Welcome to the

Presentation on Valves

By : Suresh Dewangan
What is a valve and why it is
required ?
A valve is a mechanical device that
controls the flow of fluid and pressure
within a system or process.
Valve is required for following
applications –

Stopping and starting fluid flow

Varying (throttling) the amount of fluid flow

Controlling the direction of fluid flow

Regulating downstream system or process

pressure

Relieving component or piping over

pressure
BROAD CLASSIFICATION OF VALVES
Valves can be broadly classified in to the following
types based on the relative motion of the closing
elements with the direction of the fluid flow or
pressure.

 Closing elements(Stem & disc) moves in the same

axis in which the fluid flows. Ex.- Globe valves,
Safety valves etc.
 Closing elements moves in the perpendicular
direction in which the fluid flows. EX:- Gate valves,
 Rotate a disc or ellipse about a shaft extending
across the flow. EX:- butterfly or ball valve
 Move a flexible material into the flow passage.
Ex.:- Diaphragm
 (1) Gate Valve
A gate valve is a linear motion valve used to start or
stop fluid flow; however, it does not regulate or throttle
flow. The name gate is derived from the appearance of
the disk in the flow stream.
 (2) Globe Valve
A globe valve is a linear motion valve used to stop,
start, and regulate fluid flow.
 (3) Ball Valves
A ball valve is a rotational motion valve that uses a ball-
shaped disk to stop or start fluid flow.

When the valve handle is turned to open the valve, the

ball rotates to a point where the hole through the ball
is in line with the valve body inlet and outlet. When the
valve is shut, the ball is rotated so that the hole is
perpendicular to the flow openings of the valve body
and the flow is stopped.
 (4) Diaphragm Valves
A diaphragm valve is a linear motion valve that is used
to start, regulate and stop fluid flow. The name is
derived from its flexible disk, which mates with a seat
located in the open area at the top of the valve body to
form a seal.
Diaphragm valves are particularly suited for the
handling of corrosive fluids, fibrous slurries, radioactive
fluids, or other fluids that must remain free from
contamination.
 (5) Butterfly valve
A butterfly valve, illustrated in Figure is a rotary motion
valve that is used to stop, regulate, and start fluid flow.
Butterfly valves are easily and quickly operated
because a 90 Deg rotation of the handle moves the disk
from a fully closed to fully opened position.
 (6) Needle Valve
A needle valve, as shown in Figure is
used to make relatively fine adjustments
in the amount of fluid flow. The
distinguishing characteristic of a needle
valve is the long, tapered, needlelike
point on the end of the valve stem. This
"needle" acts as a disk. The longer part
of the needle is smaller than the orifice
in the valve seat and passes through the
orifice before the needle seats. This
arrangement permits a very gradual
increase or decrease in the size of the
opening. Needle valves are often used as
component parts of other, more
complicated valves. This valve most
commonly used where very precise flow
regulation is necessary.
 (7) Regulating Globe valve (Control Valves)

Regulating the quantity or pressure of the flowing

fluid---- Regulating Globe valve (RGLV).A special
profile on the disc is provided to regulate the flow in
linear characteristic.

This may be Pneumatic Type or Motorized type

Motorized Regulating Globe Valve
(8) Safety Valves

Prevent
excessive
pressure build
up in a pipe line
or vessel.
 Safety Valves
 pressure relief
valves
 (9) NRV/CHECK VALVES

Prevent backflow
of the fluid in to
downstream side
of equipments,
which might get
damaged due to
back flow.
 Lift Check Valves
 swing check
valves or flap
valves
Gate ,Globe & Non Return
Valves
Construction of Gate Valves
Construction of Globe valve
 COMPARISION BETWEEN GLOBE AND GATE VALVE

GLOBE VALVE GATE VALVE

Full flow around the The wedge has to
periphery of the globe completely travel
valve is obtained by a across the bore of the
lift of ‘ d/4’ where ‘d’ is valve and the lift is
the nominal bore of the about 4 times that of
valve. globe valve.
Less head room More head room
required required(4 times)
Less time required to More time required to
open the valve. open the valve.
More turbulence and The flow is straight
pressure drop due to without turbulence
GLOBE VALVE GATE VALVE
Valve weighs less Valve weighs more.
Globe valve has only The manufacture and
one pair of seats to be maintenance of a gate
matched and the body valve is more difficult
seat is easily than since the two
accessible for lapping tapered seats in the
in situ. wedge have to
perfectly match with
that of the seats in the
body.

Possible to control the Intermediate opening

flow in intermediate will cause erosion and
opening with a special fluttering due to swirl
profile on the disc. occurred at the back of
Globe valve has only one The manufacture and
pair of seats to be matched maintenance of a gate valve
and the body seat is easily is more difficult than since
accessible for lapping in the two tapered seats in
situ. the wedge have to perfectly
match with that of the seats
in the body.

Globe valve the disc has to Gate valve,the gate/wedge

function against the full cuts across the medium and
medium pressure and hence hence only partial load is
the steam load is quite high. transmitted to the stem.

More effort required to Effort required to operate

operate the globe valve.Due the gate valve is less
to this reason the the sizes
of the globe valves are
normally limited to 200mm
and for higher sizes only
gate valves are used.
 Use of Globe valve
Globe valves are used where frequent on –off
service is required.
Throttling purpose
Generally confined to applications where the
valve is normally closed and pressure drop is
not important, When the valve is open.
 Seating Method of Globe Valve

41O
PLUG
Valve 40 0
seat

SEATING AREA(Line contact

only)

The contact face of a plug/disc and valve

seat are at different angles.
 Seating Method of Gate Valve

SEALING METHOD FOR SEALING METHOD FOR

HO VALVES(LP) MOTORISED WEDGE VALVE
 Types of wedges for Gate Valves
Solid Wedge
This is the most common wedge
type.It is also the
strongest,simplest and highly
resistant to vibration.It is not self
compensating to seat distortion
caused by high temp. thermal
expansion or bending moments.
 Flex wedge
The flex wedge is machined with
a circumferential groove to allow
the seating faces to move
independently and adjust to
movement of the body seats.It is
used where line loads or thermal
expansion of the system is likely
to distort the seat face in the
valve.This type of wedge is ideally
suitable for steam or high temp.
application.
 NON RETURN VALVE

(1) SWING CHECK VALVE:

Swing Check valve allows the flow in a
definite direction and prevents it from
flowing backward. The valve closes
automatically by the fluid back
pressure. The valve will be closed by
the moment of disc weight when fluid is
not flowing. The valve shall be installed
on horizontal piping only. SCVs have
low pressure drop and are suitable for
moderate velocity applications.
(2) LIFT CHECK VALVE
A lift check valve is commonly used in piping
systems in which globe valves are being used as
a flow control valve. They have similar seating
arrangements as globe valves.
Lift check valves are suitable for installation in
horizontal or vertical lines with upward flow.
They are recommended for use with steam, air,
gas, water, and on vapor lines with high flow
velocities
 END CONNECTION TO THE PIPE FOR
VALVES

 Flanged joints:
Used in low pressure and medium pressure
lines up to 40 bar.
 Screwed Joints:
Low pressure lines up to 10 Bar
 Socket Welded joints :
These are used for medium and high pressure
lines and recommended for sizes up to 50mm.
 Butt Welded Joints:
Reliable and leak proof joints and used in high
pressure lines. Very careful attention required
for preparation of edges and during welding.
 Selection of materials for
Valve
Based on the actual working pressure and
temperature, the material of the valve and the
basic rating for the valve is selected from the
charts available in the standards.
 Carbon steel valves(ASTM A105) --------
Max. temp. of medium 425 0C
 High alloy steel valves(ASTM A 182 F22)-------
Max. temp. of medium 5500C
 High alloy steel valves(ASTM A 182 F91)-------
Max. temp. of medium 6000C
 SS valve for corrosive media ------ ----
Max. temp. of medium 600 0C
 CODES & STANDARDS APPLICABLE TO VALVES
 The pressure and temperature ratings have
been standardized as per the American
National Standard Institute(ANSI)
standard(ANSI B16.34).
 In German standards(DIN), the rating is
indicated by the nominal pressure of the
valve.The nominal pressure is defined as the
maximum pressure at 20 oC for which the
valve is designed. The pressure and temp.
charts given in the standard indicate the
permissible working pressure at various
temperatures to which a valve of a specific
nominal pressure can be used.
 Contd.
 In the American system, the ratings are
indicated as class
150,300,800,1500,2500,3000 etc. The
permissible working pressures for these
ratings at different temperatures are
given in the ANSI standard B16.34.
 Generally valves used in high pressure
lines satisfies all the requirements of
various international codes like
ASME/API/ANSI/IBR.
 4250C

370C 20kg/cm2 -52 -69 -104 -156 -260 -433

- 780

4500C -4.5 -18.6 -24.5 -37.6 -56.6 -94 -156

- 281

5370C -1.4 -3.5 -4.92 -7.38 -10.89 -18.27 -30.23

- 54
370C -440
KSC

5930C - 176 KSC

 Valve Body material Selection
The valve bodies are normally forged in small
sizes up to 2” and cast more than 2” sizes.
Body material specification for cast steel valves
:-
o ASTM A216 GR. WCB
o ASTM A216 GR.WCC
o ASTM A217 GR.WC6
o ASTMA217 GR.WC9
o ASTM A217 C12A
Body Material specification for forged steel
valves
 ASTM A105- FCS (FORGED CARBON STEEL).
 ASTM A182 F11,ASTM A182 F22 -FAS (FORGED
ALLOY STEEL),
 Valve Seating & Stem Material
Selection

** Stellite alloy is a range of Cobalt-Chromium alloy designed for wear resistance. It may also contain tungsten or Mo and a small
but important amount of carbon.

** 17-4 PH® is a martensitic precipitation-hardening stainless steel that provides an outstanding combination of high strength, good
corrosion resistance
Valve Material Selection for
Body
Materials of Construction for Gate Valves
Materials of Construction for Globe valves
 IBR FOR VALVE DESIGN
IBR lays down certain regulations regarding
the raw material, design and testing of
valves in order to ensure safety of the
Equipments and operating personnel.
 IBR stipulates certain minimum strength
requirements of various materials that is
used in manufacturing of the components.
 A list of recognized steel makers from whom
the steels shall be used for the construction
of valve.
 Chemical composition and mechanical tests
shall be conducted at the steel makers’
works and the boiler inspector or their
authorized representative witness the tests
and issue material test certificate.
 CONTD.

 The calculation for body chest

thickness,bypass tube wall thickness shall
be approved.
 The valves shall be hydro tested for
strength and seating as per IBR.
 The Boiler Inspector witnesses the test and
issues test certificate also stamps the
valves.
 The certificate shall be sent to the users of
the valve and local boiler inspector approve
the use of the valve only if the seal and the
test certificate are available
 Important things about Valves

In small size valves the yoke and bonnet are

forged or cast as a single piece.In large size
valves for convenience during
manufacturing in foundry, forge shop and
machine shop, the bonnet and yoke are
made as separate pieces.Yoke is mounted
on the bonnet by means of bolts.
The disc or wedge seats, the body seat and
the stem are normally termed as the ‘trim’
of the valve.
The disc/wedge seat and the body seat are
lapped to a fine finish, so that when the
valve is closed a perfect seal is formed
between the seats and the flow of fluid is
completely arrested.
GLAND PACKINGS
 The gland packings have to provide seal
around the stem with minimum friction
resistance to movement of the stem.
 The packings are made of braided
asbestos/graphite with stainless steel or
inconel wire reinforcement and contain solid
lubricants like graphite powder. For corrosive
chemicals, fuel oil lines etc. Teflon packings
are used.
 When the valve installed in a line is operated
for some time, it is likely that the organic
compound contained in the packing rings
gets burnt and reduced in quantity due to
high temp. and pressure.So, leak starts.This
can be prevented by further tightening as
 Contd.
 If the top two rings are renewed, the sealing
effect will be greater.
 Replacing packing rings during operation is
very dangerous.
 BACK SEAT
 Back seats are provided to enable repacking of
glands when the valve is in service. The back seat
is provided bush of yoke with a mating seat on the
stem. When the valve is fully open, the
engagement of backseat enables additional
packings to be inserted without isolating the line.
 Function of Bypass valve
By pass valves are
additionally
provided to the
main valve in high
temp. service to
warm up the
downstream line
before opening the
main valve.
Function of Body Pressure Relief Valve
 Motor Actuated valves

Operation of valves requires use of

electric actuators where the valve is
 Too large or has too high differential
shutoff pressure for manual operation.
 Is not accessible for manual operation.
 Is part of a system requiring
simultaneous operation of many valves.
 Must be triggered from a remote
location,as is often essential for
emergency shutoff.
 Require to be operated quickly.
 Require opening/ closing very frequently.
 BEST OPERATION & MAINTENANCE PRACTICES OF VALVES

 Avoid control of flow under partial opening

except flow control valves(RGLV).
 Use the valves in full open or close condition.

MASTER SLAVE
(Inlet Valve) (Outlet
Valve)

 Two globe valves are used in series(drain, vent

lines etc.).The outlet valve(Slave) is only
opened after inlet valve(Master) is opened.For
closing the inlet valve is closed only after the
outlet valve is closed.
 Tighten the gland packing nuts evenly so
that uniform loading is applied throughout
the packing areas.
 Wedge gate valve shall not be over
tightened. This may causes locking of the
disc in between the two valve body seats.
 Ensure the setting of the motorized valves
with required torque. Excess setting may
damage the valve while lower setting may
cause leakage and seat damage.
 Close/open the manual operated valve by
‘F’ handle instead of hammering. “F’
handle should be used in start and end
hand operation, to make handle free &
tight.
 When it is required to open the valve in full
open position engagement of back seat
ensures that the gland packings are not
constantly subjected to the line pressure and
thus the life of packing increased.
 Valve is operated by rotating the hand wheel
in clockwise direction to close and counter
clockwise to open.
 Replace the sealing gaskets and packings
during overhauling of the valve.
 Contd.
 All valve shall be installed in horizontal lines
with stem or spindle in vertical position for
easy disassembly/ assembly and lapping.
 Straight pipe length at inlet/outlet of the
regulating valves:
 Inlet of valve: 12 to 20 times of pipe OD.
 Outlet of valve: 6 to 10 times of pipe OD.
 Contd.
The gland packings are to be
procured only from reputed agencies
Pure graphite packings are used in
intermediate position and metallic
reinforced packings are used at top
and bottom position for better sealing.
Skilled persons should be employed
for valve servicing.
 Contd.

Hot tightening of valve glands shall

be done just after unit start up.
Any drop wise leakage observed in
daily inspection shall be attended
immediately.
 ON LINE LEAK SEALING

Benefits of on line leak sealing

 Prevention of unit shutdown
 Reduce Noise pollution
THANKS FOR PATIENCE HEARING