Transcript

Welcome to our lesson on Valves used in Piping!

Valves are essential tools in controlling the flow of fluids in many industries and
applications. Whether it's managing the flow of water in plumbing systems or directing
the movement of oil and gas in industrial processes, valves are crucial for ensuring
systems operate efficiently and safely.

At their heart, valves are mechanisms meant to regulate fluid flow by opening, closing,
or partially obstructing passageways within piping systems. They come in various types,
sizes, and designs, each suited to specific operational needs and environmental
conditions.

Throughout this lesson, we will explore the different types of valves, their functions, and
how they contribute to the smooth operation of various systems. By understanding the
basics of valves, we can appreciate their importance in controlling the movement of
liquids and gases in different industries.

The contents covered in this lesson include:

• Classification of Valves

• Gate Valves

• Globe Valves

• Ball Valves

• Check Valves

• Check Valves

• Control Valves

Valves and pressure relief devices are crucial components within industrial piping
systems. Valves are designed to control the direction and magnitude of fluid flow by
utilizing flow control elements, allowing for diversion, restriction, or regulation of the
flow.

Next, we'll delve into sound engineering practices and selection criteria for valves.

Valves make up approximately 20 to 30% of the cost of a plant's piping system,

depending on the type of process involved. The cost of valves can vary based on factors
such as type, size, and materials used. Therefore, selecting the right valves is essential
for the economics and operation of a process plant.

Valve specification is a meticulous process that involves various considerations and

concepts. Some of the key criteria include:
a) Valve type

b) Material of construction, especially the material in contact with the fluid

c) Type of connection (threaded, welded, flanged, etc.)

d) Operating pressure range

e) Nominal diameter

f) Type of control element and seat

g) Stem and bonnet specifications

h) Handwheel or actuator

i) Temperature requirements

Each of these factors plays a crucial role in ensuring the proper functioning and
efficiency of the valve within the piping system.

Valves are available in a diverse range of types, each serving specific purposes and
often meeting multiple criteria.

Here's a breakdown of valve classification based on their functions:

a) On-Off Valves: These valves are designed to efficiently control the flow by either fully
opening or closing the valve.

b) Regulating Valves: Regulating valves are used to adjust and modify the flow rate in
proportion to the desired requirements.

c) Check Valves: Check valves permit fluid flow in one direction only, preventing
backflow and ensuring fluid moves in the intended direction.

d) Safety Valves: Safety valves play a critical role in relieving excess pressure within the
system, safeguarding against potential overpressurization and ensuring system integrity
and safety.

Gate valves are primarily intended for starting or stopping flow, especially when minimal
flow restriction or a straight-line flow of fluid is necessary. During operation, these
valves are typically either fully open or fully closed, offering a straightforward approach
to flow control. They are often more economical compared to other valve types.
These valves regulate flow by lowering a gate into the flow path. Despite being an older
valve design, gate valves remain preferred for applications requiring uninterrupted flow
and minimal pressure drop. However, they are not recommended for regulating services
because partially closing the gate to restrict flow can lead to erosion or damage to the
gate and seal. Additionally, turbulence may occur when the gate is partially open,
affecting performance.

When a gate valve is fully open, the gate is raised entirely out of the flow passage,
allowing fluid to pass through an aperture with a diameter equivalent to that of the pipe.
These valves are primarily employed in non-regulating services, where operations are
either completely open or completely closed, or where minimal flow resistance is
desired.

A gate valve comprises several components, as depicted in the figure above: the
handwheel, stem, bonnet, trim, and body. The body typically connects to other pipes or
equipment through flanged, screwed, or welded connections. The bonnet houses the
moving parts and is usually bolted to the body to facilitate maintenance. The valve trim
consists of the stem, gate, disc or wedge, and seat rings.

Gate valves come with different types of discs or wedges as control elements:

1. Solid disc or wedge with conical seats: This is the most commonly used disc due to
its simplicity and strength. It can be installed in either position and is suitable for a wide
range of liquids, including oil, gas, air, sludge, and heavy liquids. The solid wedge is a
single-piece construction, making it suitable for turbulent flow.

2. Flexible wedges: These discs are solid only partway through, with flexible seating
surfaces on both the top and bottom of the wedge. They are particularly useful in
applications with fluctuating pressure and temperatures.

3. Split wedge: This design features a ball-cavity design where the two shoulders of the
wedges are joined, allowing each disc to move independently for a better seal. It is
suitable for non-condensing gases and liquids at normal temperatures, especially
corrosive liquids.

Seats for gate valves can either be integral with the valve body or a separate component
known as a seat ring. Seat rings may be threaded into position or pressed into position
and seal welded to the valve body. Seat rings are recommended for higher temperature
services. Integral seats are typically made of the same material as the valve body, but
variations are possible with pressed-in or threaded-in seats. Rings with hard facings are
available if the service requires them.

Globe valves are designed to proportionally control the flow using a disc attached to the
end of a threaded stem. They are primarily used for regulating fluid flow but can also
function in an open-closed condition. However, the change in direction of fluid flow
through the valve, which involves two right angles, causes turbulence and pressure
drop, limiting the life of the seat.

The design of globe valves must consider factors such as the range of flow control,
pressure drop, and operational duty to prevent premature failure and ensure
satisfactory service. Valves operating under high-differential pressure-throttling service
require specially designed valve trim.

Globe valves are suitable for services requiring frequent operation and positive closure
for gases and air. They are effective for throttling flow to any desired degree but
introduce a tolerably high flow resistance and pressure drop. The main structural
elements of a globe valve include the handwheel, stem, bonnet, seat, disc, and body.

The common flow control elements for globe valves include:

a) Compound disc: This disc features a flat face pressed against a flat seat annular
metal surface, providing a positive seal for gases and air. However, it's not suitable for
steam, gasoline, and other liquids.

b) Metal disc: This type involves a conical or spherical disc shape that contacts a
conical seat, ensuring positive closure for liquids. It's not recommended for control
service but is desirable where deposits could damage the seats.

c) Conical solid disc: With an extended conical configuration, this disc allows extensive
contact with the seat, facilitating effective closure for liquids and gases. Additionally, it
offers minimal resistance to erosion and corrosion, enhancing durability in demanding
conditions.

Seats for globe valves are typically integrally cast, although sometimes replaceable seat
rings screwed into the body are used.

Leak points in globe valves are similar to those in gate valves, but in globe valves, leaks
must also be prevented on the downstream side of the disc.

For globe valves, if the pressure requirement is not too high, an elastic material is
preferred for the disc. This choice ensures contact between the metal surface and the
elastomer, reducing the risk of damaging the seal if a particle becomes trapped
between the surfaces.

Stem packing materials such as graphite, Teflon, etc., are available in different durable
materials selected based on the temperature requirements of the piping system.

The ends of valve bodies may be flanged, threaded, etc., and are available in sizes
ranging from 1/8" to 30" NPS.
Similar to the globe valve, a needle valve features a relatively small orifice and a long,
tapered seat with a needle-shaped plunger on the end of a screw, which precisely fits
the seat. When the rotating stem moves away the plunger, the valve opens.

Throttling of low volume flow is achievable due to the variable orifice formed between
the plunger and the corresponding seat. As the screw turns and retracts the plunger,
flow between the seat and the plunger is enabled. However, until the plunger is fully
retracted, fluid flow is significantly impeded. Because it takes many turns of the fine-
threaded screw to retract the plunger, precise regulation of the flow rate is possible.

Needle valves are typically used in instruments or hydraulic services and are not
suitable for high-temperature applications. They are manufactured using materials
such as brass, stainless steel, carbon steel, and alloys, with threaded ends in diameters
ranging from 3.1 mm to 25 mm.

Due to the stringent machining tolerances required for these valves, the materials used
are usually of high quality and therefore expensive.

Ball valves are characterized by their quarter-turn operation, utilizing a hollow,

perforated, and pivoting ball to control flow based on its orientation. When the ball's
hole aligns with the flow, the valve is open; however, when it is pivoted 90 degrees, the
valve is closed. The handle lies flat in alignment with the flow when the valve is open,
and perpendicular to it when closed, allowing for easy visual confirmation of the valve's
status.

Previously, the use of ball valves was restricted because they couldn't achieve a metal-
metal seal due to the valve's design. However, with the growing use of plastics, this
limitation has been overcome. The ball features an admission groove that connects with
the body in the open position. Ball valves are primarily utilized for on-off services and
aren't ideal for flow control. They offer rapid operation, minimal maintenance
requirements, do not need lubrication, and provide a tight seal with low torque.
Additionally, pressure drop, determined by the selected throat size, is minimal.

Ball valves exhibit durability, remaining reliable even after numerous cycles, and they
securely close even after extended periods of disuse. These attributes render them well-
suited for shutoff and control purposes, often preferred over gate and globe valves.
However, they are not optimal for fine control in throttling applications.

One of the notable advantages of ball valves is their versatility in handling various fluids,
including steam, water, oil, gas, air, corrosive fluids, slurries, and dry powder.
Nonetheless, their usage is restricted to temperatures and pressures within the limits of
the fabrication materials. The key structural components of ball valves include the body,
seats, and ball.
Ball valves come with three types of throats: nominal diameter, reduced passage and
Venturi. The nominal diameter throat is equal to the inner diameter of the pipe, but has
the disadvantage of requiring a greater diameter body.

Generally, most manufacturers use the following polymers as seating materials: TFE,
Nylon, Buna N and Neoprene; their use is limited by temperature. Graphite seats were
developed for operation up to 538 C. Normally, the stem is sealed with "O" rings or
conventional packaging: TFE or different materials impregnated with TFE held in place
by compression rings.

Ball valves are produced in a wide range of materials including cast iron, ductile iron,
bronze, aluminium, stainless steel, brass, titanium, zirconium, tantalum and many
corrosion resistant materials in addition to plastics.

Ball valves come in different sizes, ranging from 6.3 mm to 760 mm nominal diameter.

The ends are usually flanged, threaded and welded. There is also the possibility of
changing the connection pieces to various construction materials.

Butterfly valves

A butterfly valve is a valve that either isolates or regulates the flow of a fluid. The closing
mechanism is a rotating disc perpendicular to the valve axis which is supported on both
ends. Butterfly valves are one of the oldest types of valve known; they are simple, light
and inexpensive; maintenance costs are also low because they have a minimum of
moving parts.

Butterfly valves serve primarily in control or on-off services, typically in large diameter
systems handling liquids and gases at lower pressures. The design of the valve, with its
disc in the open position, prevents solid materials from accumulating on the seat.

Flow regulation occurs as the disc interacts with the seats, offering fully open, fully
closed, or controlled flow positions. The valve ensures positive closure for gases and
liquids while maintaining a low pressure drop.

Operation is straightforward: a simple 90-degree turn of the handle transitions the valve
between fully open and fully closed states. Moreover, their slim profile requires minimal
space within the piping system.

Key structural components of a butterfly valve include the flow control disc (butterfly)
and the housing body.

Check valves, essential components in piping systems, are engineered to halt backflow
through a pipe. Fluid pressure in one direction prompts the valve to open, lifting the
weight of the retention mechanism. Conversely, when fluid attempts to flow in the
opposite direction, the mechanism automatically closes, effectively blocking the flow.
Various types of check valves exist, and selecting the appropriate type hinges on factors
such as temperature, permissible pressure drops, and fluid cleanliness.

Swing check valves operate by responding to line pressure: when flow occurs in the
normal direction, the disc swings open, moving away from the seat. As pressure
decreases and reaches zero, the disc closes, often held against the seat by its own
weight. In some instances, external counterweights connected to the swing shaft via
the valve body can also aid in closing the valve.

One drawback associated with swing check valves is the potential for the swing
mechanism to become blocked in the open position, often due to the accumulation of
dirt or corrosion. Consequently, swing check valves are typically utilized in scenarios
characterized by low fluid velocities and infrequent backflows, often in conjunction with
a gate valve. These valves are well-suited for applications involving minimal flow
services and occasional changes in flow direction.

An issue commonly encountered with swing check valves is water hammer, a

phenomenon that occurs when the valve closes abruptly, causing a surge of pressure
and high-velocity shock waves within the piping system. If left unaddressed, water
hammer can lead to the rupture of pumps, valves, and pipes, along with excessive
stress on the metal components and vibrations throughout the system.

The key components of a swing check valve include the body, disc, swing, and cap.
These valves come in two primary designs: straight and tee-shaped. In the straight
configuration, the disc hangs from above, enabling it to oscillate slightly when subjected
to low pressures.

The ball check valve operates similarly to swing check valves, but instead of a swinging
disc, it features a ball as the closing mechanism. The ball is free to move and rests on
the seating surface until it is lifted by the pressure of the fluid flowing in the desired
direction.

Ball check valves are typically employed in applications requiring small sizes and flows.
They serve to prevent backflow in systems where fluid movement needs to be strictly
regulated and controlled.

In industrial plants, numerous systems are responsible for measuring, recording,

transmitting, and ultimately controlling various processes within the plant. These
systems work in tandem to ensure that control valves receive the appropriate signals to
operate effectively and efficiently.

Control valves serve as vital components in facilities where precise control is required
across multiple systems. Through a throttling mechanism, these valves regulate
processes to align with desired variables. They come in various types tailored to specific
control needs, including flow control valves, pressure control valves, and temperature
control valves.

Control valves play a pivotal role in control systems and are typically specified by
specialists due to their critical function. For detailed insights and guidance on control
valves, referring to resources like the "Control Valve Handbook" by Fisher, an Emerson
Process Management manual, can be immensely beneficial.

A standard configuration of a control valve comprises the valve body, the control
mechanism, and the actuator responsible for valve operation. Additionally, a range of
ancillary equipment may be included, such as positioners, transducers, pressure
regulators, manual actuators, snubbers, limit switches, and more. These components
work together to ensure precise control and efficient operation within industrial
processes.

Wrap Up, valves are essential components within piping systems, serving critical
functions in regulating fluid flow, pressure, and direction. From gate valves to ball
valves, butterfly valves to check valves, each type offers unique features and benefits
suited to various applications and industries.

Valves play a crucial role in controlling processes within industrial plants, ensuring
efficient operations and safety. They are designed to withstand specific pressures,
temperatures, and fluid characteristics, making their selection and specification a
meticulous process.

Understanding the different types of valves, their mechanisms, and their operational
requirements is essential for engineers and technicians working in fluid handling
systems. Moreover, ongoing maintenance and monitoring of valves are necessary to
prevent malfunctions, leaks, and other operational issues.

In essence, valves are the gatekeepers of fluid flow, facilitating the smooth operation of
pipelines, machinery, and systems across a wide range of industries, from oil and gas to
water treatment, manufacturing, and beyond.