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Plug ValvesThe Solution For The Valve Problems

Sleeved &LinedPlug Valve

Plug ValvesThe Solution For The Valve Problems

Soft Seated Plug Valves

Sleeved Plug Valves

>> 24

3Z StandardPort Plug Valve

FIG 120, 320, 620

3Z Full PortPlug Valve

FIG 120FB,320FB, 620FB

3Z 3-WayPlug Valve

FIG 130,330, 630

3Z 5-WayPlug Valve

FIG 150, 350,650

3Z JacketedPlug Valve,

Full or PartialFIG 120FJ, 320FJ,

620FJ, 120PJ,320PJ, 620PJ

3Z NuclearPlug Valve

FIG 122N BW,322NBW,622N BW

3Z Screwed EndPlug Valve

FIG 122SE,322SE, 622SE

3Z 3-Way FullPort Plug ValveFIG 130FB, 330FB,

630FB

3Z SocketWelded End

Plug ValveFIG 122SW,

322SW, 622SW

3Z Severe ServiceValve

FIG 120SS, 320SS,620SS

3Z Live Loaded Plug ValveFIG 120LL, 320LL,620LL

Control Valves / Specialty Valves

25 <<

3Z Electric ControlPlug ValveFIG 120CVE

120CVE 3Z Sleeved valves arealso available forvarious HydrofluoricAcid applications.

3Z CAGED PLUG ValveFIG 120CG,320CG,620CG

3Z Autoclave Line Plug Valve

3Z Black Liquor Line Plug Valve

3Z Bleed Systems Valv

3Z Cryogenic Plug Valve

3Z Chlorine Valve

3Z Caged Plug Valve

3Z Diverted Type Plug Valve

3Z Fingertrol Plug Valve

3Z Fire Safe Plug Valve

3Z Gas Distribution Plug Valve

3Z Metal Proving Plug Valve

3Z Piloted Plug Valve

3Z Power Plant Plug Valve

3Z Spandex Plug Valve

3Z System Flush Plug Valve

3Z Tandem Plug Valve

3Z Underground Plug Valve

3Z Vacuum Plug Valve

3Z Direct Mounted PneumaticControl Plug Valve

FIG 120CVD

3Z PneumaticControl Metal

Seated Plug ValveFIG 123CV

3Z InterlockedType Plug Valve

FIG 120CVT

3Z Direct Mounted PneumaticFingertrol Control valve

FIG 120CVD

Construction of Sleeved Plug Valves

>> 26

PLUG

SLEEVE

BODY

Upper rib

Port lips PLUG

BODY

Basic structure is plug, sleeve,body. Sleeve is inserted andencaged inside the body. Taperedplug is inserted onto the sleeve.The sleeve is acting as a soft seat.And completely surrounds plugcreating areal sealing surfaces.Also not permitting any deadspace in the flow path. Plug isrotating 90 degree. When it isaligned with the body port, flow isopen. When the plug is rotated sothat plug port is perpendicular tothe body port the flow is blocked.The media kept in the plug whileat closed position, will becontained in the plug port only,and when the valve is open again,the flow will flush the out. And noremains

PTFE is an plastic material, eventhough they are high gradeengineering material. All plasticsare subject to cold flow.; at highertemperature volume increase,escape to the low pressure areaand don’t get back to its originalposition even after removal oftemperature, pressure. But, if theyget confined , they would not coldflow. Upper boundary and lowerboundary, and 360 port lips.Recessed wall is acting asabsorption of inflated volume ofPTFE when volume is increaseddue to temperature.The vertical, upper horizontal, andlower horizontal pressure ribs areprovided to provide pressure seallines along plug any time.True circularity of body center boreis very important for firm sealing.Ribs and lips must be truly circularand concentrically defined as caststate. 3Z is has its own foundry.Did this for over 20 years. Reliable.

Plug is tapered. Monolithic design.Wedge action. Lowering 1 mm willresult in side pressure vectors.Adjustable. Solid not unstable aspressure dependent.Materials can be upgraded for theplug alone to be better resistivethan the body corrosion rate.

Sleeve is also tapered to acceptedthe configure of plug. They aresnuggly fit into the void spacecreated by upper, lower and metalport lips.The PTFE materials are rigidenough, resilient enough, elasticenough. Corrosion resistant.Temperature, pressure.For highly radioactiveenvironment, higher temperatures,several different materials areused.

SLEEVE

Threefold Sealing System

27 <<

Threefold Sealing System

The zero leakage stem sealing is achieved by threefold sealing system. The primary seal is provided by the sleeve. The sealing is so tight that no leakage can be observed evenwithout a valve cover.

The secondary and tertiary seal (top seal package) are provided by a PTFE delta ring and a diaphragm.The sealing is also so tight that no leakage can be observed even without a sleeve.A test report is available at request

Solution for Valve Problem

>> 28

1.0 Types of generic valve failuresValves fail to serve their functionwhen they indicate leakage orinoperability. They have to berepaired to function properly.Any valve design have a movingpart which close or open the flowpath. The part protrudes throughthe pressure boundary to beoperated outside. At gate valvedesign it is called wedge/stem;globe valve, plug/stem; ball valve,ball/stem; etc.1.1 Leakage - This type of failurecan occur internally or externallyat this moving part. Externalleakage can be generated at thepressure boundary through stemof the valve. Internal leakage canbe generated between the seat ofthe body and the moving part.When leakage develops the valvescan be judged failed. The leakagedamages various factors.Depending on the degree ofseriousness, users determinewhether to repair the valve or touse it as is.1.2 Inoperability - This type offailure occurs when the movingpart of the valve cannot beengaged or disengaged due tovarious reasons, such as by theslurry accumulated at the creviceof wedge way in gate valvedesign. This type of failurehampers serious problems in flowcontrol. They have to be repairedright away to perform theintended role of the valve.1.3 Life-time - At initial inspectionand test stage, almost all thevalves function properly. That is, itdoes not leak and open/close well.But when installed and exposed atactual conditions, after a certainperiod of time, the valve start tofail. The time is called “Life-time”of the valve. If the life-time ispractically and economically tooshort, the valve is not suitable forthe service.

2.0 Factors influencing valve failures/life-timeNatures and conditions of flowmedia, modes of operation andenvironmental conditions areimportant factors. The valvedesign employed must havefeatures to overcome the givenconditions.2.1 Phase of Media - The flowmedia can be in the phase of solid,liquid, or gas. The solids can be inpowder, granule or larger particles.They can be dissolved orsuspended in a solution. They cancrystallize, precipitate, solidify,polymerize, crack, react chemicallyor physically, etc. They can in theform of slurry/sludge. They maycarry unexpected impurities orwastes, generated from reactors orpipe lines.2.2 Nature of Media - The mediacan be corrosive, toxic wheningested or inhaled, carcinogenic,irritative to skin and eyes,explosive, flammable, oxidizingwith air infiltrated in, etc. 2.3 Modes of operation - Theymay be in different cycle time,temperature/pressure variations,start up mode, shut down mode,emergency mode, etc.2.4 Environmental Conditions - They may be under hot or coldweather, facing salty sea wind, atcorrosive atmosphere.3.0 Valve problems cost a lot of moneyWhen improperly designed valvesare use, capital cost for repeatedprocurement of valves, materialsand labor cost for frequent repairof installed valves, productiondisturbance cost, safety protectioncost, environmental protectioncost, administrative cost for valvemaintenance management cost,etc., adds up to enormous costand expenses.

4.0 Conventional valves, too shorta life-timeThe conventional valves had beendeveloped to meet therequirement of steam handlingsince the industrial revolution of200 years ago. The new industrialrevolution of hydrocarbonprocessing of oil, gas andpetrochemicals outbroke 50 yearsago. The conventional valves havebeen used for the processindustries but with failures. Thelife-time is too short to be safe,reliable and economic.4.1 Gate valves - Valve cannot beclosed when solids accumulates atthe void space at the seat wherethe wedge seats in. It galls. Over-tightening when closing damagevalve seals quickly. Gland seal failsquickly.4.3 Globe valves - Directionchanges, 6 times of 90 degree,may be okay for throttling butprohibitive for normal flow use.Over-tightening when closingdamage valve seals quickly. Slurryclogs port quickly. Gland seal failsquickly.

4.2 Ball valves - Valve seal ringfails quickly due to the slurry keptin dead space between ball andbody. Gland seal fails quickly.4.3 Diaphragm valves - Rubbercontaining diaphragm ages abouta year. Quickly torn away byaging and over-tightening. Glandseal fails quickly. Diaphragm getsdamaged by solids in the media.4.4 Butterfly valves - Slurry gottenin dead space at the bottom stemdamage the valve. Excessiverubbing action and aging wearsand tears off seat rubber. Glandseal fails quickly. 5.0 3Z, the solution for valveproblems3Z sleeved plug valves arespecifically designed to overcomethe problems described above.

Solution for Valve Problem (3 Zero Features)

29 <<

Zero Leakage

The zero leakage stem sealing is achieved by the Threefold Stem Sealing System. The primary seal is provided by the sleeve. The sealing is so tight that no leakage can be observedeven without a valve cover. The secondary and the tertiary seal (top seal package) are provided bya delta ring and a diaphragm made of RTFE (Reinforced Teflon). The sealing is also so tight thatno leakage can be observed even without a sleeve.

3Z PLUG VALVE OTHER VALVES

Zero Cavity

Plug is always surrounded by PTFE sleeve 360 degree around and therefore the liquid in theplug internal cannot flow into no dead space whether it’s open or close. When the valve is open, the line flow would flush out the liquid in the plug internals.Ball Valve & other Valve : When the ball is closed, the liquid containing slurrywhich was kept in ball openings, flows into the dead space between ball and body.

The liquid imprisoned at the dead space will stay during life time of the valve. When PVC slurry of sludge is precipitated and accumulated in this dead space the burdened solids willblock the rotation of ball, pushes out the seal surface of Teflon ring, and gives damages to the seal,which eventually produces the leakage.

Zero Maintenance

Owed to the merits of its structure, the valve is zero leakage and no maintenance is required. When seal pressure adjustment is required due to PTFE sleeve wear, a quarter turn of adjustment bolts pushes the plug down regenerating a sealing pressure as if it is a new valve. Therefore no disassembles, no repair is required for more than 10 yearsfor the most of cases. Line repair is possible because the plug is the top entry type.

Live Loaded Valves

>> 30

For lethal, toxic and sub-zero fluid services where an absolute stem seal is required.

Live Loaded Design Options

3Z Live Loaded Plug Valve

Fig. 120, 320, 620LL

Wide Range of Stuffing Box Options

Cup and cone packingwith lantern ring

Chevron packing set Chevron packingwith lantern ring

Combination packingset cup and cone(upper)chevron(lower) withlantern ring

Compression packingwith lantern ring

Compression packing set

Designed and built to eliminate fugitiveemissions and to handle the toughestservices such asChlorineHydrofluoric AcidAnhydrous HCl

A true stuffing box design with all the positive shut-off, corrosion resisting features of other 3Z Sleeved Plug Valves.

Will accommodate all standard packing.

Many options such as bonnet tap forinsertion of chlorine compatible lubricant orother greases, for inert gas pad, or as aleak-off connection.

V-Port and 3-way plug configuration areavailable as options.

Port : 2-5 wayClass : 150/300/600Size : 1/2”- 24”Temperature Range : -30 to 260

Multiport Valves

31 <<

3 way Port Arrangement

3Z 3-WayPlug Valve

FIG 130, 330, 630

3Z 5-WayPlug Valve

FIG 150, 350, 650

3Z 4-WayPlug Valve

FIG 140, 340, 640

3Z 3-Way FullPort Plug Valve

FIG 130FB, 330FB,630FB

The versatility of 3Z multiport valves and the variety of flow arrangements in which they areavailable make these valves ideal for many types of piping systems handling liquids, gases,slurries or other applications where tight shutoff is required.

FORMS A AX D C I T L

FLOW

POSITION 10°

POSITION 290°

POSITION 3180°

POSITION 4270°

Nuclear Plug Valves

>> 32

Designed for Nuclear Power Plant application.Standard type : Sleeve is “UHMWPE”

Port : 2-5 wayClass : 150/300/600Size : 1/2”- 24”

Temperature Range : -30 to 260

3Z FIG 322N.BW BUTT WELD END

NUCLEAR PLUG VALVE

2-WayClass 150/300

1/2-6 inch

3Z FIG 322N.PPUP WELDED

NUCLEAR PLUG VALVE

2-WayClass 150/300

1/2-6 inchPup Welded

3Z FIG 322N.SWSOCKET WELD END

NUCLEARPLUG VALVE

2-WayClass 150/300

1/2-6 inchFor Nuclear Service

3Z FIG 332N BUTT WELD END

NUCLEAR PLUG VALVE

3-WayClass 150/300

1/2-6 inch

3Z FIG 322N.CV PNEUMATIC

NUCLEARCONTROL

PLUG VALVE

Double Acting Type2-Way

Class 150/3001/2-6 inch

3Z FIG 322N.CV PNEUMATIC

NUCLEARCONTROL

PLUG VALVE

Spring Return Type2-Way

Class 150/3001/2-6 inch

Lined Plug Valves and Lined products

41 <<

3Z 2-way Lined Plug Valve

FIG 121, 321

3Z Lined BallCheck ValveFIG 171, 371

3Z Lined Live Loaded

Plug ValveFIG 121LL, 331LL

3Z Lined Swing Check Valve

FIG 181, 381, 681

3Z Lined Strainer

FIG 190

3Z 3 way Lined Plug Valve

FIG 131, 331

3Z Lined Y-Type StrainerFIG 191Y

3Z 5-way Lined

Plug ValveFIG 151, 351

Fully-lined, quarter turn non-lubricated plug valveideally suited for corrosive application. Locking of linerto body and molding technique permit use on manychemical services with higher pressure and vacuumwithout fear of liner collapse, shrinkage, stresscracking and blowout. Excellent sealing capability

Construction of Lined Plug Valves

>> 42

ZERO MAINTENANCE

ZERO LEAKAGEZERO DEAD SPACE

THREEFOLD STEM SEALallows no stem leakage.

ADJUSTING BOLTSrenews sealing.

MONOLITHIC STEM AND PLUGprovides reliability.

THICK PFA/FEP TEFLON LININGfights corrosion

DOVE-TAIL LOCKholds lining firmly.

TAPERED PLUGassures independentmechanical force forperfect line sealing.

All sealing surfaces are machined to close tolerances, providing tight shutoff.

(1) Independent wrench stops are cast in the cover.(2) Three stainless steel adjusting screws, silver-plated for added corrosion resistance, give parallelism

to the plug through the thrust collar, assuring uniform position of the plug in the body.(3) The multiple top seal is designed to transmit sealing forces diagonally across the delta ring and

vertically on the diaphragm to seal the plug shank, providing an added safeguard against hazardous fluids escaping to atmosphere.

(4) FEP and PFA are melt processible and offer maximum density and elimination of stress cracking atthe corners, affording longer maintenance-free service for the liner and the valve.

(5) The liner is locked to the casting by means of cast dovetail recesses and machined grooves,permitting the valve to be used on high vacuum and pressure applications without liner collapse,shrinkage or blowout.

(6) The bottom seal adjustment provides a positive means of maintaining tight shutoff.(7) The body of the valve is coated with corrosion- resistant paint to retard external corrosion and rust.(8) Three-way valve has side entry design with choice of three port arrangements.

90°QUICK TURNINGAND POSITION INDICATION

allows no crud trap.

ADJUSTING BOLT

COVER

BODY

PLUG

TERTAIRY SEAL

SECONDARY SEAL

PRIMARY SEAL

ZERO LEAKAGE

Construction & Materials

43 <<

3Z Lined Plug Valve, 2-way

Fig 121, 321

Handle SteelSnap ring SteelStatic eliminator Stainless steelCover nuts Stainless steelAdjusting screws Stainless steel, silver platedTop cover :

Ductile iron / Carbon steelThrust collar Stainless steelFormed diaphragm RTFEDelta ring RTFEFlat diaphragm PTFEBody : FEP or PFA lined ductile iron

/ Carbon steelPlug : FEP or PFA lined ductile iron

/ Carbon steel

Fully-lined, quarter turn non-lubricated plug valveis ideally suited for corrosive application. Lockingof liner to body and molding technique permit useon many chemical services with higher pressureand vacuum without fear of l iner collapse,shrinkage, stress cracking and blowout. Excellentsealing capability.

Linings : FEP, PFASizes : 1/2” - 18”Rating ANSI Class 150, 300

Materials of construction

Fully Lined Ball Check Valves

>> 44

FIG 171Size 1/2 through 6 inch, Class 150

ConstructionThe valve body is fully lined with either PFA or FEP teflonmaterial. A RTFE ball is freely moving internally on spacer,but the movement is stopped by either flanged water way.Back pressure or backflow of the flow moves the ballupstream and the ball blocks the flow. Spacer at downstream has openings like a comb construction. Therefore,when there occurs a normal flow to downstream, the flowis free to flow.

Use & Function1) Protection of pump motor from backflow damage.2) Protection of pump impeller from backflow damage.3) Certain degree of shut-off function when backhead is

high.

Operation1) 3Z FIG 171 can be mounted on “A” or “B”.2) When a pump stop signal is given during operation of

the pump, the pump motor will be stopped but keepsrunning for a short period of time an gradually stops. Atthis time, if there is not 3Z FIG 171 installed, thebackflow caused by back head will flow backwardtowards the pump.

3) On this occasion, motor and pump impeller can bedamaged by the back flowing fluids because of thefighting direction of rotation.

4) But when a 3Z FIG 171 is mounted on the exit side ofthe pump, the backflow will push the ball inside 3Z FIG171, seats the ball against the flanged water way boreinstantly. Then, the back flow will seat the ball on theflange seat.

5) The higher the back pressure is, the greater thebackflow forces. Therefore, the ball performs a shut-offfunction, but not tight shut-off. When a backhead issmall, ball instantly

Fully Lined Ball Check Valves

45 <<

prevents impact to the pump, but may move slightlyfrom the shut off position. In this case, a partialbackflow can occur to the pump, would not damagethe pump impeller or motor because the backflowforces negligible.

6) 3Z FIG 171 can be mounted both horizontally andvertically. When mounted vertically, it operates withand aid of gravity.

7) When a thight shut-off is required for the back flow,and additional shut-off valve should be installed.Check valves are not designed for a shut-offfunction.

DIMENSIONS

SIZE BOLT HOLE

IN MM L D PCD NO DIA g t f

1/2 15 152 89 60.5 4 16 35 15.5 3.2

3/4 20 152 98 70 4 16 43 15.9 3.2

1 25 152 108 79.5 4 16 51 17.3 3.8

1.1/2 40 178 127 98.5 4 16 73 18.1 3.8

2 50 203 152 120.5 4 19 92 20.3 4.4

2.1/2 65 242 178 139.5 4 19 105 24.1 5.0

3 80 242 190 152.5 4 19 121 24.1 5.0

4 100 292 229 190.5 8 19 147 29.2 5.3

6 150 394 279 241.5 8 22 206 31.2 5.8

8 20 482 343 298.5 8 22 264 35.1 6.5

Swing Check Valves

>> 46

FIG 1813Z SWING CHECK VALVESANSI Class 150 : 2”-12”

FeaturesTo be mounted horizontally and vertically in piping.To be used to replacing high alloy steel for corrosive process materialNo application of spring/pin causing corrosion orabrasion in Body.

MaterialsBODY WCB(316) / PFA (FEP)DISC FEP (PFA) : 4” and Under

WCB/PFA (FEP) : 6” and OverNot less than 2.4mm of Lining thickness

Pressure Temperature Ratings

DIMENSIONS

2 40 40 30 40.6 53 89 172 1.9 45 43 49

3 46 55 45 56 55 127 190 3.2 100 71 82

4 46 80 70 78 64 157 266 5.9 234 92 100

6 57 125 111 124 65 216 319 12.7 667 142 148

8 67 172 158 165 61 298.5 373 22.7 1404 188 195

10 76 222 184 221 53 324 394 28.6 1965 239 260

12 86 256 232 267 53 381 510 42.2 3160 290 310

SIZE A B C D E F G Wt(kg) CvMax.matingIFlange I.D

Min Max.

Quick Reference Selection Table

The table below provides a brief overview of the most commonly specified valves.Wrench ordering be sure to specify all options including body, plug, and sleeve materials.

No. ofPorts Type * ANSI

ClassSize

Range Operator FlgureNumber Additional Information

150 122SC

300 322SC

½ - 2 120

4 - 24 Enclosed Gear 120G

½ - 4 Wrench 320


1 - 4 Wrench 120PJ

4 - 12 Enclosed Gear 120PJG

1 - 4 Wrench 320PJ


2x1x2-6x4x6 Wrench 120FJ

6x4x6-8x6x8 Enclosed Gear 120FJG

2x1x2-6x4x6 Wrench 320FJ

6x4x6-8x6x8 Enclosed Gear 320FJG

150 ½ - 2 132

300 ½ - 2 332

½ - 4 130


½ - 4 Wrench 330


1 - 4 Wrench 130PJ


1 - 4 Wrench 330PJ


Screwed End ½ - 2 142

Flanged End ½ - 2 140

Screwed End ½ - 2 152

Flanged End 1 - 4 150

Screwed End

Flanged End

Partial Jacket

Full Jacket

Screwed End

Flanged End

Partial Jacket

½ - 2

150

300

150

300

150

300

150

Wrench

Wrench

Wrench

150

300

150

300

2-way 3Z Sleeved Plug Valvesprovide tight shutoff from highvacuum through rated pressure attemperatures from -20℉ to 400℉

Standard jacketed valves areavailable in carbon steel or 316stainless steel. All jackets are ratedat 235 psi at 400℉. Full jacketedvalves have over-sized flanges.

When ordering 3-way valves, besure to include the port configuration.Refer to page 5.

Bodies are available in carbon steelor 316 stainless steel. Standardpressure/temperature ratings apply,with the exception that pressure dropshould not exceed 170 psi at 100℉when switching.

2

3

4

5

How To Order

■ Sizes Available

1/2 inch - 40 inch

■ Ports2: 2 way 7: Lined Ball Check 3: 3 way 8: Swing Check4: 4 way 9: Lined Strainer5: 5 way

■ Standards Available

ANSI, JIS, DIN, BS, API, JPI, KS

■ Ratings Available

Class #150 - #3000

1:Class #1503:Class #3006:Class #6009:Class #90015:Class #150025:Class #250030:Class #3000

■ Materials Available

· Body/PlugWCB, LCB, C5, DICF8(304), CF8M(316), CF3(304L), CF3M(316L), CN7M(A20), CD4M, MONEL, INCONEL,HB, HC, TI, ZR, NI, BR

· SeatFEP, PFA,PTFE, RTFE,250EP, 320EPUHMWPE,Metals, Sealant

■ Types Available

0: Teflon Sleeved1: Teflon Lined2: Screwed & Welded3: Metal Seated4: Double Block & Bleed5: Lubricated6: Eccentric

■ Options Available

PJ: Partially JacketedFJ: Fully JacketedFB: Full BoreLD: Locking DeviceCV: Control ValveFT: FingertrolFS: Fire SafeFF: Flat FaceRTJ: Ring Type JointTG: Tongue&GrooveSC: Screwed(NPT,PT)SW: Socket WeldedBW:Butt WeldedA,AX,C,D,L,T: 3Way Ports

Arrangement

PLUG VALVESPECIALISTS

3Z CORPORATIONe-mail:[email protected]

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