7.

Calculation of the diameter of pipes

To estimate the optimal diameter of a pipe, and correspondingly the valve the following formula can
be used to get an approximate value:

Where
Q: flow in m3/sec.
D: diameter of the pipe in meter
W: flow speed in m/sec

As flow speed the following values can be used as reference:

For liquids for natural gradient

viscous liquids 0,1 up to 0,5 m/sec
Non viscous liquids 0,5 up to 1 m /sec
For pressurized lines
Inlet of pumps 0,8 up to 2 m/sec
Output of pumps 1,5 up to 3 m/sec

For gases low pressure (fans) 4 up to 15 m/sec

High pressure 15 up to 25 m/sec

For steam Saturated steam 30 up to 50 m/sec

Superheated steam 15 up to 75 m/sec (depending on the pressure)

8. Types of valves

8.1 Ball valves

The ball valve is basically a plug valve with a spherical plug and a round hole. The materials of
construction of the ball valve have been developed such that the ball valve is becoming the most
popular valve for most process applications. The valve is a quarter turn valve.
There are two primary options for the ball valve design
• Floating Ball Design - This is low cost option for the lower duties
• Trunnion Ball Design - This is a more costly option for the higher duties
The ball valve can be provided in a full-bore version, in which the internal diameter of the valve is
identical to the internal diameter of the pipe. In this design the pass of scrappers to clean the pipes is
possible (pigable design). They can also be provided in a reduced bore design allowing a smaller body
but still with relatively low head loss compared to most other valve options e.g. a 25 mm nominal bore
valve has a 20 mm reduced bore. Ball valves can be manufactures with a multi-port design for flow
diverting (three or four ways)

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Ball valves can be designed as “top entry” when all the internals are accessible by removing the top
flange and allows a replacement without dismounting the valve from the pipe. Another method is to
use a three-piece body based on a central piece sandwiched between two pieces connecting the valve
to the pipework.

Others design of ball valves are:

• Top entry, in which all the internal components are accessible by dismantling the top cover,
without extracting the valve from the pipeline. Another version is to use a body of three pieces
installed between the two pieces which make the connection to the pipe.
• Twin valve, in which two independent balls are installed in one body

Top entry Doble (Twin ball)

Ball valves are available in all materials in sizes from 5 mm to over 1400 mm (and larger in special
cases). The valves can be used at pressures up to 700 bar, higher pressures are possible. The sealing
of the fluid can be achieved either by soft seat inserts, in which seats are elastomer inserts. Soft seated
valves have restrictions in the temperature limits of the elastomer used as insert, in general the
maximum temperature for soft seats is 250°C. The seats can also be designed for a metal / metal
sealing, which has no restriction in relation of the temperature and is also suitable for abrasive media.
Using metal / metal sealing, the ball and the seats must be coated with hard material to prevent
scratching when the fluid has solids in suspension.

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In general ball valves are used for on-off service, the characteristic is not lineal through the movement.
There are special versions which can be used for control purposes,
One of these versions use a ball with segmented design, with which a linear characteristic can be
achieved.
In another version an orifice plate is installed at the outlet, with orifices distributed in such a way that
the requires characteristic is obtained.

8.2 Gate valves

Gate valves are generally used in the process industry for on-off service. The valve is a multi-turn valve.
The design is not suitable for throttling duty because the sealing surfaces can easily suffer from erosion
when low flows are being maintained against high differential pressures and the design give very poor
flow control characteristics.

The gate valve can be manufactured in a wide range of sizes from 5mm to above 2000mm dia. The
designs are proven and well tested.

There is a great number of different gate valves for specific applications.

Solid wedge Flexible wedge Split wedg

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Gate valves are available in “twin” versions, in which two valves are installed in one body.

Gate valves are pigable in their full-bore version, which means that a pig can pass the valve without
interruption.

8.3 Butterfly valves

The butterfly valve is used to interrupt or regulate the flow of a fluid in a pipe, increasing or reducing
the passage section by means of a disc, called "butterfly", which rotates on an axis. By decreasing the
passage area, the pressure loss in the valve increases, reducing the flow. The valve has a quarter turn
operating system.

The main variations of this valve are the methods of sealing the disc in its closed position.
Those with a central axis have a body completely covered with an elastomer and have the advantage
that it is protected against possible corrosion of the fluid transported, in addition to being
bidirectional.
The other variations are based on offsetting the plane of the disc on the axis of rotation, allowing the
disc to close against a circular face seal (Seat) so that fluid pressure increases the sealing effect. The
modification of the axis of rotation is achieved with a single, double, or triple axis eccentricity. There
is also the variant of using metal seals, which allows the valve to be used in a wide range of fluids at
high temperatures.

The butterfly valve is suitable for many tasks as it provides an optimal solution for an on-off valve,
watertight that could supplant the gate valve. The butterfly valve is designed in diameters from 25mm
to extremely large sizes over 5000mm in diameter. Depending on the size of the valve, working
pressures of up to 100 bar can be handled.

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Butterfly valves are not suitable for the passage of scrapers, they cannot be used in pipes that must be
cleaned or inspected with this system

8.4 Plug valves

The plug valve is the oldest of the valves. Plug valves have been in use for over 2000 years. This valve
has been in continuous development over recent years. The plug valve is basically, and on-off valve
based on a plug with a rectangular hole through which the fluid flows. The plug is either tapered or
cylindric is located in the valve body and can be rotated through a quarter turn to line the hole up with
the pipe when open or across the pipe when closed.

The plug can be adapted for multi-port use allow the valve to be used for diverting flow. The valve can
be engineered with a lubricated plug which uses the lubricant to enable convenient operation over a
wide range of pressures. The lubrication film also provides a seal.

The unlubricated design includes seals in the plug and requires plastic bearing systems. The valve can
include a cage between the plug and the body which includes the bearing a sealing system and allow
convenient maintenance. These valves have been specially developed for use in industries requiring
high performance operation under arduous conditions and allowing remote maintenance e.g. the
nuclear industry.

The valve is a full bore and has virtually no internal cavities but is not pigable in its standard version.
Special versions which are pigable are available on the market, but this design increases drastically the
size and weight of the valve.

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8.5 Globe valves

The globe valve includes an orifice set into the body through which the fluid flows. A disc located on
the end of the spindle is engineered to move in and out along the axis of the orifice. When the disc is
moved to sit in the orifice the flow path is shut-off. The flow path is progressively increased as the
disc is moved away from the orifice.

The surface of the orifice (seat) is generally engineering as a replaceable item made from erosion
resistant material with a polished surface finish. The disc can be fitted with a soft seat if a tight shut-
off is required. For flow control duties the disc is supplied with an engineered shape (lineal, equal
percentage, etc.).

For manually operated valves the spindle screwed so that rotation of the handle moves the disc in
and out. For actuated control valves the spindle is moved in and out using a linear actuator which can
be pneumatic, hydraulic, or electric.

The fluid flow path through globe valves is such that there is normally a high fluid head loss through
the valve. The inline body design has the highest head loss, the angle pattern body design has a lower
head loss. There are certain designs of globe valves which have been engineered to have low head
loss characteristics. Globe valves are supplied in sizes from 3 mm bore through 400 mm and can be
used, size limiting at pressures up to 450 barg. Depending on the sealing systems the valves can be
used at temperatures the 600°C.

Globe valves are not pigable and cannot be used in pipes which must be cleaned or inspected with
pigs.

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8.6 Needle valves

The needle valve is used specifically for accurately controlling the flow of fluids at low flows and/or
micro flows. The valve is basically a globe valve with a obturator that remembers a needle. It is
generally used provided in small sizes of up to 20 mm bore, but there are manufacturers that offer
larger sizes.
Needle valves are not pigable and cannot be used in pipes which must be cleaned or inspected with
pigs.

8.7 Diaphragm valves

The diaphragm valve has no gland seal requirement. The fluid flows straight through the valve via a
chamber over which is an elastomer diaphragm. This diaphragm is normally arranged to provide no
resistance to the flow. The perimeter of the diaphragm is simply clamped to a seal face of the valve
body as a static seal.
To close off the valve the diaphragm is simply forced down into the chamber to block off the flow. The
chamber can include a weir across the flow path against which the diaphragm can be pressed to affect
a more efficient seal with reduced diaphragm distortion.

The straight through variation is effectively a full-bore valve design with all the associated benefits.
However, this option results in a much more arduous duty on the diaphragm which must be a softer
material.

This type of valve is manufactured in sizes from 6mm to 400mm and is generally limited to relatively
low fluid pressures (less than 7 bar). However, in the smaller sizes (up to 50mm) valves can be specially
engineered for use at pressures up to 30 barg. The diaphragm must be chosen to be compatible with
the fluid. Whatever the fluid the diaphragms must be replaced at regular intervals and it is advisable
to operate the valves frequently.

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These valves are often used for duties which require a high degree of cleanliness as they can be
supplied lined, and polished and can be very conveniently cleaned and for transport of solids slurry.
In this last application the advantage is the low cost of the valve, the disadvantage is that the
diaphragm must be replaced very often.

Diaphragm valves can be supplied in pigable versions.

8.8 Pinch valves

The pinch valve is a theoretically ideal solution for fluid on-off duties. The valve is simple a length of
pipe made from an elastomeric material with a mechanical system for squeezing the tube closed
when a shut off is required. The valve is a true full-bore valve - there are no mechanical parts in
contact with the fluid- The operation of the valve is ideally simple; the valve can be easily engineered
as a tight-shut off valve.

The valve is often supplied with the pinch tube contained within an outer pipe between the end
flanges.

The valve has similar limitations to the diaphragm valve. The diaphragm valve is really a variation on
the pinch valve principles. Pinch valves are supplied is for diameters 25 mm - 1000 mm,
temperatures -50 C - +160 C, and pressures 0 - 50 bar.

Pinch valves can be supplied in pigable versions

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8.9 Check valves

Check valves are normally auto actuated and designed to prevent reversal of flow of the fluid in the
pipe. The valves are maintained open by the flow of fluid in the forward direction and are closed by
back pressure of the fluid or by the weight of the closing mechanism or by a spring force. Various
designs are available as listed below.
• Swing check
• Tilting disc
• Ball lift type
• Disc lift type
• Piston check
• Stop check
The range of check valve sizes range from 6mm to massive units of 3000 mm diameter and more.

The swing check variation is a low pressure drop unit based on a hinged disc. This type of valve is
suitable for low velocity applications with infrequent velocity reversals. The valve can be fitted with
external weights to allow faster closure to reduce water hammer or shock pressure on flow reversal.
External systems can also be included to force the valve closed in the event of a local fire.

The tilting disc variation on the swing check valve provides improve speed of operation and pressure
performance and is probably the most popular design of check valve used in the process industry.

At the ball check valve, the function is like the piston type, in which a ball inside the body is used to
control the flow. The ball can move freely, what results in a uniform erosion and cleaning of the areas
between the ball and the seats. This makes this type of check valve ideal for viscous liquids.

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The lift check valve has a seat design like a globe valve. The disc is generally in the shape of a piston or
a ball.
Lift check valves are particularly suitable for high pressure service where the flow rate is high. On lift
check valves the disc is precisely guided and fits snugly on the dash. The lift check valves are suitable
for installation in horizontal or vertical pipes with up flow.

Piston check valves are used to avoid problems in the piping and pumping systems (cavitation)
avoiding any reversal of the flow. They are opened by the passage of the fluid and use a spring to close
them. They also keep the pipes full of fluid if the pumping equipment is stopped.

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Stop check valve. In the stop verification configuration, the stem head floats on the balloon disk (i.e. it
is not connected). Stop check valves have two main purposes: 1) as a globe valve, they isolate or
regulate flow, and 2) modified as a check valve, they prevent reverse flow. In other words, they are
generally used as a globe valve to start or stop media flow, but they also act as a check valve to
automatically close in the event of pressure loss, thus preventing back flow that could cause damage.
to equipment such as boilers or pumps.

Because of this, having a stop check valve is like having two valves in one. The inner disc, which is not
attached to the stem, functions as a lift control that allows the freely move up and down when the
stem is raised to adjust opening and closing. This controls the flow rate, but when a return flow occurs,
the disconnected disc works like a piston control and closes quickly, thus preventing reverse flow into
the boiler. If necessary, the stem can be lowered manually to stop flow or close completely.
These valves are mainly used in power plants, among others, in applications such as boiler circulation,
generation of steam and boiler feed water, turbine cooling, starting water and safety systems.

If the passage of scrapers is required in the check valves, the corresponding version must be selected.

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