Valve Basics PDF

VALVE
ENGINEERING
AND SELECTION
PATRICK. M. MORRELL.
PIPING MATERIAL
SPECIFICATION ENGINEER.
FOSTER WHEELER
ENERGY LTD.
READING.
UNITED KINGDOM.
TOPIC 1 VALVE SELECTION CRITERIA
TOPIC 2 BALL VALVE CONSTRUCTION AND SELECTION
TOPIC 3 GATE VALVE CONSTRUCTION AND SELECTION
TOPIC 4 GLOBE VALVE CONSTRUCTION AND SELECTION
TOPIC 5 CHECK VALVE CONSTRUCTION AND SELECTION
TOPIC 6 BUTTERFLY VALVE CONSTRUCTION AND

SELECTION
TOPIC 7 NOT USED
TOPIC 8 VALVE STEM PACKING DESIGN
TOPIC 9 SELECTION OF VALVE TRIM MATERIALS AND

DESIGN
TOPIC 10 BASIC TYPE OF NDE TESTING FOR VALVES
TOPIC 11 VALVE PRESSURE TESTING TO INTERNATIONAL

STANDARDS
TOPIC 1.1
VALVE SELECTION
CRITERIA
TOPIC 1.2
Introduction
I The selection of any valve is

based upon a number of factors.
I It is important that engineers

understand the selection process
for valves in order to ensure the
most efficient, safe, reliable and
cost effective valve is utilized
without excessive maintenance.
TOPIC 1.3
Areas of Discussion in this
section
I Factors that drive the selection of

valve types.
1. Codes / practices, standards and

regulations.
2. Function.
3. Valve Standard design features.
4. Service conditions.
5. Sealing philosophy.
6. Operability and Maintainability.
7. Safety considerations.
8. Weight and size limitations.
9. Cost, availability and delivery.
10. Standard material form and grades.
11. Standard material, Hydro test and general
certification requirements
TOPIC 1.3.1/1
Codes / practices, standards and
regulations.
I THE DESIGN CODE APPLIED TO THE PIPING SYSTEM WILL

USUALLY DETERMINE THE CODES AND STANDARDS USED
FOR THE VALVES.
I SOME VALVE TYPE STANDARDS ARE NOT COVERED BY

THE RESPECTIVE ORGANIZATIONS.
I CLIENT CORPORATE DESIGN STANDARDS SHOULD

ALWAYS BE REVIEWED FOR DEVIATIONS TO NATIONAL AND
INTERNATIONAL STANDARDS
I LOCAL STATUTORY REGULATIONS MAY APPLY IN VARIOUS

AREAS OF THE WORLD. MAY INVOLVE APPROVED
SUPPLIERS, TESTING, CERTIFICATION. EXAMPLE –
SINGAPORE – PUB REQUIREMENTS. CHINESE – DESIGN
INSTITUTE AND INSPECTION REQUIREMENTS
I NATIONAL AS WELL AS INTERNATIONAL STANDARDS MAY

APPLY TO VALVE DESIGN AND TESTING.
I WHOSE INTERESTS ARE COVERED / REPRESENTED BY

INTERNATIONAL CODES AND STANDARDS. ?
TOPIC 1.3.1/2.
regulations.
LIST OF ORGANIZATIONS APPLICABLE TO VALVE DESIGN.
I ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS) –

ASME B16.34 - THIS STANDARD APPLIES TO VALVE
CONSTRUCTION AND COVERS THE MAJOR PARAMETERS IE
WALL THICKNESS, PRESSURE / TEMP RATING, ETC
I ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS).

USED EXTENSIVELY FOR MATERIAL GRADING
I API (AMERICAN PETROLEUM INSTITUTE)

API 6D – PIPELINE VALVE CONSTRUCTION. APPLIED
GENERALLY TO PIPELINE VALVES.
I BS - (BRITISH STANDARDS).
I ISO - INTERNATIONAL STANDARDS ORGANIZATION.

NOT GENERALLY APPLIED TO VALVE STANDARDS AS IT
NEVER GAINED POPULARITY AMONG MANUFACTURERS,
SPECIFIERS OR ENDUSERS.
I EN - (EUROPEAN NORM).
HARMONIZED STANDARDS ARE CURRENTLY BEING
DEVELOPED AND ARE AT VARYING STAGES OF ISSUE. A
LARGE NUMBER ARE ALREADY ISSUED FOR USE. MANY
STANDARDS ARE NOW CLASSED AS BS EN ISO OR BS EN
OR EN ISO.
TOPIC 1.3.1/3.
regulations.
LIST OF ORGANIZATIONS APPLICABLE TO VALVE DESIGN –
CONTD.
I PER – PRESSURE EQUIPMENT REGULATIONS –

EUROPEAN REGULATORY BODY
I MSS – MANUFACTURERS STANDARDISATION SOCIETY.

(AMERICAN).
MSS-SP-92 – VALVE USER GUIDE.
I EEMUA – ENGINEERING EQUIPMENT AND MATERIAL USERS

ORGANIZATION.(UK)
A NUMBER OF GUIDES AVAILABLE FOR VALVE SELECTION.
I NACE – NATIONAL ASSOCIATION OF CORROSION

ENGINEERS.
MR0175 – PART 1 & 2 - PETROLEUM AND NATURAL GAS
INDUSTRIES. MATERIALS FOR USE IN H2S-CONTAINING
ENVIRONMENTS IN OIL AND GAS PRODUCTION.
BVAMA – BRITISH VALVE AND ACTUATOR MANUFACTURERS

ASSOCIATION
A NUMBER OF GUIDES AND BOOKS AVAILABLE FOR
INFORMATION.
TOPIC 1.3.2
Function.
I ON / OFF (ISOLATION VALVES)
USED IN FULLY OPEN OR FULLY CLOSED POSITION
I FLOW CONTROL / THROTTLING

USED FOR CONTROLLING OR THROTTLING THE FLOW
I REVERSE FLOW VALVES

USED TO ENSURE FLOW IS UNI-DIRECTIONAL (ONE WAY)
I FAIL SAFE (FAIL OPEN OR FAIL CLOSE)
I ON / OFF (ISOLATION VALVES) – FREQUENT OR

INFREQUENT USE
USED IN FULLY OPEN OR FULLY CLOSED POSITION
TOPIC 1.3.3/1
Valve standard design features.
STANDARDS
I BUYING A VALVE TO RECOGNIZED STANDARDS SHOULD

GIVE THE FOLLOWING BENEFITS:
a) A LEVEL OF STANDARDIZATION TO THE VALVE DESIGN.
b) ALLOWS COMMERCIAL AVAILABILITY OF VALVES FROM

DIFFERENT SOURCES.
c) ALLOWS INTERCHANGEABILITY OF VALVES FROM

DIFFERENT SOURCES.
d) A LEVEL OF STANDARDIZATION TO THE VALVE TESTING

AND CERTIFYING.
e) A LEVEL OF QUALITY IN THE PRODUCT.
f) TRACE-ABILITY OF THE DESIGN.
g) A KNOWN LEVEL OF INTEGRITY.
THIS LEADS TO A VARYING LEVEL OF BUYER

CONFIDENCE IN THE VALVE.
I SOME VALVES WHICH HAVE BEEN DEVELOPED TO

OVERCOME SPECIFIC PROBLEMS DO NOT HAVE
ASSOCIATED STANDARDS AND ARE CLASSED AS
PROPRIETARY VALVES.
TOPIC 1.3.3/2
STANDARD DESIGN FEATURES
I END TO END DIMENSIONS for THREADED AND

SOCKETWELD VALVES
- End to end dimensions for small bore valves are not
covered by the relevant international standards and are
therefore subject to variation. However as valves are
generally used for small bore field run piping it seldom
presents a problem.
I FACE TO FACE DIMENSIONS for FLANGE AND

BUTTWELD VALVES
- For commercial valves generally to ASME B16.10
- For proprietary valves manufacturers standard .
Ball valves can be supplied in a long and short pattern

design as stated in ASME B16.10. Care should be taken
to ensure the procured valve face to face dimension suits
your design.
Copper alloy valve face to face dimensions are covered

by BS 5154 and MSS-SP-80.
Refer to next page for extract from ASME B16.10.

TOPIC 1.3.3/3
I FACE TO FACE DIMENSIONS FOR FLANGED AND
BUTTWELD VALVES.
TOPIC 1.3.3/4
I END CONNECTIONS
Valve end connection type is shall be closely aligned to the pipe class
end connection criteria.
Exceptions to this are ball valves or other soft seated valves which are
commonly specified as flanged when the pipe class fittings specify
socket weld, threaded or butt weld
SOCKET ½” – 1 ½” – CLASS 800/ GEN HYDROCARBONS.

WELD 1500 GEN UTILITIES.
NON FLAMMABLES.
NON CORROSIVE.
THREADED ½” – 1 ½” – CLASS 125/150/ GEN HYDROCARBONS.

800 GENERAL UTILITIES.
NON FLAMMABLES.
NON CORROSIVE.
FLANGED FF/RF
2” – + CLASS 125/150/ GEN HYDROCARBONS.
300/600/900 GEN UTILITIES.
FLANGE RTJ 900/1500/2500 FLAMMABLE
(HIGH PRESSURE) NON FLAMMABLES
(HIGH TEMPERATURE) CORROSIVE
NON CORROSIVE.
CORROSIVE
HYDROCARBONS.
TOPIC 1.3.3/5
I END CONNECTIONS
WAFER RF /FF
½” - + CLASS 150/300 UTILITIES
GEN HYDROCARBONS
BUTTWELD ½” – + CLASS 900/ COR HYDROCARBONS

(HIGH PRESSURE) 1500/2500 GEN UTILITIES
(HIGH TEMPERATURE) FLAMMABLE
NON FLAMMABLES
CORROSIVE
NON CORROSIVE
COMPRESSION
½” – 2” UTILITIES
CAPILLARY ½” – 6” WATER UTILITIES

OFFSHORE UTILITIES
TOPIC 1.3.3/6
I VALVE OPERATION (MANUAL)
WRENCH –
ASSOCIATED WITH QUARTER TURN VALVES.
HANDWHEEL –
ASSOCIATED WITH MULTI TURN VALVES. HANDWHEELS
SHOULD BE CAST, FORGED OR WROUGHT MATERIAL NOT
PRESSED PLATE AS IT IS MORE SUSCEPTIBLE TO
CORROSION WHICH CAN RESULT IN SHARP EDGES BEING
EXPOSED AND THEREFORE A DANGER TO PERSONNEL
T- BAR –
ASSOCIATED WITH QUARTER TURN VALVES HAVING HIGHER
FRICTIONAL RESISTANCE BETWEEN SEAT AND OBTURATOR.
SPRING RETURN WRENCH –

FAILSAFE FEATURE, FOR QUARTER TURN VALVES. THEY ARE
USUALLY PROPRIETARY ITEMS. WHERE THE REQUIRED
OPERATING TORQUE EXCEED THE LIMIT OF THE SPRING
RETURN WRENCH A SPRING RETURN ACTUATOR CAN BE
FITTED AND A LEVER ATTACHED TO THE CENTRE PINION OF
THE ACTUATOR
OVAL SAFETY HANDWHEEL –

USED ON QUARTER TURN VALVES IN LIEU OF A LEVER TO
REDUCE RISK OF ACCIDENTAL OPEN / CLOSING.
TOPIC 1.3.3/7
I VALVE OPERATION (MANUAL)
GEAR OPERATORS –
GENERALLY USED WHERE THE EFFORT / FORCE REQUIRED
TO OPERATE THE VALVE EXCEEDS AN ACCEPTABLE LEVEL.
CAN BE COSTLY THEREFORE CAREFUL CONSIDERATION

SHOULD BE GIVEN WHEN APPLYING HANDWHEEL / GEAR
OPERATOR TO VALVE SIZE BREAK .
THE UNIT SHALL BE A WEATHERPROOF / SEALED HOUSING,

FULLY LUBRICATED.
IT SHALL HAVE A RATIO WHICH ENSURES A SUITABLE

OPENING TIME FOR THE VALVE. LIMIT STOPS ARE FITTED TO
ENSURE OVER TRAVEL DOES NOT OCCUR RESULTING IN
DAMAGE TO THE STEM AND SEATS..
FREQUENCY OF OPERATION MAY ALSO DETERMINE IF GEAR

OPERATOR IS FITTED.
NOTE: FWEL 51A2 VALVE DOCUMENT DEFINES SIZE SPLIT

BETWEEN MANUAL AND GEAR OPERATED VALVES BY VALVE
TYPE. CLIENT TECHNICAL DOCUMENTS (IF ANY) SHOULD ALSO
BE REVIEWED.
TOPIC 1.3.4
Service conditions
• SERVICE FLUID CONDITIONS DICTATE BOTH VALVE TYPE

AND THE MATERIAL SELECTION.
• GENERALLY VALVE BODY MATERIAL GRADES ARE

CLOSELY ALIGNED TO THE PIPE CLASS MATERIAL
SPECIFICATION FOR ECONOMIC REASONS.
• VALVE TRIM MATERIAL GRADES VARY DEPENDANT UPON

SERVICE CORROSIVE AND P/T RATINGS.
• VALVE DESIGNS TO ASME B16.34. HAVE A MAXIMUM

CORROSION ALLOWANCE OF 3MM DESIGNED INTO THE
WALL THICKNESS. IF CORROSIVE SERVICES REQUIRE
C/A IN EXCESS OF THIS THEN IT SHALL BE SPECIFIED AS
AN ADDITIONAL WALL THICKNESS. THIS APPLIES TO THE
PRESSURE ENVELOPE COMP0NENTS.
• IN CORROSIVE SOUR SERVICE CONDITIONS (SUCH AS

WET HYDROGEN SULPHIDE, WET H2S) IT IS FWEL POLICY
TO APPLY NACE STANDARD MR0175.
• UTILITIES – CAN BE CORROSIVE IE . SALTWATER.

• NON CORROSIVE – GENERAL HYDROCARBONS / CLEAN.
• CORROSIVE – CHEMICALS, WET H2S.
• GAS
• CARCINOGENIC / TOXIC
• SLURRIES / ABRASIVE.
• IS SERVICE SENSITIVE TO VELOCITY.
• HIGH TEMPERATURE / PRESSURE
• CRYOGENIC
• OXYGEN AND HIGH PURITY SERVICES.
TOPIC 1.3.5
Sealing philosophy
• GENERALLY BASED UPON THE SEAT / DISK MATERIAL

COMBINATION.
• SOFT SEATED VALVES
A VALVE THAT HAS A SEATING COMP0NENT MADE FROM A

POLYMERIC OR ELASTOMERIC MATERIAL. GENERALLY
CONSIDERED TO ACHIEVE BUBBLE TIGHT SHUTOFF, NO
VISIBLE LEAKAGE. A MANUFACTURER OF QUALITY WILL
STATE THIS AS STANDARD.
• METAL TO METAL SEATED VALVES
• IN GENERAL THESE VALVES ARE NOT CAPABLE OF

BUBBLE TIGHT SHUTOFF AND WILL PASS A CERTAIN
AMOUNT OF MEDIA. HOWEVER THIS MUST BE WITHIN THE
REQUIREMENTS OF THE SPECIFIED TESTING STANDARD.
• A HIGHER LEVEL OF SHUT OFF CAN BE ACHIEVED ON

METAL TO METAL SEATED VALVES BY LAPPING THE TWO
MATING FACES. HOWEVER THIS ADDS CONSIDERABLE
COST AND TIME TO THE VALVE MANUFACTURING
PROCESS.
• THEREFORE WHEN SELECTING A VALVE, CONSIDERATION

MUST BE GIVEN TO THE ACCEPTABLE DEGREE OF SHUT
OFF REQUIRED FOR THE PROCESS.
• LEAKAGE RATES AND TESTING ARE DETAILED WITHIN

INTERNATIONAL STANDARDS API 598 / BS 6755 PT 1 / EN
12266 / ISO 5208.
TOPIC 1.3.6
Operability and maintainability
• CONSIDER IF THE DESIGN OF THE VALVE SELECTED
ALLOWS ECONOMIC MAINTENANCE.
• FOR EXAMPLE
BUTTWELD VALVES AFFORD HIGH INTEGRITY OF THE
PIPING SYSTEM BUT MAINTENANCE IS COMPLICATED.
VALVE SHOULD HAVE TOP ENTRY ACCESS TO INTERNALS
FOR MAINTENANCE. ON MEDIUM AND LARGE SIZED
VALVES SUITABLE ACCESS AND SPACE ENVELOPE MUST
BE ALLOWED FOR IN THE PLANT DESIGN TO ALLOW
REMOVAL OF COMPONENTS.
• CONSIDER IF THE SERVICE / SYSTEM REQUIRES HIGHER

MAINTENANCE REQUIREMENTS. IE. EXTREME
CORROSION, PRODUCT BUILD UP.
• IN GENERAL BALL VALVES AND SOFT SEATED VALVES

HAVE MORE PRECISION COMPONENTS THAN GATE,
GLOBE AND CHECK VALVES. THEREFORE MAINTENANCE
ON THE PLANT IS NOT DESIRED DUE TO INGRESS OF DIRT
AND DAMAGE TO COMPONENTS
• CLIENT MAY HAVE REQUIREMENT FOR SPECIFIC STYLE OF

VALVE IN A PARTICULAR LOCATION TO GIVE EXTRA
LONGEVITY BETWEEN PLANNED MAINTENANCE DATES.
• SPARES REQUIREMENT FOR VALVE SHOULD BE

CONSIDERED TO ENSURE COST EFFECTIVENESS OF
VALVE DESIGN. CONSIDER COMMISSIONING SPARES, TWO
YEARS SPARES, LONG TERM SPARES
• ULTIMATELY IT IS USUALLY PREFERRED THAT VALVE

MAINTENANCE IS DONE OFF PLANT.HOWEVER THIS MAY
NOT BE POSSIBLE IF THE VALVE IS REMOTE IN A PIPE
LINE.
TOPIC 1.3.7/1/1
Safety considerations
FIRESAFE DESIGN
• APPLIES IN GENERAL TO SOFTED SEATED VALVES. THE

CRITERIA DEFINES FIRESAFE AS A VALVE DESIGN WHICH
HAS BEEN EXPOSED TO A CONTROLLED FIRE TEST AND
HAS SHOWN THAT AFTER THE POLYMER SEATS AND
GASKETS HAVE BURNT AWAY THE VALVE CAN STILL EFFECT
A SEAL WHEN OPERATED. THIS APPLIES NOT ONLY TO THE
SEAT SEALS BUT ALSO BODY AND STEM SEALS.
• IT IS USUALLY PERFORMED AS A TYPE TEST AT THE VALVE

DESIGN STAGE.
• UNFORTUNATELY THE TEST DOES NOT TRULY MIMIC A FIRE

ON A REFINERY WHICH IN TURN MAY BE DIFFERENT TO A
FIRE ON A CHEMICAL PLANT AND THEREFORE RESULTS
FROM TESTING ARE BASED ON THEORETICAL CRITERIA.
• THE LARGER THE VALVE THE MORE DIFFICULT IT IS TO FIRE

TEST DUE TO SHEER AMOUNT OF METAL TO HEAT, LENGTH
OF TIME TO HEAT THE VALVE AND UNEVENNESS OF THE
TEMPERATURE
• FIRE TEST STANDARDS INCLUDE BS 6755 PT2. / API 607 / API

6FA / GENERALLY OUTLINE METHODS OF TESTING, TEST
PRESSURE, SIZE OF VALVE, DURATION OF TESTS,
ALLOWABLE LEAKAGE DURING AND AFTER TEST, FUEL,
ORIENTATION OF VALVE, MEASUREMENT OF LEAKAGE.
• CERTIFICATION SHOULD BE AVAILABLE UPON REQUEST
• VALVES ARE USUALLY THE FIRST LINE OF CONTROL IN

FLAMMABLE SYSTEMS. THEY PLAY A ROLE WHICH IS
COMPLETELY DISPROPORTIONATE TO THEIR COST AND
SIZE AND ARE A CRITICAL COMPONENT IN THE SAFETY OF
THE SYSYEM, NOT SPEFICYING FIRE TESTED VALVES
WOULD BE UNWISE.
TOPIC 1.3.7/1/2
FIRESAFE DESIGN
THE STANDARDS ONLY SPECIFY VALVE SIZES UP TO

APPROX 400NB. EXCEPT API 6FA WHICH SPECIFY ALL
SIZES AND RATINGS IN API 6D.
API 6FA SHOULD BE USED FOR LARGER VALVES.
THE FOLLOWING CRITERIA IS GENERALLY SPECIFIED

WHEN FIRE TESTING:
• STEM POSITION; GENERALLY HORIZONTAL.

• VALVE IN CLOSED POSITION.
• TEST PRESSURE DURING TEST: 700-800 DEG F. @ CLASS
RATING.
• BODY TEMP: 650 DEG.C.
• FLAME TEMP: 760-980 DEG.C.
• BURN DURATION: 30 MIN.
• LEAKAGE MEASUREMENTS: TAKEN DURING AND AFTER
TEST.
• OPERATION: 1 CYCLE CLOSED TO OPEN.
THE TEST MEDIA IS GENERALLY WATER ON THE

UPSTREAM SIDE OF THE VALVE
MAX. LEAKAGE DURING TEST (ML/MM/MIN:

SEAT (HP) = 15.7
EXTERNAL (HP) = 3.9
MAX. LEAKAGE AFTER TEST (ML/MM/MIN:

SEAT (LP) = 1.6
EXTERNAL (LP) = 0.8
TOPIC 1.3.7/2/1
FUGITIVE EMISSION DESIGN
THE TERM “FUGITIVE EMISSIONS” REFERS TO THE

HAZARDOUS AND NATURALLY UNWANTED POLLUTANTS
(GREEN HOUSE GASES), WHICH ARE RELEASED FROM VALVES
DUE TO GROWING GOVERNMENT/PUBLIC ENVIRONMENTAL

AWARENESS AND CONTINUING ENVIRONMENTAL
LEGISLATION, PLANT OPERATORS ARE NOW HAVING TO TAKE
ACTION TO IDENTIFY AND CONTROL THE RELEASE OF
HARMFUL AND UNWANTED POLLUTANTS.
THE SOURCE OF EMISSIONS FROM VALVES HAS BEEN FROM

THE FOLLOWING LOCATIONS:
A). STEM SEALING AREA.
B). BODY JOINTING POSITIONS.
C). END CONNECTION LOCATIONS.
D). BODY PENETRATIONS (DUE TO THE TYPE AND DESIGN OF
VALVE).
IN PREVIOUS DECADES, LEAKAGE WAS UNACCEPTABLE ONLY

IF IT WAS VISIBLE, AUDIBLE OR AN IMMEDIATE THREAT TO
PERSONNEL OR PROCESS LOSS.
THE PUBLICATION OF RELATIVELY RECENT US AND GERMAN

LEGISLATION HAS CAUSED PLANT OPERATORS TO
DRAMATICALLY REASSESS THIS PHILOSOPHY.
IN ADDITION TO THE BASE ENVIRONMENTAL BENEFITS,

ECONOMIC BENEFITS TO THE PLANT OPERATOR WILL ALSO
BE REALISED DUE TO REDUCED PRODUCT LOSS.
STUDIES ON A BRITISH REFINERY HAVE SHOWN THAT UP TO

70% OF THE TOTAL EMISSIONS LOST TO ATMOSPHERE WERE
FROM VALVES.
TOPIC 1.3.7/2/2
FUGITIVE EMISSION DESIGN
THE GERMAN GOVERNMENT INTRODUCED LEGISLATION TO

CONTROL AIR POLLUTION IN 1986. THIS WAS IN THE FORM OF
TA-LUFT (TECHNICAL INSTRUCTIONS ON AIR QUALITY) THIS
DOCUMENT SPECIFIES DESIGNS TO BE USED IN THE
MANUFACTURE OF VALVES, A LIST OF ORGANIC FLUIDS
WHICH ARE CONSIDERED HAZARDOUS AND MAXIMUM
PERMISSIBLE VALVE STEM LEAKAGE RATES.
THE US GOVERNMENT INTRODUCED LEGISLATION IN 1990.

THIS WAS IN THE FORM OF THE EPA (ENVIRONMENTAL
PROTECTION ACT) WHICH IS SIMILAR IN CONTENT TO THE TA
LUFT. BOTH THE GERMAN AND US LEGALISATION’S HAVE THE
SAME AIM TO REDUCE AIR POLLUTION. HOWEVER BOTH
LEGISLATIONS QUANTIFY THE MAXIMUM PERMISSIBLE
LEAKAGE RATES IN DIFFERENT TERMS WHICH ARE NOT
COMPARABLE, THIS MAKES COMPARING THE TWO DIFFICULT.
VALVE, PACKING AND GASKET MANUFACTURERS ARE IN THE

MAIN AWARE OF THESE RELATIVELY RECENT REQUIREMENTS
AND DEVELOPMENTS HAVE BEEN MADE TO IMPROVE SEALING
PERFORMANCE, THIS HAS LED TO A BETTER UNDERSTANDING
BY ENGINEERS OF WHAT EXACTLY IS REQUIRED WHEN
SPECIFYING FOR EMISSION CONTROL.
IN THE US. THE PRIMARY DOCUMENT FOR QUALIFICATION

TYPE FUGITIVE EMISSIONS TESTING IS ANSI/ISA 93.00.01
“STANDARD METHOD FOR THE EVALUATION OF EXTERNAL
LEAKAGE OF MANUAL AND AUTOMATED VALVES”.
PRODUCTION TESTING ENTAILS A NUMBER OF OPEN AND
CLOSED CYCLES (UP TO 5000), COMBINED WITH A FEW
THERMAL CYCLES AT TEMPERATURES UP TO 750OF (399OC).
METHANE IS THE USUAL MEDIA CHOICE FOR QUALIFICATION
TESTING.
TOPIC 1.3.7/3/1
LOCKING SYSTEMS
A NUMBER OF LOCKING TYPES CAN BE SPECIFIED.
THEY ARE FITTED FOR SAFETY REASONS, ACCIDENTAL OPERATION AND

TO ENSURE CORRECT MODE OF SYSTEM OPERATION.
PADLOCK AND CHAIN – CHEAP AND CHEERFUL, USED ON HANDWHEEL

OPERATED VALVE.
PADLOCKED AND FIXED BRACKET ON VALVE – ALL TYPES
INTERLOCKING SYSTEMS – ARE EXPENSIVE TO VERY EXPENSIVE

DEPENDING UPON NUMBER OF VALVES IN THE OPERATING SEQUENCE.
THEY ARE MANUFACTURED AS A PRODUCT AND CAN BE FITTED DIRECT
ONTO THE VALVE STEM OR GEAR OPERATOR HANDWHEEL STEM.
SOME AREAS OF USE INCLUDE SAFETY RELIEF VALVE SYSTEMS,

TANKER LOADING, CRITICAL SERVICES WHERE MIXING OF PRODUCTS IS
UNDESIRABLE OR DANGEROUS, AT PIPELINE PIG LAUNCHERS AND
RECEIVERS FOR OPERATOR SAFETY REASONS. IT ALLOWS SECONDARY
SYSTEM TO BE BOUGHT ON LINE WITHOUT SHUTTING DOWN THE UNIT.
THEY USUALLY WORK ON A COLOUR CODED KEY SYSTEM WHERE THE

NEXT STEP OF THE OPERATING SEQUENCE CANNOT BE TAKEN UNTIL
THE KEY IS REMOVED FROM THE PREVIOUS STEP AND SO ON. THEY CAN
ALSO BE USED ON AN INDIVIDUAL BASIS
REFER TO NEXT PAGE FOR SKETCH
OTHER LOCKING SYSTEMS INCLUDE COVERING THE HANDWHEEL WITH

A LID WHICH IS FIXED TO THE VALVE BODY, FREE ROTATING
HANDWHEELS WHICH ARE UNLOCKED TO ENGAGE ON THE STEM, USING
BARS ETC.
TOPIC 1.3.7/3/2
INTERLOCK VALVES
TOPIC 1.3.7/4
TRAPPED PRESSURE
WHEN A CLOSED DOUBLE SEATED VALVE FILLED WITH A

LIQUID OR GAS IS HEATED (DUE TO PROCESS CONDITIONS,
RADIATION OR SOLAR HEATING) THE VALVE CAVITY
PRESSURE WILL INCREASE DUE TO VOLUMETRIC EXPANSION
OF THE LQUID / GAS.
CONVERSELY WHEN COOLING AN UNDRAINED CAVITY BELOW

FREEZING (LOW TEMPERATURE, CRYOGENIC LNG SERVICE)
MAY ALSO RESULT IN A VOLUMETRIC EXPANSION OF THE
MEDIA.
THE EXPANSIONS CAN RESULT IN EXTREMELY HIGH

PRESSURES BEING TRAPPED WITHIN THE VALVE CAVITIES
LEADING TO JAMMING OF THE OBTURATOR AND PERSONNEL
RISK DUE TO CRACKING OR EXPLOSION OF THE VALVE WHEN
OVERHAULING.
WHERE TRAPPED OR RESIDUAL PRESSURE CAN BE

IDENTIFIED THE SPECIFICATION ENGINEER SHOULD
CONSIDER DETAILING A POSITIVE MEANS BY WHICH TO
PREVENT OVER PRESSURISATION.
THIS IS USUALLY DONE BY ENSURING THERE IS A HOLE IN THE

OBTURATOR WHICH CAN RELIEVE PRESSURE FROM THE
CAVITY TO THE UPSTREAM SIDE OF THE VALVE.
HOWEVER THIS MEANS THE VALVE CAN ONLY BE FITTED IN

ONE DIRECTION AND THE VALVE SHOULD HAVE PERMANENT
ARROW MARKINGS (CAST INTO THE BODY) TO INDICATE FLOW
DIRECTION.
TOPIC 1.3.7/5
LOW TEMPERATURE AND CRYOGENIC SERVICE
THE FOLLOWING ISSUES APPLY TO MOST VALVES USED IN THE

ABOVE SERVICES.
IN SOME CASES VALVES MUST BE FITTED WITH AN EXTENDED

STEM AND BONNET GENERALLY AT TEMPERATURES BELOW –
46 DEG.C. ALTHOUGH SOME CLIENTS SPECIFY BELOW –70
DEG.C.
THIS IS TO RAISE THE STEM PACKING TO A HEIGHT ABOVE THE

“VAPOUR LINE”. IF PACKING IS SUBJECTED TO CRYOGENIC
SERVICE IT HARDENS AND DOES NOT EFFECT A SATISFACTORY
SEAL, LEADING INCREASED STEM LEAKAGE.
EXTENDED BONNETS ALSO ASSIST IN PERSONNEL SAFETY TO

ENSURE THE VALVE CAN STILL BE MANUALLY OPERABLE.
SOME VENDORS SPLIT EXTENSION LENGTHS INTO 2

TEMPERATURE RANGES. To –101 DEG.C & to -196 DEG.C. AS
BONNET CAN BE EXTREMELY LONG.
THE EXTENSION LENGTH MUST BE IDENTIFIED EARLY IN ORDER

THAT MODELLING CAN BE ACCURATE AND CLASHING
REDUCED
ADDITIONAL LEAKAGE AND PRESSURE TESTING OF THE VALVE

MUST ALSO BE CARRIED OUT ON THE VALVE TO ENSURE THAT
THE LOW TEMPERATURE / CRYOGENIC SERVICE DOES NOT
RESULT IN INCREASED LEAKAGE DUE TO EMBRITTLEMENT OF
SEATS / SEALS AND DISTORTION OF THE VALVE BODY AND
INTERNAL COMPONENTS. BS EN 1626 IS A STANDARD FOR
CRYOGENIC VALVES
TESTING IS EXPENSIVE DUE TO THE EQUIPMENT, LOCATION

AND TIME SCALES INVOLVED.
TOPIC 1.3.7/6
LOW TEMPERATURE AND CRYOGENIC SERVICE
CAVITY OVERPRESSURE IS ALSO AN ISSUE ON THIS SERVICE

(REFER TO PREVIOUS PAGE)
VALVES FOR CRYOGENIC SERVICE CAN BE EXTREMELY

COSTLY DUE TO THE REQUIRED MODIFICATIONS AND TESTING.
ALTHOUGH IT SHOULD BE NOTED THAT TESTING CAN BE DONE
ON A BATCH BASIS AND NOT INDIVIDUALLY, WITH THE
AGREEMENT OF THE CLIENT.
TOPIC 1.3.7/7
ANTISTATIC DESIGN
SOME PROCESSES CAN PRODUCE A STATIC CHARGE WHICH IN

A METALLIC PIPING SYSTEM CAN BE DANGEROUS.
USUALLY THE PIPING SYSTEM IS BONDED AND EARTHED FOR

CONTINUITY AND DISCHARGE.
DURING THE 1960s AND AFTER A NUMBER OF ACCIDENTS ON

VALVES WITH SOFT SEATS AND SOFT SEALS THAT DUE TO THE
DESIGN, STATIC CHARGING BY THE PROCESS OCCURRED IN
THE OBTURATOR AND STEM. THE RESULTS OF THIS WERE
- HIGH POTENTIAL FOR SPARKING IN VOLATILE ATMOSPHERES

- SHOCK AND BURNS TO THE OPERATORS.
- DAMAGE TO THE SEATS AND SEALS
THIS WAS OVERCOME BY INSERTING A POSITIVE METALLIC

CONTACT POINT BETWEEN BALL, STEM AND VALVE BODY IN
THE FORM OF BALL BEARINGS. THEREFORE FULLY BONDING
THE VALVE INTERNALS.
ALL QUALITY MANUFACTURERS SHOULD OFFER THIS AS

STANDARD.
THIS DOES NOT AFFECT METAL SEATED VALVES.

TOPIC 1.3.7/8
FULLY WELDED DESIGN
IN SOME INSTANCES IT IS DESIRED THAT THE VALVE HAS NO

BODY OR BONNET JOINTS.
SERVICES REQUIRING THIS FEATURE MAY BE HIGHLY

CORROSIVE, WET H2S, POISONOUS, CARCINOGENIC
PERMEABLE GAS SERVICES.
IT MAY ALSO BE REQUIRED ON LARGER VALVES ESPECIALLY IN

PIPE LINES AS IT REMOVES THE REQUIREMENT FOR BULKY
FLANGES WITH THE EFFECT OF A CONSIDERABLE WEIGHT
SAVING.
THIS CAN BE ACHIEVED BY SPECIFYING A FULLY WELDED

VALVE CONSTRUCTION.
ALL WELDS WHETHER BODY OR BONNET SHOULD BE OF A FULL

PENETRANT TYPE TO REMOVE THE CHANCE OF CREVICE
CORROSION AT THE WELD INTERFACE.
UNFORTUNATELY IT MAKES MAINTENANCE DIFFICULT AS THE

VALVE WILL REQUIRE CUTTING FROM THE LINE AND THE
WELDS MACHINED OUT TO OPEN THE VALVE. THIS IS QUITE
SPECIALISED.
TO REDUCE DOWN TIME, A SPARE VALVE MAY BE INSTALLED

AND THE EXISTING ONE REFURBISHED IF PRACTICAL.
SMALL BORE VALVES ARE GENERALLY CUT OUT AND THROWN

AWAY AS THE COST OF REFURBISHMENT IS EXPENSIVE.
TOPIC 1.3.7/9
SPECIAL CLEANING REQUIREMENTS
I CERTAIN SERVICES REQUIRE SPECIAL CLEANING OF THE VALVE
AFTER TESTING. EG.
-OXYGEN
-DRY CHLORINE GAS
-CLEAN PROCESSES
I CLEANING IS REQUIRED FOR A NUMBER OF REASONS:

1).IN OXYGEN SERVICE GREASE, PARTICLES AND DIRT CAN GENERATE
SPONTANEOUS COMBUSTION / AUTOIGNITION IN THE LINE.
2).IN DRY CHLORINE SERVICE ANY WATER LEFT IN THE VALVE WILL
REACT WITH THE CHLORINE AND CAUSE IMMEDIATE AND SEVERE
CORROSION
3).IN CLEAN PROCESSES SUCH AS PHARMACEUTICAL PRODUCTS OR

INGREDIANTS . THE EMPHASIS IS ON REMOVING CHANCES OF
CONTAMINATION OF THE FINAL PRODUCT
CLEANING MAY TAKE THE FORM OF:

A). WASHING THE VALVE INTERNALS WITH A CLEANING CHEMICAL
(AQEUOUS SOLVENT).
B). DRYING (SOMETIMES IN AN OVEN) THE INTERNALS.
C). INSPECTING THE INTERNAL SURFACES WITH A SPECIAL UTLRA
VIOLET SPECTRO-SCOPIC LAMP TO CHECK FOR PARTICLES /
IMPERFECTIONS OR FUNGAL BLOOMS.
D). IF IT IS CLEAN THEN THE VALVES ARE INDIVIDUALLY BAGGED.
I THE EXACT REQUIREMENTS WILL VARY DEPENDANT UPON THE

PROCESS.
I THE VENDOR SHOULD ALWAYS SUPPLY A PROCEEDURE FOR

APPROVAL.
I CARE SHOULD BE TAKEN NOT TO OVER SPECIFY THE CLEANING

PROCESS. FOR EXAMPLE UN MACHINED AREAS OF THE INTERNAL
SERVICE MAY NOT SEEM TO BE CLEAN WHEN VIEWED WITH THE
FLUORESCENT LAMP DUE TO IMPERFECTIONS IN THE CAST OR
FORGED SURFACE. UNLESS A DECISION IS MADE TO MACHINE ALL
INTERNAL SURFACES THIS MUST BE ACCEPTED.
TOPIC 1.3.8
Size and weight restrictions
• SIZE AND WEIGHT CAN BE INFLUENTIAL IN THE SELECTION OF ONE
VALVE TYPE OVER ANOTHER.
• FOR EXAMPLE VALVES SUCH AS GATE AND GLOBE CAN BECOME

EXTREMELY HEAVY AND REQUIRE A LARGE ENVELOPE OF AREA AT A
RELATIVELY SMALL SIZE WHEN COMPARED TO A BALL OR BUTTERFLY
VALVE.
EXAMPLE: CLASS 150 API 600 EXAMPLE: CLASS 150 BS 5351

GATE VALVE BALL VALVE
2” = 25KG 2” = 10 KG
6” = 165 KG 6” = 60 KG
10” = 360 KG 10” = 200 KG
16” = 960 KG 16” = 380 KG
24” = 2000 KG 24” = 1000 KG
• WAFER TYPE BUTTERFLY / CHECK VALVES OFFER CONSIDERABLE

SAVING ON BOTH WEIGHT AND SPACE. THEY ARE USED EXTENSIVELY
ON INSTALLATIONS SUCH AS OFFSHORE PLATFORMS WHERE WEIGHT
AND SPACE IS A PREMIUM. HOWEVER MANY CLIENTS RESTRICT THE
USE OF WAFER / LUG TYPE VALVES TO A MAX TEMP OF APPROX 300
DEG.C. WITH A REQUIREMENT FOR LUGGED VALVES IN HYDROCARBON
SERVICES.
• BUTTWELD END VALVES REDUCE THE WEIGHT OF VALVE

CONSIDERABLY BY REMOVING THE NEED FOR FLANGES. THIS IS MORE
EFFECTIVE AT HIGHER PRESSURES WHERE THE FLANGES ARE OF A
CONSIDERABLE THICKNESS. HOWEVER EASE OF MAINTENANCE MUST
BE CONSIDERED.
• THE USE OF COUPLING / CLAMP TYPE CONNECTIONS CAN ALSO

REDUCE THE VALVE WEIGHT AS THE FLANGES CAN BE MACHINED
DOWN TO A HUB FOR LOCATION OF THE CLAMPS. THIS IS COMMON ON
OFFSHORE HIGH PRESSURE SYSTEMS WHERE “GRAYLOC” TYPE
CLAMPS ARE USED. CLIENT APPROVAL IS USUAL FOR THESE.
TOPIC 1.3.9/1
Cost and delivery - cost
• COST AWARENESS IS ANOTHER IMPORTANT FACTOR WHEN
SELECTING VALVES.
• VALVES COMPLYING TO INTERNATIONAL STANDARDS AND

STANDARD SUPPLY MATERIALS ARE THE MOST ECONOMICAL
.
• IT IS IMPORTANT TO REVIEW COST COMPARISONS BETWEEN

VALVES
• FACTORS AFFECTING COSTS
- SPECIAL OR PROPRIETARY VALVES, INCREASED COSTS

DUE TO BATCH SET UP COSTS AND SMALL BATCH QUANTITY.
- VARIATION FROM NORMAL IN DESIGN.
- VARIATION IN TRIM MATERIAL.
- THE USE OF EXOTIC MATERIALS.
- ADDITIONAL MATERIAL / PRESSURE TESTING.
- NON DESTRUCTIVE TESTING.
- ADDITIONAL CERTIFICATION.
- THIRD PARTY INSPECTION
- INCREASED PACKING REQUIREMENTS.
- SHIPPING.
• CARE SHOULD BE TAKEN NOT TO OVER SPECIFY VALVES IN

EXCESS OF WHAT IS REQUIRED FOR THE SERVICE AND PIPE
CLASS.
• REFER TO NEXT 2 PAGES FOR COST COMPARISONS AS

VARIATION MAY BE FOUND SURPRISING .
TOPIC 1.3.9/2
Cost and delivery – price comparisons
TOPIC 1.3.9/3
TOPIC 1.3.9/4
Est Weight
Trim Unit Price
Class Ends Bore Description Body mat. (Valve+Act -
mat. (Euro)
Kgs)
Through Conduit Slab Slab & Seat

Gate Valve to API 6A. : F316 +
Bolted bonnet, OS & Y, ASTM A352 Tungsten
1500 HUB* Full 2070 €28,202.00
rising stem. Spring LCC Carbide.
energised, floating and Stem : 17/4
renewable seats. PH
Trunnion mounted, split

Ball & Seat
body,full bore to API
: F316 +
6D,metal seated;
ASTM A350 Tungsten
1500 HUB* Full antistatic device & anti- 1100 €21,546.00
LF2 Carbide.
blow-out stem; Double
Stem : 17/4
Block & Bleed, self
PH
relieving seats.
Inc 625 W/O. Seat & BS 8010

Gas Testing Stem FEA 24 Hour
Hydro
Size Body Seat Packing Areas Test
8" €1,200.00 €400.00 €1,750.00 €4,000.00 €2,060.00
* Based on Project Free Issue Clamp Sets for FAT

TOPIC 1.3.9/5
Cost and delivery – delivery
• DELIVERY OF VALVING, AS WITH OTHER COMPONENTS IS A
CRITICAL ACTIVITY
• DELIVERY LEAD TIMES VARY CONSIDERABLY FROM DAYS TO

30 WEEKS DEPENDING UPON A NUMBER OF FACTORS.
- QUANTITY OF VALVES – IF LARGE QUANTITY DELIVERY

MAY BE STAGED.
- TYPE OF VALVES ORDERED – HIGH PRESSURE VALVES
MAY BE ON A LONG LEAD TIMES AS MOST VENDORS DO
NOT STOCK FULL RANGES.
- SIZES OF VALVES – LARGER BORE VALVES MAYBE ON
LONG LEAD TIMES
- SPECIAL VALVES
- SPECIAL FEATURES
- EXOTIC MATERIALS – WILL INCREASE LEAD TIMES DUE TO
FOUNDRY CASTING FORGING SCHEDULES.
- INCREASED TESTING – NDE OF CASTINGS / FORGINGS OR
CRYOGENIC TESTING MAY ADD A NUMBER OF WEEKS
DEPENDENT UPON QUANTITIES TO BE TESTED.
- INSPECTION – CAN ADD A WEEK OR TWO
- SHIPPING – DEPENDANT UPON WHERE VENDORS
RESPONSIBILITIES FINISH, ETC.
- VENDOR WORK LOAD
MANUFACTURERS, AGENTS AND STOCKISTS ARE ALL

USED BY FOSTER WHEELER TO A VARYNG DEGREE AND
TO A VARYING SUCCESS.
TOPIC 1.3.10/1
Standard material form and grade
• THE FOLLOWING CHART (PAGE 6) SHOWS STANDARD COMMERCIAL
GRADES OF MATERIAL GENERALLY AVAILABLE WITHIN THE MARKET.
• AS STATED PREVIOUSLY THE MATERIAL STANDARDS USED SHOULD

REFLECT THE DESIGN CODE FOR THE PIPING SYSTEM .
• THEREFORE IF USING THE ASME B31.3 PIPING DESIGN CODE THEN

ASTM MATERIAL STANDARDS SHOULD BE USED IF POSSIBLE.
• FORGED VALVES
• GENERALLY USED FOR SMALL BORE VALVE DESIGNS WITH A MAX.
VALVE SIZE OF APPROX. 2” RESTRICTION IS DUE TO THE COMMERCIAL
CAPABILITIES OF THE DROP FORGE METHOD.
• HOWEVER LARGER FORGED VALVES ARE USED IN SITUATIONS WHERE

THE FINISHED FORGING IS OF A SIMPLE DESIGN OR THE VALVE IS
MADE UP OF A NUMBER OF FORGINGS – SUCH AS TWO / THREE PIECE
BALL VALVES.
• ANOTHER EXCEPTION IS LARGER BORE HIGH PRESSURE BUTT WELD

GATE VALVES WHICH ARE SOMETIMES MANUFACTURED FROM
FORGINGS. EXAMPLE “RING O VALVES”
• USUALLY MUCH MACHINING IS REQUIRED TO ACCOMPLISH THE FINAL

GEOMETRY WITH THE RESULT OF HIGH MATERIAL WASTAGE.
• SOME VENDORS PREFER THIS FORM BECAUSE THE FORGINGS DO NOT

SUFFER FROM THE SAME IMPERFECTIONS AS THOSE FOUND IN
CASTINGS AND THEREFORE DO NOT NEED THE SAME NDE
REQUIREMENTS APPLYING.
• HOWEVER THE FORGING AND MACHINING PROCESSES CAN INDUCE

UNEVEN STRESS INTO THE COMPONENT DUE TO MACHINING ACROSS
THE FLOW OF THE GRAIN AND SUITABLE HEAT TREATMENT HAS TO BE
PERFORMED TO REMOVE THESE STRESSES.
• ANOTHER DISADVANTAGE IS THAT BY MACHINING THE INTERNAL BORE

AND CAVITY IT IS POSSIBLE THE REDUCE THE WALL THICKNESS
BELOW THAT REQUIRED FOR PRESSURE RETENTION IN ACCORDANCE
WITH THE ASME 16.34. THIS REDUCTION IS DIFFICULT TO CHECK.
TOPIC 1.3.10/2
• CAST VALVES
• GENERALLY USED FOR LARGER BORE VALVE DESIGNS 2” AND ABOVE.
• GENERALLY USED FOR MORE COMPLICATED GEOMETRIES.
• FLANGED BALL VALVES ARE AN EXCEPTION AND ARE USUALLY CAST

DOWN TO ½”.
• STANDARD METHOD OF CASTING IS BY USING THE SAND / SILICA

CASTING METHOD. SMALL BORE, INTRICATE DESIGNS ARE
INVESTMENT CAST (LOST WAX METHOD) AS THIS GIVES A FINER
TOLERANCE ON THE CASTING AND REQUIRES MINIMAL MACHINING.
• RESTRICTED BY THE PATTERN SIZE THE FOUNDRY IS ABLE TO CAST.
• CASTINGS GIVE A CONSISTANT WALL THICKNESS AND CONSISTANT

METALLIC GRAIN FLOW THROUGHOUT THE COMPONENT
• TOLERANCES ARE DEPENDANT UPON THE QUALITY OF THE WOOD /

ALUMINIUM PATTERN, THE QUALITY OF THE MOULD, THE QUALITY OF
THE MELT AND THE QUALITY OF THE POUR.
• THE CASTING METHOD GIVES A ROUGHER FINISH THAN FORGING AND

ADDITIONAL PROCESS OF FETTLING / BLASTING IS REQUIRED TO
CLEAN THE CASTING.
• PROBLEMS CAN OCCUR WHEN POURING LARGE AMOUNTS OF METAL

DUE TO VARYING COOLING RATES.
• DUE TO THE CASTING METHOD, IMPERFECTIONS AND AIR POCKETS

ARE MORE LIKELY THAN FORGINGS THEREFORE WHERE VALVES ARE
USED IN CRITICAL, CORROSIVE AND HIGH PRESSURE SERVICES NDE
IS AN IMPORTANT ISSUE TO ENSURE INTEGRITY OF THE CASTING.
TOPIC 1.3.10/3
GENERAL
• CAST ALLOYS SOMETIMES HAVE DIFFERENT CORROSION PROPERTIES
TO THEIR WROUGHT COUNTERPARTS. CORROSION DATA TABLES DO
NOT INDICATE THIS AND IT IS IMPORTANT TO CHECK THIS PRIOR TO
FINAL SELECTION.
• ANOTHER DIFFERENCE BETWEEN CAST AND WROUGHT ALLOYS IS

THEIR MECHANICAL PROPERTIES. CAST FORMS OFTEN HAVE A LOWER
PROOF STRESS THAN THE WROUGHT ONES AND HENCE THIS SHOULD
BE INCORPORATED IN THE DESIGN.
• HIGH NICKEL ALLOY CASTINGS
• MONEL, HASTALLOY, INCONEL, NICKEL
• NICKEL ALLOY CASTINGS HAVE BEEN A PROBLEM THROUGHOUT THE

INDUSTRY WITH CASTING DEFECTS, POOR WELDABILITY AND POORER
THAN EXPECTED CORROSION RESISTANCE ARE PRIMARY PROBLEMS.
• THEY ARE MORE DIFFICULT TO CAST .
• THEY ARE PRONE TO HOT TEARS, CRACKING AND POROSITY WHICH

MAY APPEAR AT ANY POINT IN THE MANUFACTURING PROCESS, IE
DURING SOLIDIFICATION, HEAT TREATMENT, MACHINING.
• FOUNDRIES MAY HAVE TO RE POUR SEVERAL TIMES BEFORE THEY

GET A SATISFACTORY PRODUCT.
• WELDING OF CAST NICKEL ALLOYS IS ALSO A PROBLEM THEREFORE

CASTINGS WITH EVEN MINOR POROSITY / INCLUSION HAVE TO BE
SCRAPPED DUE TO CRACKING WHILST WELD REPARING
• QA LEVELS SHOULD BE HIGH AND ORIGIN OF CASTING SHOULD BE

IDENTIFIED AND REVIEWED.
TOPIC 1.3.10/4
• HIGH ALLOY CASTINGS
• IN GENERAL HIGH ALLOY CASTINGS SHOULD ALWAYS BE TREATED AS

SPECIAL AND NOT COMMERCIAL BECAUSE THE PERFORMANCE AND
RELIABILITY OF THESE VALVES IS GENERALLY CRITICAL.
• UNEXPECTED BODY FAILURES ARE NEARLY ALWAYS DUE TO

MICROSTRUCTURAL VARIATIONS, METALLURGICAL FACTORS, CASTING
TECHNIQUES
• HIGH ALLOY CASTINGS DO NOT GENERALLY FAIL IN A UNIFORM

MANNER. THEY ARE LIKELY TO FAIL DUE TO LOCALISED PITTING /
CORROSION AT A MANUFACTURING DEFECT.
• HIGH ALLOY CASTINGS ARE GENERALLY MORE DIFFICULT TO

MANUFACTURE
• MATERIAL GRADES SHOULD BE CHOSEN WISELY, ENSURE SUITABLE

METALLURGICAL TESTS ARE PERFORMED.
DEALLOYING
• THE MOST WELL KNOWN FORM OF DE-ALLOYING IS PROBABLY

DEZINCIFICATION, WHICH AFFECTS SOME BRASSES. IN THIS TYPE OF
ATTACK, ZINC IS PREFERENTIALLY REMOVED LEAVING A POROUS,
SPONGY COPPER REMAINDER WITH THE DIMENSIONS OF THE
ORIGINAL COMPONENT, BUT OBVIOUSLY MUCH WEAKER. A SIMILAR
TYPE OF ATTACK, CALLED DEALUMINIFICATION, CAN OCCUR WITH
ALUMINIUM BRONZES. IN BOTH CASES ATTACK ONLY OCCURS IN
CERTAIN FLUIDS, BUT USUALLY INVOLVES CHLORIDES.
• THE ABOVE IS WELL DOCUMENTED IN SALTWATER APPLICATIONS.

TOPIC 1.3.10/5
• DUCTILE CAST IRON
• DUCTILE IRON MATERIAL SHOULD GENERALLY NOT BE USED

IN PROCESS SERVICES DUE TO ITS LOW MELTING POINT.
RESTRICTIONS ON THE USE OF DUCTILE IRON, CAST IRON
AND LOW MELTING POINT MATERIAL VALVES ARE
NECESSARY TO PREVENT THEIR FAILURE IN THE EVENT OF A
FIRE. SUCH A FAILURE WOULD EITHER FEED THE FIRE OR
INTERRUPT FLOW OF A REQUIRED PROCESS,
UNNECESSARILY INCREASING THE HAZARDOUS CONDITION.
• IT IS ALSO A BRITTLE MATERIAL SUSCEPTIBLE TO

CORROSION .
• SOME VENDORS DO USE DUCTILE IRON FOR CERTAIN

COMPONENTS, FOR INSTANCE TWIN SEAL PLUG VALVES
UTILISE DUCTILE IRON SEAT PADS. THIS PRODUCT IS
GENERALLY ACCEPTABLE FOR NON SOUR / NON WET H2S
SERVICE AND HAS A PROVEN RECORD FOR USE IN
HYDROCARBON SYSTEMS. HOWEVER IT IS PRUDENT TO
SEEK CLIENT COMMENT PRIOR TO PROCURING.
• CAST IRON MATERIAL SHOULD ONLY BE USED IN WATER

SERVICES.
TOPIC 1.3.10/6
TOPIC 1.3.10/7
TOPIC 1.3.10/8
Material, hydro test and general certification
MATERIAL CERTIFICATION
I BS EN 10204 (FORMERLY DIN 50049) DETAILS DOCUMENTATION
REQUIREMENT FOR MATERIAL TEST CERTIFICATION AND IS BROKEN
DOWN INTO THE FOLLOWING CATEGORIES:
I .2.1 - CERTICATE OF CONFORMITY WITH PURCHASE ORDER, NO

SPECIFIC TESTS, NO TESTING WHICH IS CARRIED OUT WILL BE
RECORDED, DOCUMENT CONFIRMED BY MANUFACTURER. GENERALLY
ADEQUATE FOR NON PRESSURE RETAINING COMPONENTS MADE
FROM BAR FORM PRODUCTS.
I .2.2 – CERTICATE OF CONFORMITY WITH PURCHASE ORDER, NO

SPECIFIC TESTS, BUT IN THE EVENT A NON SPECIFIC TEST IS CARRIED
OUT IT WILL BE DOCUMENTED. DOCUMENT CONFIRMED BY
MANUFACTURER. GENERALLY ADEQUATE FOR BOLTING AND NON
PRESSURE RETAINING PARTS OF A STEEL VALVE. USUALLY ALSO
APPLIED TO CAST IRON AND BRONZE VALVES.
I .2.3 – NOT GENERALLY USED
I .3.1A – NOT GENERALLY USED
I .3.1B – INSPECTION CERTIFICATE 3.1B SUPPLIED FOR COMPONENT –

SPECIFIC TESTS CARRIED OUT IN ACCORDANCE WITH TECHNICAL
STANDARDS - DOCUMENTATION CONFIRMATION BY : AUTHORISED
REPRESENTATIVE OF MANUFACTURER INDEPENDENT OF
MANUFACTURING UNITS. GENERALLY REQUIRED FOR ALL PRESSURE
CONTAINING STEEL VALVE PARTS.
I .3.1C – AS 3.1B EXCEPT DOCUMENTATION CONFIRMATION BY :

AUTHORISED REPRESENTATIVE OF BUYER. IE THIRD PARTY
INSPECTION.GENERALLY REQUIRED WHERE PRESSURE CONTAINING
STEEL VALVE COMPONENTS REQUIRE ADDITIONAL TESTING OR
SPECIAL DESIGN .
TOPIC 1.3.10/9
Material, hydro test and general certification
MATERIAL, HYDRO TEST AND GENERAL CERTIFICATION
HYDRO TEST CERTIFICATION
I GENERALLY SPECIFIED IN ACCORDANCE WITH API 598 IF USING

AMERICAN STANDARDS. HOWEVER THIS STANDARD WILL NOT ENSURE
BUBBLE TIGHT SHUT OFF . (REFER TO SECTION 11.1)
I SOMETIMES SPECIFIED AS BS 6755 PART 1. ALTHOUGH THIS STANDARD

HAS NOW BEEN WITH DRAWN AND REPLACED WITH BS EN 12266-1 & 2.
GENERALLY OFFERED BY BRITISH / EUROPEAN MANUFACTURERS
I IT IS THE SPECIFICATION ENGINEERS RIGHT TO EXTEND TEST

DURATIONS, TIGHTEN SEAT LEAKAGE RATES AND SPECIFY
ALTERNATIVE TEST METHODS AND MEDIA IF HE FEELS IT IS
NECESSARY FOR QUALITY OR PROCESS REASONS. THIS HAS BEEN
DONE BY FWEL ON NUMEROUS OCCASIONS FOR THE ABOVE
MENTIONED REASONS.
I VENDORS SHOULD BE WILLING TO ACCEPT THESE VARIATIONS.
GENERAL CERTIFICATION
I MAY INCLUDE FIRE TEST TYPE CERT.S, FUGITIVE EMISSION

CERTIFICATE,
PER CERTIFICATION
I PRESSURE EQUIPMENT REGULATIONS – EUROPEAN CERTIFICATION

REQUIREMENTS IN ADDITION TO THE ABOVE REQUIREMENT TO
ENSURE SUITABLE FOR SERVICE . BASED UPON PRESSURE /
TEMPERATURE / SERVICE.
I ALL VALVES PROCURED AND INSTALLED WITHIN THE EUROPEAN UNION

MUST BE CERTIFIED AS “PER” COMPLIANT.
TOPIC 2.
BALL VALVE
CONSTRUCTION AND
SELECTION
I Service Applications valves.

I Pressure / Temperature limitations.
I Why consider the use of a ball valve.
I Current international design standards.
I Types of ball valve construction.
I Restrictions on the various types of
ball valve construction.
I Materials (and grades) of construction.
I List of manufacturers of ball valve.
I General costs, availability and delivery.
I Examples of ball valve failures
TOPIC 2.1/1/1 – BALL VALVES
SERVICE APPLICATIONS
I SUITABLE FOR MOST SERVICES SUBJECT TO DESIGN AND TRIM

MATERIAL MODIFICATIONS ALTHOUGH NOT FIRST CHOICE DUE TO
COST .
I WIDELY USED ON CHEMICAL PLANTS AND PHARMACEUTICAL PLANTS

BECAUSE BALL VALVES ARE SEEN TO BE A COMPARATIVELY CLEANER
VALVE.
I INCREASINGLY POPULAR IN LOW TEMPERATURE AND CRYOGENIC

APPLICATIONS. THEY HAVE AN ADVANTAGE OVER GATE VALVES DUE
QUARTER TURN OPERATION GIVING HIGHER INTERGRITY STEM SEAL.
I LARGE BORE BALL VALVES ARE USED IN PIPE LINES DUE TO WEIGHT
SAVING, QUICK CLOSING FEATURES.
I IDEAL FOR USE WITH ACIDS AND CORROSIVE MEDIA SUBJECT TO

MODIFICATION. GENERALLY PREFERRED FOR USE ON SERVICES SUCH
AS CHLORINE, HYDROFLUORIC ACIDS, OXYGEN, AMMONIA.
I NOT GENERALLY SUITED TO ABRASIVE, SLURRY AND DIRTY SERVICE

ALTHOUGH CAN BE MODIFED AT A COST.
I THEY ARE INTENDED FOR A FULLY OPEN OR FULLY CLOSED POSITION

ALTHOUGH CAN BE MODIFIED FOR CONTROL APPLICATIONS. “V” OR “C”
BALL DESIGN.
I USED EXTENSIVLEY IN EMERGENCY SHUTDOWN APPLICATIONS DUE

TO ITS QUICK CLOSING FEATURE.
I USED IN SAMPLING SYSTEMS FOR SAME REASON AS ABOVE.
I USED FOR UNINTERRUPTED FLOW DUE TO THE BALL ROTATING FULLY

TO ALLOW CLEAR AREA CREATING MINIMUM PRESSURE DROP ON
WATER, GAS AND MANY OTHER FLUIDS.
I NOT RECOMMENDED FOR REGULATING PURPOSES AS:

A). Severe corrosion can occur around the leading edge of the ball as it
approaches the closed position. For this reason ball valve should not be used in
steam service.
B). No control of flow effect can be seen until valve is approx 60% closed.
I BALL VALVE DESIGNS ARE DIVIDED INTO DIFFERENT TYPES AND HAVE
BEEN DEVELOPED TO SUIT VARIOUS APPLICATIONS.
I SUITABLE FOR BUBBLE TIGHT SHUT OFF DEPENDANT UPON SEAT

MATERIAL SPECIFIED.
PRESSURE / TEMPERATURE LIMITATIONS
I THE BALL VALVE CONSTRUCTION HAS A WIDE RANGE FOR PRESSURE

AND TEMPERATURES BUT THIS REQUIRES CERTAIN DESIGN CHANGES.
I BALL VALVES CAN BE USED BETWEEN –196 DEG C. UP TO APPROX 800

DEG. C. SUBJECT TO DESIGN, MATERIALS AND MODIFICATIONS.
I BELOW IS PRESSURE / TEMP. GRAPH FOR SOFT SEATED FLOATING

BALL VALVE AND SOFT SEATED TRUNNION MOUNTED ON NEXT PAGE
TOPIC 2.1/3 – BALL VALVES
WHY CONSIDER THE USE OF A BALL VALVE
I SOFT SEATED VALVES ALLOW BUBBLE TIGHT SHUT OFF WHICH IS

DESIRABLE OR MANDATORY FOR CERTAIN PROCESSES.
I THE MODE OF OPERATION DOES NOT IMPLY MECHANICAL FORCE

ONTO THE SEATS AS HAPPEN S WITH A GATE VALVE. GENERALLY
ALLOWING LONGER LIFE BETWEEN MAINTENANCE.
I THEY ARE A QUARTER TURN OPERATING VALVE AND THERFORE THE

ORIENTATION GIVES A QUICK VISUAL AID AS TO WHETHER THE VALVE
IS OPEN OR CLOSED .
I BALL VALVES HAVE A SMOOTH LOW OPERATING TORQUE,. THEREFORE

ACTUATOR UNITS CAN BE OF A SMALLER CAPACITY AND REDUCED
COST.
I BALL VALVE DIMENSIONAL ENVELOPE IS SMALLER THAN GATE THUS

SAVING SPACE. MAY BE A HELP TO PLANT DESIGN.
I DUE TO ROTATIONAL OPERATION STEM DOES NOT TRAVEL THROUGH

PACKING, THEREFORE WEAR CHARACTERISTICS ARE GENERALLY
BETTER THAN FOR GATE VALVE
I RELATIVELY PROBLEM FREE OPERATION.
I LOW MAINTENANCE COSTS.
I ADEQUATE AVAILABILITY FROM MANUFACTURERS, STOCKISTS AND

AGENTS.
I MANY DESIGNS TO COVER VARYING APPLICATIONS FROM EXTREME

ACIDS TO CLEAN PROCESSES .
I BALL VALVES CAN BE FORGED OR CAST FROM MOST MATERIALS
I CAN BE SPECIFIED TO INTERNATIONAL STANDARDS.
I THE DESIGN ALLOWS THE SEALING FACE TO BE WIPED CLEAN AS THE

VALVE IS OPERATED AND IN THE OPEN POSITION THE SEAT SURFACE
IS PROTECTED OUT OF THE FLOW PATH
CURRENT INTERNATIONAL DESIGN STANDARDS
DESIGN STANDARDS SHOULD FOLLOW THE ALLOCATED DESIGN CODE

FOR THE PLANT, THEREFORE IF USING ASME B31.3 THEN AMERICAN API /
ASME STANDARD SHOULD BE USED WHERE POSSIBLE.
BS 5351 – Steel Ball valves for Petroleum, Petrochemical and Allied industires
GENERALLY FIRST CHOICE SPECIFIED FOR BALL VALVES
API 608 – Metal Ball Valves - Flanged and Butt-Welding Ends

GENERALLY SAME AS BS 5351
BS 5159 - Specification for Cast iron and Carbon steel ball valves for General
purposes
ASME B16.34 - Valves - Flanged, Threaded, and Welding End
API 6D - Petroleum and Natural Gas Industries-Pipeline Transportation Systems-

Pipeline Valves .
TYPE OF BALL VALVE CONSTRUCTION
I BALL VALVES EVOLVED FROM THE DESIGN OF PLUG VALVES.
I THEY ARE AVAILABLE IN FULL AND REDUCED PORT DESIGNS

(FLOATING DESIGN IS RESTRICTED BY SIZE)
I VALVE CONSISTS OF BODY, BALL, SEATS, STEM, SEALS AND

TRUNNION IF APPLICABLE.
I THE STEM IS LOCATED IN A SLOT IN THE TOP OF THE BALL. IT IS NOT

POSITIVELY SECURED TO ALLOW FOR MOVEMENT. THIS IS FOR BOTH
DESIGNS.
FLOATING BALL DESIGN
- SEAT SUPPORTED BALL..

- GENERALLY USED IN LOW PRESSURE APPLICATIONS (CLASS 150 &
300).
- THE BALL AGAINST THE SEAT AND RELIES ON THE UPSTREAM
PRESSURE TO FORCE THE BALL ONTO THE DOWNSTREAM SEAT.
- CHEVRON PTFE FORMED STEM PACKING GENERALLY USED WITH A
GRAPHITE SECONDARY FIRE SEAL. ALTHOUGH FULL GRAPHITE
PACKING MAY BE USED.
- FLOATING BALL DESIGN CAN BE INTERNALLY LINED.
TRUNNION MOUNTED
- TRUNNION SUPPORTS THE BALL (THE BALL IS FIXED TOP AND

BOTTOM.
- SEATS LOCATED IN METALLIC RINGS AND ARE SPRING LOADED
AGAINST THE BALL. THE SPRING LOADING HELPS THE SEAT TO SEAL
IF USED IN LOWER PRESSURE APPLICATIONS.
- GENERALLY USED ON HIGHER PRESSURE APPLICATIONS (CLASS 600
AND ABOVE) DUE TO LOCATION OF THE SEAT IN A METALLIC SEAT
RING THUS PREVENTING EXTRUSION, WARPING AND DISTORTION OF
THE SOFT SEAT.
- THE UPSTREAM PRESSURE ACTS UPON THE BACK OF THE SEAT
FORCING IT ONTO THE BALL.
- O RING TYPE STEM SEALS GENERALLY USED TO ACHIEVE HIGHER
PRESSURES
I BOTH DESIGNS CAN BE FITTED WITH SOFT OR HARD METAL SEATS.

I THERE ARE FOUR METHODS OF INSERTING THE BALL INTO THE

VALVE
1). TWO / THREE PIECE BODY - BODY SPLIT IN ONE OR MORE PLACES IN
SAME PLANE AS VALVE FLANGES. BODY BOLTED AROUND BALL.
THEY ARE SIMPLER TO MAINTAIN.
2). TOP ENTRY – BALL IS LOWERED THROUGH BONNET OF THE VALVE.

CAN BE MAINTAINED IN LINE.
3). END ENTRY – BALL IS INSERTED FROM THE END AND IS SECURED IN
PLACE BY A SCREWED INSERT.
REMOVE POTENTIAL BODY JOINT LEAKAGE PATH.
BALL IS SOMETIMES SPLIT TO ALLOW FOR EASIER LOCATION AND
ALSO REDUCES OVERALL SIZE OF VALVE.
4). ALL WELDED CONSTRUCTION, NON MAINTAINABLE.

HIGH INTERGRITY.
I THE BODY SEAT, STEM HOUSING AND BODY JOINT AREAS SHOULD BE
DESIGNED AND MACHINED TO EFFECT A SATISFACTORY SEAL IN THE
EVENT THAT THE SOFT SEALS DISINTEGRATE IN A FIRE .
I ALL BALL VALVES SHOULD BE SPECIFIED WITH AN ANTI BLOWOUT

STEM WHICH IS INSTALLED THROUGH THE VALVE BODY.
I FACE TO FACE DIMENSIONS ON BALL VALVES CAN BE CONFUSING AS

THERE IS A LONG AND SHORT PATTERN LENGTH. AS A RULE,
A). FULL BORE ARE GENERALLY LONG PATTERN DUE TO THE
GEOMETRY OF THE
BALL.
B). REDUCED PORT VALVES ARE GENERALLY SHORT PATTERN DUE
TO THE SMALLER BALL.
HOWEVER THIS IS CONFUSED EVEN MORE BY THE FACT THAT LONG

AND SHORT ARE THE SAME FOR SMALLER SIZES AND BECAUSE ALSO
DIFFERENT VENDORS SPLIT BETWEEN SIZE VERSUS LONG / SHORT
PATTERN.
ONE PIECE, FLOATING BALL DESIGN
TWO PIECE, FLOATING BALL DESIGN
TRUNNION MOUNTED BALL VALVE DESIGN
TRUNNION MOUNTED BALL VALVE DESIGN
FLOATING BALL PTFE LINED VALVE DESIGN
TOP ENTRY VALVE DESIGN
RESTRICTIONS ON VARIOUS TYPE OF BALL VALVES
I GENERALLY RESTRICTED TO ON / OFF SERVICE.
I SOFT SEATED BALL VALVES ARE LIMITED BY TEMPERATURE TO MAX.

200 DEG.C. DUE TO SEAT MATERIAL CHARACTERISTICS. SOME
CLIENTS RESTRICT EVEN LOWER FOR SAFETY.
I FLOATING / SEAT SUPPORTED BALL VALVE HAS REDUCED PRESSURE /

TEMPERATURE RATINGS. DUE TO THE PRESSURE LOADING OF THE
BALL ONTO THE VALVE SOFT SEATS.
I BALL VALVES ARE GENERALLY MORE EXPENSIVE THAN GATE VALVES.
I FLOATING BALL VALVES ARE RESTRICTED BY SIZE TO APPROX 14”-18”

DEPENDING UPON CLASS RATING – BALL BECOMES TOO HEAVY
WITHOUT TRUNNION SUPPORT.
I FLOATING BALL VALVES ARE RESTRICTED TO CLASS 150 / 300 (SOME

SMALLER BORE CLASS 600 VALVES ARE AVAILABLE).
I SOFT SEATED VALVES GENERALLY NOT SUITABLE FOR DIRTY

SERVICES.
I QUARTER TURN LEVERS CAN BE ACCIDENTALLY OPENED AND IT IS

SUGGESTED THE LEVER BE LOCKED IN PLACE.
I THREE PIECE FLOATING BALL VALVE DESIGN, SOMETIMES CALLED A

“TRI-SEAL” SHOULD ONLY BE USED FOR UTILITY SERVICES SUCH AS
AIR AND WATER AS THEY ARE GENERALLY OF INFERIOR QUALITY.
THEY CONSIST OF A CENTRE PIECE WHICH HOLDS THE BALL AND TWO
OUTER PIECE WHICH HOLD THE SEATS. THE OUTER PIECES ARE
BOLTED TO THE CENTRE THUS PRESSING THE SEATS AGAINST THE
BALL. HOWEVER THEY ARE SUSCEPTIBLE TO OVERTIGHTENING AND
LEAKING. THEY ARE GENERALLY SMALLBORE 15-40NB. WIT H SOCKET
WELD OR THREADED ENDS.
I THE WEIGHT OF THE BALL MAY BE A LIMITING FACTOR ON ACTUATED

BALL VALVES DUE TO INCREASED TORQUE ON STEM AT LARGER
SIZES.
RESTRICTIONS ON VARIOUS TYPE OF BALL VALVES
THREE PIECE BALL VALVE.
MATERIALS (AND GRADES) OF CONSTRUCTION
I THE LOWER PRESSURE CLASS 150/300 FLOATING BALL VALVE BODIES

ARE GENERALLY MANUFACTURED (OR CAN BE SPECIFIED) IN MOST
CASTABLE MATERIALS.
I BALL COMPONENT MATERIAL FORM CAN BE CAST OR FORGED OR

WROUGHT AND VENDOR SHOULD BE REQUESTED TO CLARIFY
I 2 / 3 PIECE TRUNNION MOUNTED VALVE BODIES, BALLS AND SEAT

RINGS ARE GENERALLY MANUFACTURED FROM FORGED MATERIALS.
I AS A MINIMUM BALL VALVE TRIM COMPONENTS, BALL, STEM ETC.

SHALL BE STAINLESS STEEL GRADE 316. NOT 13CR ETC.
I LARGE BORE VALVES BALL MAY BE OFFERED AS CAST CARBON STEEL

WITH AN ELETROLESS NICKEL PLATING. CARE SHOULD BE TAKEN TO
CLARIFY PLATING THICKNESS AND COATING PROCEEDURE
I STEMS ARE GENERALLY MADE FROM WROUGHT BAR. IN SOME CASES

WHERE THE TORSIONAL SHEAR STRESS IMPLIED ON THE STEM BY AN
ACTUATOR EXCEEDS THAT ALLOWED BY THE MATERIAL AN
ALTERNATIVE MATERIALSUCH AS STAINLESS STEEL GRADE 17-4PH
VICKERS MAY BE REQUIRED.
I IF EXOTIC BODY OR TRIM MATERIALS ARE SPECIFIED IT IS IMPORTANT

THAT THE VENDOR SPECIFIES THE FORM. THE VENDOR SHOULD ALSO
DETAIL AND PROVE HIS EXPERIENCE IN USING THE EXOTIC MATERIAL
I WHEN NACE MR0175 IS SPECIFIED FOR A VALVE IN WET H2S SERVICE,

RESTRICTIONS ARE PLACED ON CERTAIN MATERIALS. THE
ALLOWABLE MATERIAL GRADES AND FORMS SHALL BE USED.
I SOFT SEATING MAYBE PTFE, PTFE WITH ADDITIVES, NYLON. REFER TO

VALVE TRIM SECTION FOR ADDITIONAL DATA.
I O RINGS MAY BE VITON, AFLAS OR OTHER ELASTOMERIC MATERIALS.

REFER TO STEM PACKING SECTION FOR ADDITIONAL DATA.
I METAL SEATED BALL VALVES WILL GENERALLY BE OFFERED WITH

METALLIC SEAT RINGS HARD FACED
I IN CORROSIVE SERVICES THE VALVE BODY MAY NEED TO BE

SPECIFIED WITH SEAT AND STEM AREAS OVERLAYED WITH A HARD
METALLIC COATING TO ENHANCE CORROSION PROTECTION.
I BODY JOINT SEALS MATERIALS VARY BY CONSTRUCTION TYPE, AND

MAY BE A GRAPHITE FLAT RING OR RUBBER O RING. HOWEVER FOR
FIRESAFE VALVES NEARLY ALL ARE A METAL TO METAL JOINT WITH
THE GASKET RING ENCLOSED ON ALL FOUR SIDES
I BODY BOLTING SHALL GENERALLY SUIT THE PIPE CLASS

SPECIFICATION.
I VENDOR MAY OFFER SMALL BORE VALVES MACHINED FROM BAR

FORM MATERIAL. CARE SHOULD BE TAKEN DUE TO DIFFICULTY IN
PROVING THAT ACCEPTABLE WALL THICKNESS EXIST. IT MAY ALSO BE
DIFFICULT TO OBTAIN SUITABLE MATERIAL CERTIFICATION DUE TO
MATERIAL FORM. VENDOR CANNOT GENERALLY CONFIRM
COMPLIANCE WITH ASME B16.34.
I NON METALLIC VALVES ARE BEING DEVELOPED TO OVERCOME

SEVERE CORROSIVE MEDIA. ADVANCED VALVE TECHNOLOGIES (AVT)
HAVE A RANGE OF HIGH QUALITY GLASS REINFORCED PLASTIC
VALVES. COVERING A RANGE OF SIZES AND RATING. THEY DO NOT
COMPLY WITH THE METALLIC VALVE STANDARDS AND MUST BE
CLASSED AS SPECIAL. BUT THEY HAVE GREAT ADVANTAGES IN AREAS
OF HIGH CORROSION OR WHERE WEIGHT IS AN ISSUE. THEY ARE
ALSO FIRE SAFE.
I U-PVC / C-PVC AND OTHER POLYMERIC VALVES ARE ALSO AVAILABLE

IN LOW PRESSURES TO COMPLIMENT PLASTIC PIPING SYSTEMS
FOUND ON SERVICES SUCH AS DEMIN WATER, SULPHURIC ACIDS,
CHEMICAL DOSING.
BALL VALVE MANUFACTURERS
I THERE ARE MANY BALL VALVE MANUFACTURERS AVAILABLE.
I GROWING ECONOMIES SUCH AS CHINA AND INDIA ARE SPEEDILY

CATCHING UP WITH ESTABLISHED BALL VALVE SUPPLIERS IN ITALY,
UK, CANADA, JAPAN ETC. UNDERCUTTING THE MANUFACTURING OF
COST OF THESE ESTABLISHED COUNTRIES.
I HOWEVER QUALITY OF THE FINAL PRODUCT IS MORE OF AN ISSUE

ON BALL VALVES THAN WITH GATE VALVES DUE TO MORE PRECISION
DESIGN AND COMPONENTS AND THE GROWING COUNTRIES HAVE
YET TO COMPLETELY CONVINCE CLIENTS AND SUB CONTRACTORS
ENOUGH TO CAPTALISE ON THE EUROPEAN AND AMERICAN
MARKETS.
I IT IS FAIRLY CERTAIN THAT THIS WILL NOT TAKE TOO LONG TO

OCCUR.
COOPER CAMERON – UK –LARGE TRUNNION MOUNTED BALL VALVE

HINDLE – UK - FLOATING BALL VALVE
VELAN – PORTUGAL – CANADA - FLOATING AND TRUNNION MOUNTED
KITZ – JAPAN - FLOATING AND TRUNNION MOUNTED BALL VALVE
RAIMONDI – ITALY – TRUNNION MOUNTED BALL VALVE
FCT – ITALY - TRUNNION MOUNTED BALL VALVE
WORCESTER VALVES – UK - FLOATING AND TRUNNION MOUNTED
BALL VALVE
MC CANNA – USA - TOP ENTRY FLOATING BALL VALVE
ARGUS – FLOATING BALL VALVE
XOMOX – LINE FLOATING BALL VALVE
ATOMAC – FLOATING BALL VALVE
KEYSTONE – UK – FRANCE - FLOATING BALL VALVE
OMB – ITALY – FLOATING BALL VALVE.
PETROL VALVES – FLOATING AND TRUNNION MOUNTED BALL VALVES
COSTS, AVAILABILITY AND DELIVERY
I BALL VALVES ARE MORE EXPENSIVE THAN GATE VALVES BUT OFFER
TIGHTER SHUT OFF CAPABILITY.
I AT LARGER SIZES THE DIFFERENCE IN COST TO A GATE OR

BUTTERFLY VALVE BEGINS TO REDUCE (EVENTUALLY EQUALLING)
DUE TO THE LARGER AMOUNT OF MATERIAL COST VERSUS
MANUFACTURING COST .
I TRUNNION VALVES ARE GENERALLY MORE EXPENSIVE THAN A

FLOATING BALL VALVE.
I COSTS INCREASE CONSIDERABLY IF NON STANDARD FEATURES OR

TESTING IS SPECIFIED.
I AVAILABILITY OF BALL VALVES IS GENERALLY GOOD BUT AT SIZES

LARGER THAN 10 – 12” THEY WILL GENERALLY NEED TO BE MADE TO
ORDER.
I FOR MOST SIZES AND RATINGS OF FLOATING BALL VALVES

MANUFACTURERS AND STOCKISTS WILL CARRY A GOOD NUMBER OF
VALVES EX STOCK .
I FOR TRUNNION MOUNTED BALL VALVES MANUFACTURERS WILL NOT

GENERALLY CARRY A LARGE QUANTITY AND ABOVE CLASS 600 MOST
VALVES WILL BE MADE TO ORDER .
I BALL VALVES MANUFACTURED FROM EXOTIC MATERIALS WILL BE

MADE TO ORDER WITH SIGNIFICANT PRODUCTION LEAD TIMES.
I BALL VALVE MANUFACTUERS TEND TO CARRY A QUANTITY OF

UNMACHINED VALVE BODIES OR UNASSEMBLED VALVES IN AN
EFFORT TO REDUCE PRODUCTION LEAD TIMES WHILST NOT HOLDING
EXCESSIVE AMOUNTS OF STOCK.
TOPIC 2.1/19– BALL VALVES
EXAMPLES OF BALL VALVE FAILURES
I FAILURES IN BALL VALVES ARE GENERALLY DUE TO IMPROPER USE,

INCORRECT SPECIFICATION, POOR QUALITY VALVE
I CAVITY OVER PRESSURE LEADING TO JAMMING OF BALL. A POTENTIAL

FOR SERIOUS PERSONNEL INJURY IF CAVITY IS NOT RELIEVED PRIOR
TO UNBOLTING THE VALVE.
I DAMAGE TO VALVE SOFT SEATS DUE TO INGRESS OF DIRT,

PARTICLES, WELD CONSUMMABLES AT INSTALLATION STAGE.
I DAMAGE TO VALVE SOFT SEATS DUE TO TEMPERATURE IF VALVE IS

WELDED INTO THE PIPING.
I SHEARING OF THE STEM ON ACTUATED DUTY DUE TO EXCESSIVE

TORSIONAL SHEAR STRESS.
I JAMMING OF SEAT RINGS ON TRUNNION MOUNTED VALVES DUE TO

DIRT AND SEVERE CORROSIVE CONDITIONS.
I DISTORTION OF STEM AT BALL / STEM INTERFACE ESPECIALLY ON

PTFE LINED VALVES WHERE PTFE COVERED COMPONENTS TEND TO
ALLOW THIS DISTORTION.
I MEDIA DESIGN / PRESSURE TEMPERATURE EXCEEDS VALVE RATING.
I POOR MACHINING TOLERANCES ON STUFFING BOXES LEADING TO

PREMATURE LEAKAGE PAST GLAND PACKING.
I POOR QUALITY CASTINGS, IE POOR SURFACE FINISH, BLOW HOLES.

LEADING TO SUDDEN FAILURE..
I VALVE SUPPLIED WITH WRONG FACE TO FACE DIMENSION
I BALL SUPPLIED AS CAST HOLLOW DESIGN AND FAILED DUE TO

CRACKING AND POROSITY IN CORROSIVE SERVICE.
I ELASTOMERIC OR POLYMERIC SEATS AND SEALS FAIL DUE TO

INCOMPATIBILITY WITH SERVICE
I POORLY MACHINED COMPONENT TOLERANCES ALLOWANCE FOR

JAMMING UNDER FULL DIFFERENTIAL PRESSURE.
TOPIC 3.
GATE VALVE
CONSTRUCTION AND
SELECTION

I Why consider the use of a gate valve.
I Types of gate valve construction.
gate valve construction.
I List of manufacturers of gate valves.
I Examples of gate valve failures
TOPIC 3.1/1 – GATE VALVES
I GATE VALVES ARE STILL THE MOST COMMONLY USED VALVE.
I GENERALLY SUITABLE FOR MOST SERVICES
I GENERALLY SUITABLE FOR MOST SERVICES SUBJECT TO DESIGN TYPE

USED
I THEY ARE INTENDED FOR FULLY OPEN OR FULLY CLOSED POSITION.
I USED EXTENSIVELY FOR UNINTERRUPTED FLOW DUE TO THE GATE

RETRACTING FULLY INTO THE VALVE BONNET AND CREATING MINIMUM
PRESSURE DROP ON STEAM, WATER, GAS AND MANY OTHER FLUIDS
I THEY ARE A LINEAR OPERATING VALVE
I NOT RECOMMENDED FOR REGULATING PURPOSES AS:

A). Severe corrosion can occur around the leading edge of the wedge as it
approaches the closed position
B). No control of flow effect can be seen until valve is approx 60% closed
I GATE VALVE DESIGNS ARE DIVIDED INTO DIFFERENT TYPES AND HAVE
BEEN DEVELOPED TO SUIT VARIOUS APPLICATIONS.
I NOT SUITABLE FOR BUBBLE TIGHT SHUT OFF OR QUICK CLOSING

APPLICATIONS .
I THE GATE VALVE CONSTRUCTION HAS THE WIDEST ACCEPTABLE

RANGE FOR PRESSURE AND TEMPERATURE.
I GATE VALVES CAN BE USED BETWEEN –196 DEG C. UP TO APPROX 650

DEG. C. SUBJECT TO DESIGN, MATERIALS AND MODIFICATIONS.
WHY CONSIDER THE USE OF A GATE VALVE
I IT IS USUALLY THE MOST COST EFFECTIVE VALVE TYPE..
I SIMPLE MODE OF OPERATION .
I SIMPLE DESIGN OF VALVE AND COMPONENTS ENSURE RELATIVELY

PROBLEM FREE OPERATION.
I ROBUST DESIGN ENSURES LONG DURABLE WORKING LIFE
I MAINTENANCE COSTS ARE RELATIVELY LOW.
I WIDE AVAILABILITY FROM MANUFACTURERS, STOCKISTS AND AGENTS.

THEREFORE GENERALLY NO PROBLEMS IN WORLD WIDE SUPPLY FOR
MANY SIZES AND RATINGS.
I MANY DESIGNS TO COVER VARYING APPLICATIONS.
I GATE VALVES CAN BE FORGED OR CAST FROM MOST MATERIALS


API 600 – Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas
Industries
GENERALLY SPECIFIED FOR GATES VALVES 2” TO 24”
API 602 - Compact Steel Gate Valves - Flanged, Threaded, Welding, and
Extended-Body Ends
GENERALLY SPECIFIED FOR SMALL BORE FORGED VALVE ½” TO 2”.
API 603 - Corrosion-Resistant, Bolted Bonnet Gate Valves - Flanged and Butt-
Welding Ends - THIN WALL VERSION OF API 600
BS 1414 - Specification for steel wedge gate valves (flanged and butt-welding
ends) for the petroleum, petrochemical and allied industries
BS5352 – WITHDRAWN AND SUPERSEDED BY BS EN ISO 15761 -

Specification for steel wedge gate, globe and check valves 50 mm and smaller for
the petroleum, petrochemical and allied industries. -
BS EN ISO 15761 - Steel gate, globe and check valves for sizes DN 100 and
smaller, for the petroleum and natural gas industries.

Pipeline Valves .
TYPE OF GATE VALVE CONSTRUCTION
I STANDARD CONSTRUCTION GATE VALVE ALLOWS FOR THE

OBTURATOR (WEDGE, DISC OR SLAB) TO BE LOWERED BETWEEN
CORRESPONDING ANGLED SEATS TO BLOCK THE LINE.
I FORCE IS TRANSMITTED FROM THE HAND WHEEL OPERATOR, THRU

THE STEM THREAD (SQUARE THREAD) TO EFFECT A WEDGE SEAL
FORCE GREATER THAN THE LINE PRESSURE.
I FOR ALL PROCESS DUTIES THE OPERATING MECHANISM FWEL PREFER

IS GENERALLY OF AN OUTSIDE STEM AND YOKE (O,S & Y) DESIGN.
I THE STEM IS FIXED TO THE WEDGE (TONGUE AND GROOVED). THE

ACTIVATING STEM THREAD IS OUT SIDE THE BODY AND PASSES THRU
THE THREADED BUSH WITHIN THE HANDWHEEL MECHANISN WHICH IS
BOLTED TO THE YOKE. THE ADVANTAGE OF THIS IS THAT THE
THREADED PORTION OF THE STEM IS NOT WITHIN THE PROCESS
MEDIA AND THEREFORE NOT SUBJECT TO CORROSION.
I IT IS DESIRABLE THAT BODY SEATS (ON NON ENERGISED/SPRING

LOADED SEATED VALVES) AND STEM BACK BUSHING ARE WELDED
INTO THE BODY TO REMOVE RISK OF LOOSENING IN SERVICE.
I BODY / BONNET JOINTING IS GENERALLY CIRCULAR PROFILE AND IS IN

LINE WITH ASME B16.5. THEREFORE STANDARD TANGED AND SPIRAL
WOUND GASKETS CAN BE USED AND THESE SHOULD CORRESPOND TO
THE PIPE CLASS GASKETS SPECIFICATION. ON LARGER BORE VALVES
RECTANGULAR BONNET JOINTING MAY BE REQUIRED DUE TO SIZE
RESTRICTIONS.
I API 600 GATE VALVES ARE GENERALLY FULL BORE AND MINIMUM
PORT SIZES ARE DETAILED WITHIN THE STANDARD.
API 602 GATE VALVES ARE GENERALLY REDUCED PORTAND MINIMUM
PORT SIZES ARE DETAILED WITHIN THE STANDARD.
IN ALL CASES THE VENDOR SHOULD CONFIRM THE PORT TYPE AS FULL
OR REDUCED,
I REDUCED OR REGULAR PORT IS GENERALLY NOT AN ISSUE UNLESS

THE LINE REQUIRES PIGGING OR THE INCREASED VELOCITY
/TURBULANCE CAUSED BY THE RESTRICTION IS UNDESIRABLE.
SOLID WEDGE GATE VALVE
I IS USUALLY CONSIDERED FOR LOW PRESSURE SMALL BORE

APPLICATIONS.
I THE WEDGE IS SOLID MATERIAL, PLAIN OR HARD FACED DEPENDANT

UPON TRIM TYPE SPECIFIED .
I IT CAN SEAL ADEQUATELY AGAINST RELATIVELY LOW LINE PRESSURES

WITHOUT EXCESSIVE HANDWHEEL EFFORT.
I GENERALLY RESTRICTED TO SMALL BORE PROCESS VALVES.(UP TO 2”)
I IT HAS BEEN FOUND THAT USING A SOLID WEDGE ON LARGER VALVES

CAN LEAD TO HIGH WEAR AND JAMMING OF THE WEDGE INTO THE
SEATS DUE TO INFLEXIBILITY.
I STANDARD FOR UTILITY WATER GRADE VALVES (IE CAST IRON

VALVES).
I FOR LOW PRESSURE WATER SERVICES THE WEDGE AND BODY

INTERNALS ARE GENERALLY COATED IN AN EPOXY OR RUBBER BASED
MATERIAL GIVING A DURABLE CORROSIVE PROTECTION..
FLEXIBLE WEDGE GATE VALVE
I THE FLEXIBLE WEDGE IS GENERALLY “H” SHAPED AND OBTAINS ITS

FLEXIBILITY FROM THE PROFILE.
I GENERALLY USED ON LARGER SIZES (2” AND ABOVE) AND/OR HIGHER

PRESSURES WHERE THE FLEXING MOTION ALLOWS TIGHTER SEATING
USING LOWER OPERATING FORCE.
I DEVELOPED TO OVERCOME:
- JAMMING
- ALLOWS BETTER ALIGNMENT OF SEAT TO WEDGE,
- COMPENSATES FOR BODY DISTORTION DUE TO HEAT
- REDUCES SEAT WEAR.
DOUBLE DISC VALVE
I THE GATE IS IN THE FORM OF TWO SEPARATE DISCS WHICH ARE

FORCED APART (BY THE DOWNWARD STEM TRAVEL) AGAINST TWO
PARALLELL BODY SEATS BY A WEDGE SHAPED SPREADER CAST ONTO
THE BACK OF THE SEATS. THIS PROVIDES TIGHT SEALING AGAINST
BOTH UPSTREAM AND DOWNSTREAM SEATS.
I SEATS AND SEALING SURFACES ARE PERPENDICULAR AND PARALLEL

THEREFORE RE MACHINING IS MUCH EASIER.
I WEAR BETWEEN SEALING SURFACES IS REDUCED AS THE FIRST

OPENING MOVEMENT RELEASES THE DISCS FROM THE SEAT AND
CONTINUED OPERATION THEN RAISES THE SEATS.
I GENERALLY USED IN LARGER BORE PIPE LINES FOR WATER, OIL AND
GAS.
I NOT SUITABLE FOR STEAM SERVICE AS RAPID TEMPERATURE

FLUCTUATIONS AND HIGH VELOCITY MAY CAUSE VIBRATION
RESULTING IN LOOSENING OF INTERNAL COMPONENTS AND WEAR.
I ALSO SUSCEPTIBLE TO JAMMING DUE TO OVER PRESSURISING TO

THE VALVE CAVITY IN THERMAL CYCLING SERVICE.
WEDGE GATE VALVE CONSTRUCTION
CONDUIT VALVE
I THE CLOSURE IS IN THE FORM OF A RELATIVELY THIN PLATE WITH

PARALLEL FACES.
I THE PLATE INCORPORATES A CIRCULAR APERTURE OF THE SAME

DIAMETER AS THE VALVE BORE AND A BLANK AREA.
I THE PLATE IS RAISED AND LOWERED SO THAT IT IS OPEN WHEN THE

APERTURE IS ALIGNED WITH THE PIPE BORE.
I THE VALVE IS CLOSED WHEN THE PLATE IS LOWERED THUS MOVING

THE APERTURE BELOW THE BODY BORE.. THIS GIVES THE VALVE A
DISTINCT APPEARANCE TO THE BODY.
I THE SEAL IS MADE BY THE SPRING LOADED SEATS WHICH ARE

ENERGISED ONTO THE PLATE BY THE UPSTREAM LINE PRESSURE AND
SEALED AGAINST THE DOWNSTREAM SEATS. VARYING SEATING
SURFACES CAN BE APPLIED TO REDUCE WEAR AND TEAR.
I A SMOOTH FULL BORE, AND CONTINUOUS FLOW PATH IS OBTAINED.
I SUITABLE FOR DIRTY SERVICES.
I IDEAL FOR PIGGING APPLICATIONS.
I A SUITABLE LINE PRESSURE IS REQUIRED.
I GENERALLY USED IN LARGER BORE VALVES DUE TO WEIGHT

REDUCTION.
I CONSIDERATION MUST BE GIVEN TO THE ADDITONAL SPACE

REQUIRED.
I SOFT SEAL RINGS CAN BE UTILISED FOR TIGHTER SHUT OFF.
I GREASING POINTS CAN BE ADDED TO HELP SEALING PROPERTIES

CONDUIT GATE VALVE CONSTRUCTION
CONDUIT GATE VALVE CONSTRUCTION
PARALLEL SLIDE VALVE
I PARALLEL SEAT DISCS ARE HELD AGAINST THE BODY SEATS BY MEANS
OF A SPRING LOCATED BETWEEN THE DISCS. SEAT TIGHTNESS IS
EFFECTED ON THE DOWNSTREAM SIDE AS LINE PRESSURE MOVES
THE UPSTREAM DISC OF ITS SEAT AND TRANSFERS THE FORCE TO
THE DOWNSTREM DISC.
I PROCESS REQUIRES TO BE RELATIVELY CLEAN TO REDUCE FOULING

OF SEATS AND INTERNAL COMPONENTS.
I SMALL DIFFERENTIAL PRESSURE REQUIRED TO SEAL.
I THE SEAT DESIGN IS HIGHLY FLEXIBLE AND CAN COMPENSATE FOR

DISTORTION
I SUITABLE FOR HIGH PRESSURE STEAM AND HIGH THERMAL CYCLING

APPLICATIONS.
PARALLEL SLIDE GATE VALVE CONSTRUCTION
PARALLEL SLIDE GATE VALVE CONSTRUCTION
KNIFE GATE VALVE
I SPECIALISED PROPRIETARY VALVE FOR POWDER, SLURRY, LIQUID

TYPE MEDIA.
I THE KNIFE PLATE PASSES THRU THE BODY AND THEREFORE THE
CONSTRUCTION IS VERY DIFFERENT TO THE PREVIOUS DESIGNS.
I SHORT FACE TO FACE DIMENSION GENERALLY WAFER LUGGED IN

ORDER THAT NO MEDIA COLLECTS WITHIN THE VALVE BODY.
I THE DISC IS THIN PLATE GAUGE AND ACTS AS A GUILLOTINE.
I GENERALLY LOW PRESSURE SERVICE.
I USED IN BREWING, FOOD, MINING, SEWAGE APPLICATIONS.
I CAN HAVE METAL TO METAL OR SOFT SEALING DEPENDING UPON

SHUTOFF REQUIREMENT AND ABRASIVE CONTENT OF MEDIA.
KNIFE GATE VALVE CONSTRUCTION
KNIFE GATE VALVE CONSTRUCTION
RESTRICTIONS ON VARIOUS TYPE OF GATE VALVES
I RESTRICTED TO ON / OFF SERVICE.
I REGULAR MAINTENANCE IS PROMOTED ESPECIALLY ON STEM

PACKING DUE TO LINEAR MOVEMENT OF STEM THRU PACKING,
PARTICLE PICKUP AND RELAXATION OF PACKING ANG BOLTING
LEADING TO LEAKAGE.
I GENERALLY AS THE GATE VALVE SIZE INCREASES THE GEOMETRIC

ENVELOPE OF THE VALVE INCREASES. THEREFORE LARGE AREA
REQUIRED ON LARGE BORE VALVES FOR MAINTENANCE AND
REMOVAL.
I THE PARALLEL SLIDE VALVES ARE RESTRICTED BY SIZE TO APPROX

10” AND ABOVE AND HIGHER PRESSURES.
I PARALLELL SLIDE VALVES DISC SPRING CAN BE A WEAK POINT IN THE

DESIGN.
I WEDGE TYPE GATE VALVES BECOME INCREASINGLY HEAVY AT

LARGER SIZES AND HIGHER PRESSURE RATINGS.
I PARALLEL SLIDE VALVES ARE SUSCEPTIBLE TO LEAKAGE IF THE

PROCESS IS DIRTY AND PARTICLES ARE PRESENT. THE GROOVE IN
THE BASE IS LIABLE TO BLOCKAGE.
I WEDGE, PARALLEL AND KNIFE ARE SUSCEPTIBLE TO OVER SHUTTING

(ESPECIALLY IF ACTUATED) WHICH CAN LEAD TO SEIZURE AND
BENDING OF SPINDLES .
I KNIFE GATE VALVES HAVE LOW PRESSURE LIMITATIONS.
I KNIFE GATE VALVES CANNOT GENERALLY ACCOMMODATE TIGHT

SHUT OFF REQUIREMENTS.
I GATE VALVE BODIES ARE AVAILABLE (OR CAN BE SPECIFIED) IN MOST

MATERIALS.
I BODY / BONNET: GENERALLY CAST OR FORGED MATERIAL,

DEPENDANT UPON SIZE AND PRESSURE.
I WEDGES SOLID / FLEXIBLE: CAST OR FORGED REFER TO API TRIM

TABLES
I GATE IN CONDUIT VALVES/ PARALLELL SLIDE / KNIFE GATES :

GENERALLY PLATE MATERIAL GRADE.
I STEMS ARE GENERALLY MADE FROM WROUGHT BAR
I BODY SEATS ARE GENERALLY FORGED MATERIAL.
I INTERNAL TRIM COMPONENTS IDENTIFIED BY A TRIM NUMBER MUST

MEET THE SPECIFIC MATERIAL REQUIREMENTS AND FORM OF THE
REFERENCED DESIGN STANDARD. API 600 / API 602
I IF SPECIAL TRIM MATERIAL ( NOT COVERED BY THE STANDARDS) ARE

REQUIRED CARE SHOULD BE TAKEN TO ENSURE SUITABLE GRADES
ARE SPECIFIED AND OFFERED BY THE VENDOR.


I BONNET GASKET MATERIAL SHOULD BE GRAPHITE SPIRAL WOUND,

GRAPHITE TANGED OR RING TYPE JOINT DEPENDANT UPON
PRESSURE RATING AND PIPE CLASS REQUIREMENTS.
GATE VALVE MANUFACTURERS
I DUE TO ITS SIMPLE DESIGN AND LARGE MARKET THERE ARE

THOUSANDS OF GATE VALVE MANUFACTURERS IN EXISTANCE
AROUND THE WORLD.
CATCHING UP WITH ESTABLISHED GATE VALVE SUPPLIERS IN ITALY,
I HOWEVER QUALITY OF THE FINAL PRODUCT IS AN ISSUE AND THE
GROWING COUNTRIES HAVE YET TO COMPLETELY CONVINCE
CLIENTS AND SUB CONTRACTORS ENOUGH TO CAPTALISE ON THE
EUROPEAN AND AMERICAN MARKETS.
OCCUR.
COOPER CAMERON – UK –CONDUIT GATE VALVES

HOPKINSON – UK – CONDUIT GATE VALVES
VELAN – CANADA / PORTUGAL- WEDGE GATE VALVES
OMB – ITALY- WEDGE GATE VALVE
BONNEY FORGE – ITALY – WEDGE GATE VALVE
FASANI – ITALY – WEDGE / PARALLEL / CONDUIT GATE VALVE
RAIMONDI – ITALY – WEDGE / CONDUIT GATE VALVE
GROVE – ITALY – WEDGE / CONDUIT GATE VALVE
KITZ – JAPAN – WEDGE GATE VALVE
SUFA – CHINA – APPROVED BY SHELL – WEDGE GATE VALVE
VOGT - USA – WEDGE GATE VALVE
AUDCO INDIA – INDIA – WEDGE GATE VALVE
I
I AS PREVIOUSLY STATED AND IN GENERAL, GATE VALVES ARE THE

CHEAPEST ON/OFF VALVE AVAILABLE.
I AT LARGER SIZES THE DIFFERENCE IN COST TO A BALL OR

BUTTERFLY VALVE BEGINS TO REDUCE (EVENTUALLY EQUALLING)
DUE TO THE LARGER AMOUNT OF MATERIAL COST COMPARED TO THE
OTHER VALVES.
I CONDUIT, PARALLEL SLIDE VALVES ARE GENERALLY MORE

EXPENSIVE THAN WEDGE TYPE GATE VALVES.

I AVAILABILITY OF GATES VALVES IS GENERALLY GOOD FOR MOST

SIZES AND RATINGS OF VALVES. MANUFACTURERS AND STOCKISTS
WILL CARRY A GOOD NUMBER OF VALVE EX STOCK
I CONDUIT / PARALLEL GATE VALVES, VALVES MANUFACTURED FROM

EXOTIC MATERIALS, HIGH PRESSURE RATED GATE VALVES AND/OR
LARGER BORE GATE VALVES WILL BE LESS AVAILABLE OR NOT
AVAILABLE EX STOCK. THE CAN INCREASE LEAD TIMES
CONSIDERABLY.
EXAMPLES OF GATE VALVE FAILURES
I FAILURES IN GATE VALVES ARE GENERALLY DUE TO POOR

QUALITY MANUFACTURE
I LEAKAGE DUE TO POOR MACHINING OF SEAT AND WEDGE

CAUSING JAMMING AND SEIZURE.
I LOOSENING OF BODY SCREWED IN SEAT RINGS , DUE TO

VIBRATION, CORROSION OF THREAD WITH SUBSEQUANT
JAMMING OR PARTING OF COMPONENTS.
I JAMMING OF THE WEDGE DUE TO OVER TRAVEL OF THE

VALVE STEM
I JAMMING OF THE VALVE DUE TO BENDING OF THE STEM

(OVERTRAVEL ON ACTUATED VALVE).
I SEIZURE OF THE STEM DUE TO PACKING OXIDISING AND

BONDING TO STEM - PACKING NOT IMPREGNATED WITH
CORROSION INHIBITOR. THIS HAPPENS WHEN VALVES ARE
TESTED AND TEST WATER IS NOT THROUGHLY REMOVED
FROM THE VALVE INTRNALS, AFTER TESTING THEY MAY BE
PACKED AND NOT USED FOR A NUMBER OF MONTHS GIVING
TIME FOR RUSTING TO OCCUR.
I POOR QUALITY PATTERNS BEING USED IN CASTING

PROCESS LEADING TO POOR CASTING GEOMETRY AND
TOLERANCES.
EXAMPLES OF GATE VALVE FAILURES
I WEDGE GUIDE CHANNEL IN VALVE BODY AND / BONNET NOT

ALIGNED PROPERLY DUE TO POOR CASTING PATTERNS
LEADING TO JAMMING OF THE WEDGE AND BENDING OF THE
STEM.
I POOR MACHINING TOLERANCES ON STUFFING BOXES

LEADING TO PREMATURE LEAKAGE PAST GLAND PACKING.
I STUFFING BOX TOO DEEP LEADING TO THE USE OF PACKING

BUSHES.
I POOR MACHINE FINISH ON STEM AND INTERNAL OF

STUFFING BOX LEADING TO PREMATURE WEAR OF PACKING
AND HENCE LEAKAGE.
I POOR QUALITY CASTINGS, IE POOR SURFACE FINISH, BLOW

HOLES. LEADING TO SUDDEN FAILURE..
I INTERNAL CORROSION DUE TO OUT OF SPEC. TRIM

MATERIALS.
I FAILURE DUE TO WATER HAMMER OR SURGE CONDITIONS.
I FAILURE DUE TO THERMAL FATIGUE

TOPIC 4.
GLOBE VALVE
CONSTRUCTION AND
SELECTION

I Why consider the use of a globe valve.
I Types of globe valve construction.
globe valve construction.
I List of manufacturers of globe valves.
I Examples of globe valve failures
TOPIC 4.1/1 – GLOBE VALVES

USED
I NOT SUITABLE FOR SLUGGISH, DENSE LIQUIDS DUE TO ABRUPT

CHANGES IN FLOW PATH
I THEY ARE INTENDED FOR REGULATING AND CONTROL ALTHOUGH CAN

BE USED FOR SHUT OFF.
I USED EXTENSIVELY FOR FREQUENT OPERATION. IE DOMESTIC WATER

TAPS ARE A GOOD EXAMPLE.
I THEY ARE A LINEAR OPERATING VALVE
I VARIOUS GLOBE VALVE DESIGNS HAVE BEEN DEVELOPED TO SUIT

VARIOUS APPLICATIONS.
I NOT SUITABLE FOR BUBBLE TIGHT SHUT OFF (UNLESS FITTED WITH
SOFT SEATING).
I THE GLOBE VALVE CONSTRUCTION HAS A WIDE ACCEPTABLE RANGE

FOR PRESSURE AND TEMPERATURE.
I GLOBE VALVES CAN BE USED BETWEEN –196 DEG C. UP TO APPROX

650 DEG. C. SUBJECT TO DESIGN, MATERIALS AND MODIFICATIONS.
WHY CONSIDER THE USE OF A GLOBE VALVE
I THE MOST COST EFFECTIVE REGULATING VALVE TYPE..
I WIDELY USED.
I SIMPLE MODE OF OPERATION .
I DUE TO THE DESIGN GLOBE VALVES OPEN AND SHUT QUICKLY

PROVIDING PRECISE THROTTLING AND CONTROL. THEREOFORE
ADVANTAGEOUS WHERE FREQUENT OPERATION AND REGULATING IS
REQUIRED.
I THEY HAVE HIGH-PRESSURE LIMITS AND RELTIVELY LOW LEAKAGE

RATE.
I SIMPLE DESIGN OF VALVE AND COMPONENTS ENSURE RELATIVELY

PROBLEM FREE OPERATION.
I ROBUST DESIGN ENSURES LONG DURABLE WORKING LIFE
I MAINTENANCE COSTS ARE RELATIVELY LOW.
I WIDE AVAILABILITY FROM MANUFACTURERS, STOCKISTS AND AGENTS.

THEREFORE GENERALLY NO PROBLEMS IN WORLD WIDE SUPPLY FOR
MANY SIZES AND RATINGS.
I VARYING DESIGNS TO COVER VARYING APPLICATIONS.
I GLOBE VALVES CAN BE FORGED OR CAST FROM MOST MATERIALS


NO SPECIFIC AMERICAN DESIGN STANDARD EXIST FOR GLOBE VALVES

AND THEREFORE IT IS FOSTER WHEELER STANDARD PRACTICE
TOSPECIFY BRITISH STANDARDS SPECIFICATIONS.
BS 5352 – Steel Wedge Gate, Globe and Check Valves 50 mm and Smaller for
the Petroleum, Petrochemical and Allied Industries
BS 1873- Steel Globe and Globe Stop and Check Valves (Flanged and Butt-
Welding Ends) for the Petroleum, Petrochemical and Allied Industries
BS EN ISO 15761 - Steel gate, globe and check valves for sizes DN 100 and
smaller, for the petroleum and natural gas industries.

Pipeline Valves .
TYPE OF GLOBE VALVE CONSTRUCTION
I STANDARD CONSTRUCTION GLOBE VALVE ALLOWS FOR THE DISC TO

BE LOWERED ONTO A CORRESPONDING ANGLED SEAT TO BLOCK THE
LINE.
I FORCE IS TRANSMITTED FROM THE HAND WHEEL OPERATOR, THRU

THE STEM THREAD (SQUARE THREAD) ONTO THE DISC TO EFFECT A
THRUST SEAL FORCE GREATER THAN THE LINE PRESSURE.
I THE SEAT IS GENERALLY IN THE HORIZONTAL PLAIN UNLESS OBLIQUE

TYPE GLOBE VALVE IS NECESSARY.
I FOR ALL PROCESS DUTIES THE OPERATING MECHANISM FWEL PREFER

IS GENERALLY OF AN OUTSIDE STEM AND YOKE (O,S & Y) DESIGN.
I THE DISC IS FIXED TO THE STEM BUT THE DISC IS ALLOW TO SPIN TO
REMOVE GALLING BETWEEN SEAT SURFACES AND ALLOW THE
SEATING POSITION TO VARY.
I THE ACTIVATING STEM THREAD IS OUT SIDE THE BODY AND PASSES
THRU THE THREADED BUSH WITHIN THE HANDWHEEL MECHANISN
WHICH IS BOLTED TO THE YOKE. THE ADVANTAGE OF THIS IS THAT THE
THREADED PORTION OF THE STEM IS NOT WITHIN THE PROCESS
MEDIA AND THEREFORE NOT SUBJECT TO CORROSION.
I IT IS DESIRABLE THAT BODY SEATS AND STEM BACK BUSHING ARE

WELDED INTO THE BODY TO REMOVE RISK OF LOOSENINGIN SERVICE.
I BODY / BONNET JOINTING IS GENERALLY CIRCULAR PROFILE AND IS IN

LINE WITH ASME B16.5. THEREFORE STANDARD TANGED AND SPIRAL
WOUND GASKETS CAN BE USED AND THESE SHOULD CORRESPOND TO
THE PIPE CLASS GASKETS SPECIFICATION.
I GLOBE VALVES ARE GENERALLY FULL BORE AND MINIMUM PORT

SIZES ARE DETAILED WITHIN THE STANDARD.
I IN ALL CASES THE VENDOR SHOULD CONFIRM THE PORT TYPE AS FULL
OR REDUCED,
I THE VALVE IS CLOSED BY TURNING THE VALVE STEM IN UNTIL THE

DISK IS SEATED INTO THE VALVE SEAT. THIS PREVENTS FLUID FROM
FLOWING UP THROUGH THE VALVE.
I THE EDGE OF THE DISK AND THE SEAT ARE VERY ACCURATELY
MACHINED SO THAT THEY FORM A TIGHT SEAL WHEN THE VALVE IS
CLOSED.
I WHEN THE VALVE IS OPEN THE FLUID FLOWS THROUGH THE SPACE
BETWEEN THE EDGE OF THE DISK AND THE SEAT.
I SINCE THE FLUID FLOWS EQUALLY ON ALL SIDES OF THE CENTER OF

SUPPORT WHEN THE VALVE IS OPEN, THERE IS NO UNBALANCED
PRESSURE ON THE DISK TO CAUSE UNEVEN WEAR.
I THE RATE AT WHICH FLUID FLOWS THROUGH THE VALVE IS

REGULATED BY THE POSITION OF THE DISK IN RELATION TO THE SEAT.
I THE GLOBE VALVE SHOULD NEVER BE JAMMED IN THE OPEN POSITION.

AFTER A VALVE IS FULLY OPENED, THE HANDWHEEL SHOULD BE
TURNED TOWARD THE CLOSED POSITION APPROXIMATELY ONE-HALF
TURN. UNLESS THIS IS DONE, THE VALVE IS LIKELY TO SEIZE IN THE
OPEN POSITION, MAKING IT DIFFICULT, IF NOT IMPOSSIBLE, TO CLOSE
THE VALVE. MANY VALVES ARE DAMAGED IN THIS
I THESE VALVES ARE NOT SUITABLE FOR PIGGED LINES.
I HARD FACED SEATS ARE GENERALLY SPECIFIED TO OVERCOME THE

HIGH PRESSURE DROP AND HGH TURBULANCE CHARACTERISTICS
WHICH LEAD TO INCREASED WEAR AND EROSION OF THE VALVE.
I THE DISCS ARE AVAILABLE WITH DIFFERENT PROFILES TO ACHIEVE

BETTER FLOW CHARACTERISTICS.
I THESE CAN INCLUDE CONICAL DESIGN GIVING REASONABLE FLOW AND

GOOD RESISTANCE TO GALLING, EROSION, WIREDRAWING UNDER
REGULATING CONDITIONS. GENERALLY SPECIFIED FOR HIGHER
PRESSURE AND TEMPERATURES
I FLAT SEAT DISCS FOR NORMAL PRESSURE / TEMPERATURE SERVICES.

NOT RECOMMENDED FOR STEAM, GASOLINE
I PLUG TYPE DISC, GENERALLY SPECIFIED BUT OFFERS MINIMUM

RESISTANCE TO WEAR AND EROSION.
I PLUG DISCS WITH GUIDES TO REDUCE DISC VIBRATION IN SEVERE

CONDITIONSOLLOW DISC WITH V CONTOURS ON SEAT FOR VARYING
FLOW CHARACTERISTICS.
I SPHERICAL / TAPER NOT RECOMMENDED FOR THROTTLING BUT GIVE

GOOD SHUT OFF FOR LIQUIDS. ALSO SUITABLE WHERE DEPOSITS MAY
BUILD UP IN SEAT AREA.
I THE CHOICE OF SEAT IS AT MANUFACTURERS DISGRESSION UNLESS

SPECIFIED.
I IT IS IMPORTANT THAT GLOBE VALVES BE INSTALLED WITH THE

PRESSURE AGAINST THE FACE OF THE DISK TO KEEP THE SYSTEM
PRESSURE AWAY FROM THE STEM PACKING WHEN THE VALVE IS
SHUT.
THERE ARE ARE NUMBER OF VARYING GLOBE VALVE DESIGNS TO

CONSIDER. THE MOST COMMON ARE LISTED BELOW:
STRAIGHT STEM
I GIVES AN “S” TYPE FLOW PATH GIVING THE GREATEST PRESSURE

DROP ACROSS THE VALVE
Y TYPE (OBLIQUE PATTERN)
I WITH THE STEM INCLINED THIS DESIGN GIVES A FLATTER FLOW PATH
WITH A LOWER PRESSURE DROP. PROCESS GROUP WOULD
GENERALLY ADVISE WHERE THE PRESSURE DROP CONDITIONS ARE
CRITICAL.
NEEDLE VALVE
I A MODIFIED GLOBE VALVE WITH A POINTED PLUG GIVING ACCURATE

FLOW CONTROL. USED AT SAMPLE POINTS. GENERALLY SMALLBORE
VALVES ONLY.
STRAIGHT STEM GLOBE VALVE CONSTRUCTION
RESTRICTIONS ON VARIOUS TYPE OF GLOBE VALVES
I NOT SUITABLE IN SERVICES WHERE TURBULANCE WILL BE

DETRIMENTAL TO THE SYSTEM.
I NOT SUITABLE WHERE HIGH PRESSURE DROPS/LOSSES ARE

UNDESIRABLE
I REGULAR MAINTENANCE IS PROMOTED ESPECIALLY ON STEM

PACKING DUE TO LINEAR MOVEMENT OF STEM THRU PACKING,
PARTICLE PICKUP AND RELAXATION OF PACKING ANG BOLTING
LEADING TO LEAKAGE.
I GENERALLY AS THE GLOBE VALVE SIZE INCREASES THE GEOMETRIC

ENVELOPE OF THE VALVE INCREASES. THEREFORE A RELATIVELY
LARGE AREA REQUIRED ON LARGE BORE VALVES FOR MAINTENANCE
AND REMOVAL..
I PIPING CANNOT BE PIGGED.
I GLOBES VALVES ONLY PASS FLOW IN ONE DIRECTION.
I GLOBE VALVES ARE MORE SUSCEPTIBLE TO CLOGGING IN DIRTY

SERVICES. THEY ARE ALSO NOT EASILY CLEANED
I SIZES ARE RESTRICTED TO APPORX 8” – 10”. THEY BECOME DIFFICULT

TO OPERATE ABOVE THIS SIZE DUE TO AXIAL LOAD IMPOSED ON THE
STEM BY THE FLUID PRESSURE ACTING ON THE DISC AREA.
ALTHOUGH LARGER BORE VALVES ARE AVAILABLE THEY ARE
EXPENSIVE AND ALTERNATIVE VALVES SHOULD BE REVIEWED. ONE
ALTERNATIVE IS A PRESSURE BALANCED GLOBE VALVE. SEE NEXT
PAGE FOR DETAILS.
PRESSURE BALANCED GLOBE VALVE
I GLOBE VALVE BODIES ARE AVAILABLE (OR CAN BE SPECIFIED) IN

MOST MATERIALS.
I BODY / BONNET: GENERALLY CAST OR FORGED MATERIAL,

DEPENDANT UPON SIZE AND PRESSURE.
I PLUG / DISC: FORGED OR CAST REFER TO API TRIM TABLES
I STEMS ARE GENERALLY MADE FROM WROUGHT BAR
I BODY SEATS ARE GENERALLY FORGED MATERIAL OR INTEGRAL.
I INTERNAL TRIM COMPONENTS IDENTIFIED BY A TRIM NUMBER.

ALTHOUGH NOT COVERED BY API STANDARD IT IS COMMON TO
UTILISE THE SPECIFIC MATERIAL REQUIREMENTS AND FORM
REFERENCED IN DESIGN STANDARD. API 600 / API 602
I IF SPECIAL TRIM MATERIAL ( NOT COVERED BY THE STANDARDS) ARE




GLOBE VALVE MANUFACTURERS
I DUE TO ITS SIMPLE DESIGN AND LARGE MARKET THERE ARE

THOUSANDS OF GLOBE VALVE MANUFACTURERS IN EXISTANCE
AROUND THE WORLD.
I THEY ARE CLOSELY ALIGNED WITH GATE VALVES AND THEREFORE IT
IS USUAL FOR BULK MANUAL GLOBE VALVES TO BE MANUFACTURED
BY THE SAME SUPPLIERS AS GATES VALVES.
I HOWEVER A NUMBER OF COMPANIES DO SPECIALISE IN GLOBE
VALVES FOR CONTROL PURPOSES.
CATCHING UP WITH ESTABLISHED GLOBE VALVE SUPPLIERS IN ITALY,
OCCUR.
VELAN – CANADA / PORTUGAL

OMB – ITALY
BONNEY FORGE – ITALY
FASANI – ITALY
RAIMONDI – ITALY
GROVE – ITALY
KITZ – JAPAN
SUFA – CHINA – APPROVED BY SHELL
VOGT - USA
AUDCO INDIA – INDIA
SAPAG
YARWAY
DESCOTE.
I GLOBE VALVES ARE NOT THE CHEAPEST OPTION AS BUTTERFLY

VALVES ARE GENERALLY COMPETITIVELY PRICED.
I LARGER THAN 8” THEY BECOME EXTREMELY EXPENSIVE DUE TO THE

SMALL QUANTITIES IN WHICH THEY ARE MANUFACTURED.

I AVAILABILITY OF GLOBE VALVES IS GENERALLY GOOD UP TO 8” AND IN

MOST CLASS RATINGS OF VALVES. MANUFACTURERS AND STOCKISTS
WILL CARRY A GOOD NUMBER OF VALVES EX STOCK
I OBLIQUE ANGLED AND SPECIALISED GLOBE VALVES DESIGNED TO

REDUCE TURBULANCE ARE NOT AS READILY AVAILABLE.
I
EXAMPLES OF GLOBE VALVE FAILURES
I FAILURES IN GLOBE VALVES ARE GENERALLY DUE TO POOR QUALITY

MANUFACTURE
I LEAKAGE DUE TO POOR MACHINING OF SEAT AND WEDGE CAUSING

JAMMING AND SEIZURE.
I LOOSENING OF BODY SCREWED IN SEAT RINGS , DUE TO VIBRATION,

CORROSION OF THREAD WITH SUBSEQUANT JAMMING OR PARTING
OF COMPONENTS.
I SEIZING OF THE DISC TO SEAT DUE TO NON USE.
I JAMMING OF THE VALVE DUE TO BENDING OF THE STEM

(OVERTRAVEL ON ACTUATED VALVE).
I SEIZURE OF THE STEM DUE TO PACKING OXIDISING AND BONDING TO

STEM - PACKING NOT IMPREGNATED WITH CORROSION INHIBITOR.
THIS HAPPENS WHEN VALVES ARE TESTED AND TEST WATER IS NOT
THROUGHLY REMOVED FROM THE VALVE INTRNALS, AFTER TESTING
THEY MAY BE PACKED AND NOT USED FOR A NUMBER OF MONTHS
GIVING TIME FOR RUSTING TO OCCUR.
I POOR QUALITY PATTERNS BEING USED IN CASTING PROCESS

LEADING TO POOR CASTING GEOMETRY AND TOLERANCES.
I POOR MACHINING TOLERANCES ON STUFFING BOXES LEADING TO

PREMATURE LEAKAGE PAST GLAND PACKING.
I STUFFING BOX TOO DEEP LEADING TO THE USE OF PACKING BUSHES.
I POOR MACHINE FINISH ON STEM AND INTERNAL OF STUFFING BOX

LEADING TO PREMATURE WEAR OF PACKING AND HENCE LEAKAGE.
EXAMPLES OF GLOBE VALVE FAILURES

I INTERNAL CORROSION DUE TO OUT OF SPEC. TRIM MATERIALS.
I INTERNAL CORROSION DUE TO EXCESSIVE TURBULANCE.
I FAILURE DUE TO WATER HAMMER OR SURGE CONDITIONS.
I FAILURE DUE TO THERMAL FATIGUE.
I ACTUATED CONTROL GLOBE VALVES SUFFER FROM CAVITION/

VIBRATION, FLASHING OF THE PROCESS.
I SOME POOR QUALITY GLOBE VALVES HAVE THE BOTTOM OF THE

PACKING BOX FORMED BY A THREADED PLUG THAT IS SCREWED INTO
THE VALVE BODY FROM THE INSIDE. THE PLUG IS TACK WELDED TO
KEEP IT FROM UNSCREWING. DURING HIGH VIBRATING CONDITIONS,
THE TACK WELD CAN FAIL WHICH WOULD ALLOW THE PACKING BOX
PLUG TO UNSCREW AND FALL INSIDE THE VALVE AND REST AGAINST
THE VALVE DISK. WHEN THIS HAPPENS, THE VALVE PACKING ALSO
STARTS TO MOVE TO THE INSIDE. WHEN THE VALVE IS OPENED TO
THE PRODUCT STREAM, A MAJOR PACKING LEAK OCCURS BECAUSE
THERE IS NO REAL PACKING. AN X-RAY WAS USED TO PROVE THIS
CONDITION DID HAPPEN.
TOPIC 5.
CHECK VALVE
CONSTRUCTION AND
SELECTION

I Why consider the use of a check valve.
I Types of check valve construction.
check valve construction.
I List of manufacturers of check valves.
I Examples of check valve failures
TOPIC 5.1/1 – CHECK VALVES
I GENERALLY SUITABLE FOR MOST SERVICES SUBJECT TO

DESIGN TYPE USED
I THEY ARE INTENDED TO PREVENT BACK FLOW / REVERSE

FLOW OF FLUIDS.
I USED EXTENSIVELY AT PUMPS, COMPRESSORS AND ANY

EQUIPMENT WHERE REVERSE FLOW WOULD BE
DETRIMENTAL.
I VARIOUS CHECK VALVE DESIGNS HAVE BEEN DEVELOPED

TO SUIT VARIOUS SERVICE APPLICATIONS.
I GENERALLY NOT SUITABLE FOR BUBBLE TIGHT SHUT OFF

(UNLESS FITTED WITH SOFT SEATING).
I TO CHECK THE PRESSURE SURGES ASSOCIATED WITH

YDRAULIC FORCES, FOR EXAMPLE, WATERHAMMER. THESE
HYDRAULIC FORCES CAN CAUSE A WAVE OF PRESSURE TO
RUN UP AND DOWN PIPEWORK UNTIL THE ENERGY IS
DISSIPATED.
I PREVENTION OF REVERSE FLOW ON SYSTEM SHUTDOWN.
I PREVENTION OF FLOODING.
I RELIEF OF VACUUM CONDITIONS.

I THE CHECK VALVE CONSTRUCTION HAS A WIDE ACCEPTABLE RANGE

FOR PRESSURE AND TEMPERATURE.
I CHECK VALVES CAN BE USED BETWEEN –196 DEG C. UP TO APPROX

650 DEG. C. SUBJECT TO DESIGN, MATERIALS AND MODIFICATIONS.
WHY CONSIDER THE USE OF A CHECK VALVE
I THEY ARE REQUIRED FOR THE PROTECTION OF IN LINE PIPING

EQUIPMENT AND MUST BE CONSIDERED FOR SAFETY REASONS..
I THERE IS NO ALTERNATIVE TO A CHECK VALVE ALTHOUGH MANY

VARIATIONS HAVE BEEN DEVELOPED.
DESIGN STANDARDS SHOULD FOLLOW THE ALLOCATED

DESIGN CODE FOR THE PLANT, THEREFORE IF USING ASME
B31.3 THEN AMERICAN API / ASME STANDARD SHOULD BE
USED WHERE POSSIBLE.
NO SPECIFIC AMERICAN DESIGN STANDARD EXIST FOR CHECK

VALVES AND THEREFORE IT IS FOSTER WHEELER STANDARD
PRACTICE TOSPECIFY BRITISH STANDARDS SPECIFICATIONS.
BS 5352 – Steel Wedge Gate, Globe and Check Valves 50 mm and

Smaller for the Petroleum, Petrochemical and Allied Industries
BS 1868- Steel Check Valves (Flanged and Butt- Welding Ends) for the
Petroleum, Petrochemical and Allied Industries
BS EN ISO 15761 - Steel gate, globe and check valves for sizes DN
100 and smaller, for the petroleum and natural gas industries.
API 6D - Petroleum and Natural Gas Industries-Pipeline Transportation

Systems-Pipeline Valves .
TYPE OF CHECK VALVE CONSTRUCTION
I As with isolation valves, there are a number of different check valve

designs, each suited to specific applications. The different types of
check valve and their applications are discussed in this module,
along with the correct sizing method.
LIFT CHECK VALVES
I Lift check valves are similar in configuration to globe valves, except

that the disc or plug is automatically operated. The inlet and outlet
ports are separated by a cone shaped plug that rests on a seat
typically metal; in some valves, the plug may be held on its seat
using a spring. When the flow into the valve is in the forward
direction, the pressure of the fluid lifts the cone off its seat, opening
the valve. With reverse flow, the cone returns to its seat and is held
in place by the reverse flow pressure.
I If a metal seat is used, the lift check valve is only suitable for
applications where a small amount of leakage, under reverse flow
conditions, is acceptable. Furthermore, the design of a lift check
valve generally limits its use to water applications, subsequently,
they are commonly used to prevent reverse flow of condensate in
steam traps and on the outlets of cyclic condensate pumps.
I The main advantage of the lift check valve lies in its simplicity, and
as the cone is the only moving part, the valve is robust and requires
little maintenance. In addition, the use of a metal seat limits the
amount of seat wear. The lift check valve has two major limitations;
firstly, it is designed only for installation in horizontal pipelines, and
secondly, its size is typically limited to DN80, above which, the valve
would become too bulky.
LIFT CHECK VALVE

LIFT CHECK
LIFT CHECK VALVES - Contd
I The piston-type lift check valve is a modification of the standard lift check valve.
It incorporates a piston shaped plug instead of the cone, and a dashpot is
applied to this mechanism. The dashpot produces a damping effect during
operation, thereby eliminating the damage caused by the frequent operation of
the valve, for example, in pipeline systems, which are subject to surges in
pressure, or frequent changes in flow direction (one example would be a boiler
outlet).
I FWEL Would generally restrict size to 40 nb. Max.
SWING CHECK VALVES
I A swing check valve consists of a flap or disc of the same diameter as the pipe
bore, which hangs down in the flow path. With flow in the forwards direction, the
pressure of the fluid forces the disc to hinge upwards, allowing flow through the
valve. Reverse flow will cause the disc to shut against the seat and stop the fluid
going back down the pipe. In the absence of flow, the weight of the flap is
responsible for the closure of the valve; however, in some cases, closure may
be assisted by the use of a weighted lever. The whole mechanism is enclosed
within a body, which allows the flap to retract out of the flow path.
I Swing check valves produce relatively high resistance to flow in the open
position, due to the weight of the disc. In addition, they create turbulence,
because the flap ‘floats’ on the fluid stream. This means that there is typically a
larger pressure drop across a swing check valve than across other types.
SWING CHECK VALVE

SWING CHECK
SWING CHECK VALVES - Contd
I With abrupt changes in flow, the disc can slam against the valve seat, which
can cause significant wear of the seat, and generate water hammer along the
pipe system. This can be overcome by fitting a damping mechanism to the disc
and by using metal seats to limit the amount of seat wear.
WAFER CHECK VALVES
I Both lift and swing check valves tend to be bulky which limits their size and
makes them costly. To overcome this, wafer check valves have been
developed. By definition wafer check valves are those that are designed to fit
between a set of flanges. This broad definition covers a variety of different
designs, including disc check valves and wafer versions of swing or split disc
check valves.
DISC CHECK VALVES
I The disc check valve consists of four main components: the body, a disc, a
spring and a spring retainer. The disc moves in a plane at right angles to the
flow of the fluid, resisted by the spring that is held in place by the retainer. The
body is designed to act as an integral centring collar that facilitates installation.
Where a ‘zero leakage’ seal is required, a soft seat can be included.
I It is not FWEL first choice to use these type of check valves as the overall
design generally does not comply to any international standards although wall
thickness is generally in accordance with ASME B16.34 and they are generally
only used in low pressure duties. They are relatively more common in
petrochemical and pharmaceutical environments.
DISC CHECK VALVE

DISC CHECK VALVES – Cont,d
I When the force exerted on the disc by the upstream pressure is greater than the
force exerted by the spring, the weight of the disc and any downstream
pressure, the disc is forced to lift off its seat, allowing flow through the valve.
When the differential pressure across the valve is reduced, the spring forces the
disc back onto its seat, closing the valve just before reverse flow occurs. The
presence of the spring enables the disc check vale to be installed in any
direction.
I The differential pressure required to open the check valve is mainly determined
by the type of spring used. In addition to the standard spring, there are several
spring options available:
I No spring - Used where the differential pressure across the valve is small.
I Nimonic spring - Used in high temperature applications.
I Heavy-duty spring - This increases the required opening pressure. When

installed in the boiler feed water line, it can be used to prevent steam boilers
from flooding when they are un pressurised.
I The design of disc check valves allows them to be installed in any position,
including vertical pipelines where the fluid flows downwards
I As with all wafer check valves, the size of the disc check valve is determined by
the size of the associated pipe work. This usually ensures that the valve is
correctly sized, but there are cases where the valve is over or undersized.
TOPIC 5.1/14 –CHECK VALVES
DISC CHECK VALVES – Cont,d
I An oversized check valve is often indicated by continuous valve chatter, which is

the repeated opening and closing of the valve that occurs when the valve is only
partially open. It is caused by the fact that when the valve opens, there is a drop
in the upstream pressure; if this pressure drop means that the differential
pressure across the valve falls below the required opening pressure, the valve
will slam shut. As soon as the valve shuts, the pressure begins to build up again,
and so the valve opens and the cycle is repeated.
I Oversizing can usually be rectified by selecting a smaller valve, but it should be

noted that this will increase the pressure drop across the valve for any one flow.
If this is not acceptable, it may be possible to overcome the effects of chatter by
reducing the closing force on the disc. This can be done either by using a
standard spring instead of a heavy-duty one, or by removing the spring
altogether. Another alternative is to use a soft seat; this does not prevent the
chatter but rather, reduces the noise. Care must be taken however, as this may
cause excessive wear on the seat.
I Undersizing results in excessive pressure drop across the valve and, in the
extreme, it may even prevent flow. The solution is to replace the undersized
valve with a larger one.
I Disc check valves are smaller and lighter than lift and standard swing check
valves and subsequently cost less. The size of a disc check valve is however
limited to DN125; above this, the design becomes complicated. Typically, such a
design would include a cone shaped disc and a small diameter spring that is
retained and guided along the centre line of the cone, which is more difficult and
expensive to manufacture. Even then, such designs are still limited in size to
DN250.
TOPIC 5.1/15 –CHECK VALVES
DISC TYPE CHECK VALVES – Contd
I Standard disc check valves should not be used on applications where there is
heavily pulsating flow, for example, on the outlet of a reciprocating air
compressor, as the repeated impact of the disc can lead to failure of the spring
retainer and high levels of stress in the spring. Specifically designed retainers
are available for such applications. These designs typically reduce the amount of
disc travel, which effectively increases the resistance to flow and therefore
increases the pressure drop across the valve.
SWING TYPE WAFER CHECK VALVES
I It is not FWEL first choice to use these type of check valves as the overall
design generally does not comply to any international standards although wall
thickness is generally in accordance with ASME B16.34 and they are generally
only used in low pressure duties. They are relatively more common in
petrochemical and pharmaceutical environments.
I These are similar to the standard swing check valves, but do not have the full-
bodied arrangement, instead, when the valve opens, the flap is forced into the
top of the pipeline. Subsequently, the flap must have a smaller diameter than
that of the pipeline, and because of this, the pressure drop across the valve,
which is often high for swing type valves, is further increased.
I Swing type check valves are used mainly on larger pipeline sizes, typically
above DN50, because on smaller pipelines the pressure drop, caused by the
disc ‘floating’ on the fluid stream, becomes significant. Furthermore, there are
significant cost savings to be made by using these valves on larger sizes, due to
the small amount of material required for the construction of the valve.
SWING TYPE WAFER CHECK VALVE
I There is however one problem with using larger size valves; due to their size,
the discs are particularly heavy, and therefore possess a large amount of kinetic
energy when they close. This energy is transferred to the seat and process fluid
when the valve slams shut, which could cause damage to the seat of the valve
and generate waterhammer.
SPLIT DISC CHECK VALVES
I The split disc check valve or dual plate check valve is designed to
overcome the size and pressure drop limitations of the swing and
disc type wafer check valves. The flap of the swing check valve is
essentially split and hinged down its centre, such that the two disc
plates will only swing in one direction. The disc plates are held
against the seat by a torsion spring mounted on the hinge.
I In order to hold the hinge in the centre of the flow path, externally
mounted retainer pins can be used. These retainer pins are a
common source of leakage from the valve. An improved design
secures the hinge internally, and as the valve mechanism is entirely
sealed within the body, leakage to atmosphere is prevented.
I The frequent opening and closing of the split disc check valve would
soon cause seat damage if the heels of the disc plates were allowed
to scuff against the seat during opening. To overcome this, the heel
of the disc plates lift during the initial opening of the valve and the
plates rotate purely on the hinge as opposed to the seat face.
I The split disc type of check valve has several advantages over other
types of check valves:
a). The split disc design is not limited in size and these valves have
been produced in sizes of up to DN5400.
SPLIT DISC WAFER CHECK VALVE

SPLIT DISC CHECK VALVES - Contd
b). The pressure drop across the split disc check valve is significantly
lower than across other types.
c). They are capable of being used with lower opening pressures.
d). Split disc check vales can be installed in any position, including
vertical pipelines.
OTHER CHECK VALVE TYPES
I The above mentioned types of check valve are the most commonly
encountered types in steam, condensate, and liquid systems.
However, several other types are also available. The three types
listed below are mainly suited to liquid applications and subsequently
may be found in condensate systems:
I Ball check valve - This consists of a rubber-coated ball that is

normally seated on the inlet
to the valve, sealing off the inlet. When pressure is exerted on the
ball, it is moved off its seat along a guide rail, allowing fluid to pass
through the inlet. When the fluid pressure drops, the ball slides back
into its position on the inlet seat. Note: Ball check valves are typically
only used in liquid systems, as it is difficult to obtain a tight seal using
a ball.
BALL TYPE CHECK VALVE

Diaphragm check valve - A flexible rubber diaphragm is placed in a

mesh or perforated
cone with the point in the direction of flow in the pipeline. Flow in the
forwards direction deflects the diaphragm inwards, allowing the free
passage of the fluid. When there is no flow or a backpressure exists,
the diaphragm returns to its original position, closing the valve. Note:
The diaphragm material typically limits the application of the
diaphragm check valve to fluids below 180°C and 16 bar.
I Tilting disc check valve - This is similar to the swing type check
valve, but with the flap pivoted in front of its centre of pressure and
counterweighted or spring loaded to assume a normally closed
position. When flow is in the forwards direction, the disc lifts and
‘floats’ in the stream offering minimum resistance to flow. The disc is
balanced so that as flow decreases, it will pivot towards its closed
position, closing before reverse flow actually commences. The
operation is smooth and silent under most conditions. Note: due to
the design of the tilting disc check valve, it is limited to use on liquid
applications only. These valves should be specified as one piece
body design.
I Nozzle check valve – This is a high specification check valve

generally used on compressor unit inlets where backflow safety is
required whilst ensuring low pressure loss (which affects other
designs) across the valve. It also allows non slam closure under high
velocity conditions
RESTRICTIONS ON VARIOUS TYPE OF CHECK VALVES
I DUE TO THE VARIATIONS IN NON RETURN VALVE DESIGNS WHICH

EACH HAVE THERE OWN TYPES OF RESTRICTIONS. PLEASE REFER TO
THE INDIVIDUAL VALVE TYPE DESIGN NOTES.
I ASSESS APPLICATION AND APPLY MOST SUITABLE TYPE.
I
I CHECK VALVE BODIES ARE AVAILABLE (OR CAN BE SPECIFIED) IN

MOST MATERIALS.
I BODY / COVER: GENERALLY CAST OR FORGED MATERIAL, DEPENDANT

UPON SIZE AND PRESSURE.
I INTERNALS: FORGED OR CAST REFER TO API TRIM TABLES.
I NOZZLE CHECK VALVE INTERNALS AND COMPONENTS SUCH AS

SPRINGS, NOT COVERED BY THE STANDARD API TRIM DESIGNATIONS
WILL GENERALLY BE SUPPLIER STANDARD AND SHOULD BE REVIEWED
FOR ACCEPTABILITY.
I BODY SEATS ARE GENERALLY FORGED MATERIAL OR INTEGRAL.
I INTERNAL TRIM COMPONENTS IDENTIFIED BY A TRIM NUMBER.

ALTHOUGH NOT COVERED BY API STANDARD IT IS COMMON TO
UTILISE THE SPECIFIC MATERIAL REQUIREMENTS AND FORM
REFERENCED IN DESIGN STANDARD. API 600 / API 602
I IF SPECIAL TRIM MATERIAL (NOT COVERED BY THE STANDARDS) ARE




CHECK VALVE MANUFACTURERS
I FOR THE STANDARD NON RETURN VALVE TYPES AND DUE TO ITS
SIMPLE DESIGN & LARGE MARKET THERE ARE THOUSANDS OF CHECK
VALVE MANUFACTURERS IN EXISTANCE AROUND THE WORLD.
I STANDARD TYPES OF NON RETURN VALVE (SWING, PISTON, LIFT) ARE
HISTORICALLY CLOSELY ALIGNED WITH GATE AND GLOBE VALVES
AND THEREFORE IT IS USUAL FOR BULK MANUAL VALVES TO BE
MANUFACTURED BY THE SAME SUPPLIERS AS GATES VALVES.
CATCHING UP WITH ESTABLISHED GATE VALVE SUPPLIERS IN ITALY,
OCCUR.
I SPECIALISED NON RETURN VALVES ARE AVAILABLE FROM A
RESTRICTED NUMBER OF COMPANIES GENERALLY IN EUROPE.
VELAN – CANADA / PORTUGAL - SWING, PISTON

OMB – ITALY – SWING, PISTION
BONNEY FORGE – ITALY – SWING PISTON
FASANI – ITALY – SWING, PISTON
RAIMONDI – ITALY – SWING, PISTON
GROVE – ITALY– SWING, PISTON
KITZ – JAPAN – SWING, PISTON
SUFA – CHINA – APPROVED BY SHELL – SWING, PISTON
VOGT - USA – SWING, PISTON
AUDCO INDIA – INDIA– SWING, PISTON
MOKVELD - NOZZLE
ENTECH – NOZZLE
MANNESMAN DEMAG - NOZZLE
CRANE / STOCKHAM – NOZZLE / WAFER PLATE / SWING / PISTON
GOODWIN - WAFER PLATE
I CHEAPEST TYPE ARE WAFER SWING DESIGN.
I SMALL BORE FORGED PISTON/SWING/BALL/LIFT TYPE CHECK VALVES

AND LARGER BORE SWING TYPE CHECK VALVES ARE STILL THE MOST
COMMON DESIGN AND THEREFORE MORE COMPETIVELY PRICED,

I AVAILABILITY OF MOST CHECK VALVES (NOT INCLUDING NOZZLE

TYPE) IS GENERALLY GOOD FOR MOST SIZES AND IN MOST CLASS
RATINGS OF VALVES. MANUFACTURERS AND STOCKISTS WILL CARRY
A GOOD NUMBER OF VALVES EX STOCK
I NOZZLE CHECK VALVES AND VALVES REQUIRED IN EXOTIC MATERIALS

ARE NOT READILY AVAILABLE AND MAY HAVE LONG LEAD TIMES.
EXAMPLES OF CHECK VALVE FAILURES
FAILURES ON CHECK VALVES CAN BE CATASTROPHIC AS THEY ARE

GENERALLY FITTED TO STOP DAMAGE TO OTHER IN LINE EQUIPMENT.
THEREFORE THE COST OF A FAILURE CAN BE MANY TIMES THE COST
OF A CHECK VALVE
I FAILURES IN GLOBE VALVES ARE GENERALLY DUE TO POOR QUALITY

MANUFACTURE
I LEAKAGE DUE TO POOR MACHINING / MISALIGNMENT OF SEAT AND

DISC CAUSING JAMMING (OPEN AND CLOSED) AND SEIZURE.
I DISC SEIZING IN OPEN POSITON.
I CORROSION OF INTERNAL COMPONENTS RESULTING IN PARTING OF

COMPONENTS.
I LOOSENING OF BODY SCREWED IN SEAT RINGS , DUE TO VIBRATION,

CORROSION OF THREAD WITH SUBSEQUANT JAMMING OR PARTING
OF COMPONENTS.
I SEIZING OF THE DISC TO SEAT DUE TO NON USE.
I POOR QUALITY PATTERNS BEING USED IN CASTING PROCESS

LEADING TO POOR CASTING GEOMETRY AND TOLERANCES.
I POOR MACHINING TOLERANCES LEADING TO PREMATURE LEAKAGE.
I INCORRECT ORIENTATION OF CHECK VALVES RESULTING IN FAILURE

TO OPEN OR CLOSE.
EXAMPLES OF CHECK VALVE FAILURES

I INTERNAL CORROSION DUE TO OUT OF SPEC. TRIM MATERIALS.
I INTERNAL CORROSION DUE TO EXCESSIVE TURBULANCE.
I FAILURE DUE TO WATERHAMMER EFFECT OR SURGE CONDITIONS.
I FAILURE DUE TO THERMAL FATIGUE.
I EXCESSIVE SPRING FORCE (WHERE FITTED OR REQUIRED BY DESIGN)

RESULTING IN VALVE NOT OPERATING.
I HINGE PINS NOT SECURED, NOT WELDED IN OR CORRODED DUE TO

UNSUITABLE MATERIAL GRADE RESULTING IN HINGE PIN / PARTING
FROM BODY.
I FAILURE OF HINGE PIN DUE TO WEAR AND POOR MAINTENANCE.
I LIFT CHECK VALVES SUSCEPTIBLE TO SMALL PARTICLES JAMMING OR

CLOGGING BETWEEN DISC AND SEAT DUE TO CLOSE TOLERANCES
RESULTING IN HIGH LEAKAGE RATES
TOPIC 6.
BUTTERFLY VALVE
CONSTRUCTION AND
SELECTION

I Why consider the use of a butterfly
valve.
I Types of butterfly valve construction.
butterfly valve construction.
I List of manufacturers of butterfly
valves.
I Examples of butterfly valve failures
TOPIC 6.1/1 – BUTTERFLY VALVES

USED
I USED IN MANY INDUSTRIES FROM WATER TREATMENT, BREWING,

FOOD, REFINING, OIL AND GAS.
I MORE SUITED TO LARGER BORE PIPING AND PIPELINE SYSTEMS

WHERE GOOD CONTROL / REGULATING COMBINED WITH SHUT OFF
CAPABILTIY IS DESIRED.
I SUITABLE FOR SEVERE, SLUGGISH, DENSE LIQUIDS WITH HIGH

PARTICLE CONTENT AS DESIGN DOES NOT ALLOW FOR PARTICLE
BUILD UP.
I GOOD BUBBLE TIGHT SHUT OFF WHEN FITTED WITH SOFT SEATING.
I CAN BE USED IN HIGH TEMPERATURE IF METAL SEATED BUT NOT

TIGHT SHUT OFF
I THEY ARE A QUARTER TURN OPERATING VALVE THEREFORE QUICK

SHUT OFF
I VARIOUS BUTTERFLY VALVE DESIGNS HAVE BEEN DEVELOPED TO

SUIT VARIOUS APPLICATIONS.
I SUITABLE FOR EMERGENCY SHUT OFF APPLICATIONS

I THE BUTTERFLY VALVE CONSTRUCTION HAS A WIDE RANGE FOR

PRESSURE AND TEMPERATURES BUT THIS REQUIRES CERTAIN DESIGN
CHANGES.
I BUTTERFLY VALVES CAN BE USED BETWEEN –196 DEG C. UP TO

APPROX 600 DEG. C. SUBJECT TO DESIGN, MATERIALS AND
MODIFICATIONS.
I RUBBER LINED AND PTFE BUTTERFLY VALVES ARE GENERALLY

LIMITED TO A SPECIFIC PRESSURE AND TEMPERATURE UP TO APPROX
300 NB:
I PTFE LINED - APPROX. 10 BAR AT UP TO APPROX 200 DEG.C. SPECIAL

DESIGNS CAN REACH 16 BAR.
I RUBBER LINED – MAX APPROX. 10 BAR UP TO 120 - 140 DEG.C.
I BELOW IS PRESSURE / TEMP. GRAPH FOR A SOFT SEATED HIGH

PERFORMANCE BUTTERFLY VALVES AND A METAL SEATED BUTTERFLY
VALVE.
SOFT SEATED BUTTERFLY VALVE CLASS 150

SOFT SEATED BUTTERFLY VALVE CLASS 600

METAL SEATED BUTTERFLY VALVE

WHY CONSIDER THE USE OF A BUTTERFLY VALVE
I SOFT SEATED VALVES ALLOW BUBBLE TIGHT SHUT OFF WHICH IS

DESIRABLE OR MANDATORY FOR CERTAIN PROCESSES.
I THE MODE OF OPERATION DOES NOT IMPLY MECHANICAL FORCE

ONTO THE SEATS AS HAPPEN S WITH A GATE VALVE. GENERALLY
ALLOWING LONGER LIFE BETWEEN MAINTENANCE.
I THEY ARE A QUARTER TURN OPERATING VALVE AND THERFORE THE

ORIENTATION GIVES A QUICK VISUAL AID AS TO WHETHER THE VALVE
IS OPEN OR CLOSED .
I BUTTERFLY VALVES HAVE A SMOOTH LOW OPERATING TORQUE,.

THEREFORE ACTUATOR UNITS CAN BE OF A SMALLER CAPACITY AND
REDUCED COST.
I THEY HAVE A LOW COEFFICIENT OF FRICTION VALUE THEREFORE LOW

PRESSURE DROP ACROSS THE VALVE
I THEY CAN BE USED TO BOTH REGULATE AND SHUT OFF
I BUTTERFLY VALVE FACE TO FACE DIMENSION IS SMALL WHICH

ALLOWS MORE SCOPE FOR LOCATION
I BUTTERFLY VALVE OVERALL DIMENSIONAL ENVELOPE IS SMALLER

THAN GATE THUS SAVING SPACE. MAY BE A HELP TO PLANT DESIGN.
I CAN WEIGH UP TO 10 TIMES LESS THAN GATE VALVE

WHY CONSIDER THE USE OF A BUTTERFLY VALVE
I LOW MAINTENANCE COSTS DUE TO MINIMUM INTERNAL COMPONENTS.
I BUTTERFLY VALVE OVERALL DIMENSIONAL ENVELOPE IS SMALLER

THAN GATE THUS SAVING SPACE. MAY BE A HELP TO PLANT DESIGN.
I CAN WEIGH UP TO 10 TIMES LESS THAN GATE VALVE WHICH MAY SAVE
ON PIPING SUPPORTS.

I LOW MAINTENANCE COSTS.
I ADEQUATE AVAILABILITY FROM MANUFACTURERS, STOCKISTS AND

AGENTS.
I MANY DESIGNS TO COVER VARYING APPLICATIONS FROM EXTREME

ACIDS TO CLEAN PROCESSES .
I BUTTERFLY VALVES GENERALLY CAST MATERIALS
I SOME DESIGNS ALLOW FOR MINIMAL SEAT WEAR DUE TO OFFSET

DESIGN OF STEM.
I TOP ENTRY BUTTERFLY VALVES ARE AVAILABLE.
I
DESIGN STANDARDS SHOULD FOLLOW THE ALLOCATED

DESIGN CODE FOR THE PLANT, THEREFORE IF USING ASME
B31.3 THEN AMERICAN API / ASME STANDARD SHOULD BE
USED WHERE POSSIBLE.
BS EN 593- Industrial Valves - Metallic Butterfly Valves
PREN ISO 16136- Industrial Valves - Butterfly Valves of Thermoplastic

Materials
BS5155 -Butterfly Valves-AMD 6990; May 1, 1992; Superseded by BS

EN 593: 1998
PREN 13326 Industrial Valves - Butterfly Valves of Thermoplastic

Materials-ISO/DIS 16136:2001
API –609- Butterfly Valves: Double Flanged, Lug- and Wafer-Type
MSS-SP-67-Butterfly Valves
API 6D - Petroleum and Natural Gas Industries-Pipeline Transportation

Systems-Pipeline Valves .
TYPE OF BUTTERFLY VALVE CONSTRUCTION
Rotating disk
I A butterfly valve is a flow control device that incorporates a rotational disk to

control the flowing media in a process. The disk is always in the passageway,
but because it is relatively thin, it offers little resistance to flow.
I Butterfly valve technology has evolved dramatically over the past half century,
as has its industry popularity. This popularity can be partly attributed to the
quarter-turn operation, tight shutoff and its availability in a variety of materials of
construction.
I Early use of butterfly valves focused on water applications, but new designs and
component materials have allowed them to be utilized in growing industrial fluid
applications. Presently, butterfly valves can be found in almost every chemical
plant handling a variety of diverse fluids.
I Butterfly valves range in size from 1 in to more than 200 in and most have a
pressure capability of 150-psi to 740-psi cold working pressure. The general
temperature rating for a resilient seated valve is 25°F to 300°F and 400°F to
450°F for a high-performance butterfly valve.
I Butterfly valves can be either symmetric or eccentric (i.e., the stem is offset from
the center of the disc).
Basic components
The butterfly valve consists of only four main components: body, disk, stem and
seat.
I Body. Butterfly valves generally have bodies that fit between two pipe flanges.
The most common body designs are lug and wafer. The lug body has protruding
lugs that provide bolt holes matching those in the pipe flange. A wafer body does
not have protruding lugs. The wafer valve is sandwiched between the pipe
flanges, and the flange bolts surround the body.
I Each type of body has advantages, some of which are listed:
I The wafer style is less expensive than a lug style.
I Wafer designs do not transfer the weight of the piping system directly through
the valve body.
I A lug body allows dead-end service or removal of downstream piping.
Disk. The flow closure member of a butterfly valve is the disk. Many variations of
the disk design have evolved relative to the orientation of the disk and stem in
an attempt to improve flow, sealing and/or operating torque. The disk is the
equivalent of a plug in a plug valve, gate in a gate valve or a ball in a ball valve.
Rotating the disk one-quarter turn or 90° opens and closes the butterfly valve.
Stem. The stem of the butterfly valve may be a one-piece shaft or a two-piece
(split-stem) design.
The stem in most resilient seated designs is protected from the media, thus
allowing an efficient selection of material with respect to cost and mechanical
properties.
In high-performance designs, the stems are in contact with the media and,
therefore, must be compatible, as well as provide the required strength for
seating and unseating the disk from the seat.
Seat. The seat of a resilient-seat butterfly valve utilizes an interference fit

between the disk edge and the seat to provide shutoff. The material of the seat
can be made from many different elastomers or polymers. The seat may be
bonded to the body or it may be pressed or locked in.
In high-performance butterfly valves, the shutoff may be provided by an

interference-fit seat design or a line-energized seat design, where the pressure
in the pipeline is used to increase the interference between the seat and disk
edge. The most common seat material is polytetrafluoroethylene (PTFE) or
reinforced PTFE (RTFE) because of the wider range of compatibility and
temperature range.
Metal seats are also offered in high-performance butterfly valves. These metal
seats allow a butterfly valve to be used in even higher temperatures to 1,000°F.
Fire-safe designs are offered that provide the shutoff of a polymer seat valve
before a fire, and the metal seal backup provides shutoff during and after a fire.
"Non-wetted" and "wetted"

Lined butterfly valves rely on elastomers (rubber) and/or polymers (PTFE) to
completely isolate the valve body and stem journal area from the corrosive
and/or erosive effects of the line media. When the body and stem journal area
are isolated from the line media, the valve is considered a "non-wetted" design.
By isolating the valve body and stem with rubber or PTFE, it is not necessary for
the valve body to be made of expensive corrosion-resistant materials such as
stainless steel, Alloy-20 and C-276.
When the valve body and journals are exposed to the line media such as in gate
valves, globe valves and lubricated plug valves, the valve is considered to have
"wetted" parts.
Characteristics of high performance butterfly valves.

Modern, high-performance butterfly valves frequently have a double-
eccentric design. First, the sealing plane of the disc is offset from the axis of
rotation. This provides an uninterrupted circular sealing surface on the disc
that makes it possible for a circular sealing element to be placed in the valve.
It can be easily removed from the valve without disassembly of the shaft/disc
closure elements.
Second, the axis of rotation of the disc is laterally displaced from the true
center of the disc so that it will "cam" away from the seat to eliminate
jamming or squeezing as the valve is opened and closed. This design
eliminates wear points around the disc at the top and bottom of the seat.
When closing, the disc cams tightly into its seat to create a bubble-tight seal
with consistent torque. This eccentric rotation has a tremendous impact of
extending the duration of the valve's leak-free performance.
Metal seats, which are more popular in Europe, provide consistent, long-
lasting shutoff, but they are not considered bubble-tight. Services which
require 100% tight shutoff must rely on soft seats.
Characteristics and system requirements

The following are some general control valve terms and characteristics for
butterfly valves when used for modulating service. A valve having a stated
inherent characteristic may provide a different installed characteristic due to
interaction with the system.
Linear. The flowrate is directly proportional to the amount of disk travel. For
example, at 50% open, the flowrate is 50% of maximum flow.
Equal percentage. Equal percentage characteristic means that equal

increments of valve travel produce equal percentage changes in flowrate as
related to the flowrate that existed at the previous travel position.
For example, if a valve travel change from 20% open to 30% open produced a
70% change in flowrate, then a valve travel change from 30% open to 40% open
would produce another 70% change in flowrate. If the flowrate at 20% open was
100 gpm, then flowrate at 30% open would be 170 gpm and the flowrate at 40%
open would be 70% greater than at 30% travel or 289 gpm. The same would be
true for each additional incremental travel position.


RESTRICTIONS ON VARIOUS TYPE OF BUTTERFLY VALVES
I SOFT SEATED / LINED BUTTERFLY VALVES ARE LIMITED BY

TEMPERATURE TO MAX. 200 DEG.C. DUE TO SEAT AND LINER
MATERIAL CHARACTERISTICS. SOME CLIENTS RESTRICT EVEN LOWER
FOR SAFETY. SOFT SEATED MATERIALS SHOULD BE REVIEWED PRIOR
TO SPECIFYING TO ENSURE THEY COVER THE REQUIRED P/T RANGE
I BUTTERFLY VALVES ARE RESTRICTED TO A MINIMUM SIZE OF APPROX

3” AS BELOW THIS SIZE THE DISC AND STEM COVER TOO MUCH BORE
AREA TO BE AN EFFECTIVE VALVE .
I SOFT SEATED HIGH PREFORMANCE BUTTERFLY VALVES ARE

GENERALLY RESTRICTED TO CLASS 150 / 300.
I LINED BUTTERFLY VALVE ARE GENERALLY RESTRICTED TO CLASS 150
I SOFT SEATED VALVES GENERALLY NOT SUITABLE FOR DIRTY

SERVICES.
I QUARTER TURN LEVERS CAN BE ACCIDENTALLY OPENED AND IT IS

SUGGESTED THE LEVER BE LOCKED IN PLACE.
I THE LINE CANNOT BE PIGGED DUE TO POSITION OF DISC AND STEM.
I WHERE LINERS ARE SUPPLIED THEY SHALL BE COMPATIBLE WITH TO

REMOVE CHANCE OF EARLY DETERIOTION.
I SOME VENDORS RESTRICT WAFER DESIGN BY SERVICE AND

TEMPERATURE DUE TO EXPOSURE OF BOLTING
TOPIC 6.1/19 – BUTTERFLY
VALVES
BUTTERFLY VALVE MANUFACTURERS
I THERE ARE A GROWING NUMBER OF BUTTERFLY VALVE

MANUFACTURERS AVAILABLE BUT NOT AS MANY AS FOR BALL AND
GATE VALVES.
I AGAIN GROWING ECONOMIES SUCH AS CHINA AND INDIA ARE

SPEEDILY CATCHING UP WITH ESTABLISHED BUTTERFLY VALVE
SUPPLIERS IN ITALY, UK, CANADA, JAPAN ETC. UNDERCUTTING THE
MANUFACTURING OF COST OF THESE ESTABLISHED COUNTRIES.
I HOWEVER AS WITH BALL VALVES THE QUALITY OF THE FINAL

PRODUCT IS MORE OF AN ISSUE ON BUTTERFLY VALVES DUE TO A
MORE PRECISION DESIGN AND COMPONENTS. THE GROWING
COUNTRIES HAVE YET TO COMPLETELY CONVINCE CLIENTS AND SUB
CONTRACTORS ENOUGH TO CAPTALISE ON THE EUROPEAN AND
AMERICAN MARKETS.

OCCUR.
WINN VALVES – UK – HIGH PERFORMANCE

BATLEY VALVES – UK – HIGH PERFORMANCE
KEYSTONE VALVES – UK – LINED AND HIGH PERFORMANCE
VELAN – PORTUGAL – CANADA – HIGH PERFORMANCE
TOMOE – JAPAN – LINED AND HIGH PERFORMANCE
CRANE – UK / USA - LINED
FLOWSERVE – UK / USA – LINED AND HIGH PERFORMANCE
XOMOX – USA - LINED AND HIGH PERFORMANCE
ATOMAC - LINED
BRAY – GERMAN - LINED
SOLENT & PRATT – UK – HIGH PERFORMANCE
FCC VALVES – ITALY – HIGH PERFORMANCE
CHEMLINE – PLASTIC BUTTERFLY VALVES
THIS PAGE TO BE FINALISED

TOPIC 6.1/21– BUTTERFLY VALVES
EXAMPLES OF BUTTERFLY VALVE FAILURES
I POOR QUALITY BUTTERFLY VALVES UTILISE SPLIT UPPER AND LOWER

SHAFTS TO WHICH THE DISC IS PINNED. FAILURE HAS OCCURED DUE
TO CORROSION OR LOOSENING OF THE PINS LEADING TO
CATASTROPHIC FAILURE AND DAMAGE TO DOWN STREAM PIPING.
ONE PIECE SHAFTS SHOULD ALWAYS BE SPECIFIED.
I POOR QUALITY DESIGNS MAY ALSO ALLOW THE SHAFT TO BLOW OUT
DUE TO SHAFT DESIGN NOT INCORPORATING A STEPPED SHOULDER
PROFILE FOR ANTI BLOWOUT PURPOSE. THIS IS PROPOGATED BY
CORROSION OF INTERNAL RETAINING PINS AND SHAFT, HIGH
THERMAL CYCLES LEADING TO SHEARING OF THE PINS OR DISC.
I EXCESSIVE MATING PIPE WALL THICKNESS LEADING TO INABILITY TO

OPERATE VALVE DUE TO JAMMING OF DISC INTO THE PIPE BORE. THIS
OCCURS ON WAFER TYPE BUTTERFLY VALVES WHERE THE DISC
PROTRUDES INTO THE PIPE BORE. ADVISE THE VENDOR OF MATING
PIPE BORE BY SPECIFYING ON VALVE DATASHEET OR USE DOUBLE
FLANGED BUTTERFLY VALVE.
I INCOMPATIBILITY OF LINER MATERIAL WITH THE SERVICE LEADING TO

EARLY DETERIATION OF THE LINER
I FAILURE OF WAFER LUGGED TYPE VALVE DUE TO UNEVEN

TIGHTENING EVENTUALLY LEADING TO CRACKING OF THE VALVE
BODY.
I LEAKAGE DUE TO SEAT DAMAGE, THE SEATS ARE MORE SUSCEPTIBLE

TO DAMAGE DUE TO THEIR LOCATION IN THE FLOW PATH.
TOPIC 8.
VALVE STEM SEALING

/ PACKING DESIGN
TOPIC 8.1
Introduction
I How has valve stem sealing /
packing design improved
significantly over the last decade
I As a piping material specification

engineer it is necessary to
understand why this subject is
important and how to apply the
requirements to the various valve
types available
I Why it should be important to all

engineers
TOPIC 8.2
Areas of Discussion in
this section
I Why stem sealing / packing has
improved.
I What factors drive the selection of
valve sealing / packing.
I Reasons for selecting the correct stem
sealing / packing.
I What data does the specification
engineer need to know to specify the
correct valve stem sealing / packing
design.
I Valve sealing / packing types.
I Relevant standards, corporate,
national and international.
I The cost of packing types.
I Examples of stem sealing / packing
failures.
I Conclusion.
TOPIC 8.3.1/1
VALVE STEM SEALING / PACKING DESIGN
VALVE STEM PACKING SYSTEMS HAVE IMPROVED SIGNIFICANTLY

OVER THE LAST DECADE.
THIS IS DUE TO:
• GLOBAL, INTERNATIONAL AND NATIONAL LEGISLATION

REQUIREMENTS
• NEW MATERIALS
• ENHANCED PHYSICAL PROPERTIES OF EXISTING SEAL COMPOUNDS
• SOPHISTICATED QUALITY ASSURANCE TECHNIQUES
SELECTION OF VALVE PACKING IS DEPENDANT UPON:
• TYPE OF VALVE
• SERVICE EXPERIENCE
• CLIENT PREFERENCES
• COMMERCIAL AVAILABILITY
TOPIC 8.3.1/2
REASONS FOR SELECTING CORRECT VALVE STEM PACKING/ SEALING
• TO REMOVE AND / OR REDUCE LEAKAGE TO ATMOSPHERE.
• TO COMPLY WITH LOCAL AND INTERNATIONAL FUGITIVE EMISSION

LEGISLATION.
• TO ENSURE SATISFACTORY RESISTANCE TO WEAR.
• TO ENSURE SATISFACTORY RESISTANCE TO CORROSION.
• REDUCE LIFE CYCLE COSTS. I.E. MAINTENANCE IN SERVICE.
• STANDARDISATION OF PACKING / SEALING TYPES USED ON SITE.
• HEALTH AND SAFETY – I.E. VOLATILE ORGANIC CHEMICAL

PROCESSES – CARCINOGENIC PROCESSES.
• ENSURE SATISFACTORY OPERATION OF THE VALVE IN THE

REQUIRED DUTIES. THIS COULD INVOLVE CONSTANT CYCLING OR
INTERMITTENT CYCLING. I.E. USED ONCE A YEAR.
TOPIC 8.3.1/3
WHAT DO I NEED TO KNOW IN ORDER TO SELECT AND SPECIFY THE

CORRECT VALVE STEM PACKING / SEALING
• THE TYPE OF VALVE TO BE USED
• FLUID PROPERTIES :GAS, SLURRY, LIQUID, VOLATILE CHEMICALS,

CLEAN PROCESS, CORROSIVE, ACID.
• SERVICE CONDITIONS
• DESIGN PRESSURE / TEMPERATURE
• NUMBER OF ANTICIPATED CYCLES, WITH MANUAL VALVES THERE IS A

RELATIVELY LOW NUMBER OF CYCLES COMPARED TO ACTUATED
AND CONTROL VALVES.
• IT IS NOT JUST THE PACKING WHICH ENSURES A SATISFACTORY

SEAL. OTHER VALVE COMPONENTS AND FACTORS AFFECT THE
SEALING CAPABILITY. (SEE FURTHER ON).
• CLIENT COMPANY MAY ALREADY HAVE A PREFERRED CORPORATE

PACKING REGIME.
TOPIC 8.3.1/4
VALVE STEM / PACKING SEALING TYPES
THESE CAN BE SPLIT INTO TWO AREAS.
1. VALVE PACKING FOR USE IN A CONVENTIONAL STUFFING BOX WHERE

THE VALVE STEM ROTATES AND / OR RISES THROUGH THE PACKING.
GENERALLY RELEVANT BUT NOT LIMITED TO GATE/GLOBE VALVE
(SPECIALISED BALL VALVES UTILISE THIS OPERATION).
2. VALVE PACKING SEAL FOR USE ON A QUARTER TYPE VALVE SUCH AS

BALL, PLUG, BUTTERFLY VALVE
VALVE PACKING FOR USE IN A CONVENTIONAL STUFFING BOX.
FOR REFINERY AND CHEMICAL PLANTS AND IN GENERAL, MOST GATE AND
GLOBE VALVES WILL UTILISE A CONVENTIONAL STUFFING BOX WITH
GRAPHITE PACKING. WHERE STRONG ACIDS ARE USED THE PACKING MAY
BE PTFE BASED
FOR GRAPHITE PACKING FOSTER WHEELER GENERALLY USE A 5 RING

COMPRESSION PACKING DESIGN WHERE THE END RINGS ARE DIE
FORMED HIGH DENSITY BRAIDED GRAPHITE REINFORCED WITH INCONEL
WIRE AND THE INTERMEDIATE RINGS ARE DIE FORMED FOIL MEDIUM
DENSITY FLEXIBLE EXPANDED GRAPHITE.
A CORROSION INHIBITOR IS IMPREGNATED INTO THE RINGS TO PREVENT

RUSTING AND BONDING TO THE STEM WHEN THE VALVE IS NOT USED FOR
A PERIOD OF TIME.
TOPIC 8.3.1/5
VALVE PACKING FOR USE IN A CONVENTIONAL STUFFING BOX. CONT,D
THE 5 RING TYPE OF PACKING IS USED FOR NON OXIDISING GENERAL

HYDROCARBON, STEAM, CAUSTIC SERVICES. IT IS NOT GENERALLY
SUFFICIENT FOR CARCINOGENIC, ACID, CLEAN PROCESS OR VOLATILE
ORGANIC CHEMICAL SERVICES.
THIS 5 RING TYPE OF PACKING CAN COVER MOST REQUIRED

TEMPERATURES FOUND ON GENERAL PLANTS
THE USE OF PRE FORMED ONE PIECE PACKING RINGS IS NOW A

COMMON SUPPLY BY MANUFACTURERS. PRE FORMED RINGS SHOULD
ALWAYS BE USED.
BASIC OPERATING PRINCIPLE – THE PACKING RESPONDS TO AN APPLIED

PRESSURE IN INVERSE PROPORTION TO THE HARDNESS OF THE
PACKING CONSTRUCTION AND RELIES ON AN EXTERNAL FORCE TO
PRODUCE A RADIAL PRESSURE REQUIRED FOR EFFECTIVE SEALING.
THE METHOD OF GENERATING THIS FORCE IS USUALLY BY MEANS OF A

BOLTED GLAND COMPONENT
SPRING (LIVE) LOADING OF THIS GLAND IS SOMETIMES SPECIFIED

WHERE A VALVE IS GENERALLY INACCESSIBLE, REMOTE OR CRITICAL
SERVICE
TOPIC 8.3.1/6
TOPIC 8.3.1/7
THE MATCHING TOLERANCES AND FINISH OF THE VALVE STEM ALSO HAVE
A MARKED EFFECT ON EFFICIENCY OF OPERATION.
ISSUES WITH EXTRUSION OF THE PACKING DUE TO EXCESSIVE

DIMENSIONAL TOLERANCES OF THE STUFFING BOX AND HOUSING
RELATIVE TO THE SHAFT
PARTICLE PICK UP IS ALSO A PROBLEM ON THIS VALVE PACKING TYPE.

GRAPHITE FROM THE RINGS ADHERE TO THE VALVE STEM. THIS HAS TWO
EFFECTS
A). INCREASES FRICTIONAL DRAG THUS MAKING VALVE HARDER TO
OPERATE.
B). RESULTS IN LOSS OF GRAPHITE FROM THE RINGS ULTIMATELY
LEADING TO LEAKAGE.
THE ABOVE PROBLEMS HAVE BEEN REDUCED BY USING THE BRAIDED END
RINGS AS UTILISED BY FOSTER WHEELER.
LIVE LOADING AS MENTIONED PREVIOUSLY IS COSTLY BUT VERY

EFFECTIVE IF DONE PROPERLY. THE MANUFACTURER MUST TAKE CARE
IN MATCHING THE SPRING LOAD TO THE PACKING MATERIAL DENSITY AND
HARDNESS, EFFECTIVE SPRING LOADING ON A GLAND CAN REMAIN
SATISFACTORY FOR MANY YEARS.
PTFE IMPREGNATED FIBRE AND OTHER FIBROUS NON GRAPHITE PACKING

RINGS ARE AVAILABLE AND CAN BE FITTED INTO CONVENTIONAL
STUFFING BOXES IF REQUIRED FOR SERVICE, HOWEVER, SOME OF THESE
MATERIALS (IN PARTICULAR PURE PTFE) SUFFER GREATLY FROM CREEP,
RELAXATION AND EXTRUSION AND NEED TO BE REVIEWED THOROUGHLY
PRIOR TO USE – IF IN FLAMMABLE SERVICE GRAPHITE RINGS STILL NEED
TO BE FITTED WILL BE FITTED FOR FIRE SAFETY.
TOPIC 8.3.1/8
ALTHOUGH EXCESS DEPTH IN A STUFFING BOX IS NOT DESIRABLE IT CAN

BE TAKEN UP BY THE USE OF METALLIC (EQUIVALENT TO TRIM
MATERIAL) OR CARBON SPACERS. THIS SPACER SHOULD ALWAYS BE
LOCATED AT THE BOTTOM OF THE STUFFING BOX.
IN SOME INSTANCES A LANTERN RING IS INSTALLED BETWEEN THE

PACKING RINGS. THIS METALLIC RING IS PROFILED TO ALLOW
LUBRICANT TO BE DIRECTED RADIALLY ONTO THE STEM AND INTO THE
PACKING VIA A HOLE DRILLED THROUGH THE VALVE BODY (REFER TO
SKETCH SHOWING CORRECT POSITIONING OF LANTERN RINGS).
TO COMPLY WITH FUGITIVE EMISSION LEGISLATION AND ALSO IN

RECENT YEARS PACKING MANUFACTURERS HAVE DEVELOPED HIGHER
QUALITY PACKING SETS TO ENSURE COMPLIANCE. AS AN EXAMPLE
“GARLOCK” HAVE DEVELOPED A PACKING TRADEMARKED “EVSP 9000”.
THESE RING SETS HAVE A UNIQUE CONE TYPE GEOMETRY WHICH HAVE
BEEN PROVED TO HAVE A MARKED INCREASED SEALING QUALITY. THEY
ARE EXTENSIVELY USED BY SOME OF THE LARGE OIL COMPANIES FOR
PROCESS AND STEAM. IN FACT EXXONMOBIL ARE CURRENTLY
STANDARDISING ON EVSP9000 FOR MOST HYDROCARBON AND STEAM
SERVICES (SEE ATTACHED PAGES).
TOPIC 8.3.1/9
TOPIC 8.3.1/10
TOPIC 8.3.1/11
TOPIC 8.3.1/12
TOPIC 8.3.1/13
VALVE PACKING FOR USE ON QUARTER TURN TYPE VALVES SUCH AS

BALL, PLUG, BUTTERFLY
IN GENERAL THESE VALVES UTILISE TWO TYPES OF PACKING/SEAL

A). PTFE CHEVRON TYPE PACKING SETS
B). ELASTOMERIC O RING TYPE
PTFE CHEVRON TYPE PACKING SETS ARE LOCATED IN A STUFFING BOX

TYPE ENVIRONMENT AND ARE UNDER LOAD BY MEANS OF A GLAND
SIMILAR TO THE GATE VALVE DESIGN. HOWEVER, THE GEOMETRY OF THE
PACKING IS NOT THE SAME AND THE VALVE HOUSING IS GENERALLY
MORE COMPACT.
THE PTFE RINGS ARE PROFILED AND INTERLOCKED IN SUCH A WAY THAT
WHEN COMPRESSED THEY EXPAND RADIALLY THUS EFFECTING A SEAL.
A GRAPHITE RING ALSO FITTED TO ENSURE FIRESAFE DESIGN.
THIS DESIGN HAS BEEN COMMONLY UTILISED WITH GREAT EFFECT ON

BALL, BUTTERFLY AND PLUG VALVE.
THE CHEVRON PACKING DESIGN IS RESTRICTED TO RELATIVELY LOW

PRESSURES OF UP TO CLASS 300 RATING
DUE TO THE FACT IT IS A POLYMER THE TEMPERATURE RESTRICTED TO

200 DEG.C
IT HAS BEEN SUCCESSFUL DUE TO ITS RESISTANCE TO MOST SERVICES
GRAPHITE PACKING SETS CAN BE FITTED IN LIEU OF PFTE CHEVRON TYPE

HOWEVER MODIFICATIONS TO THE VALVE HOUSING MAY BE REQUIRED
A THRUST WASHER, USUALLY GLASS FITTED PTFE IS ALSO FITTED TO THE

STEM LOCATED BETWEEN THE STEAM AND BODY MATING FACING.
TOPIC 8.3.1/14
VALVE PACKING FOR USE ON QUARTER TURN TYPE VALVES SUCH AS

BALL, PLUG, BUTTERFLY - CONTD
ELASTOMERIC O RING TYPE STEM SEALS ARE GENERALLY USED ON

HIGHER PRESSURE VALVES, UP TO 200 BAR G (BALL, BUTTERFLY VALVE).
THEY ARE ENERGISED BY THE LINE PRESSURE AND CAN ACHIEVE

SEALING AT HIGH PRESSURES DUE TO THE SMALL SURFACE AREA ON
WHICH THEY ARE ACTING.
THE O RING IS CONTAINED WITHIN A HOUSING. HOWEVER, DUE TO THE

PRESSURE AT WHICH THE O RING CAN PERFORM EXTRUSION CAN
OCCUR BETWEEN THE HOUSING AND STEM. THIS CAN BE OVERCOME BY
PRECISION TOLERANCES AND BACK-UP RING MADE OF PTFE.
O RING MATERIAL INCLUDE “VITON”, “HYCAR”, AFLAS” AND ARE SELECTED

SUBJECT TO SERVICE, PRESSURE AND TEMPERATURES.
WHERE O RINGS ARE USED IN GAS SERVICE A CONDITION KNOW AS ANTI

EXPLOSIVE DECOMPRESSION CAN OCCUR. IT HAPPENS WHEN THE
MEDIA IS A GAS. AT HIGH PRESSURES (ALTHOUGH IT HAS BEEN
REPORTED AT CLASS 300 PRESSURE) THE GAS CAN DISSOLVE INTO THE
O RING. WHEN THE PRESSURE IS REMOVED FROM THE LINE THE GAS
TRAPPED IN THE O RING CANNOT ESCAPE AT THE SAME SPEED. IT
EXPANDS CRACKING AND BLISTERING THE RING.
A NEW ELASTOMER NAMED KALREZ HAS BEEN DEVELOPED TO REMEDY

THIS. IT IS OF A HARDNESS / DENSITY WHICH DOES NOT ALLOW INGRESS
OF GAS.
INGRESS OF DIRT ONTO THE SEAL CAN CAUSE PROBLEMS AND IT IS

THEREFORE NECESSARY TO ENSURE SUITABLE PRECAUTIONS ARE
BUILT INTO THE DESIGN. THIS MAY INCLUDE THE FITTING OF LIP SEALS
(WIPER SEAL) ABOVE THE O RING.
AS WITH THE PTFE SEALS TEMPERATURE LIMITATIONS ALSO APPLY.

TOPIC 8.3.1/15
TOPIC 8.3.1/16
TOPIC 8.3.1/17
TOPIC 8.3.1/18
TOPIC 8.3.1/19
TOPIC 8.3.1/20
TOPIC 8.3.1/21
TOPIC 8.3.1/22
TOPIC 9.
SELECTION OF VALVE
TRIM MATERIALS AND
DESIGN
TOPIC 9.1
Introduction
I The selection of valve trim

materials and design is a
specialized area that requires
investigation of certain criteria to
ensure suitable operation.
I As a piping material specification

engineer it is necessary to
understand why this subject is
important and how to apply the
requirements to the various valve
types available
I Why it should be important to all

engineers
TOPIC 9.2
Areas of Discussion in this
section
I What factors drive the selection of

valve trim materials and design
I Reasons for selecting the correct valve
trim for the specified service.
I What data does the specification
engineer need to know to specify the
correct valve trim material and design.
I Selection of valve trims.
I Relevant standards, corporate,
national and international.
I The cost of valve trims.
I Examples of valve trim failures
I Conclusion.
TOPIC 9.3.1/1
VALVE TRIM DESIGN
SELECTION OF VALVE TRIMS IS A SPECIALISED AREA
IT IS DRIVEN BY :
A). “IN SERVICE” EXPERIENCE
B). MANUFACTURERS STANDARD PHILOSOPHY
C). CLIENT PREFERENCES.
THE DISCUSSION WILL BE BROKEN DOWN INTO 3 MAIN

AREAS:
1). REASONS FOR SELECTING CORRECT VALVE TRIMS FOR

SERVICE.
2). WHAT DO I NEED TO KNOW IN ORDER TO SELECT AND

PURCHASE THE CORRECT VALVE TRIM.
3). SELECTION OF THE VALVE TRIM.

TOPIC 9.3.1/2
VALVE TRIM DESIGN
REASONS FOR SELECTING CORRECT VALVE TRIMS FOR

SERVICE
• TO ENSURE A SATISFACTORY LENGTH OF LIFE.
• SATISFACTORY RESISTANCE TO CORROSION BY THE

MEDIA.
• LONG TERM DIMENSIONAL STABILITY OF THE

COMPONENT DUE TO HEAT.
• SATISFACTORY RESISTANCE TO WEAR BY THE MEDIA.
• REDUCE EROSION DUE TO VELOCITY OF THE MEDIA.
• ACCEPTABLE SEAT TIGHTNESS ACHIEVED.
• REDUCING MAINTENANCE IN SERVICE.
• THEY ARE PRESSURE CONTAINING COMPONENTS.
• STANDARDISATION OF VALVES REQUIRED TO BE

STOCKED ON SITE.
• PREVENT MEDIA CONTAMINATION OF SOFT SEATS.
• PREVENT PARTICLE PICK UP, ESPECIALLY FOR SOFT

SEATS.
TOPIC 9.3.1/3
VALVE TRIM DESIGN
WHAT DO I NEED TO KNOW IN ORDER TO SELECT AND

PURCHASE THE CORRECT VALVE TRIM
• TYPE OF VALVE
• FLUID PROPERTIES – ABRASIVE, GAS, SLURRY,

CLEAN PROCESS
• SERVICE CONDITION, (PRESSURE / TEMPERATURES)

BELOW 175 DEGREE. C OR ABOVE.
• VALVE CORROSION ALLOWANCE.
• PIPE CLASS MATERIAL.
• MINIMUM ALLOWABLE MATERIAL GRADE.
• VALVE TRIMS COMMERCIALLY AVAILABLE.
• VALVE TRIMS ALLOWABLE BY INTERNATIONAL

STANDARDS.
• SIZE AND RATING OF THE VALVE.

TOPIC 9.3.1/4
VALVE TRIM DESIGN
SELECTION OF THE VALVE TRIM
We are discussing manual valves not control type. The difference

being that with control type valves the co-efficient of friction on
the surface of the trim has a marked effect on the performance of
the valve.
The valve types in discussion are on/off isolating type or manual

throttle type such as a globe valve.
We can split the valve trim types into two distinct areas
A) METAL TO METAL SEATED TRIM
B) SOFT SEATED TRIM
Various types of valves can be generally aligned with trim types

although this is rule of thumb
Gate, globe, check

Most common trim : metal to metal
But can be fitted with soft seats if required
Ball, butterfly
Most common trim : soft seated
But can be fitted with metal to metal
The valve trim generally includes the body seats, the closure
member / seating area and the stem or hinge pin
TOPIC 9.3.1/5
VALVE TRIM DESIGN
METAL TO METAL SEATED VALVE TRIM
As a minimum the metal valve trim shall be of the same material

composition as the piping system. However this is rarely
adequate.
Because the seating surfaces are metal to metal the valves are
not zero leakage as a standard. This must be understood and
accepted.
API 600 standard is a specification for the design of metal seated

gate valves used in the oil and gas industries. This standard
includes a table detailing basic trim materials for stem and seats.
In the latest edition of the API 600 standard the various trim
options are identified by combination numbers (CN). These were
previously referred to as trim numbers
It is important to note that these combination numbers do not

advise which trims to use, it serves only as a list of numbers
versus material.
TOPIC 9.3.1/6
TOPIC 9.3.1/6
VALVE TRIM DESIGN
METAL TO METAL SEATED VALVE TRIM - CONTD
For carbon steel valves it is usual to make a selection between

CN 1, 8 and 5 – although in recent years and on recent projects,
option CN 1 has been abandoned in favour of using CN 8. The
reasons being:
- For standardisation
- Covers a wider range of services
- Higher wear resistance
CN 1 is a 13 CR stainless steel trim used for the body seat or

closure member seat area. It requires a differential variation in
hardness between the two seating areas to prevent galling. This
hardness differential is specified within API 600
CN 8 is a 13 CR stainless steel trim having a chromium cobolt

(CO-CR) – hard facing on either the body seat or closure member
seat area. But not on both, this is commonly termed as a 1/2
STELLITE trim
This CO-CR hard facing alloy is weld over laid onto the seat area.
It is then ground and lapped to give a polished finish suitable to
pass the required leakage tests.
Vendors may specify the hardfacing by a trade name such as

STELLITE 6”, STOODY 6 and WALLEX 6.
TOPIC 9.3.1/8
TOPIC 9.3.1/9
VALVE TRIM DESIGN
The 13 CR trim material may be supplied in a cast or forged form

and therefore may refer to it as CA 15 or F6 respectively.
The API 600 standard trim table although specific for gate valves
has been generally accepted and applied to globe and check
valves by both specification engineers and vendors.
CN 5 is hard faced on both the body seats and closure seat. It is

termed as a full STELLITE trim. This trim is used for services
where a higher rate of erosion is anticipated. Such as steam
(wear due to steam velocity), slurries, hydrocarbon with particles.
CN 8 is used for most standard hydrocarbon services where low

corrosion and wear is anticipated it is not generally satisfactory for
H2S and sour service.
It should also be noted that hardness of the material is important

because the higher the hardness value or the material the more
difficult it is to effect a satisfactory seal. Harder seats require more
manufacturing effort and therefore more cost.
TOPIC 9.3.1/10
VALVE TRIM DESIGN
When trims are to be specified for valves in wet H2S service

where severe corrosion may take place it is normal to specify all
trim in 316 stainless steel as a minimum. This is done for two
main reasons. It obviates the requirement to specify a minimum
hardness value and also removes any problems affecting lower
grade materials.
For wet H2S and sour services foster wheeler generally specify
CN10 – 316 stainless steel trim for carbon steel valves as this
obviates any problems which may occur using a lower grade of
material on such a sensitive component.
For abrasive wet H2S and sour services foster wheeler generally
specify CN 12 – 316 stainless steel trim for carbon steel valves as
this obviates any problems which may occur using a lower grade
of material on such a sensitive component.
For CR MO piping systems where temperatures are usually high it

is again usual to specify CN 5 where the base material is equal in
corrosion resistance to the body and a hard facing is applied.
TOPIC 9.3.1/11
VALVE TRIM DESIGN
For higher alloy materials it is necessary to specify the trim

material to the same grade as the body. It should be noted that
API 600 does not cover all requirements for variations in trim.
For sulphuric acid where it has been identified that a carbon steel
body is satisfactory it is FWEL practice to specify a higher grade
trim material such as MONEL.
Where a client or the service requires a ball or butterfly valve to

be metal seated. (For example abrasive or high temperature
service requiring a quick shut off valve).The ball and seat surface
are overlaid with a coating such as E.N.P. Or, for more arduous
services STELLITE 6. It must be noted that hard facing increases
seat leakage. Lapping the ball /disc and seat may be required to
reduce leakage to an acceptable level. This is usually an
expensive option as it is time consuming, therefore it is important
to identify an acceptable leakage rate.
Gate valve wedge closures are usually termed “solid” for small
bore up to 1 ½” and “flexible” above. Some clients now prefer that
most small bore gate valves are supplied with CN 5 trim
TOPIC 9.3.1/12
VALVE TRIM DESIGN
SOFT SEATED VALVE TRIM
As previously mentioned soft seated trims are predominantly used

in ball and butterfly valves but not exclusively as soft seats can be
fitted into gate, globe and check valves.
The use of soft seating is limited by:
Temperature, maximum temperature for utilisation of soft seats is

usually around 175-200 deg, c. (Varies slightly subject to selected
manufacturers) but this value reduces relative to pressure and
size of the valve
Problems with soft seating include:
-Material creep under load
-high wear rate
-particle pickup causing damage to seats
-Not suitable for partial flow conditions where high
-velocities will damage the seats. (Known as wiring).

TOPIC 9.3.1/13
VALVE TRIM DESIGN
SOFT SEATED VALVE TRIM - CONTD
Various soft seat materials for ball valves are available, the most
popular are listed:
Pure PTFE
Nylon
Glass reinforced PTFE
Carbon filled PTFE
PEEK (Poly Ether Ethyl Ketone).
UHMPE (Ultra high molecular polyethylene)
The above materials are used at varying temperatures, services

and valve design:
Pure PTFE whilst being the most regular selection due to its
overall high compatibility with most medias has the lowest
allowable temperature limit and tends to lose its rigidity (creep)
quickly at higher temperatures.
PEEK is a much harder material (like ceramic) and can be used at

higher than 200 degree c. Temperatures. However it is
susceptible to cracking and allows higher leakage, it is used for
specific duties only.
TOPIC 9.3.1/14
VALVE TRIM DESIGN
Nylon seats are used for higher pressure requirements due to its
more rigid structure and higher resistance to creep. They are
usually located in a metallic housing to restrict the seat from
excessive movement
In general the stem and ball components are usually specified in

316 stainless steel material (unless media requires a body
material is of higher grade) as this ensures that the seating
contact surfaces are clean and do not damage the soft seat.
However on larger valves where cost becomes a major issue it is
usual for manufacturers to use forged carbon steel balls which are
ENP coated to ensure a clean surface. However it is necessary to
ensure the ENP application procedure is satisfactory as badly
applied coatings can flake off the ball in service causing damage
to the soft seats.
Some vendors may offer hollow balls on larger valves to reduce

the weight of the valve and reduce the torque required to open the
valve. Be careful when accepting hollowing balls, they will
generally be cast and may require non destructive examination.
Hollow balls should be treated in the same manner as the valve
body in respect to casting quality, NDE, and inspection.
TOPIC 9.3.1/15
VALVE TRIM DESIGN
Butterfly valves are split into 2 types, utility type and high
performance.
UTILITY TYPE BUTTERFLY VALVES:
Used on varying water services, air, etc usually lined internally

with a rubber compound such as EPDM, NBR or polymer such as
PTFE (dependant upon water quality).
Restricted to low pressure and low temperature approx 10 bar, or

140 deg.C.
Disc and stem material usually 316 stainless steel, bronze,

MONEL (dependant upon water quality).
HIGH PERFORMANCE TYPE BUTTERFLY VALVES:
Used on varying utility and process services, hydrocarbons,

water, air, etc. Soft seating material is usually as used on ball
valves.
TOPIC 9.3.1/16
VALVE TRIM DESIGN
Disc and stem material usually 316 stainless steel unless body
material is of a higher material grade in which case the material is
to be of equal corrosion resistance. (For utility water disc and
stem material is dependant upon water quality).
For both type of butterfly valves it is important to ensure that the

valve stem is of a one piece design and is positively secured to
the disc. Cheaper valves may have a stem at the top of the disc
and a separate stem at the bottom. Failure and separation of this
arrangement has occurred at the connection between stem and
disc with the effect of damage to the pipe line due to the disc and
stem travelling down the line.
Pressure and temperature limits similar to ball valve.
CONCLUSION
• Define and understand the service requirements
• Identify the design pressure, temperature requirements.
• Identify type of valve preferred and trim options.
• Ensure the selected trim satisfies the considerations

listed above .
TOPIC 9.3.1/16
VALVE TRIM DESIGN

TOPIC 10.1
BASIC TYPES OF NDE
TESTING FOR VALVES
I Why is NDE testing necessary.
I How are NDE requirements for valves identified.
I What valve components are generally NDE tested.
I What are the common types of NDE in use.

TOPIC 10.1.1
WHY IS NDE TESTING NECESSARY
wNON DESTRUCTIVE EXAMINATION IS NECESSARY TO VERIFY

THE MECHANICAL INTEGRITY OR SOUNDNESS OF A
COMPONENT.
wNDE REQUIREMENTS ARE APPLIED TO ENHANCE THE

QUALITY OF THE FINAL PRODUCT.
TOPIC 10.1.2
HOW ARE NDE REQUIREMENTS FOR VALVES IDENTIFIED
VARYING NDE REQUIREMENTS ARE APPLIED DUE TO THE CATEGORY OF

THE SERVICE (IE. D, E, M.)
VARYING NDE REQUIREMENTS ARE APPLIED DUE TO THE VALVE

MATERIAL SPECIFIED.
VARYING NDE REQUIREMENTS ARE APPLIED DEPENDING UPON THE

CRITICALITY OF THE SYSTEM IN WHICH THE VALVE IS BEING USED.
VARYING NDE REQUIREMENTS ARE APPLIED DEPENDING UPON THE

CRITICALITY OF THE VALVE TO THE SAFETY OF THE PIPING SYSTEM .
VARYING PERCENTAGES OF NDE ARE APPLIED DEPENDANT UPON THE

FOLLOWING:
CONFIDENCE IN THE MANUFACTURERS QUALITY.
CRITICALITY OF THE SERVICE.
CRTICALITY OF THE VALVE.
THE MATERIAL OF CONSTRUCTION.
IDENTIFY WHAT TYPE OF NDE IS REQUIRED. FOR EXAMPLE SURFACE OR

SUBSURFACE EXAMINATION.
FOR CRITICAL SERVICES, SURFACE AND SUBSURFACE NDE SHALL BE

APPLIED.
IDENTIFY AN ACCEPTANCE CRITERIA FOR THE NDE. THIS CRITERIA

SHOULD BE RELATED TO THE CRITICALITY OF THE SERVICE
IDENTIFY A TEST METHOD.
BE CAREFUL - OVERLY STRINGENT CRITERIA WILL ADD DIRECTLY TO

THE VALVE COST.
TOPIC 10.1.3
WHAT VALVE COMPONENTS ARE GENERALLY NDE TESTED.
WHEN IDENTIFED AS NECESSARY THE FOLLOWING TYPES OF VALVE

COMPONENTS ARES ARE GENERALLY SUBJECT TO NDE.:
THICK WALLED CASTINGS AND FORGINGS ARE MORE PRONE TO

DEFECTS.
PRESSURE CONTAINING COMPONENTS ARE THE MOST CRITICAL

COMPONENTS. BODY, BONNET, WEDGE,
GENERALLY CAST COMPONENTS ARE SUBJECT TO THE MOST

STRINGENT NDE TESTING DUE TO THE METHODS OF PRODUCTION AND
THE INHERENT QUALITY ISSUES THEREIN.
FORGINGS ARE GENERALLY NOT SUBJECT TO THE SAME LEVEL OF NDE.

BUT MOST METHODS ARE AVAILABLE IF REQUIRED.
HOWEVER ANY COMPONENT CAN HAVE SOME FORM OF NDE

PERFORMED. IN EXTREME CASE SUCH AS THE NUCLEAR INDUSTRY, ALL
INTERNAL COMPNENETS ARE SUBJECT TO NDE.
MACHINED SURFACES ARE GENERALLY IDENTIFIED AS REQUIRING NDE.

TO ENSURE THERE ARE NO HAIRLINE CRACKS
MACHINED PREPPED ENDS ON BUTT WELDED VALVES ARE GENERALLY

EXAMINED TO ENSURE CRACKS ARE NOT PRESENT IN THE WELD ZONE
VALVE CONSTRUCTION WELDS WOULD BE RADIOGRAPHED.

TOPIC 10.1.4
WHAT ARE THE COMMON TYPES OF NDE IN USE.
VISUAL EXAMINATION
EQUIPMENT REQUIRED: SURFACE COMPARATOR, POCKET RULE,

STRAIGHT EDGE,
WORKMANSHIP STANDARDS
ENABLE DETECTION OF: SURFACE FLAWS, CRACKS, POROSITY.
ADVANTAGES: LOW COST, APPLIED WHILE WORK IN PROGRESS

ALLOWING CORRECTIVE ACTION.
LIMITATIONS: SURFACE DEFECTS ONLY, PROVIDES NO PERMANENT

RECORD.
REMARKS: SHOULD ALWAYS BE SPECIFIED AS THE PRIMARY METHOD

OF INSPECTION, NO MATTER WHAT OTHER TECHNIQUES ARE APPLIED.
STANDARDS:
ASTM A802/A802M – STANDARD PRACTICE FOR STEEL CASTINGS,

SURFACE ACCEPTANCE STANDARDS, VISUAL EXAMINATION
SCRATA COMPARATORS – STEEL CASTING RESEARCH AND TRADE

ASSOCIATION (SCRATA) COMPARATOR PLATES FOR ESTABLISHING
MUTUALLY AGREEABLE ACCEPTANCE CRITERIA FOR A SPECIFIC PART.
MSS-SP-55 – QUALITY STANDARD FOR STEEL CASTINGS FOR VALVES,

FLANGES AND FITTINGSAND OTHER PIPING COMPONENTS (VISUAL
METHODS FOR EVALUATION OF SURFACE IRREGULARITIES).
TOPIC 10.1.5
LIQUID PENETRANT (PT)
EQUIPMENT REQUIRED: COMMERCIAL KITS, CONTAINING FLUORESCENT

OR DYE PENETRANTS AND DEVELOPERS. APPLICATION EQUIPMENT FOR
DEVELOPER. A SOURCE OF ULTRAVIOLET LIGHT (IF FUORESCANT
METHOD IS USED)
ENABLE DETECTION OF: SURFACE DISCONTINUITIES NOT READILY

VISIBLE TO THE UNAIDED EYE.
ADVANTAGES: APPLICABLE TO MAGNETIC AND NON MAGNETIC

MATERIALS, IT IS EASY TO USE. IT IS LOW COST
LIMITATIONS: ONLY SURFACE DISCONTINUITIES ARE DETECTABLE
REMARKS:
STANDARDS:
ASTM A903/A903M – STEEL CASTINGS, SURFACE ACCEPTANCE

STANDARDS, MAGNETIC PARTICLE AND LIQUID PENETRANT INSPECTION
ASTM E165 – STANDARD TEST METHOD FOR LIQUID PENETRANT

EXAMINATION
ASTM E433- STANDARD TEST METHOD FOR LIQUID PENETRANT

EXAMINATION.
ISO 3452 – NON DESTRUCTIVE TESTING- PENETRANT INSPECTION.
MSS-SP-93 – QUALITY STANDARD FOR STEEL CASTINGS AND FORGINGS

FOR VALVES, FLANGES AND FITTINGSAND OTHER PIPING COMPONENTS
(LIQUID PENETRANT).
TOPIC 10.1.6
MAGNETIC PARTICLE EXAMINATION (MT, MPI)

A MAGNETIC FIELD IS APPLIED TO THE COMPONENT . IF THE ITEM IS
SOUND THE MAGNETIC FLUX CONCENTRATES BELOW THE SURFACE. IF
THERE IS A FLAW THE FLUX IS DISTORTED AND LEAKAGE OF THE
MAGNETIC FLUX OCCURS BETWEEN THE SURFACE AND THE DEFECT
AREA THUS ATTRACTING THE MAGNETIC PARTICLES.
EQUIPMENT REQUIRED: SPECIAL COMMERCIAL EQUIPMENT. MAGNETIC

POWDER-DRY OR WET FORM (BLACK IRON PARTICLES OR RED/ YELLOW
IRON OXIDES). MAY BE FLUORESCENT FOR VIEWING UNDER UV LIGHT.
ENABLE DETECTION OF: EXCELLENT FOR DETECTING SURFACE

DISCONTINUITIES AND SUBSURFACE DISCONTUITIES TO APPROX 5MM
BELOW SURFACE (ESPECIALLY CRACKS).
ADVANTAGES: PERMITS CONTROLLED SENSITIVITY. RELATIVELY LOW

COST.
LIMITATIONS: APPLICABLE TO FERROMAGNETIC MATERIALS ONLY.

REQUIRES SKILL IN INTERPRETATION OF RESULTS AND RECOGNITION
OF IRRELEVANT RESULTS.
REMARKS: CRACKS RUNNING PARALLEL TO THE MAGNETIC FIELD CAUSE

LITTLE DISTURBANCE AND MAY NOT BE SEEN, THEREFORE ENSURE ALL
ORIENTATIONS ARE COVERED
STANDARDS:
ASTM A903/A903M – STEEL CASTINGS, SURFACE ACCEPTANCE

STANDARDS, MAGNETIC PARTICLE AND LIQUID PENETRANT INSPECTION
ASTM E709 – STANDARD GUIDE FOR MAGNETIC PARTICLE EXAMINATION
ASTM E125- STANDARD REFERENCE PHOTOGRAPHS FOR MAGNETIC

PARTICLE INDICATIONS ON FERROUS CATINGS..
ASTM E1444 –STANDARD PRACTICE FOR MAGNETIC PARTICLE

EXAMINATION.
MSS-SP-53 – QUALITY STANDARD FOR STEEL CASTINGS AND FORGINGS

FOR VALVES AND FITTINGS AND OTHER PIPING COMPONENTS (MPI
METHOD).
TOPIC 10.1.7
RADIOGRAPHIC EXAMINATION (RT)
EQUIPMENT REQUIRED: COMMERCIAL X RAY OR GAMMA UNIT

DEVELOPED ESPECIALLY FOR INSPECTING WELDS, CASTINGS AND
FORGINGS. FILM AND PROCESSING FACILITIES.
ENABLE DETECTION OF: INTERNAL MACROSCOPIC FLAWS, CRACKS,

PRORSITY, BLOWHOLES, NON METALLIC INCLUSIONS, SHRINKAGE,
ADVANTAGES: IMAGES ARE RECORDED ON FILM AND GIVES A

PERMANENT RECORD.
LIMITATIONS: REQUIRES SKILL IN CHOOSING THE ANGLES OF

EXPOSURE, OPERATING EQUIPMENT AND INTERPRETING THE RESULTS.
DIFFICULT ON SMALL VALVE BODIES DUE TO SMALLER GEOMETRIC
SURFACE AREAS. IT IS EXPENSIVE. REQUIRES HIGH SAFETY
PRECAUTIONS. CRACKS ARE DIFFICULT TO DETECT.
REMARKS: RADIOGRAPHIC EXAMINATION IS REQUIRED BY MANY CODES

AND STANDARDS. DUE TO COST ITS USE SHOULD BE LIMITED TO AREAS
WHERE OTHER METHODS WILL NOT PROVIDE THE ASSURANCE
REQUIRED.
STANDARDS:
ASTM E94 – STANDARD GUIDE FOR RADIOGRAPHIC TESTING
ASTM E142 – STANDARD METHOD FOR CONTROLLING QUALITY OF

RADIOGRAPHIC TESTING
ASTM E446- STANDARD REFERENCE RADIOGRAPHS FOR STEEL

CASTINGS UP TO 2” IN THICKNESS (3 SETS, X-RAY, IRIDIUM,COBALT).
ASTM E186 – STANDARD REFERENCE RADIOGRAPHS FOR HEAVY

WALLED 2” TO 4 ½” STEEL CASTINGS (3 SETS, X-RAY, GAMMA,
BETATRON).
ASTM E280 – STANDARD REFERENCE RADIOGRAPHS FOR HEAVY

WALLED 4½” TO 12” STEEL CASTINGS (2 SETS, X-RAY, BETATRON).
ISO 5579 – NON DESTRUCTIVE TESTING- RADIOGRAPHIC EXAMINATION

OF METALLIC MATERIALS BY X AND GAMMA RAYS-BASIC RULES).
TOPIC 10.1.8
ULTRASONIC EXAMINATION (UT)
EQUIPMENT REQUIRED: SPECIAL COMMERCIAL EQUIPMENT OF THE

PULSE ECHO OR TRANSMISSION TYPE.
ENABLE DETECTION OF: SUB SURFACE DISCONTINUITIES, INCLUDING

THOSE TOO SMALL TO BE DETECTED BY OTHER METHODS. ESPECIALLY
SUITABLE FOR DETECTING SUBSURFACE PLANAR DEFECTS.
ADVANTAGES: VERY SENSITIVE. PERMITS PROBING OF JOINTS WHICH

ARE INACCESSIBLE TO RADIOGRAPHY
LIMITATIONS: REQUIRES A HIGH DEGREE OF SKILL IN INTERPRETTING

PULSE ECHO PATTERNS. PERMANENT RECORD IS NOT READILY
AVAILABLE.
STANDARDS:
ASTM A609/609M – STANDARD PRACTICE FOR CASTINGS, CARBON, LOW

ALLOY AND MARTENSITIC STAINLESS STEEL, ULTRASONIC EXAMINATION
THERE OF
MSS-SP-94 – QUALITY STANDARD FOR FERRITIC AND MARTENSITIC

STEEL CASTINGS FOR VALVES, FLANGES AND FITTINGS AND OTHER
PIPING COMPONENTS (ULTRASONIC METHOD).
TOPIC 11.1
VALVE PRESSURE TESTING TO
I What standards are available

I Why is factory testing of the valve
important.
I What type of pressure testing is
done to a valve
I What type of information do the
standards contain.
I Are these standards really
adequate for the valve.
I What the engineer can do to
ensure satisfactory testing is
done.
I Comparison charts.
TOPIC 11.2
VALVE PRESSURE TESTING TO
INTRODUCTION DATA
API 598. CONDENSED
BS 6755 PT 1. CONDENSED
EN 12266. CONDENSED
ISO 5208. CONDENSED
EN 10434 & 17292 CONDENSED.
EEMUA RECOMMENDATIONS.
LEAKAGE RATE ACHIEVABLE BY GOOD QUALITY

VALVES.
THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION
INFORMATION SHEET
A SERVICE FOR MEMBERS
Number: 32 Month / Year: September 2003
TEST REQUIREMENTS IN VALVE STANDARDS

This Information Sheet, developed by EEMUA Valves Technical Committee, is intended to
provide valve users and purchasers with single page summaries of the requirements
included in commonly referenced valve test standards, namely: API Std 598, BS 6755-1, EN
12266-1 & -2, and ISO 5208. In addition, summaries are provided for prEN/ISO/FDIS 10434
*
(API 600) and prEN/ISO/FDIS 17292 (API Std 608).
Requirements vary from standard to standard (although there is increasing convergence in
allowable seat leak rates e.g. between BS 6755, ISO 5208 and EN 12266), and purchasers
may not always realise what they get from a particular reference. Using the summary tables
it is possible to quickly see what is included and to call up additional or alternative tests
where appropriate. Two additional tables are included for guidance: recommended tests for
different valve types, covering both bulk purchased commodity valves and valves having a
more critical function, and leak rates typically achievable by good quality valves.
It is a common assumption that such standards contain all that is required to ensure
adequate performance, but this is not the case. Standards committees dominated by
manufacturers, and the difficulties involved in achieving universal agreement often result in a
‘lowest common denominator’ which may not always fulfil the user’s expectations, particularly
for critical services.
For example, API 598 (and the ISO gate and ball valve standards derived from API) requires
only a low pressure gas seat test for wedge gate valves in the lower pressure ratings despite
the fact that these valves are closed by application of mechanical force. EN 12266-1 allows
the manufacturer to choose such a test and also permits some tests to be conducted on
sample valves only. Seat leak test pressures should ideally reflect the seating mechanism of
the valve (i.e. whether it utilises externally applied force or differential pressure) but often do
not.
In addition, test times are often very short; EN12266-1, for example, requires a maximum
seat test hold time of 30 seconds for metal seated valves using gas regardless of size, and
for valves up to DN 200 the time is only 15 seconds. Purchasers should consider the value of
such short test times when the time taken for conditions to stabilise might be several
minutes.
In the case of ‘commodity’ type valves for non-critical applications it may often be difficult
(and costly) to apply additional or non-standard tests, but such an approach applied to valves
in more critical service will usually pay dividends. The EEMUA Valves Committee hopes that
this Information Sheet will allow those who specify or purchase valves to determine where
more searching or extended testing may be appropriate.
*
The tables are based on the versions of the standards current at the date of issue of this Information
Sheet. Note that BS 6755 has been withdrawn as a result of the issue of EN 12266. Note also that the
following EEMUA Specifications for the Production Testing of Valves are available, and provide
detailed test methods for most valve types:
Pt 1 Ball Valves (Pub 170), Pt 2 Plug Valves (Pub 171), Pt 3 Gate Valves (Pub 172), and Pt 4 Butterfly
& Globe Valves (Pub 173).
LIST OF APPENDED SPREADSHEETS AND TABLES
Sht No
2 API Std 598, 7th Edn, Oct 1996 (Valve Inspection and Testing)
3 BS 6755-1 : 1986 (Testing of Valves: Pt 1— Specification for Production Pressure
Testing Requirements)
4 EN 12266-1 : 2003 & -2 : 2002 (Industrial Valves. Testing of Valves: Pt 1— Pressure
Tests, Test Procedures and Acceptance Criteria. Mandatory Requirements; Pt 2—
Tests, Test Procedures and Acceptance Criteria. Supplementary Requirements)
5 ISO 5208 : 1993 (Industrial Valves—Pressure Testing of Valves)
6 prEN/ISO/FDISs 10434 (Bolted Bonnet Steel Gate Valves for the Petroleum and
Natural Gas Industries) and 17292 (Metal Ball Valves for Petroleum, Petrochemical
and Allied Industries). (These standards have been developed from API 600 and 608
respectively.)
7 EEMUA Valve Committee’s Valve Test Recommendations for Oil, Gas, Chemical and
Petrochemical Applications
8 Leak Rates Typically Achievable by Good Quality Valves
API STD 598: VALVE INSPECTION AND TESTING (7TH EDITION, OCT. 1996) EEMUA Information Sheet No 32 (2)
SCOPE THIS STANDARD COVERS INSPECTION, EXAMINATION, SUPPLEMENTARY EXAMINATIONS AND PRESSURE TEST REQUIREMENTS FOR RESILIENT SEATED, NONMETALLIC SEATED
AND METAL-TO-METAL SEATED VALVES OF THE GATE, GLOBE, PLUG, BALL, CHECK, AND BUTTERFLY TYPES.
NOMENCLATURE P = MAXIMUM ALLOWABLE PRESSURE @ 38ºC (100ºF), PER ASME B16.34.
PRESSURE TESTS ALL SIZES & PRESSURES IN ACCORDANCE WITH ASME RATINGS. TEST FLUID1 For HP tests, fluid to be water (or other suitable liquid) air or inert gas. For LP tests fluid to be air or inert gas.
REQUIREMENTS PER VALVE TYPE

TEST VALVE SIZE / CLASS PRESSURE BUTTERFLY & TRUNN-
GATE GLOBE PLUG CHECK FLOATING BALL
ION-MOUNTED BALL
HP SHELL All 1.5 x P 2 Required Required Required Required Required Required

BACKSEAT 3
All 1.1 x P (HP) / 4–7 barg (LP) Required Required NA NA NA NA
(A) ≤ DN 100 (4") ≤ cl 1500 and 4–7 barg Required Optional Required 4 Alternative 5 Required Required
> DN 100 (4") ≤ cl 600
LP CLOSURE
(B) ≤ DN 100 (4") > cl 1500 and
4–7 barg Optional Optional Optional Alternative 5 Required Optional
> DN 100 (4") > cl 600
As for (A) above Optional Required 7 Optional 4 Required Optional Optional
HP CLOSURE5 1.1 x P
As for (B) above Required Required 7 Required Required Optional Required
NOTES
1
FOR TESTING OF AUSTENITIC STAINLESS STEEL VALVES, WATER WITH CHLORIDE CONTENT NOT EXCEEDING 100 PPM SHALL BE USED
2
THIS TEST PRESSURE APPLIES TO STEEL VALVE BODIES
3
NOT APPLICABLE TO BELLOWS SEAL VALVES
4
FOR LUBRICATED PLUG VALVES THE HIGH PRESSURE CLOSURE TEST IS MANDATORY AND THE LOW PRESSURE CLOSURE TEST OPTIONAL
5
IF AGREED TO BY THE PURCHASER, THE VALVE MANUFACTURER MAY USE THE LOW PRESSURE CLOSURE TEST INSTEAD OF THE HIGH PRESSURE CLOSURE TEST
6
THE HIGH PRESSURE CLOSURE TEST OF RESILIENT SEATED VALVES MAY DEGRADE SUBSEQUENT SEALING PERFORMANCE IN LOW PRESSURE SERVICE
7
FOR POWER-OPERATED GLOBE VALVES, THE HIGH PRESSURE CLOSURE TEST SHALL BE PERFORMED AT 110% OF THE DESIGN DIFFERENTIAL PRESSURE USED FOR SIZING THE POWER OPERATOR
LEAK RATES MAXIMUM PERMISSIBLE SEAT TEST LEAKAGE RATES
ALL RESILIENT SEATED

NOM. VALVE SIZE (DN) ALL METAL SEATED VALVES EXCEPT CHECKS METAL SEATED CHECK VALVES 10
VALVES 9
Liquid Test Gas Test
Liquid Test (cm 3/min/inch of NPS) 1 Gas Test (std m 3/hr/inch of NPS)
(drops/min)1, 8 (bubbles/min)
≤ 50 (2") 0 09 09 3 0.042
65 (2½") to 150 (6") 0 12 24 3 0.042
200 (8") to 300 (12") 0 20 40 3 0.042
> 300 (12") 10 0 28 56 3 0.042
NOTES (contd)
8
FOR LIQUID TEST 1 CM3 IS CONSIDERED EQUAL TO 16 DROPS.
9
THERE SHALL BE NO LEAKAGE FOR THE MIN. SPECIFIED TEST DURATION. FOR LIQUID TEST, ZERO DROPS MEANS NO VISIBLE LEAKAGE DURING MIN. SPECIFIED TEST DURATION.
FOR GAS TEST ZERO BUBBLES MEANS LESS THAN ONE BUBBLE DURING MINIMUM SPECIFIED TEST DURATION
10
FOR CHECK VALVES LARGER THAN 24" NPS, THE ALLOWABLE LEAKAGE RATE SHALL BE PER AGREEMENT BETWEEN PURCHASER AND MANUFACTURER.
TEST DURATION MINIMUM DURATION OF REQUIRED TEST PRESSURE (sec)
SHELL TEST SEAT (CLOSURE) TEST

NOM. VALVE SIZE (DN) BACK SEAT TEST
Check valve (API 594) Other Valves Check valve (API 594) Other Valves
≤ 50 (2") 60 15 60 15 15
65 (2½") TO 150 (6") 60 60 60 60 60
200 (8") TO 300 (12") 60 120 60 120 60
> 300 (12") 120 300 120 120 60
API STD 598: VALVE INSPECTION AND TESTING (7TH EDITION, OCT. 1996) EEMUA Information Sheet No 32 (2)
BS 6755 - TESTING OF VALVES - PART 1 : 1986 PRODUCTION PRESSURE TESTING REQUIREMENTS EEMUA Information Sheet No 32 (3)
SCOPE THIS STANDARD COVERS PRESSURE TEST REQUIREMENTS FOR VALVES OF THE GATE, GLOBE, PLUG, BALL, CHECK, GLOBE STOP & CHECK, BUTTERFLY & DIAPHRAGM TYPES UP TO DN 600 (24").
TEST REQUIREMENTS IN VALVE PRODUCT STANDARDS REFERENCED IN BS 6755-1 (E.G. BSs 1414, 5351, 5353 ETC.) TAKE PRECEDENCE
NOMENCLATURE P = MAXIMUM PERMISSIBLE WORKING PRESSURE @ 20ºC DEPENDENT UPON MATERIALS
PRESSURE TESTS PRESSURE ALL VALVES (except where stated otherwise)

HP SHELL (LIQUID) 1.5 X P REQUIRED
HP SEAT(LIQUID) 1.1 X P REQUIRED 1 & 2
HP BACKSEAT(LIQUID) 1.1 X P REQUIRED Gate and Globe Valve ONLY
BUTTERFLY DISC STRENGTH (LIQUID) 1.5 X P REQUIRED Butterfly Valve ONLY
LP SHELL (GAS) 6–7 barg (NOTES) 3 & 4
LP SEAT (GAS) 6–7 barg (NOTES) 3 & 5
LP BACKSEAT(GAS) 6–7 barg (NOTES) 3 & 5
LOW PRESSURE CLOSURE (GAS) (NOTES) 6
NOTES
1
VALVES WITH A SEAT RATING LESS THAN P @ 20ºC SHALL BE SEAT TESTED AT 1.1 X MAX SEAT RATING, OR 6 BARG GAS MAX.
2
SOFT SEATED BALL VALVES SUBJECTED TO A HYDROSTATIC SEAT TEST MAY HAVE A REDUCED PERFORMANCE IN SOME SUBSEQUENT SERVICES AT LOW DIFFERENTIAL PRESSURES.
IF A HIGH PRESSURE SEAT TEST IS SPECIFIED AND IS TO BE CARRIED OUT BEFORE A LOW PRESSURE GAS SEAT TEST, IT MAY BE NECESSARY TO ALLOW TIME FOR THE SEAT MATERIAL
TO RECOVER.
3
REQUIRED IF SPECIFIED IN THE VALVE PRODUCT STANDARD.
4
ALTERNATIVE TO LIQUID TEST FOR VALVES ≤ DN 50 & ≤ CL 300 (BUT REQUIRES LIQUID TYPE TEST AT 2.25 x P)
5
ALTERNATIVE TO LIQUID TEST FOR VALVES ≤ DN 80 ALL RATINGS OR ≤ DN 200 & ≤ CL 300 (BUT REQUIRES LIQUID TYPE TEST AT 1.1 x P)
6
LOW PRESSURE GAS CLOSURE TEST WITH LOW DIFFERENTIAL (1 BAR) OR VACUUM / PRESSURE. TO BE REQUESTED BY PURCHASER AT ENQUIRY / ORDER STAGE.
LEAK RATES MAXIMUM PERMISSIBLE SEAT TEST LEAKAGE RATES (mm3/sec) MAXIMUM PERMISSIBLE BACKSEAT TEST LEAKAGE RATES (mm3/sec)
TEST RATE A RATE B RATE C RATE D TEST RATE A/B/C RATE D

ZERO VISIBLE
LIQUID 0.01 x DN 0.03 x DN 0.1 x DN LIQUID 0.03 x DN 0.1 x DN
LEAKAGE
ZERO VISIBLE
GAS 0.3 x DN 3.00 x DN 30 x DN GAS 3.00 x DN 30 x DN
LEAKAGE
GENERAL NOTES FOR LEAKAGE RATES

– REFER TO VALVE PRODUCT STANDARD FOR APPLICABLE LEAKAGE RATE CLASS (A, B, ETC).
– FOR CLASS RATED VALVES ABOVE DN 600 (24") THE NOMINAL BORE SIZE OF THE VALVE SHOULD BE CONVERTED INTO mm AND THIS VALUE SUBSTITUTED FOR DN WHEN
CALCULATING LEAKAGE RATES IN ABOVE TABLES
TEST DURATION MINIMUM TEST DURATIONS CAN BE FOUND IN THE APPROPRIATE VALVE PRODUCT STANDARD. THE TABLE BELOW GIVES TEST DURATIONS FOR VALVES WHICH DO NOT HAVE A PRODUCT STANDARD
OR WHERE TEST TIMES ARE NOT SPECIFIED.
MINIMUM TEST DURATIONS (sec)
NOMINAL VALVE SIZE SHELL SEAT TEST BACK SEAT

(DN) TEST METAL SEAT SOFT SEAT TEST
≤ 50 (2") 15 15 15 10
65 (2½") to 200 (8") 60 30 15 15
250 (10") to 450 (18") 180 60 30 20
> 450 (18") 180 120 60 30
(4) EN 12266 INDUSTRIAL VALVES - TESTING OF VALVES EEMUA Information Sheet No 32
(PART 1 :2003 MANDATORY REQUIREMENTS; PART 2 : 2002 SUPPLEMENTARY REQUIREMENTS)
SCOPE SCOPE: INDUSTRIAL VALVES (no size or pressure limitation but relates to EN Valve Product Standards)
NOMENCLATURE P = ALLOWABLE PRESSURE @ ROOM TEMP. (5 ºC TO 40 ºC) DN = NOMINAL VLAVE SIZE

DP = MAX. PERMISSIBLE DIFFERENTIAL PRESSURE N/A = NOT APPLICABLE
TEST ADDITIONAL TESTS & SPECIFIC LEAK RATES CALLED UP IN PRODUCT STANDARDS
(TESTS ARE OPTIONAL UNLESS ACCEPTANCE
ALL VALVES PRESSURE GATE GLOBE CHECK BALL BUTTERFLY PLUG DIAPHRAGM
OTHERWISE STATED) CRITERIA
EN 1984 prEN 13709 prEN 13341 prEN 1983 EN 593 prEN 12304 EN 13397
SHELL STRENGTH (Liquid) 1 Required 2 1.5 X P No visible leakage 3
SHELL TIGHTNESS (Liquid) 4 OR Required 1.5 X P No visible leakage 3
SHELL TIGHTNESS (LP gas) 4 Required 6 barg 5 No continuous bubbles
HP SEAT (Liquid) 4 OR Required 1.1 X P Table below B A or B 7 A
LP SEAT (Gas) 4 Required 6 barg 6 Table below B A or B 7 A
OBTURATOR STRENGTH (Liquid or gas) 1.5 X DP No visible leakage
HP BACKSEAT (Liquid) 4 OR 1.1 X P Table below
LP BACKSEAT (Gas) 4 6 barg 6 Table below
OPERABILITY N/A Free movement Yes
ANTI-STATIC (5 operations) 12 V dc R < 10 ohms
FIRE TEST ISO 10497
FLOW TEST EN 1267
1
THE CONCEPT OF THE SHELL STRENGTH TEST IS NOT FOUND IN OTHER TEST STANDARDS
2
MAY BE CONDUCTED ON INDIVIDUAL; COMPONENTS PROVIDED ASSEMBLED VALVES THEN SUBJECTED TO SHELL TIGHTNESS TEST. FOR PRODUCTION LINE
MANUFACTURE, TEST TIME MAY BE REDUCED PROVIDED CONTROL SAMPLES ARE TESTED FOR FULL DURATION.
3
GLAND LEAKAGE IS PERMITTED PROVIDED IT DOES NOT OCCUR AT 1.1 x P
4
THE ALTERNATIVE TESTS ARE AT MANUFACTURER'S DISCRETION
5
OR 1.5 x P IF P < 6 BARG
6
OR 1.1 x P IF P < 6 BARG
7
RATE A FOR SOFT SEATED VALVES; RATE B FOR METAL SEATED
LEAK RATES MAXIMUM PERMISSIBLE SEAT AND BACKSEAT LEAK RATES (mm3/sec)
Test Rate A Rate B Rate C Rate D Rate E Rate F RateG

Medium
Liquid Zero 0.01 x DN 0.03 x DN 0.1 x DN 0.3 x DN 1.0 x DN 2.0 x DN
visible
Gas Zero 0.3 x DN 3.0 x DN 30 x DN 300 x DN 3000 x DN 6000 x DN
visible
TEST DURATION MINIMUM TEST DURATION (sec)
DN Shell Seat Backseat Obturator

Metal Seat Soft Seat Liquid/ Strength
Liquid Gas Liquid/Gas Gas
≤ 50 15 15 15 15 15 15
65 to 200 60 30 15 15 15 60
250 to 450 180 60 30 30 30 180
> 450 180 120 30 60 60 180
ISO 5208 : 1993 INDUSTRIAL VALVES - PRESSURE TESTING OF VALVES EEMUA Information Sheet No 32 (5)
SCOPE THIS STANDARD SPECIFIES TESTS TO CONFIRM THE PRESSURE-CONTAINING CAPABILITY OF THE SHELL OF AN INDUSTRIAL VALVE UNDER PRESSURE
AND TO VERIFY THE TIGHTNESS AND PRESSURE-RETAINING ADEQUACY OF THE VALVE SEAT AND CLOSURE MECHANISM FOR ALL SIZES AND PRESSURE RATINGS.
NOMENCLATURE P = MAXIMUM PERMISSIBLE WORKING PRESSURE @ 20ºC DEPENDENT UPON MATERIALS
PRESSURE TESTS PRESSURE ALL VALVES

HP SHELL (LIQUID) 1.5 x P Required 1, 2
HP SEAT(LIQUID) 1.1 x P Required 3, 4,5
2
LP SHELL (GAS) Up to DN 50 & up to PN 50 5–7 barg Manufacturer's discretion
NOTES
1
GAS TEST AT PRESSURE OF 6 ± 1 BARG MAY BE USED AT THE MANUFACTURER'S DISCRETION FOR VALVE SIZES UP TO AND
AND INCLUDING DN 50 AT NOMINAL PRESSURES UP TO AND INCLUDING PN 50.
2
NO VISIBLY DETECTABLE LEAKAGE ALLOWED.
3
SEAT CLOSURE TEST CAN ALSO BE PERFORMED USING A GAS AT A PRESSURE OF 6 ± 1 BARG FOR THE FOLLOWING:
a) VALVE SIZE ≤ DN 80 AT ALL PRESSURES.
b) VALVE SIZE ≥ DN 100 & ≤ DN 200 AT PRESSURE UP TO PN 50, AT MANUFACTURER'S DISCRETION.
4
VALVES WITH A SEAT RATING < P @ 20ºC SHALL BE SEAT TESTED AT 1.1 X MAX SEAT RATING, OR 6 BARG GAS MAX.
5
FOR VALVE SIZE ≥ DN 100 & ≤ DN 200 AT PRESSURE ≥ PN 110, AND VALVE SIZE ≥ DN 250 AT ALL PRESSURES, TEST MAY BE PERFORMED USING GAS AT PRESSURE 1.1P.
LEAK RATES MAXIMUM PERMISSIBLE SEAT TEST LEAKAGE RATES (mm 3/sec)
TEST RATE A RATE B RATE C RATE D

LIQUID No visible leakage 0.01 x DN 0.03 x DN 0.1 x DN
GAS No visible leakage 0.3 x DN 3.00 x DN 30 x DN
GENERAL NOTES
REFER TO VALVE PRODUCT STANDARD FOR REQUIRED LEAKAGE RATE.
NO BACKSEAT TESTS ARE STATED WITHIN THIS STANDARD.
TEST DURATIONS MINIMUM DURATION FOR SHELL AND SEAT TIGHTNESS TESTS (sec)
NOMINAL VALVE SIZE SHELL SEAT TEST

(DN) TEST METAL SEAT SOFT SEAT
≤ 50 (2") 15 15 15
65 (2½ ") to 200 (8") 60 30 15
250 (10") to 450 (18") 180 60 30
> 450 (18") 180 120 60
prEN/ISO/FDISs (FOR PETROLEUM & RELATED INDUSTRIES) 10434—BOLTED BONNET STEEL GATE VALVES & 17292—METAL BALL VALVES:
TESTING REQUIREMENTS
SCOPE GATE VALVES DN 25 (1”) TO DN 600 (24”), CL 150 TO CL 2500

BALL VALVES DN 8 (¼”) TO DN 500 (20”), CL 150, 300, 600 & 800, PN 16, 25 & 40
NOMENCLATURE P = RATED PRESSURE AT 38ºC
TEST PRESSURE BALL VALVES ACCEPTANCE CRITERIA GATE VALVES ACCEPTANCE CRITERIA
SHELL PRESSURE (Liquid) 1.5 x P Required No visible leakage Required No visible leakage1
P P
2
SEAT TIGHTNESS (Liquid) 1.1 x P Metal seat Table below P P Table below
3, 4
SEAT TIGHTNESS (Gas) 4 to 7 barg Soft seat No visible leakage P P Table below
BACKSEAT (Liqid) 1.1 x P N/A No visible leakage
BACKSEAT (Gas) 4 to 7 barg N/A No visible leakage
1
P FOR GATES ONLY, GLAND LEAKAGE IS PERMITTED PROVIDED PRESSURE IS MAINTAINED.
P
2
P VALVES > DN 100, > CL 600, & ALL VALVES > CL 1500. OPTIONAL FOR ALL OTHER SIZES & RATINGS.
P
3
P VALVES ≤ DN 100, ≤ CL 1500, & VALVES > DN 100, ≤ CL 600.
P
4
P ALL VALVES COVERED BY NOTE (3) ABOVE MUST HAVE RECORDS OF SAMPLE LIQUID TESTS.
P P P
LEAK RATES MAXIMUM PREMISSIBLE SEAT TEST LEAK RATES

DN GAS (mm3/s) P P GAS (bubbles/s) LIQUID (mm3/s) P P LIQUID (drops/s)
≤ 50 05 P P 05 P P 06
P P 06P P
65 to 150 25 0.4 12.5 0.2

200 to 300 42 0.7 20.8 0.4
> 300 58 0.9 29.2 0.5
5
P P GATE VALVES ONLY: ‘ZERO’ IS < 3 mm3/s P P
6
P P BALL VALVES ONLY: ‘ZERO’ IS 6 mm3/s or 0.1 drops/s P P
TEST DURATION MINIMUM TEST DURATIONS IN SECONDS

DN SHELL SEAT BACKSEAT
≤ 50 15 15 15
65 to 150 60 60 60
200 to 300 120 120 60
> 300 300 120 60
EEMUA Information Sheet No 32 (6)

EEMUA VALVES COMMITTEE VALVE TEST RECOMMENDATIONS FOR OIL, GAS, CHEMICAL AND PETROCHEMICAL APPLICATIONS
NOMENCLATURE Y = TEST RECOMMENDED

N = TEST NOT RECOMMENDED
A = DISCRETIONARY ACCORDING TO SERVICE CONDITIONS
T = TYPE TEST
RECOMMENDATIONS COMMODITY VALVES CRITICAL SERVICE VALVES

TEST DESCRIPTION GATE 1 GLOBE BUT'FLY PLUG BALL GATE
1
GLOBE BUT'FLY PLUG BALL
SHELL STRENGTH (liquid) Y Y Y Y Y Y Y Y Y Y
SHELL TIGHTNESS (liquid) Y Y Y Y Y Y Y Y Y Y
2
SHELL TIGHTNESS (LP gas) N N N N N A A2 A2 A2 A2
3
HP SEAT (liquid) Y Y Y Y A Y Y Y Y Y
2
A2 A2 A2
2
LP SEAT (gas) A Y A A2 A2 A2 Y
HP SEAT (gas) 4 N N N N N A
2, 5
A 2, 5 A 2, 5 A 2, 5 A 2, 5
6
OBTURATOR STRENGTH (liquid/gas) N N N N N N N Y N N
5 5
HP BACKSEAT (liquid) Y Y N N N Y Y N N N
LP BACKSEAT (gas) N N N N N N N N N N
OPERABILITY (function) Y Y Y Y Y Y Y Y Y Y
5
TORQUE / FORCE MEASUREMENT N N N N N Y Y5 Y5 Y5 Y5
7
ANTI-STATIC N N N Y Y7 N N N Y
7
Y7
FIRE TEST 8 Y 7, 9 N Y
7, 9
Y 7, 9
Y 7, 9 Y 7, 9 N Y
7, 9
Y 7, 9
Y 7, 9
5, 10 5, 10 5 5, 10 5, 10 5
BODY CAVITY RELIEF TEST Y N N Y Y Y N N Y Y
1
NOTES WEDGE GATE, EXPANDING GATE AND SLAB GATE.
2
GAS SERVICE APPLICATIONS. ALLOWABLE LEAK RATE FOR HP TEST SHOULD BE AGREED WITH MANUFACTURER:
WILL NORMALLY BE SEVERAL TIMES LP RATE
3
STRONGLY RECOMMENDED WHERE SEALING FORCE IS MECHANICAL, E.G. "ORBIT" TYPE VALVES.
4
MAY BE SUBSTITUTED FOR HP LIQUID SEAT TEST.
5
SAMPLE.
6
"A" FOR SIZES DN < 350
7
TYPE TEST.
8
NOT APPLICABLE TO BURIED OR SUBSEA VALVES.
9
WHERE POLYMER OR ELASTOMER SEALS EMPLOYED
10
ONLY TYPES WHICH CAN LOCK LIQUID INTO BODY CAVITY IN CLOSED POSITION, AND WHICH MAY SUBSEQUENTLY BE HEATED.

LEAK RATES TYPICALLY ACHIEVABLE BY GOOD QUALITY VALVES
The leakage rates tabulated below are those which in the opinion of EEMUA VVS Committee
are achievable by ‘good quality’ valves under test conditions. These rates are provided for
guidance purposes.
Rates ‘A’, ‘B’ etc, are as defined in ISO 5208 and EN 12266 (see relevant preceding table).
VALVE TYPE LIQUID SEAT TEST LP GAS SEAT TEST HP GAS SEAT TEST
at 1.1 x Rated at 6 barg at 1.1 x Rated
Pressure Pressure
Gate B C 3xC
Ball Soft seat— A Soft seat— A Soft seat— B
Metal seat— C Metal seat— C Metal seat— 3 x C
Check D 3xD 9xD
Globe B B 3xB
Butterfly B C 3xC
Plug A A B

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VALVE

TOPIC 2 BALL VALVE CONSTRUCTION AND SELECTION

TOPIC 3 GATE VALVE CONSTRUCTION AND SELECTION

TOPIC 4 GLOBE VALVE CONSTRUCTION AND SELECTION

TOPIC 5 CHECK VALVE CONSTRUCTION AND SELECTION

TOPIC 6 BUTTERFLY VALVE CONSTRUCTION AND

TOPIC 7 NOT USED

TOPIC 8 VALVE STEM PACKING DESIGN

TOPIC 9 SELECTION OF VALVE TRIM MATERIALS AND

TOPIC 10 BASIC TYPE OF NDE TESTING FOR VALVES

TOPIC 11 VALVE PRESSURE TESTING TO INTERNATIONAL

I The selection of any valve is

I It is important that engineers

I Factors that drive the selection of

1. Codes / practices, standards and

I THE DESIGN CODE APPLIED TO THE PIPING SYSTEM WILL

I SOME VALVE TYPE STANDARDS ARE NOT COVERED BY

I CLIENT CORPORATE DESIGN STANDARDS SHOULD

I LOCAL STATUTORY REGULATIONS MAY APPLY IN VARIOUS

I NATIONAL AS WELL AS INTERNATIONAL STANDARDS MAY

I WHOSE INTERESTS ARE COVERED / REPRESENTED BY

I ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS) –

I ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS).

I API (AMERICAN PETROLEUM INSTITUTE)

I ISO - INTERNATIONAL STANDARDS ORGANIZATION.

I PER – PRESSURE EQUIPMENT REGULATIONS –

I MSS – MANUFACTURERS STANDARDISATION SOCIETY.

I EEMUA – ENGINEERING EQUIPMENT AND MATERIAL USERS

I NACE – NATIONAL ASSOCIATION OF CORROSION

BVAMA – BRITISH VALVE AND ACTUATOR MANUFACTURERS

I FLOW CONTROL / THROTTLING

I REVERSE FLOW VALVES

I FAIL SAFE (FAIL OPEN OR FAIL CLOSE)

I ON / OFF (ISOLATION VALVES) – FREQUENT OR

I BUYING A VALVE TO RECOGNIZED STANDARDS SHOULD

a) A LEVEL OF STANDARDIZATION TO THE VALVE DESIGN.

b) ALLOWS COMMERCIAL AVAILABILITY OF VALVES FROM

c) ALLOWS INTERCHANGEABILITY OF VALVES FROM

d) A LEVEL OF STANDARDIZATION TO THE VALVE TESTING

e) A LEVEL OF QUALITY IN THE PRODUCT.

f) TRACE-ABILITY OF THE DESIGN.

g) A KNOWN LEVEL OF INTEGRITY.

THIS LEADS TO A VARYING LEVEL OF BUYER

I SOME VALVES WHICH HAVE BEEN DEVELOPED TO

STANDARD DESIGN FEATURES

I END TO END DIMENSIONS for THREADED AND

I FACE TO FACE DIMENSIONS for FLANGE AND

Ball valves can be supplied in a long and short pattern

Copper alloy valve face to face dimensions are covered

Refer to next page for extract from ASME B16.10.

SOCKET ½” – 1 ½” – CLASS 800/ GEN HYDROCARBONS.

THREADED ½” – 1 ½” – CLASS 125/150/ GEN HYDROCARBONS.

BUTTWELD ½” – + CLASS 900/ COR HYDROCARBONS

CAPILLARY ½” – 6” WATER UTILITIES

SPRING RETURN WRENCH –

OVAL SAFETY HANDWHEEL –

CAN BE COSTLY THEREFORE CAREFUL CONSIDERATION

THE UNIT SHALL BE A WEATHERPROOF / SEALED HOUSING,

IT SHALL HAVE A RATIO WHICH ENSURES A SUITABLE

FREQUENCY OF OPERATION MAY ALSO DETERMINE IF GEAR

NOTE: FWEL 51A2 VALVE DOCUMENT DEFINES SIZE SPLIT

• SERVICE FLUID CONDITIONS DICTATE BOTH VALVE TYPE