VALVES

VALVE DEFINITION
VALVES ARE MECHANICAL DEVICES
SPECIFICALLY DESIGNED TO:
•DIRECT
•START FLOW, PRESSURE OR
•STOP TEMPERATURE OF A
PROCESS FLUID
•MIX
•REGULATE
• Valves can be designed to handle either
LIQUID or GAS applications.
• Industrial Valves : Size 0.5” Nominal Dia
(DN15) to 48” (DN1200).
• 90% of Valves are 4” (DN100) or smaller in
size.
 SERVICE
Vacuum to over 13,000 psi (897 bar)

MATERIALS OF CONSTRUCTION
Iron, Steel, Plastic, Brass, Bronze (or) a
number of special Alloys
 HISTORY
• In 1712, Englishman Thomas Newcomen invented
a simple Iron Plug Valve, to regulate the flow of
steam to the piston – The first known application
of a Throttling valve.
• Corliss Steam Engine unveiled in 1876 was
designed with Self-acting Control Valves.
• Invention of Crude oil as an inexpensive and
plentiful form of power in early 19th century
spawned the creation of Petroleum Refinery,
Petrochemicals, Process Industries, Paper, Food,
Beverage Industries creating need for various
types of valves.
 VALVE CLASSIFICATION
a) Function classifications:
• ON-OFF (Block valves) – Block or allow
flow
• Non-return (Check valves) – Allow flow to
travel in one direction
• Throttling (Full open to full close) –
Regulation of flow (Can be used as ON-OFF
also)
b) Application Classification:
• General Service valves (Manual or
Automated) – -46oC to 343oC, Class 150 to
600, Non-corrosive applications.
• Special service – Custom engineered – High
pressure, high temperature, corrosive/erosive
medium.
• Severe service – Valves with special features
to handle volatile applications, very high
pressure drops, severe cavitation, flashing,
choking, beyond 593oC, liquid Sodium
applications.
c) According to motion:
• Linear motion – sliding stem design.
• Rotary motion – through quarter turn or 45o
range to open or block the flow.

d) According to Port size:

• Full port valves
• Reduced port valves
 Other types of Valves
• Block & Bleed valves – To prevent
intermixing of fluids (Fin Fan cooler, wash
water systems)
• Butterfly valves – Water applications
(AWWA standards)
• Blow-off valves – Steam systems
 TERMS AND DEFINITIONS
• ANSI rating class – Numerical pressure design
class defined in ASME B 16.5 and used for
reference purposes.
• ANSI rating class is designated by the word
‘CLASS’ followed by a number. Ex: Class 150.
• Bi-directional valve – Valve designed for blocking
the fluid in both downstream and upstream
direction.
• Bleed – drain or vent.
• Block valve – Gate, Plug or Ball valve that blocks
flow to downstream when in closed position
• Locking device – Part or an arrangement of parts
for securing a valve in the open and (or) closed
position.
• NPS – Nominal pipe size.
• PN – Numerical pressure design class as defined
in ISO-7005-1. (PN followed by a number). Ex:
PN16.
• Pressure containing parts – Parts such as body,
bonnet, gland, stem, gasket, bolting designed to
contain pipeline fluid.
• Process wetted parts – Parts exposed directly to
pipeline fluid.
 ABBREVIATIONS
BM Base Metal
Carbon Equivalent =
{%C+(%Mn/6)+(%Cr+%Mo+%V)/5+(%Ni+
CE
%Cu)/15}
Limit: 0.43 – Heat analysis, 0.45 – Product.
DBB Double Block and Bleed
DN Nominal Size
HAZ Heat Affected Zone
HR Rockwell Hardness
HV Vickers Hardness
MPD Maximum Pressure Differential
MT Magnetic Particle Testing
NDE Non-Destructive Examination
NPS Nominal Pipe Size
NP Nominal Pressure
WPS Welding Procedure Specification
PQR Procedure Qualification Record
WQR Welder Qualification Record
WM Weld Metal
PT Penetrant Testing
PWHT Post Weld Heat Treatment
 ANSI PRESSURE CLASS
POUNDS OF FORCE NOMINAL PRESSURE
PER SQUARE INCH – ALLOWABLE
OF SURFACE AREA PRESSURE IN BAR
150 16
300 40
600 100
900 160
1500 250
2500 400
4500 700
 VALVE SELECTION
• Valve co-efficient or Flow co-efficient
Cv = Flow X m sqrt Sp. Gravity at flowing
temperature / pressure drop

Cv = One US gallon (3.78 litres) of 60oF (16oC) water

that flows through an opening (valve) during 1
minute with a 1 psi (0.1 bar) pressure drop
 END CONNECTIONS
• Threaded (1.5” and smaller sizes) (NPT)
• Flanged End (2” and larger) – Integral,
separable
• Welded End (Class 900 and higher) –
Socket welded (2” and smaller), Butt
welded (3” and higher)
 PRESSURE CLASSES
• Six standard classes – 150, 300, 600, 900,
1500 or 2500 – As per B 16.34 standard
• Special classes – 15, 4500 Etc.
• Intermediate classes – Ex. 3300 (CS valve
for 150oC, 450 bar)
 Casting Quality Factors
• ASME Codes / B 16.34
Especially for corrosive, high pressure, high
temperature applications
• Level – 1
• Level – 2
• Level – 3
• Level indicates severity levels of
imperfections
 Casting imperfections include
• A – Gas porosity
• B – Sand, slag inclusions
• C – Shrinkage
• D – Cracks
• E – Hot tears
• F – Inserts
• G – Mottling
 Examination of Steel castings
are done as per

• ASME Sec:VIII Div:1 Mandatory Appendix:7

• ANSI B 16.5
• ANSI B 16.34
Radiographic examination standards
Thickness Standard
ASTM E 446
Up to 2” (51 mm)
(Std Reference Radiographs)
ASTM E 186
2” – 4.5” (51-114 mm)
(Std Reference Radiographs)
4.5” – 12” (114mm- ASTM E 280
305mm) (Std Reference Radiographs)
ASTM E 280 / UT exam is
Above 12”
done
As per sketch in B 16.34
RT spots
standards
 VALVE MANUFACTURING
• Valve design
• Pattern development
• Establish methoding process with Statistical
Quality Control
• Pilot casting
• Tests / Acceptance standards
• Fix quality factors
• Machining of castings
• Bought out items (other items like stem,
gasket, packing, fasteners, hand wheel, disc,
yoke, seat ring)
• Assembly
• Testing
• Marking / Punching
• Despatch
• VTR / Release note of TPI
• Spares, valve key Etc.
 MATERIAL
• Carbon Steel – up to 425oC
• Chrome-Moly Steel – Corrosive, H2S
environment
• SS - >535oC, high temperature, corrosive
applications
• A216 WCB (CS), A217 C5 (AS), A351
CF8M, CF3M (SS)
 TRIM MATERIAL
API 600 Body seat Back seat
Service Stem Wedge
Trim No. ring bush

Body
Body
MP / LP SS 410 MOC + SS 410
8 MOC +
Steam RC22 max 13% Cr RC22 max
HF
RC22 max
Body
Body
Corrosive MOC + SS SS 316
12 SS 316 MOC +
service 316 RC22 RC22 max
HF
max

5 HP Steam Both body seat / wedge is Stellited.

 MATERIAL TESTING
• Chemical composition – basic, alloying
elements
• Mechanical properties – UTS, YS, %
elongation, hardness Etc.
• Special properties – Impact, high corrosion
resistant properties Etc.
Various Heat Treatment processes
conducted in valve manufacturing

• Normalizing
• Hardening
• Annealing
• Tempering
• Solution Annealing
 EXAMINATIONS
• Visual
• Liquid Penetrant
• Magnetic particle examination
• Radiography
• Ultrasonic examination
 TEST PROCEDURE – API 600
• Gate valve : Shell
Backseat
Air seat
Hydro seat
• Globe valve : Shell
Backseat
Air seat
Hydro seat
• Check valve : Shell
High pressure closure test
Low pressure closure test
Low pressure air seat test (optional)
 REPAIR
• Weld repairs should be approved by TPI /
Client
• WPS / PQR / Welder qualifications – check
• NDT
• Post weld heat treatment
• Tests as above
 Gasket Selection

• Purpose : Prevent leakage from joint

Prevent leakage to atmosphere
Allow function of internal mechanism
• Material / : CAF, Spiral Wound, Ring Joint type
types
 PACKING
Any soft material encased in a bonnet or in a
body used to seal a valve closure elements
stem or shaft is called packing. It is held by
a packing follower or guides.

Ex: Graffoil, Impregnated Graffoil Etc.

 CLOSING ELEMENTS
• GATE
• GLOBE
• BALL
• PLUG
• BUTTERFLY Etc.

TYPES OF OPERATION
• MANUAL
• GEAR OPERATED
• ACTUATOR OPERATED
COMMON VALVE PROBLEMS
• High pressure drop – Result in cavitation,
flashing, choked flow, high noise levels,
vibrations.
• Water hammer effects – Due to sudden
stoppage of flow, shock waves are generated,
avoid sudden pressure surges.
• Erosion, Corrosion
• Defects, leaks (Gland leaks)
• Operational issues – closing, opening Etc.
 ACCREDITATIONS
• API – Monogram
API – 6D for Gate, Plug, Ball, Check valves
• ISO – 9001
• ISO – 14000
• IBR / EIL, TDC, TPI approvals
 Purchasing Issues
• Valve data sheet
• Drawing
• Specifications
• QAP
• Stage / Final inspections
• Storage, Installation
• Spares
• Warranty, Guarantee issues
• Vendor surveys for enlistment
 INSTALLATION
• For best performance, it is recommended that
Gate, Globe valves are installed in vertical
position with the stem operating end at the top,
horizontal or at an angle in between.
• Swing check valves can be installed in vertical
or horizontal pipelines. However, in vertical
pipelines the flow should always be in the
upward direction.
• Swing check valves should never be installed at
the outlet of a Reciprocating pump – as the
pulsating flow will damage internals of the
valve.
• Gate valves have bi-directional capabilities and
can be installed in any direction.
• Globe valves to be installed in the direction of
arrow.
• Check valves are unidirectional. Flow
direction and arrow direction should coincide.
 OPERATION
• GATE VALVES : Should be fully open or fully
closed. Throttling will cause wire drawing at
seating area leading to damage, leak. Clockwise:
close, anticlockwise: open.
• GLOBE VALVES : Used for throttling. It is
advisable not to use Globe valves for flow control
below 10% of full opening. Clockwise: close,
anticlockwise: open.
• CHECK VALVES : All are swing type which
automatically open by the velocity pressure of
flow and close by the gravitational force when
flow reverses or stops.
 Maintenance Issues
• Periodical cleaning, flushing, greasing
• Check gear box, actuator mechanisms
• Installation issues
• Online leak arresting (clamps, cold repairs
Etc.)
 PARTS
• Disc and Seat that directly affect the flow
• Stem that moves the Disc
• Body and Bonnet that house the Stem /
internal parts
• Operator that moves the Stem
DESIGN / TESTING CODES

VALVE DESIGN TESTING

API 600, BS 1414,

GATE
DIN 3202 API 598,
ANSI B 16.34,
GLOBE BS 5352 BS 6755,
BS 5352 (Forged) / DIN 3230
CHECK
BS 1868 (Cast)
Other relevant Standards include:
• API 6D – Petroleum & Natural Gas
Industries – Pipeline Transportation Systems
– Pipeline Valves
• ASME B 16.5 – Pipe flanges and flanged
fittings (1/2” to 24”)
• ASME B 16.10 – Face to face and end to
end dimensions of valves
• ASME B 16.25 – Butt welded ends
• ASME B 16.34 – Flanged, threaded and
welding ends.
• ASME B 16.47 – Large Dia steel flanges
(26” to 60”)
• NACE TM 0284 – HIC testing
• NACE MR0175 – Sulfide Stress Cracking
resistant metallic materials for oil field
equipment
• API 6 FD / API 607 – Fire safe testing of
valves
 PRESERVATION
• End caps
• Water ingress
• Check prior to installation
 Special Applications
• NACE – MR0175
• IBR – FORM - III C
• AWWA Stds. – Water applications
• Custom designed – PAREX rotary valves
• Cryogenic applications – very low
temperatures : N2, LPG (-180oC)
 TRACEABILITY
• Manufacturer Name Plate
• Heat No. / Lot No. / Sl. No.
• Size / Rating
• W.O. No.
• VTR / Release Note of TPI
 Famous / Approved
Manufacturers
• AUDCO
• KSB
• FOURESS
• SANMAR
 COST ASPECTS
• Size, Rating
• Additional Features (Gear, Actuator)
• Special Requirements (NACE, RT Quality)
• Location of Supplier vs. User
• Mandatory Requirements
 QUESTIONS / VALIDATION:
• What is a Valve?
• What is the purpose of a Valve?
• What are types of Valves?
• What are the Design/Testing standards?
• What NDT are done in manufacturing stage?
• What is AWWA Std? Where is it applicable?
• What is Cv?
• What are Appurtenances for valves? Name any 03.
• What are different types of ends of valves?
• What are NACE application Standards?
• What is an IBR valve? What is the Form No.?
THANK YOU