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The
ultimate valve
Kitz cast steel valves stocked by Traeger Brothers offer the
ultimate in performance and efficiency. Kitz Corporation’s
engineering and design is without peer, however their greatest
competitive advantage is that of their production method. The unique
Kitz factory design is that of a single undisturbed flow of
processes from foundry operation to machine shops, assembly shops,
tests, inspections and the final valve makeup works. Human
engineered layouts of all manufacturing processes are equipped with
state-of-the-art machinery and apparatuses, making KITZ production
efficiency unrivaled anywhere in Japan. Their newest facility in
China transfers all of this technology, engineering and focus on
perfection into a new factory for the production of commodity cast
steel valves that maintains the highest degree of perfection at a
market correct price.
The
ultimate foundry
Kitz unique integrated production system covers all phases of valve
manufacturing including its in-house steel foundry operation. By
controlling the metallurgy and casting process from the raw
materials through to the finished casting, Kitz insures that their
advances in engineering quality are carried through to the final
product. For example, Kitz has sourced silica sand with unique
qualities that allow their casting process to provide the best
possible steel consistency and particle alignment in the final
product. The ovens used in mixing the raw materials of the special
alloys to be poured are state of the art, and allow any impurities
contained in the molten alloy to be reduced to previously
unattainable levels through a closed vessel vacuum process.
Special Alloys
Kitz is a world leader in the production of stainless and high alloy
steel valves. Their foundry operation allows the casting of small
batches of special alloy bodies in record times compared to the rest
of the industry, without contracting out work to non-Kitz owned
foundries.
Kitz’s
small batch foundry can cast valve bodies in many steel alloys,
including:
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Martensitic Stainless Steel; A743 CA6NM.
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Austenitic Stainless Steel: A351 CF8 – 304, A351 CF3 – 304L, A351
CF8M – 316, A351 CF3M – 316L, A351 CF8C – 347, A351 CG8M – 317,
A351 CG3M – 317L, A351 CN7M - Alloy 20, A990 CN3MCu – Alloy 20 and
A351 CK20 – 310.
-
Super
Austenitic Stainless Steel; A351 CN3MN and A351 CN3MN – modified
-
Duplex Stainless Steel; A351 CD3MWCuN – modified
-
Super
Duplex Stainless Steel; A351 CD3MWCuN
-
Ni-Cu
Alloy; ASTM A494 M-35-1, M-30-C – Monel
-
Ni-Mo
Alloy; A494 CW-12MW – Hastalloy B, , N-7M – Hastalloy
-
Ni-Cr-Mo Alloy; A494 CW-12MW – Hastelloy C, A494 CX2MW – Hastelloy
-
plus
other special material grades, such as Inconel.
-
Low
emissions
KITZ’s
wide product range helps customers save on procurement costs by
reducing the number of suppliers. This product range has recently
been expanded with the introduction of low emission service valves
that exceed US federal environment protection requirement of 500 ppm
limit on external leakage of toxic gas from valves and other plant
equipment. Every customer is trying hard to improve his plant life
cycle by targeting valve maintenance problems as his essential
management program. KITZ’s low emission service valves offer
hydrocarbon and chemical industries a realistic and timely solution.
Kitz
Quality
To complement its state-of-the-art production system and facilities,
KITZ has committed itself to quality assurance management to an
extent unparalleled in the valve industry. Its aggressive employment
of quality management was confirmed by the Bureau Veritas Quality
International of London when they chose KITZ for their premiere
presentation of the ISO 9001 certification in 1989, the earliest in
the valve industry.
Body
Construction
The Kitz cast steel valves stocked by Traeger Brothers feature a
shell wall thickness and general valve design specifications to API
600, BS1873 (for globe valves) and BS1868 (for check valves).
Pressure-temperature ratings meet ASME B16.34 and BS1560.
Face-to-face dimensions are to ASME B16.10 and BS2080, and
end-to-end dimensions are to ASME B16.10 and BS2080. End flange
dimensions and gasket contact facing meet ASME B16.5 and BS1560,
BS1414 (for gate valves). Welding end dimensions meet ASME B16.25 or
BS1873 (for globe valves).
Seat
Rings
Body seat rings of KITZ cast steel valves are mounted on the valve
body by either threading or seal welding. Unless specifically
requested in advance, mounting of body seat rings shall be made at
the manufacturer's discretion. Specify your own method of mounting,
noting your purchase orders with adequate KITZ product code numbers.
NACE
Valves
For servicing sour gases or other Hydrogen Sulfide bearing
hydrocarbon fluids, KITZ offers NACE valves made of component
materials specially heat-treated and hardness-controlled in
conformity with NACE MR0175 Standard. A note should be taken on the
fact that NACE hardness requirement conflicts with one of the valve
seating surface specified by APl 600, Table 3. KITZ NACE steel
valves are available at your option.
Valve Wedge Options
Among the four different shapes of wedge gates recognized by API 600
Paragraph 2.3.1, KITZ has adopted solid wedges for smaller valves
such as 11/2’’to 4’’ of Class 150 / 300 / 900 / 1500 / 2500
(excluding class 600) gate valves, and flexible wedges for all other
sizes of all pressure classes and 2" & larger of class 600. H-shaped
flexible wedges are featured with mechanical flexibility to adjust
its own shape following the shape of the body seats for tightly
secured mutual contact. This is particularly important when larger
gate valves service extremely high pressure and temperature, where
temporary deformation of the valve body always occurs. Operational
torque is smaller, seat wear is less and valve closure is tighter
when H-shaped flexible wedges are provided.
Heavily
designed KITZ wedge gates are forged or cast solid, single piece of
steel without any welding work. Specially heat-treated wedges are
firmly coupled with integral T-head of the valve stems, which are
also ruggedly designed and specially heat-treated for the highest
possible durability of stem to wedge connection. API 600 Paragraph
2.6.2 particularly emphasizes the importance of the mechanical
strength of this connection.
As
another unique feature, KITZ wedge gates are designed for always
accurately maintained concentricity and accurately lapped for
leak-free contact.
Inspection and Warranty
Every piece of KITZ cast carbon and low alloy steel valves is
subjected to 100% pressure tests, according to API 598 or BS 6755
part 1 requirements. Manufacturer’s material test reports and
inspection certificates are available on your request, while each
valve is guaranteed for 12 months after placement in service, but
not exceeding 18 months after shipment from the factories of KITZ
Corporation.
Unless
otherwise specified, all KITZ cast steel valves shall be subjected
to these testing or inspection methods and evaluation criteria:
Chemical composition analysis, mechanical property test , pressure
tests , radiographic inspection , wet magnetic particle inspection,
liquid penetrant inspection, low temperature impact test,
dimensional inspection, visual inspection, emission test.
Kitz
Low Emissions Service Valves
In the United States, the Federal Clean Air Act was dramatically
amended in 1990, to realize the new environmental protection policy
of a 95% reduction in fugitive emission or leak levels of toxic gas
from plant equipment. Promulgated in April, 1994, the new law
requires all plants handling the toxic gas specified by the
Environmental Protection Agency, to periodically monitor their plant
equipment for detection of leaks exceeding 500 ppm, and repair or
replace all defective parts immediately.
Our
newly developed low emission valves, the proud fruits of several
years of trial and error at our laboratory, are designed,
engineered, manufactured and tested to now meet the 100 ppm maximum
emission level. This is the standard specification in North America
for KITZ flanged and butt-welding end carbon or low alloy steel
valves rated Class 150, 30 and 600. In other markets, all these low
emission valves are optionally available. Major design
considerations for having upgraded our standard valves to the low
emission performers are introduced below. Gland packing: KITZ’s
original ‘‘SEALEVER®’’ flexible graphite packing set, consisting of
4 die-formed flexible graphite rings and 2 braided flexible graphite
rings, combined with a pure carbon spacer bush for Class 300 and 600
rated valves.
Bonnet
gaskets (including check valve cover gaskets) Class 150 : Flexible
graphite sheet with stainless steel insert and permeation protective
barrier for low emission service; Class 300 : Spiral wound (flexible
graphite filler and stainless steel hoop) with a stainless steel
inner ring; Class 600 : Ring joint metal gasket. Straightness and
roundness are precision controlled according to KITZ design and
manufacturing standards.
Stuffing box: Maximum 125 RMS surface finish. Cylindricity and
verticality are precision controlled according to KITZ design and
manufacturing standards.
Plug
gaskets for check valves: Class 150 / 300 : Flexible graphite sheet
with stainless steel insert and permeation protective barrier; Class
600 : Spiral wound metal, flexible graphite filled.
Product
identification: Stainless steel ID plates with the letters ‘‘LOW
EMISSION’’ in orange are welded on the bonnet flanges.
Low
Emission Acceptance Test
KITZ Corporation has developed its own test method and evaluation
criteria basing on the results of laboratory tests carried out for
the last several years. Most significantly, KITZ employs 10 ppm as
the acceptance criteria for the random test done prior to shipment
to customers, in consideration of stress relaxation of packing
material during transportation and storage.
For more information on Kitz cast steel valves
please go to
www.kitz.com |
