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Coating Materials For Metal-Seated Ball Valves: Ensuring Tight Shut-Off and Extreme Reliability in Service
Coating Materials For Metal-Seated Ball Valves: Ensuring Tight Shut-Off and Extreme Reliability in Service
Ensuring tight
shut-off
and extreme
reliability
in service
Coating materials for
metal-seated ball valves
Metso’s Neles metal seated ball valves offer superior performance and
long lasting tightness over a broad range of services in numerous
industries. Every application presents unique challenges that must be
considered when determining the most suitable valve. Many choices
are straightforward such as size, pressure class, and body material, but
one of the most critical decisions is often the least understood and is
sometimes overlooked. Proper selection of trim coating materials is
essential to ensure that a valve is configured to meet the demands of
the application.
The importance of Properly selected coatings reduce the Selection of trim coatings
trim coatings friction between the ball and seats allowing Valve body, ball and seat materials are
Metal seated ball valves achieve sealing by for smooth sliding operation over many nu- selected based on factors such as pressure,
metal to metal contact between the ball and merous cycles, minimizing damage and wear temperature and chemical compatibility.
seat. When “soft” metals of similar hardness due to galling, abrasion, erosion, particle These criteria must also be considered when
slide against each other under even moder- impact, cavitation and thermal swings. Re- choosing trim coatings. Improper selection
ate pressure, galling occurs. ducing friction in the trim lowers the valve’s can cause almost instant failure of the valve
Microscopic protrusions on the seating operating torque which has several advan- upon startup. It is also important to note that
surfaces catch on each other, resulting in tages. Lower valve torque allows a smaller properly selected trim coatings cannot make
surface friction, heat buildup and plastic de- actuator to be used which is more economi- up for unsuitable base materials.
formation. Typically the damage gets worse cal, results in smaller envelope dimensions Most coatings are porous to some
as the valve cycles until it becomes inoper- of the assembly, improves signal response degree and do not isolate the base material
able due to seizure. If no coatings are applied in control service and simplifies selection of against the effects of corrosive media. Base
to the trim, galling will be visible almost as accessories to meet cycle speed targets and material and coating must both be selected
soon as the valve is cycled on the test bench. other special requirements. to meet the demands of the application.
Once installed in service, the various effects
of difficult media would increase wear rate
exponentially.
Coating materials
Overview of coatings, overlays,
and surface treatments
Hard Chromium (HCr) coating for steam service, catalyst handling,
Hard Chromium is the standard coating slurry services and coal gasification. NiBo
for most Metso valves and is suited to a has limited corrosion resistance and is not
wide range of applications in liquids and recommended for use with acids and wet
gases at moderate temperatures and chlorine. NiBo coating is available on aus-
pressures. Corrosion resistance of HCr is tenic stainless steels like CF8M (316 SS) balls
generally comparable with stainless steels. up to 24” size.
HCr is not compliant with strong acids like
hydrochloric acid (HCl), hydrofluoric acid (HF) Tungsten Carbide (WC-Co)
or sulfuric acid (H2SO4), and it should not Tungsten Carbide is very resistant to wear
be used with seawater, wet chlorine or other from high cycle operations and erosion
media with high chloride content. from abrasive catalysts, muds, slurries and
powders. It is ideal for cryogenic applica-
Nickel Boron (NiBo) tions, oxygen service and non-lubricative
Nickel Boron performs very well in high dry gas services. WC-Co is not suitable for
temperature and high pressure applica- use in corrosive services and condensates
tions. It is resistant to damage from erosion, such as water, but generally performs well in
cavitation and thermal shocks. NiBo is ideal hydrocarbon gases and liquids.
Chromium Carbide (CrC) and suitability for use on different types of Nitriding Thermal Diffusion
Chromium Carbide is well suited to very parts such as seats, plugs, shafts and bearings. Process
high temperature gas or liquid applications Nitriding is a process in which nitrogen
and has excellent resistance to wear, erosion Boride thermal diffusion atoms are diffused into the surface of ferrous
and corrosive media. It performs well in sour process metals like carbon steels or martensitic stain-
(H2S) hydrocarbon gas, high chloride waters, Boride is a proces in which boron is diffused less steels. The nitrogen atoms attach to the
coal liquefaction, catalyst handling and geo- into the surface of the base material and chromium, iron, and other alloying elements,
thermal brine. Low Friction version CrC-LF is can be applied to many ferrous, nickel and which then form hard nitride compounds.
applied to seat surfaces to improve sliding cobalt alloys and carbides. Wear and erosion The hard nitrided surface is useful in extend-
performance. resistance is greatly increased while corro- ing the life of a valve bearing surfaces in high
sion resistance is retained or improved. It is temperature and abrasive applications.
Cobalt Based Alloy well suited to high temperature and abrasive
Metso utilizes multiple coating materials applications and services with demand-
classified as cobalt based hard facings ing material requirements and corrosion
often referred as Stellites® (Deloro Stellite). concerns. There is no adhesive division point
Examples include Alloy 50Nb, Alloy 6 and between the surface boride and substrate,
Alloy 12. Specific materials in this class are resulting in excellent resistance to impact
applied based on their individual properties and thermal shocks.
Recommended applications
Temperature Corrosion Erosion
Ball range, °C resistance resistance Liquid media Dry gas
HCr -50 to +450 Good Good Yes No
NiBo -200 to +600 Good Very good Yes Yes
WC-Co -200 to +450 Moderate Excellent No Yes
CrC -200 to +600* Very good Very good Yes Yes
HVOF carbide coating structure HVOF carbide coating powder Cobalt based weld overlay (PTA)