07 Valves
07 Valves
VALVES
T. N. GOPINATH
INTRODUCTION
Estimates reveal that a substantial
portion, approximately 8-10%, of the
total capital expenditure of the chemical
process industry is used for the
procurement of valves. In terms of the
number of units also, valves exceed any
other piping component. Hence, proper
Functions of Valves
Isolation
Regulation
Non-Return
Special Purpose
2.2
Needle Valves
2.3
Butterfly Valves
2.4
Diaphragm Valves
2.5
Piston Valves
2.6
Pinch Valves
1.0
ISOLATION
1.1
Gate Valves
1.2
Ball Valves
3.0
NON-RETURN
1.3
Plug Valves
3.1
Check Valves
1.4
Piston Valves
4.0
SPECIAL PURPOSE
1.5
Diaphragm Valves
4.1
Multi-port Valves
1.6
Butterfly Valves
4.2
1.7
Pinch Valves
4.3
Float Valves
4.4
Foot Valves
2.0
REGULATION
2.1
Globe Valves
4.5
4.6
Valves
4.0
Gun metal
5.0
Carbon Steel
6.0
Stainless Steel
7.0
8.0
9.0
10.0
11.0
Poly Propylene,
UHMW-HDPE etc.
UHMW-PE,
Special Alloys
Fluoro polymer/Elastomer lined
metals
Glass
1.0
Screwed ends
2.0
3.0
Flanged ends
4.0
5.0
Socketted ends
6.0
2. Class
7.0
Buttress ends
Cast Iron
2.0
Ductile Iron
3.0
Bronze
Valves
Class 150
2.2
Class 300
2.3
Class 400
2.4
Class 600
2.5
Class 900
2.6
Class 1500
2.7
Class 2500
2.8
Class 800
2.9
Class 4500
3. Trim
The trim is comprised of Stem, Seat
Surfaces, Back Seat Bushing and
other small internal parts that
normally contact the service fluid.
The table below indicates trim of
Globe
Swing Check
Lift Check
Stem
Seat Ring
Wedge Ring
Bushing
Stem
Seat Ring
Disc nut
Bushing
Seat Ring
Disc holder
Side plug
Holder pin
Disc nut pin
Disc guide
Seat ring
4. Wetted Parts
All parts, which come in contact with the
service fluid, are called the wetted parts.
5. Wire Drawing
This term is used to indicate the
premature erosion of the valve seat
caused by excessive velocity between
seat and seat disc. An erosion pattern is
left as if a wire had been drawn between
the seat surfaces. Excessive velocity can
occur when the valve is not closed
tightly. A WOG (Water-Oil-Gas,
relatively cool liquids) disc is the best
defense against wiredrawing because its
resilience makes it easier to close tightly.
Discs of harder material are to be closed
carefully to prevent wire drawing. In
LPG Service, the wire drawing effect
causes a threat of anti-refrigeration. The
ice formation on the wedge will obstruct
movement thereby increasing the leak
through seat further.
6. Straight - Through Flow
This refers to the valve in which the
closing element is retracted entirely so
that there is no restriction of flow.
Valves
Position
Gate
Fully
open
Globe
Angle globe
Swing check
Plug
Rectangular
Plug Port
Ball Regular
port
Ball Full port
Equivalent
length in pipe
dia (L/D)
13
340
145
50
18
40
9. Upstream Pressure
This is the pressure of the fluid that
enters the valve. This is sometimes
referred to as inlet or supply pressure.
Maximum seat
leakage
Class I
A modification of
any class II, III or
IV valve where
design intent is the
same as the basic
class, but by
agreement between
user and supplier.
No test is required.
0.5% of rated
valve capacity
0.1% of rated
valve capacity
Class II
Class III
Class IV
0.01% of rated
valve capacity
Class V
5 x 104 ml per
minute water per
inch of orifice
diameter per psi
differential
Class VI
Size, NB
1
1.5
2
2.5
3
4
6
8
Valves
Valves
F6
304
F310
Hard F6
Hardfaced
Hardfaced
F6 and
Cu-Ni
F6 and
Hard F6
F6 and
Hardfaced
F6 and
Hardfaced
Monel
316
Monel
Hardfaced
316 and
Hardfaced
Alloy 20
Alloy 20
and
Hardfaced
Trim
No.
1
2
3
4
5
5A
6
Trim 5 or 5A
350
13 Cr
18-8 Cr-Ni
25-20 Cr-Ni
Hard 13 Cr
h
Co Cr-Al
Ni-Cr
13 Cr
Cu-Ni
13 Cr
Hard 13 Cr
13 Cr
h
Co Cr-Al
13 Cr
Ni-Cr
Ni-Cu alloy
18-8 Cr-Ni
Ni-Cu alloy
Trim 5 or 5A
18-8 Cr-Ni
Trim 5 or 5A
19-29 Cr-Ni
19-29 Cr-Ni
b
c
c
d
750
d
350
d
350
f
250
f
175
f
300
f
750
f
300
f
350
f
300
f
350
c
c
c
f
350
c
f
350
e
c
Seat
hardness
Material
a
(HB , minimum) Type
f Hardness differential between body gate seats shall be as per the manufacturer's standard.
g Manufacturer's standard, within 30 Ni minimum
h This classification includes such trademarked materials such as stellite 6, Stoody 6, and Wallex 6.
i Manufacturer's standard hardfacing, with 25 percent Fe maximum.
See Trim 5 or 5A
Welded
Cast
13
14
12
9
10
11
8A
Nominal
Trim
TRIM:
SERVICE
Size NB
NPS NPS
11/2
Steam H.P.
NPS2NPS12
2.
Valves
Steam L.P.
NPS NPS
11/2
Isolation
Regulation
Non-return
Remarks
a)
C.S.
Body
stellited trim
Class
800
Globe with
SW ends
b) C.S.
Body
stellited trim
Class
800
Piston with
SW ends
c) C S Body SS
Ball. Special
PTFE seats.
Class 800 S
ball
valves
with
Scrd
ends.
a) C.S. Body
stellited trim
Class 800 Globe
with SW ends
b) C.S. Body
stellited trim
Class 800 Piston
with SW ends
C.S. Body
Stellited trim
Class 800
Lift check
with SW
Ends
Piston valves
are costlier.
From the point
of view of
Energy
conservation
they are O.K.
a)
CS Body
Stellited trim
Class 300 /
Class 150
Flgd Gate
with flex
Wedge
b) CS Body
13% Cr trim
Class 300/
Class 150
Flgd Piston
a) CS Body
stellited trim
Class 300 /
Class 150
Flgd
Globe
a)
a) CS Body
13% Cr. Trim
Class 800 Globe
with SW ends
b) CS Body
13% Cr. Trim
Class 800 Piston
With SW ends
CS Body
13% Cr. Trim
Class 800
Globe with
SW ends
b) CS Body
13% Cr. Trim
Class 800
Piston With
SW ends
c) C S Body SS
Ball. Special
PTFE seats.
Class 800
SW ball valve
ALL VALVES
TO BE
APPROVED
BY IBR
a) CS Body
stellited trim
Class 300/
Class 150
Flgd swing
check
b) CS Body
13% Cr trim
Class 300/ Class
150 Flgd Piston
C.S. Body
13% Cr trim
Class 800
Lift check
With SW
Ends
No IBR
APPROVAL
REQUIRED.
FOR
PRESSURE
NPS2NPS12
Condensate
NPS NPS
11/2
a)
CS Body a
13% Cr. Trim
Flex wedge
Class 150
Flgd Gate
b) CS Body
13% Cr trim
Class 150
Flgd Piston
a)
a)
a)
C.S. Body SS
ball PTFE
seat Class
800 SW Ball
b) C.S. Body
13% Cr. Trim
Class 800
SW Globe
NPS2NPS12
4.
Valves
Utilities like
Water, Air, LSHS
C.S. Body
13% Cr. trim
Class 150
Lift check
With SW
Ends
C.S. Body
13% Cr.
Trim Class
800 SW
Globe valve
SAME AS LP STEAM
a)
NPS NPS
11/2
CS Body
13%Cr trim
150# Flgd
Globe
b) CS Body
13% Cr
trim
Class 150
Flgd
Piston
C.S. Body SS
Ball PTFE
Seat Class
800 Scrd.
Ball
b) G.M. Body
Bronze trim
Scrd Gate to
IS 778
a)
C.S. Body
13% Cr.
Trim Class
800 SW
Globe
b) G.M. Body
Bronze
Trim Scrd
Globe to IS
778
a)
C.S.
Body
13% Cr.
Trim
Class
800 Lift
check
With
SW
Ends
b) G.M.
Body
Bronze
Trim
Scrd
check to
IS 778
Recommended
for Isolation
a) CI Body 13%
Cr disc Class
125 wafer type
Butterfly Gear
Operator above
6 NB
c)
CS Body
13% Cr
trim Class
150 Flgd
Gate
d) Cast Iron
Body 13% Cr
plug Class
125 Fldg
Lub. Plug
Valve
c) CS Body
13% Cr trim
Class 150 flgd
Globe
a)
a)
a)
NPS2NPS12
Valves
NPS NPS
11/2
C.S. Body
Stellited trim
Graphoil pkg
Class 800
SW Globe
b) C.S. Body
13% trim
Class 800
SW Piston
with suitable
sealing rings
b) CI Body
13% or
18% Cr
trim
Class 125
Flgd Globe
-------
CS. Body
Stellited
trim
Graphoil
pkg Class
800 SW
Globe
b) CS. Body
13% trim
Class 800
SW Piston
with
suitable
sealing
rings
a)
CS
Body
13% Cr.
trim
water
type
check
b) CI Body
13% or
18% Cr
tri Class
125 flgd
swing
check to
IS 5312
c) CS Body
13 % Cr trim
Class 150
flgd swing
check
a)
C.S.
Body
stellited
trim
Class
800
SW lift
check
a) CS Body
stellited trim
graphoil pkg
Class 300 (Min)
Flgd Gate with
125 250
AARH Flgd
finish
NPS NPS
11/2
Globe Valve
with CS Body
Monel /
Hastalloy C trim
NPS NPS 12
a)
C.S. Body SS
Ball 150 Flgd
full port Ball
valve with
PTFE/ GFT
seats
b) CS Body
13% Cr plug
Class 150
Flgd sleeved
plug seats
a)
a)
a) SS body SS
trim Class 150
Flgd Globe
a)
NPS2NPS12
Chlorine (Dry)
Solvent/ Process
(Carbon Steel)
Valves
Solvent/ Process
(Stainless Steel)
NPS NPS 12
SS Body SS
ball Class
150 Fldg full
port ball
valve with
PTFE / GFT
seats
b) SS Body SS
Plug Class
150 Flgd
sleeved plug
CS Body
stellited trim
Class 300
(Min) Flgd
swing check
with 125
250 AARH
Flgd Finish
b) CS Body
13% Cr trim
Graphoil pkg
Class 300 (Min)
Flgd Piston with
Suitable sealing
ring and 125
250 AARH Flgd
finish
C.S. Body
13% Cr.
trim Class
150 Flgd
Globe
Check (Lift /
Swing )
valve CS
Monel /
Hastalloy C
trim
a) C.S. Body
13% Cr. trim
Flgd Lift
check to
1 and
Flgd swing
check 2 &
above
SS Body SS
trim Class
150 Flgd
swing check
Solvent/ Process
(Highly
Corrosive)
Valves
NPS NPS 12
Ductile Iron
body & plug
lined with
fluoropoymer
plug valve
b) Ball valve
with suitable
plastic body
and ball
a)
____
Ductile
Iron
body
lined
with
fluoro
polymer
ball
check
valve
b) ---do---
Suitabi-lity with
Tempera-ture to
be checked
Ball Valves
1.3
Plug Valves
1.4
Piston Valves
1.5
Diaphragm Valves
1.6
Butterfly Valves
1.7
Pinch Valves
17
16
12
11
1.1.3
Wedge
1.1.4
Stem
1.1.5
Gland
1.1.6
Seat ring
1.1.7
Yoke
1.1.8
Packing
1.1.9
Gland Flange
1.1.10
Valve Port
1.1.11
Yoke Bush
1.1.12
Lantern
1.1.13
1.1.14
1.1.15
1.1.16
Hand Wheel
1.1.17
GATE VALVES
A typical Gate valve will have the
following parts, which could be
identified.
1.1.1
1.1.2
Valves
Body
Bonnet
Bonnet Gasket
1.1.1 Body
The body is the part which gets
attached to the vessel or piping. The
classification of the body could be done
depending on the end connections as
indicated earlier. Body could also be
specified based on the material of
construction of the same. This could be
cast, forged or fabricated.
The wall thickness and end to
end/face to face dimensions of the body
shall be as per the Regulatory code to
which it is designed.
The end flanges shall be
integrally cast or forged with the body. It
can also be attached by welding, if so
specified. The end connection shall suit
the rating specified. The flanged
connection shall be to ASME B 16.5 or
any of the flange standards. The buttwelding end connection shall be to
ASME B 16.25 or any other end
preparation required. The socket
weld/screw connection shall be to
ASME B 16.11 or any other equivalent
standards. The body can have auxiliary
connection such as drains, by-pass
connections, etc.
1.1.2 Bonnet
The bonnet is classified based
on the attachment of the same to the
body. The type of connection normally
adopted are Bolted, Bellow sealed,
Screwed-on, Welded, Union, Pressure
sealed etc.
The bolted connection shall be
flanged, male and female, tongue and
groove or ring type joint. In low pressure
rating valves, it may be flat faced. The
bonnet gasket is selected to suit bodybonnet connection. It can be corrugated
flat solid metal, flat metal jacketed,
asbestos filled, metal ring joint, spiral
wound asbestos filled or flat ring
compressed asbestos in case of low
pressure rating, and Teflon or Teflon
filled for corrosive applications.
Valves
Split Wedge
Valves
Size
14 NB & above
12 NB & above
8 NB & above
Valves
Lined Body
Sandwich design.
Valves
Valves
PLUG VALVES
The plug valves, like ball
valves, are quarter turn positive shut off
valves. Two major types of plug valves
are in use. They are the lubricated metalseated plug valves and Teflon sleeved
plug valves. These valves can have
flanged, butt-welded, screwed or socket
weld ends. The pressure classification is
Valves
Full
Bore
Ball
73
284
1158
1158
1950
---
Reg.
Bore
Ball
86
284
284
1158
1158
---
Pr.
Balanced
Plug
60
120
175
325
600
910
1300
Valves
1.4
PISTON VALVES
Valves
1.4.2
Bonnet
1.4.3
Piston
1.4.4
Valve rings
1.4.5
Lantern bush
1.4.6
Spindle
1.4.7
Gland
1.4.8
Packing
1.4.9
Hand wheel
1.4.10
Yoke bush
1.4.11
Bonnet stud
1.4.12
Gland eyebolt
Valves
6. Compressor
7. Hand wheel
8. Bonnet bolting
Valves
1.6
BUTTERFLY VALVES
PINCH VALVES
Pinch valves are also similar to
diaphragm valves. In Pinch valves, the
body is provided with sleeves, which get
squeezed to control or stop the flow. The
sleeve could be of corrosion resistant
materials like Rubber or PTFE. The
body is normally made from cast iron.
These are used for special services where
service pressures are very low like
isolation of the hose connections etc. in
the chemical process industry. The body
is cast and can have flanged or screwed
ends.
Of late, manufacturers have
developed these valves to endure higher
pressures and temperatures (0 to 100 bar
& up to 120C respectively) for
application in mining and mineral
industry.
These valves are also not
covered under API or ASME standards
and
are
manufactured
as
per
Manufacturers standards.
2.0 REGULATING VALVES
The valves normally used in the
plant to regulate/control the flow are:
2.1
Globe Valves
2.2
Valves
Needle Valves
2.3
Butterfly Valves
2.4
Diaphragm Valves
2.5
Piston Valves
2.6
Pinch Valves
GLOBE VALVES
A typical globe valve has the
following parts, which could be
identified.
2. Bonnet
2.1.1
3. Yoke
4. Backup Ring
5. Thrust Ring
6. Gasket
7. Gland
8. Stud and Nut
9. Plug
10. Seat Ring
11. Spindle
12. Plug Nut
13. Back seat
14. Clamp
15. Gland Bush
Body
The construction of the body
differs from that of the gate valve. The
body ports are arranged such that the
flow is from the underside of the disk.
Though the code specifies that the globe
valves shall be designed suitable for
installation in either direction of flow,
the preferred direction of flow for globe
valve shall be from under the disk.
Normally the direction of flow is cast or
embossed on the valve body.
There are two types of port
designs possible, the full port and the
reduced port. In the full port design, the
body ports shall be as large as
practicable design considerations permit.
However, in no case the net area of the
bore through the seat of globe shall be
less than the 85% of the area of the
actual pipe bore. In the reduced port
design, the port diameter is normally one
size less than that of the connected pipe.
2.1.2 Bonnet
The body bonnet connection for
the globe valve is the same as that of
gate valves.
2.1.3 Disk
The disk of the globe valves
shall be:
Plug type
Ball type
Needle type
V port type
2.1.4 Stem
In case of globe valves, the
stem is always of rising design along
with the hand wheel. The stem is
provided with a disk nut at the lower
end. The upper end is provided with a
hand wheel screwed by stem nut. In case
of bellow sealed valves, rising stem with
non-rising hand wheel is provided
similar to that in the case of gate valve.
2.2
Valves
NEEDLE VALVES
The needle valves, like globe
valves, are used for flow control.
Normally, needle valves are used in
smaller sizes and are provided with
either screwed or socket weld end The
design of the needle valve can be exactly
same as that of the globe valve except
for the disk. In globe valves, the disk is
3.2
Valves
3.1.2
3.1.3
Non-slam check
5. Guide
6. Gasket
7. Cover stud nut
The body shall be of forged or
cast construction and with socket
welded/screwed/flanged ends, integrally
cast or with welded-on flanges.
The cover shall be either bolted
or welded or with union nuts. The union
nuts could be of hexagonal or octagonal
shape. The cover material shall be same
as that of the body.
The seating shall be integral or
renewable. The hardness difference can
also be achieved by weld deposit on
seating surfaces. The renewable seat
rings shall be screwed-in type, either
shoulder seated or bottom seated.
3.1.3 NON-SLAM CHECK VALVES
The non-slam check valve is a
spring loaded lift check valve with a
modified design of the body. The valve
is designed in such a way that the same
can be sandwiched between the two
flanges. Here the disc is held in position
by a spring, which is housed, in a
housing cap or yoke.
3.2
Multi-port Valves
4.2
4.3
Float Valves
4.4
Foot Valves
Valves
4.5
FLOAT VALVES
Float valves are used to control
the level of fluid in a reservoir. Only the
inlet of the valve is connected with the
supply pipeline and the outlet is open to
the reservoir. There will be a float with
lever, which controls the movement of
the piston regulating the flow.
Valves
Pressure Tests
Pressure tests, unless otherwise
specified, shall be carried out on each
valve as follows;
PRESSURE
SHELL
CLASS (Lbs)
SEAT
(NOTE # 1)
150
30
21
300
76
54
400
100
74
600
150
110
900
225
165
1500
373
274
2500
621
456
800
210
152
1.
2.
Seat - hydrostatic
Seat - Pneumatic
Valves