.0 36.6 41.3 47.7 50.8 54.0 57.2 60.4 63.5 69.9

E
19 22 22 22 22 22 25 29 32 32 35 35 35 41 8 8 8 8 8 12 12 16 16 20 20 24 24 24

Bolt No. Dia


/8 /4 /4 3 /4 3 /4 3 /4 7 /8 1 11/8 11/8 11/4 11/4 11/4 11/2
3 3 5

C B A

Flange - Raised Face


C P E D
See Detail X

230 E

* Inclusive of raised face 1.6mm (0.06) each. Dimensions within brackets are for integral flanges

Flange - Ring Type

Large-sized End Flange Dimensions as per ASME 16.47, 1996 Series A (MSS SP 44)
ASME Class

Large-sized End Flange Dimensions as per ASME 16.47, 1996 Series B (API 605)
Bolt
ASME Class

Valve Size Size

D*
71 75 83 90 97 108 95

E
35 35 41 41 41 41 48

No.
28 28 32 32 36 44 28

Dia
13/8 13/8 11/2 11/2 11/2 11/2 13/4

olt Valve Size Size

Bolt A B C D*
48 51 57 59 68 75 94

E
22 22 25 25 28 28 41

No.
40 44 40 44 48 44 36

Dia
/4 /4 /8 7 /8 1 11/8 13/8
3 7 3

700 (28) 927 750 (30) 984 850 (34) 1111 CL. 150 900 (36) 1168 1050 (42) 1346 1200 (48) 1511 1092 CL. 300 750 (30) * Inclusive of raised face

864 800 914 857 1029 965 1086 1022 1257 1194 1422 1359 997 857 1.6mm (0.06) each.

700 (28) 837 750 (30) 887 850 (34) 1005 CL. 150 900 (36) 1057 1050 (42) 1226 1200 (48) 1392 991 CL. 300 750 (30) * Inclusive of raised face

795 762 846 813 957 921 1010 972 1171 1130 1335 1289 921 845 1.6mm (0.06) each.

ASME Class 600 Raised Face (in mm) Valve Size A B C D


25.4 28.6 31.8 38.1 44.5 47.7 55.6 63.5 66.7 69.9 76.2 82.6 88.9 102.0

ASME Class 600 Ring Type (in mm) Bolt No. Dia
/8 /4 3 /4 7 /8 1 1 11/8 11/4 11/4 13/8 11/2 15/8 15/8 17/8
3 5

Valve Size A B C D Grv. No.

E
19 22 22 25 29 29 32 35 35 38 41 45 45 51 8 8 8 8 8 12 12 16 20 20 20 20 24 24

Pitch -P
83 100 124 150 181 211 270 324 381 419 470 533 584 692

Depth E
8.0 8.0 8.0 8.4 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 9.5 11.1

Width F
12.0 12.0 12.0 8.7 12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0 13.5 16.6

Bottom Rad. R
0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 1.52 1.52

50 (2) 165 127 92 65 (21/2) 190 149 105 80 (3) 210 168 127 100 (4) 273 216 157 125 (5) 330 266 186 150 (6) 356 292 216 200 (8) 419 349 270 250 (10) 508 432 324 300 (12) 559 489 381 350 (14) 603 527 413 400 (16) 686 603 470 450 (18) 743 654 533 500 (20) 813 724 584 600 (24) 940 838 692 Height of raised face is 6.4 mm (0.25) each.

50 (2) 165 127 108 25.4 R23 65 (21/2) 190 149 127 28.6 R26 80 (3) 210 168 146 31.8 R31 100 (4) 273 216 171 38.1 R37 125 (5) 330 266 209 44.5 R41 150 (6) 356 292 241 47.7 R45 200 (8) 419 349 302 55.6 R49 250 (10) 508 432 356 63.5 R53 300 (12) 559 489 413 66.7 R57 350 (14) 603 527 457 69.9 R61 400(16) 686 603 508 76.2 R65 450 (18) 743 654 575 82.6 R69 500 (20) 813 724 635 88.9 R73 600 (24) 940 838 749 101.6 R77 Height of raised face is 6.4 mm (0.25) each. Grv. - Groove

ASME Class 900 Raised Face (in mm) Valve Size


50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12)

ASME Class 900 Ring Type (in mm) Bolt No. Dia
/8 1 /8 11/8 11/4 11/8 13/8 13/8 13/8
7 7

Valve Size A
216 244 241 292 349 381 470 546 610

A
216 244 241 292 349 381 470 546 610

B
165 191 191 235 279 318 394 470 533

C
92 105 127 157 186 216 270 324 381

D
38.1 41.1 38.1 44.5 50.8 55.6 63.5 69.9 79.2

E
25.4 28.4 25.4 31.8 35.1 31.8 38.1 38.1 38.1 8 8 8 8 8 12 12 16 20

B
185 191 191 235 279 318 394 470 533

C
124 137 146 171 209 241 308 362 419

D
38.1 41.1 38.1 44.5 50.8 55.8 63.5 69.9 79.2

Grv. No.
R24 R27 R31 R37 R41 R45 R49 R53 R57

Pitch -P
95 108 124 149 181 211 270 324 381

Depth E
8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0

Width F
12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0

Bottom Rad. R
0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76

50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12)

Height of raised face is 6.4 mm (0.25) each.

Height of raised face is 6.4 mm (0.25) each. Grv. - Groove

ASME Class 1500 Raised Face (in mm) Valve Size


50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12)

ASME Class 1500 Ring Type (in mm) Bolt No. Dia
/8 1 11/8 11/4 11/2 13/8 15/8 17/8 2
7

Valve Size
50 (2) 65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12)

A
216 244 267 311 375 394 483 584 673

B
165 191 203 241 292 318 394 483 572

C
92 105 127 157 186 216 270 324 381

D
38.1 41.1 47.8 53.8 73.2 82.6 91.9 108.0 124.0

E
25.4 28.4 31.8 35.1 41.1 38.1 44.5 50.8 53.8 8 8 8 8 8 12 12 12 16

A
216 244 241 292 349 381 470 546 610

B
185 191 191 235 279 318 394 470 533

C
124 137 146 171 209 241 308 362 419

D
38.1 41.1 38.1 44.5 50.8 55.8 63.5 69.9 79.2

Grv. No.
R24 R27 R31 R37 R41 R45 R49 R53 R57

Pitch -P
95 108 124 149 181 211 270 324 381

Depth E
8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0

Width F
12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0

Bottom Rad. R
0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76

Height of raised face is 6.4 mm (0.25) each.

Height of raised face is 6.4 mm (0.25) each. Grv. - Groove

28

Technical Information

Butt-weld End Details & Dimensions - ASME B16.25, 1997


Welding end detail for joint without backing ring
Intended for use on 22mm (0.88) and thinner nominal wall thickness. Intended for use on wall thickness greater than 22mm (0.88).

Note : Internal surface may be reformed or machined for dimensions B at root face. Contour within the envelope is manufacturers option, unless otherwise specifically ordered for.
Nominal Pipe Size
65 (21/2) 80 (3) 100 (4) 125 (5) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 600 (24)

A
75 91 117 144 172 223 278 329 362 413 464 516 619

B STD
305 337 387 438 489 591

XS
298 330 432 483 584

30
581

40
63 78 102 128 154 203 255 303 333 381 429 478 575

60
198 247 295 325 373 419 467 560

80
59 74 97 122 148 194 242 289 318 364 410 456 548

100
189 237 281 308 354 398 443 532

120
92 116 140 183 230 273 300 344 387 432 518

140
178 222 267 292 333 378 419 505

160
54 67 87 110 132 173 216 257 284 325 367 408 491

XXS
45 58 80 103 124 175 -

Cast Steel - Material Characteristics


ASTM Designation Element
Carbon Manganese Phosphorus Sulphur Silicon Copper Nickel Chromium Molybdenum Vanadium Tungsten

Carbon Steel
A216 Gr. WCB A352 Gr. LCC A217 Gr. WC6

Alloy Steel
A217 Gr. WC9 A217 Gr. C5

Stainless Steel
A351 Gr. CF8 A351 Gr. CF8M

$0.30 1.00 0.04 0.045 0.60 *0.30 *0.50 *0.50 *0.20 *0.30 -

0.25 1.20 0.04 0.045 0.60 0.30 *0.50 *0.50 *0.20 *0.30 -

0.05 - 0.20 0.50 - 0.80 0.04 0.045 0.60 *0.30 *0.50 1.00 - 1.50 0.45 - 0.65 *0.30 *0.10

0.05 - 0.18 0.50 - 0.70 0.04 0.045 0.60 *0.50 *0.50 2.00 - 2.75 0.90 - 1.20 *0.30
$

0.20 0.40 - 0.70 0.04 0.05 0.75 *0.50 *0.50 0.45 - 0.65 *0.10

0.08 1.50 0.04 0.04 2.00 -

0.08 1.50 0.04 0.04 2.00 -

6.00 - 11.00 9.00 - 12.00 0.50 2.00 - 3.00 -

4.00 - 6.50 18.00 - 21.00 18.00 - 21.00

* Total content of thee residual materials shall not exceed1%. AIL material standard is 0.25 max. Values indicated are all maximum, except when a range is specified.

Common Items - Material Characteristics


Material Element
Carbon Manganese Phosphorus Sulphur Silicon Chromium Molybdenum Nickel Cobalt Tungsten Iron Nitrogen
ASTM A194 Gr. B7 ASTM A320 Gr. L7 ASTM A194 Gr. 2H ASTM A194 Gr. 7 Hardfacing Stellite #6 ASTM A182 Gr. F6a ASTM A276 Type 316

0.37 - 0.49 0.65 - 1.10 0.35 0.04 0.15 - 0.35 0.75 - 1.20 0.15 - 0.25 -

0.38 - 0.48 0.75 - 1.00 0.035 0.04 0.15 - 0.35 0.80 - 1.10 0.15 - 0.25 -

0.40 min 1.00 0.04 0.05 0.40 -

0.37 - 0.49 0.65 - 1.10 0.04 0.04 0.15 - 0.35 0.75 - 1.20 0.15 - 0.25 -

0.90 - 1.40 1.00 2.00 26.0 - 32.0 1.00 3.00 balance 3.0 - 6.0 3.00 -

0.150 1.000 0.040 0.030 1.000 11.5 - 13.5 0.500 -

0.150 2.000 0.045 0.030 1.000 16.0 - 18.0 2.0 - 3.0 10.0 - 14.0 -

29

AIL Valve Accessories

AIL Valve Accessories


GEAR OPERATORS
AIL gate and globe valves are supplied with fully-enclosed bevel gear operators as a standard for sizes and class ratings as shown in the table below. Gear operators are available as an option in other sizes too.

CHAIN WHEELS
Chain wheels are used for the valves located too far above the floor for convenient handwheel operation. Chain wheels are available for all types of AIL Cast Steel Valves and can be substituted in place of or used along with the existing handwheel. AIL chain wheels are equipped with guards or guides, not only to keep the chain from slipping off the wheel but also to hold the chain in close contact with a large portion of the circumference of the handwheel or the gear wheel.

Valve Type

ASME Class
150 300 600 900 1500 2500 150 300 600 900 1500

API 600
Standard
24 & above 20 & above 16 & above 8 & above 6 & above 10 & above 10 & above 6 & above -

ASME B16.34
Standard
10 & above 10 & above 8 & above -

Optional
14 - 20 14 - 18 8 -14 -

Optional
6 & 8 6 & 8 6 -

Globe

Gate

LANTERN RING
As mentioned earlier in page 7, a lantern ring is used to provide further integrity to the gland packing area in gate and globe valves, to prevent escape of service fluid to the atmosphere. This finds application in stringent environmental conditions or in the case of potentially harmful service fluids.

ELECTRICAL ACTUATORS
Electrical Actuators may be used with AIL valves in all sizes and class ratings. The actuators can be operated in practically any position or location, and have a provision for manual operation. The actuators come in weatherproof enclosure as a standard, and in explosion-proof and such other special enclosures too. For correct selection of actuator, please specify details of line pressure, differential pressure when closed, power supply requirements and actuator accessories.

The lantern ring is provided between two sets of packing rings, with a leakoff plug that gives the option of removal of leakage, if any, from the lower packing rings. Alternatively, a sealing fluid can be introduced through the plug to prevent incidental leakage through the lower packing rings.

Lantern rings serve a useful purpose. But, since they are a possible source of shaft scoring, it is advisable to restrict their usage to essential applications.

BYPASS ARRANGEMENT
A bypass arrangement serves two purposes - first, in steam services, to warm up the line before opening the main valve, and secondly, in steam and other lines, to balance the pressure on both sides of the main valve wedge or disc to bring down the valve opening torque.

POSITION INDICATORS
Valves can be provided with position indicators as a visible means to indicate the open and closed positions. Typically, for gate valves, the indicator is in the form of a pointer travelling along a fixed scale.

As an option, almost all AIL valves can be furnished with bypass arrangement. The bypass consists of a single Outside Screw & Yoke globe valve with a pressure / temperature rating and corrosion resistance equal to or exceeding that of the main valve.

Size Chart
Main valve Bypass valve 2to 4
1

5to 8
3

10 or higher 1

/2

/4

LOCKING DEVICES
The bypass valve is attached to the side of the main valve with the stems of both the valves in parallel and pointing upward. Where service conditions warrant larger-than-standard bypasses, it is recommended that the installation of the bypasses be around the main valve. Locking devices are used to secure a handwheel in a fixed position, to prevent accidental or unauthorized operation of a valve. The locking arrangement typically allows the use of chain and padlock to secure the valve.

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Recognition

Reputed Clientele
AIL Cast Steel Valves have been supplied over the years, to the following end-users and EPC Contractors :
ABB-ABL ATUL PRODUCTS BHARAT ALUMINIUM CO. BHARAT HEAVY ELECTRICALS BHARAT PETROLEUM CORPN. BHARAT PUMPS & COMPRESSORS BONGAIGAON REFINERY & PETROCHEMICALS CENTURY PULP & PAPER MILLS CHAMBAL FERTILIZERS & CHEMICALS DAELIM ENGINEERS & CONSTRUCTORS INDIA DAMODAR VALLEY CORPORATION DC INDUSTRIAL PLANT SERVICES DEEPAK FERTILIZERS DEVELOPMENT CONSULTANTS ENGINEERS INDIA ESSAR GUJARAT ESSAR OIL FERTILIZER CORPORATION OF INDIA FICHTNER GAS AUTHORITY OF INDIA GUJARAT GAS CO. GUJARAT HEAVY CHEMICALS GUJARAT NARMADA VALLEY FERTILIZERS CO. GUJARAT STATE FERTILIZERS HALDIA PETROCHEMICALS HINDUSTAN PAPER CORPORATION HINDALCO HINDUSTAN DORR-OLIVER HINDUSTAN FERTILIZER CORPORATION HINDUSTAN PETROLEUM CORPORATION HINDUSTAN POLYMERS HINDUSTAN SHIPYARD HINDUSTAN ZINC HUMPHREYS & GLASGOW IBP INDIA IDEA - CHENNAI INDIAN FARMERS FERTILIZERS CO-OP. INDIAN IRON AND STEEL CO. INDIAN OIL CORPORATION INDIAN ORGANIC CHEMICALS INDIAN PETROCHEMICALS CORPN. INDO GULF FERTILIZERS & CHEMICALS JOHN BROWN TECHNOLOGIES (INDIA) KALINGA IRON WORKS KCP KOCHI REFINERIES KVAERNER POWER GAS LINDE CHENNAI PETROLEUM CORPORATION MANGALORE REFINERY & PETROCHEMICALS MECON NATIONAL ALUMINIUM CO. NEYVELI LIGNITE CORPORATION OIL & NATURAL GAS CORPORATION OIL INDIA OSWAL CHEMICALS & FERTILIZERS PDIL PIPECON CONSULTANTS POWER INDUSTRY RASHTRIYA CHEMICALS & FERTILIZERS RELIANCE INDUSTRIES SOUTHERN PETROCHEMICAL INDUSTRIES STEEL AUTHORITY OF INDIA TAMIL NADU PETROPRODUCTS TATA CHEMICALS TATA CONSULTING ENGINEERS TATA ELECTRIC COMPANY TATA IRON & STEEL CO. TECHNIMONT THERMAX TOYO ENGINEERING INDIA TRIVENI ENGINEERING UHDE VISAKHAPATNAM STEEL PLANT ZUARI AGROCHEMICALS

31

AUDCO INDIA LIMITED


Administrative Office and Manufacturing Plant

Mount-Poonamallee Road, Manapakkam, Post Bag 976, Chennai 600 089, INDIA. Tel : (044) 22492323. Fax : (044) 22495055.
Manufacturing Plants Plant 1 : Enathur, Kancheepuram 631 552, INDIA. Plant 2 : B8, MMDA Industrial Area, Maramalai Nagar 603 209, INDIA. Marketed by

LARSEN & TOUBRO LIMITED


Valves Marketing Section

Post Bag 5247, Chennai 600 002, INDIA. Tel : (044) 28462000. Fax : (044) 28462102. P.O. Box 619, Kolkata 700 071, INDIA. Tel : (033) 22822301. Fax : (033) 22827587. P.O. Box 8119, Mumbai 400 051, INDIA. Tel : (022) 28581118. Fax : (022) 28581027. P.O. Box 6223, New Delhi 110 015, INDIA. Tel : (011) 25931302. Fax : (011) 25461939.
PB No. : C1102-0/08.03 As we continuously endeavour to improve our products, the data given herein are subject to change without notice.

Bonnet Gaskets (rev dated 25th May 2009)


Valve Type ASME Class Typical Sizes up to 20": Corrugated SS316 with Graphite filler 150 Optional Sizes up to 20": Corrugated SS316 with PTFE filler

Sizes up to 20": Soft Steel + Graphite filler

Sizes 20" and above: Tanged SS316 insert graphite reinforced Gate 300 Spirally wound SS316 with Graphite filler Octogonal Ring Type (RTJ) in Soft Iron 600 Spirally wound SS316 with PTFE filler Octogonal Ring Type (RTJ) in SS316 Sizes up to 8": Spirally wound SS316 with Graphite filler Sizes up to 8": Spirally wound SS316 with PTFE filler 900 1500 150 300 Octogonal Ring Type (RTJ) in Soft Iron Octogonal Ring Type (RTJ) in Soft Iron Spirally wound SS316 with Graphite filler Spirally wound SS316 with Graphite filler Octogonal Ring Type (RTJ) in Soft Iron Globe 600 Octogonal Ring Type (RTJ) in SS316 Octogonal Ring Type (RTJ) in SS316 Spirally wound SS316 with PTFE filler Spirally wound SS316 with PTFE filler Octogonal Ring Type (RTJ) in SS316 Sizes up to 8": Spirally wound SS316 with Graphite filler Sizes up to 8": Spirally wound SS316 with PTFE filler 900 1500 150 300 Octogonal Ring Type (RTJ) in Soft Iron Octogonal Ring Type (RTJ) in Soft Iron Spirally wound SS316 with Graphite filler Spirally wound SS316 with Graphite filler Octogonal Ring Type (RTJ) in Soft Iron Check 600 Octogonal Ring Type (RTJ) in SS316 Octogonal Ring Type (RTJ) in SS316 Spirally wound SS316 with PTFE filler Spirally wound SS316 with PTFE filler Octogonal Ring Type (RTJ) in SS316 Sizes up to 8": Spirally wound SS316 with Graphite filler Sizes up to 8": Spirally wound SS316 with PTFE filler 900 1500 Octogonal Ring Type (RTJ) in Soft Iron Octogonal Ring Type (RTJ) in Soft Iron Octogonal Ring Type (RTJ) in SS316 Octogonal Ring Type (RTJ) in SS316

Note: 1. For higher grade material such as high grade stainless steels and nickel alloys, gasket material can be given suited to the valve material of construction. Contact AIL for correct gasket material. 2. For cryogenic valves in Class 600, irrespective of size only spirally wound gasket is offered.