Basic Valves

Kingdom of Saudi Arabia Saline Water Conversion Corporation
General Directorate Of Training Programs Training Center JUBAIL
MAINTENANCE DEPARTMENT
MAINTENANCE ENGINEERS SPECIFIC COURSE MECHANICAL MAINTENANCE COURSE
VALVES & VALVE MAINTENANCE
"
Course Code: VALVE & VALVE MAINTENANCE Version 1.0 Prepared by: Date:
Valve & valve maintenance
VALVES
LESSON
1
LECTURE
Objectives
VALVES
At the end of this lesson, the trainee will be able to demonstrate an understanding of Valves. 1 INTRODUCTION Valves are extensively used in piping systems and on equipment to which piping is connected. Some valves are used continuously, others intermittently, and some, like safety values, are utilized only in rare instances.
1.1
FUNCTION OF VALVES
Function of Valves is to start, stop or regulate a flow of liquid or gas through a plant system. This is accomplished by maintaining the valve in a partially open position or an open or closed liquid or gases flow from areas of higher pressure to areas of lower pressure because there control of flow is of high importance. Mechanical devices that are used in industrial piping for flow control are called valves. The term Valves includes all equipment that acts on the movement of fluid by one of the following two functions:
1. 2.
Opening or closing a circuit. Controlling of flow.
The fluid may be liquid, gas or a loose solid such as powder, sand of slurry. When a valve allows some flow, but not maximum flow it is said to be in the THROTTLING position to Throttle with a valve is to regulate the (Rate or direction) flow.
Lesson 1
Page 1
VALVES
1.2
VALVE CLASSIFICATION AND TYPES
Valves can be classified by function, by disc arrangement, by operating condition such as temperature and pressure, or by the way they are incorporated into plant systems. The most common way to classify a valve is by the arrangement or shape of the disc, which is part of the valve that controls the flow of fluid through the valve. Gate, plug, ball, or butterfly valves are most widely used for the interruption or start of flow. Diaphragm valves may be preferred in corrosive applications or in service where contamination of the fluid is not permissible, such as in the drug and beverage industry. REGULATION OF FLOW. Many applications require that the flow of the fluid or gas be regulated (or throttled) in various steps between closed and open limits. This is generally done by introducing resistance to flow either by a change in direction, or by causing a restriction, or by combinations of these. Commonly used valves designs are of the globe, angle, needle, and butterfly types.
Fig. 1-1. Families of Valves. A common method of classification is the method by which they actually control flow Fig. 1-1 illustrates these methods together with some examples of valves in each family.
Lesson 1
Page 2
VALVES
1.3 a.
CONSTRUCTION Fig. 1-2 shows the basic construction of a common valve type, namely a stop valve, and shows the principle of operation. Fluid flows into the valve through Inlet Port through the passages in the valve body past the element that controls the flow, and then flows out via the Out let or Discharge port
b.
Fig. 1-2. How a valve operates. c. If the closing element (named a disc) in the close position the passage way is blocked and no fluid can flow until it is opened again. This is done, as in the case of Fig. 1-2.
1.4
MATERIALS
Valves are subjected to the effects of heat, pressure and corrosion, so it is important that they are made from appropriate materials. That can be made from :
Bronze Cast iron Steel Stainless steel Monel Brass and other metals as well as from plastic and glass. Valves are usually made to the some standards and specifications of the pipe work I the system. They also come in a large variety of sizes. Manufacturing method relates closely to body design. Casting is well suited to complicated shapes and can give well formed fluid paths. Forging requires heavy tooling costs or considerable boring and machining to create internal passages. Welding allows buildup of the body from simple tubular and plate forms, reinforced as necessary.
Lesson 1
Page 3
VALVES
Casting is simple and cheap in many metals, such as irons and bronzes. Steel and steel alloys are more difficult. Flaws in castings may require heavy rework in demanding nuclear services. Forging, for steel and alloys, gives a body with uniformity through the metal and with good surface. Machining may create stress problems, of course. Fabrication by welding may begin with plates, rings, forging, or even castings. Stiffeners may be added as needed. Interior surface is usually smooth, but the flow passages may not be as streamlined as they are in cast bodies. Welded joints need attention to assure quality and corrosion resistance. In some designs the body itself is split into two sections that bolt together. This is common in ball and butterfly valves, and also in some control valves requiring periodic disassembly for inspection and cleaning. The bonnet complicates manufacturer, increases valve size, and introduces another potential leakage path to the outside. Fluid-control elements inside the valve include the seat, the disc, plug, or ball the stem or spindle, and any sleeves needed to guide the stem and disc. These elements are also called the trim. The disc/seat interface and the relation of disc position to seat determine valve performance to a large extent. Two basic motions are possible. Either the disc (ball or plug) can side closely past the seat to produce a change in flow opening, or else the disc can lift perpendicularly away from the seat, so that an annular orifice appears. Sliding past the seat characterizes ball, plug, and gate valves. Perpendicular movement away from the seat occurs in globe valves, check valves, and safety valves. Combination of the two basic motions is possible, too. A symmetric butterfly valves disc slides past the seat ring, but the opening quickly extends nearly all the way around the seat opening. Disc and seat interaction is a vital factor in valve tightness and actuation force. Wear from erosion or Cavitations may destroy disc and seat surfaces in a single opening of a valve on high pressure-drop or slurry service. Sliding of disc past seat under high fluid pressure or heavy interference fit can injure the sealing surfaces enough to develop leaks. Particles embedded or caught between the surfaces also scar the sealing area. On the other hand, in designs where the disc lifts off the seat, the very narrow annular orifice when the disc is close to the seat allows highspeed fluid flow with danger of erosion and Cavitation. The taper-plug
Lesson 1
Page 4
VALVES
type disc is one remedy for this, and many control valves reflect the results of especial attention to the problem. There are many aspects of valve technology and application that call for in-depth study by the manufacturer and the user. Fire safety for valves with soft Elastomer seats is an example of this. Need for many valves to fail safe, meaning that a loss of actuating force will bring into play a system for valve opening, closing, or holding in last position, is another important area. Demanding special services have involved into almost separate branches of the valve field. Nuclear valves, with radiation exposure and low-leakage requirements, are an example. Maintainability in this service is especially important if worker exposure to radiation is to be within bounds. High pressure drops through valves and noise originating in such drops are added examples of problems calling for research and experiment. At far lower pressures, but with liquids carrying heavy particle loads, there is the slurry valve problem crucial to flue-gas desulfurization, coal firing, and ash and waste disposal. In valve design work, considerable advances have been made with the help of finite-element analysis. Made possible for practical applications by the computer and pioneered in nuclear-valve design this analysis procedure has often superseded trial and error and enlightened hunches in determining stresses and deflections of irregular shapes of valve bodies and trim elements. The disc of butterfly valves and the components of pressure seals are two examples of success in reducing unnecessary metal but assuring adequate margins for strength and, above, all, stiffness for leak prevention. Service conditions and material choice are closely interconnected. Temperature is perhaps the most influential condition in power plants valve work. Pressure effects are easier to handle, requiring only moderate changes in a wall thicknesses that usually exceed by far the values needed for pressure retention alone. The way in which flow rate through the valve changes as the disc approaches the seat is another principal element of valve section. A control system can depend on the valve flow characteristic, as the curve is called. A glance at the instrument valve characteristic immediately tells the systems designer that the valve flow decreases quickly during closing from a partly open setting, which could be an important consideration in case of an emergency with an instrument or a control line. Bi-directionality of a valve is a large consideration with several types and specific models of valve. This concept involves flow characteristics, actuator sizing, trim life, and even safety. Obviously, it is to the
Lesson 1
Page 5
VALVES
advantage of cost and maintenance effort if a valve has exactly the same behavior, whichever the direction of flow. Reparability and maintainability are factors in valve section. The cost of removal of a large weld-end valve, either to be replaced or repaired in the shop, is so high that in-line repair is attractive. Leakage through the seat may call for grinding or lapping of the seat and disc or for replacement of seat ring and disc. In both cases, special tools may be needed, and the repair may demand the services of outside specialists.
1.5 1.
Fig. 1-3. Valve Components. VALVE COMPONENTS : Valve body : is the largest structural part of the valve. It provides the means for attaching the valve to the system components or piping. System flow passes through the body of the valve. The design of the valve body can allow for (1) Straight-through
Lesson 1
Page 6
VALVES
Fig. 1-4. Straight - Through Flow. 2.
Fig. 1-5. Angled Globe Valve.
Seating Area: is located inside of the valve body. This is the area where the disc closes on the valve body seat. The disc and seat must be smooth, and must fit together perfectly.
The seat can be : 1. 2. 3. 4. threaded Press-fit Welded into the body Cost as part of the valve body. See Fig. 1-6.
In high temperature, high pressure system, a combination of threading and welding is used to prevent leakage between the valve body and the seat. Materials used for seat construction: * For low-pressure low temperature system valve seat may be made of bronze or Teflon type material.
Lesson 1
Page 7
VALVES
Fig. 1-6. Threaded and Welded Seat Attachment
For high pressure & temperature the seat area must be very strong same as stellite. 3. Disc is the part of the valve that close against the seat to stop flow the could be-disc arrangement is designed for special proposals. Its used to equalize the pressure difference across the disc. Stem is connects the disc to the hand wheel. The stem transmits the motion of the hand wheel to the internal disc open & close the valve ways
4.
disc attached to the stem: * * * 5. In slip-type joint Threading is another method Stem & Disc manufactured as one piece
Bonnet: is attached to the valve body by bolting, threading, or welding. The shape of the bonnet is determined by the type and shape of the disc, since it provides housing for the disc when its raised up from the valve seat. Stuffing box: is filled with a packing to prevent leakage. A packing gland: Is to hold and compressed the packing in place to prevent leakage by the stem and through the bonnet. Hand wheel or Operator: is control the movement of the disc inside the valve. A hand wheel is generally turned manually, while an operator is controlled by an electric, pneumatic, or hydraulic motor. Bridge wall markings: is provide useful information indicates how the internal parts of the valve are arranged, will show the direction of flow. Service markings: indicates the maximum allowable pressure service the letters W, O, or G on the valve body indicate the type of service the valve is designed for. The smaller the valve, the finer the control. Reparability and Maintainability are factors
6. 7.
8.
9.
10.
* * selection. *
in
valve
The component that make up all valves are essentially the same.
Lesson 1
Page 8
VALVES
1.6
VALVES APPLICATIONS :
Lesson 1
Page 9
VALVES
Lesson 1
Page 10
VALVES
Lesson 1
Page 11
Valves & Valve Maintenance
Gate Valves
LESSON
2
LECTURE
Objectives
GATE VALVES
At the end of this lesson, the trainee will be able to demonstrate an understanding of Gate Valves. 1 INTRODUCTION Gate valve the disc arrangement is not designed to control the rate of flow. Its used for isolation or for on or off unable to throttle. Normally, gate valves are placed where straight free flow is desired and where an immediate shut off of flow may be necessary. Often described simply as a GATE, this type of valve has a gate that goes up and down in the body, integral with a stem ending in screw thread on which the hand wheel is screwed. The hand wheel rotates freely at fixed height, so that its rotation causes vertical movement of the stem or the gate depend on the stem type. The gate valve is used exclusively on lines for liquid. In a gate valve, the disc is wedge-shaped with mating surfaces on two sides. These mating surfaces close against the seats to stop the flow of fluid. Bodies of gate valves, whether small or large, can take the form of two intersecting cylinders, with one for the fluid flow and the other to house the raised disc. Fig. 2-1. Illustrates this. Bonnet closures can be simple, for small low pressure valves, or they can be as advanced as the pressure-seal type.
Lesson 2
Page 1
Gate Valves
Fig. 2-1. Gate Valve 2 GATE VALVE CONSTRUCTION The exterior construction of most gate valves is similar. The body houses the fluid, and the bonnet acts as a lid for the body. The operator (a hand wheel, for example) opens and closes the valve. The interior construction of gate valves varies, depending on the type of valve and the manufacturing design. Fig. 2-1 shows a typical example of a gate valve.
STEM BUSHING
BODY FLANGED ENDS GASKET BONNET YOKE STEM HAND WHEEL
GATE SEAT RINGS
Many valves are equipped with a neck bushing, or stem bushing, to act as guide for the stem and to form the bottom of the stuffing box. The threaded end of the stem, screws through the stem, bushing, the hand wheel and the stem bushing are solidly connected, thus raising or lowering the stem when the hand wheel is turned. Main part of the valve directly attached to the pipe. Part of the body with bolt holes to allow the connection with the flanges set on the pipes. Inserted between pipe and valve to have a tight, leak proof connection. Part of the valve mounted on the top of the body to form a tight enclosure. Part of the valve to support the hand wheel and bushing. Solidly connected to the gate, the rotation of the stem raise or lowers the gate. The operator is used to control the stem, which moves the disc up and down to control the flow of fluid through the valve. Is the part of the valve that controls the opening. When the gate is lowered, the seat rings fit with the gate to
Lesson 2
Page 2
Gate Valves
stop all flow. STUFFING BOX Every valve with a stem has (STUFFING BOX) to ensure the sealing between the fluid and the atmosphere. Special material (made of asbestos, grease, neoprene each manufacturer specifies a given type and size of packing for each stuffing box) used to fill the stuffing box. After the packing is installed the gland compresses the packing, the gland also serves as the stuffing box covers. Packing is installed in the stuffing box to control the flow of fluid along the stem. The packing is held in place and compressed by the gland follower. In order to permit re-packing under pressure, some valves are equipped with a back seat. The back seat is a tapered restriction which mates with a widened section on the stem to stop the flow of fluid along the stem. The bonnet gasket is provided to eliminate leakage between the bonnet and body. The yoke acts as a support for the stem, and has a stem nut that raises and lowers the stem.
PACKING
GLAND
BACKSEAT
BONNET GASKET
NON RISING-and RISING STEM The stem on a gate valve is either rising stem (RS) or non rising stem (NRS) as per Fig.2-2. Rising stem (RS)kind of gate valve is an indicator attached to shows the position of the disc and whether the valve is open or closed .The Yoke in this type has no threads, so the stem is kept from rising when hand wheel is rotated. A limit switch often connected to a valve to control the movement of the open & close of the valve like remote control device. It indicate the position of the valve on panels so that operator dont have to inspect the valve to tell whether it is open or close. Stem does not rise through the hand wheel. * * * Hard to tell if valve is opened or closed. Threads are exposed to the fluid Very little overhead room needed
Lesson 2
Page 3
Gate Valves
Fig. 2-2 Rising Stem
Fig. 2-3. Non-rising stem gate valve 3.1 NON RISING-STEM
In the non-rising stem valve, the lower end of the stem is threaded and screws into the disk, vertical motion of the stem being restrained by a thrust collar. Fig. 2-3. The non-rising stem (NRS) configuration places the stem threads inside, out of contact with the environment, and also assures that the stem merely rotates in the packing, without much danger of carrying dirt into the packing from outside or inside.
Lesson 2
Page 4
Gate Valves
3.2
RISING-STEM
In the rising stem type of valve, the upper part of the stem is threaded and a nut is fastened solidly to the hand wheel and held in the yoke by thrust collars. As the hand wheel is turned, the stem moves up or down. The rising stem valve requires a greater amount of space when opened. It is generally to be preferred because the position of the stem indicates at once whether the valve is open or closed. as per Fig.2-4. In the open position there valves can be recognized by the fact that the threaded stem rises above the hand wheel. Stem rises through the hand wheel easy to tell if valve is opened or closed threads are not in contact with fluid needs over head space.
Fig. 2-4. Rising stem gate valve with circular bonnet Up to a steam working pressure of 250 psig, gate valves are usually made with an oval bonnet flange to reduce the face-to-face dimension. In the valves designed for higher pressures, a bonnet flange or circular shape is preferred to provide a recessed gasket joint. 4 GATE DESIGNS Gate valve shave two vertical seating surfaces. Their discs are generally constructed in a wedge shape as Fig. 2-5 or a double disc. The seats on a gate valve are either cast as part of the valve body or are installed, which make them replaceable. Large valve generally replaceable:
Lesson 2
Page 5
Gate Valves
There are several types of gates: a. Solid wedge gate As per Fig. 2-5. Such a gate is made of one part. The complete shut off with a solid gate is accomplished through a close fit between the gates and the seat rings. A solid wedge gate is lowered into closed position. SOLID FOR HIGH FLOW RATES The flow exerts pressure on one of the gate liquids or gases flowing under high pressure tend to erode material that opposes their flow.
Fig. 2-5. Solid Wedge Gate b. Solid split Gate as per Fig. 2-6.
2-6. Solid Split Gate
SPLIT NORMALLY FOR POSSIBLE MISALIGNMENT c. Parallel discs and wedge gate Fig. 2-7. When closing, the parallel discs descend between two matching seats. When the lower wedge, or spreader, reaches the top, it cannot descend further as the upper. Spreader is forced on to the lower spreader, the discs are pushed outward against the seat rings.
Lesson 2
Page 6
Gate Valves
Fig. 2-7. Parallel Discs d. DOUBLE DISK: Disk touches the seat as soon as closing beings and used in high temperatures sealed by spring pressure sealed by fluid pressure sealed by wedging action of the stem as per fig. 2-8.
Fig. 2-8. Double Disk with Spring. The flow exerts pressure on one side of the disk or gate
Lesson 2
Page 7
Gate Valves
In the double-disk parallel-seat gate valves, the disks are forced against the valve seats by a wedging mechanism as the stem is tightened. Some double-disk parallel-seat valves employ a design which depends for its tightness mainly upon the fluid pressure exerted against one side or the other of the disk. The major advantage of this type is that the disk cannot be jammed into the body, which otherwise might make it difficult to open the valve subsequently. This is particularly important where motors are used for opening and closing. However, the tightness of the solid wedge gate valve may also result to a significant degree from the action of fluid pressure against one side or the other. Thus, the two types are essentially similar in this respect. Each disk in the parallel-seat types slides against its seat while the valve is being opened or closed. Consequently, these components must be made of metals which do not tend to gall or tear when in sliding contact with each other. By means of guides, the wedge gate does not come into contact with the seat until the closing point is almost reached. The double-disk parallel seat gate valve is often favored for high-temperature steam service because it is less likely to stick in the closed position as a result of change in temperature. Gate valves are used where a straight through flow is desired with a minimum amount of pressure loss. 4.1 LUBRICANT VALVES :
Some gate valves are furnished with lubricant seal systems to fill damaged valve seats which have become scored or pitted. In these valves, a sealing material, which is insoluble in the liquid or gas flowing through the valve, is pressed through a small port in the valve body into a groove under the seat ring From the groove, the sealing material passes through small holes in the seat ring into an annular groove in the face of the ring. The holes in the seat ring are made small in order to prevent the sealant from being washed out. The lubricant also reduces sliding friction between the seat and wedge. Lubricant-seal systems are available in cast-iron and cast steel bodies.
Fig. 2-9 Gate valve with lubricant sale system

Lesson 2 Page 8
Gate Valves
DIFFERENT TYPES OF GATE VALVES : (A) Rising stem, double wedge disk (B) Solid wedge disk, rising stem Non-rising stem single wedge disk (D) Outside screw and yoke union bonnet, single wedge disk. (E) Non-rising stem, single wedge disk, renewable seat rings.
Fig 2-10 Gate valves 5.1 IN-SERVICE INSPECTION:
Valves are inspected while in service to determine if the components function properly under routine operating conditions. When inspecting a valve, it may be necessary to perform minor adjustments, such as adjusting the packing or the operator, to keep the valve in good operating condition.
Lesson 2
Page 9
Gate Valves
Particular attention should be given to the stuffing box and flanges to check for leaks in the packing or gaskets. When defects are found that cannot be corrected immediately, they must be reported so that necessary action can be taken. 5.2 REASONS FOR MAINTENANCE :
Depending on facility procedures, repair of a valve may be required because of failure or loss of efficiency. Efficiency can be lost due to stem leaks, stem binding, improper operator adjustment , leaking while the disc is closed against the seat, leaks in flange mating surfaces, or other defects. Valves are not usually disassembled for periodic maintenance. In most instances, valves are not taken out of service until a loss of operating efficiency is noted. Of course, failure of a valve may require a complete overhaul. When performing maintenance, the manufacturers instructions should be reviewed before proceeding with any disassembly work. The maintenance of the valve follows commonsense lines. The stem threads should be kept lubricated and free from dirt. When the valve is wide open for a long period of time, the exposed stem threads should be protected by a light sheet-iron tube placed over them. To repack the valve, move the swing gland bolts out of the way. The gland is raised and rests on the ledges provided for that purpose. The stuffing box is then accessible for renewal of the packing. Each ring of new packing should be compressed by the gland before another ring is added. Splits in split ring packing should be staggered. The valve can be repacked under pressured. Should the downstream seats become scored, the upstream seats will frequently be found to be in good condition. Reverse the valve 180, and the valve will be as good as new. Should it become necessary to replace the seat rings, remove the valve from the line and prepare a correct size pipe with square notches to fit the lugs in the seat rings. As the pipe with lugs is twisted (by means of a bar), tap the body smartly with a hammer to help loosen the ring. Clean all threads and seating surfaces with a wire brush before installing new rings. Graphite or pipe dope can be used. A new disk should be installed with new rings. It may have to be lapped in. Retighten body bonnet bolts uniformly using a crisscross pattern and at least three passes. Normally valve attached to low pressure & temperature system are made of bronze or brass. Cast iron valves will be found on low-
Lesson 2
Page 10
Gate Valves
pressure steam or lubricated system valves used in high pressure & temperature systems are made of special alloy metals. Stainless steel is commonly used where there is possibility of corrosion to the valve. In large gate valve on steam service, closure of the valve in fully heated state can lead to jamming when the valve cools later. This is because the heated body expands along the pipe axis, increasing axial distance between seats. Cooling when the valve has been closed with enough thrust to make it leak proof may result in enough contraction between seats to prevent re-operating without heating the body. The parallel disc is intended to prevent this difficulty. Both low pressure iron valves and high-pressure steel types have this disc. Principle of operation is that wedge surfaces between the parallel faced disc halves are caused to press together under stem thrust and spread apart the discs to seal against the seats. The tapered wedges may be part of the disc halves or may be separate elements. The lower wedge must bottom out on a rib at the valve bottom so that the stem can develop seating force. In one version, the wedge contact surfaces are curved to keep the point of contact closed to the optimum.
Lesson 2
Page 11
Globe Valves
LESSON
3
LECTURE
Objectives
GLOBE VALVES
At the end of this lesson, the trainee will be able to demonstrate and understanding of Globe Valves. 1 GLOBE VALVES The Globe valve can be used as a regulating valve, or as a stop valve for isolating systems. If it is used for regulation it is often called a control valve. The control valve is distinguished from a regular globe valve by the shape and arrangement of the disc and seating area. By its design, the globe valve generally provides for a tight seal and has good throttling characteristics. Globe valves are similar to gate valves in that the bonnet, body, and operator are common to both. Also, the various bonnet connections and end connections used in gate valves are found in globe valves, along with rising and non-rising stems. The differences in construction between gate valves and globe valves are due to their different applications. Gate valves are used for on-off service. Globe valves can be used for this purpose, but they are primarily used in throttling applications, as showing in Fig. 3-1.
Fig. 3-1 In some of these valves the direction of flow is important, in which case an arrow will be shown on the VALVE BODY to illustrate the direction in which it should be installed. This valve is used extensively on high pressure systems and particularly on steam line. As a result, globe valves must have a disc that can be moved gradually away from the
Lesson 3
Page 1
Globe Valves
seat to increase the flow of fluid. This is done by using one circular disc which mates with a single seat. In order to insure that the disc will mate with its seat in valves operating under high pressures, a guide stem is attached to the bottom. This guide stem mates with a guide in the center of the seat. As showing in Fig. 3-2, in the next page.
Fig. 3-2. Components of Globe Valve The offset flow pattern is also related to the operation of the disc. After entering the valve inlet, the fluid stops against the disc but exerts an upward force. This force is sometimes used to help reduce the amount of work required to open the globe valve. Of course, the opposite is also true. If fluid flowed in the outlet side, the fluid pressure would tend to hold the disc closed. For this reason, it is important that the direction of flow by considered when installing globe valves. Many manufactures place flow direction arrows on their valve bodies to help in positioning the valve. The change in direction of the fluid as it flows through the valve results in increased resistance to the flow. Complete drainage of the piping system is also not readily accomplished with globe valves. Fig. 3-3.
Lesson 3
Page 2
Globe Valves
Fig. 3-3. Variation of basic valves as to design (A)Angle. (B) Globe The statement that a valve is used to completely stop of regulate flow deserves consideration, as it indicates when a globe valve or when a gate valve is to be used. A globe valve is used to regulate flow, and a gate valve should be used where the service requires the valve to be in full open or closed position. The flow through a throttled globe valve is distributed uniformly around the entire periphery of the disk, giving even and less rapid wear. The flow through a throttled gate valve is concentrated at the bottom of the wedge giving uneven and more rapid wear. This is illustrated in Fig. 3-1. Also owing to the construction of the valve, a globe valve is recommended when the valve is to be operated frequently. The disk in a globe valve touches the seat only at the instant of closing. In a gate valve, the wedge travels over the full face of the seat and consequently sliding wear will develop. When a globe valve in these services finally wears, the globe valve is easier to repair than a gate valve. Frequently, engineering specifications will state Globe valves shall be used on throttling service or where the valve is to be opened and closed frequently. Gate valves shall be used for full-flow conditions or where the valve is normally in an open or closed condition. When an ordinary globe valve is used in severe throttling service, rapid wear of the seat and the disk can result. For tight closing it is
Lesson 3
Page 3
Globe Valves
sometimes better to use two valves on the line, one for throttling and one that is either full open or closed. 2 DESIGN FEATURES Globe valves are constructed in several ways. The seat surface, the body type, and the disc arrangement differ according to the design and function of the valve. Globe valve discs come in different designs. The most widely used one is the plug disc. The plug disc is cone shaped. Basic types of disc and seat arrangement for globe valve are:
2.1
BALL - SHAPED DISC :
This disc fits on a tapered, flat surfaced seat and is usually used on relatively low pressure, low temperature system Fig. 3-4. Its generally used in a fully open or shut position, but may be for moderate throttling.
Fig. 3-4. Ball Shaped Disc. 2.2 THE COMPOSITION DISC :
A. Ball Type disc
This disc is renewable and can be adapted to varying types of flow. The seating surface is often formed by a rubber O ring or washer. Fig. 3-5.
Lesson 3
Page 4
Globe Valves
Fig. 3-5. Composition Disc 2.3 THE PLUG-TYPE DISC:
This disc is also renewable, along with its seat rings and is very useful for heavy duty throttling. Disc is cone shape and it fits into a cone shaped seat. Fig. 3-6.
Fig. 3-6. Plug-Type Disc
Lesson 3
Page 5
Globe Valves
2.4
THE NEEDLE DISC:
This disc which is very narrow and, therefore, best suited for close regulation of flow. The diameter of flow. The diameter of the seat opening is very narrow, and the disc descends well below it and into orifice formed by the seat. Fig. 3-7.
Fig. 3-7. Needle Point Disc Many globe valves used for steam service, are built with a back seat. A back seat is a seating arrangement that provides a seal between the stem and the bonnet. When the valve is fully open, the back seat on the stem seats with the bonnet seat. Fig. 3-8.
Fig. 3-8. Back Seat Design The back seat design prevents system pressure from building against the valve packing. In its fully open position, the back seat of the disc prevents leakage into the upper part of the valve. Globe valves are usually constructed with a rising stem, similar to that found on many gate valves. The stem is threaded into the bonnet or yoke bushing.
Lesson 3
Page 6
Plug, Ball & Butterfly Valves
LESSON
4
LECTURE
Objectives
PLUG, BALL & BUTTERFLY VALVES
At the end of this lesson, the trainee will be able to demonstrate an understanding of Plug, Ball and Butterfly Valves. 1 INTRODUCTION Plug, Ball and Butterfly valves are distinguished from other types of valves by the fact that they are not made with discs that rise and descend from the valve seating area. These valves design not to provides the same tight sealing as a globe valve. The seats are often made of plastic coated, self- lubricating. The disc on these valves open by rotation. When the valve is actuated the disc makes a one-quarter turn, to close or open the part. Plug & Ball Valves can be constructed with more than one part for flow through the valve. 1.1 PLUG VALVE (COCK)
Plug valves, also called cocks, generally are used for the same full flow service as gate valves, where quick shut-off is required. They are used for steam, water, oil, gas, and chemical liquid service. Plug valves are not generally designed for the regulation of flow. Nevertheless, in some applications, these valves are used for this purpose, particularly for gas-flow throttling. For low flow regulation, special plugs are available. Many differences in design and detail adapt the valve to various services. Variations on the basic concept can borrow from other types of valve, too. Flow resistance is low if the port, usually oblong Fig. 4-1 is anywhere near line size. The plug valve can throttle on moderately demanding services. Its plug has two orifices, which helps in breaking down high pressure drops.
Lesson 4
Page 1
Fig. 4-1. Plug Valve Clearances and leakage prevention are the chief considerations in plug valves. Many plug valves are of all metal construction Fig. 4-2. In these versions, the narrow gap around the plug can allow leakage. If the gap is reduced by sinking the taper plug deeper into the body, actuation torque will climb rapidly and galling can occur. Lubrication remedies this. A series of grooves around the port openings, in plug or body, is supplied with grease prior to actuation, not only to lubricate the plug motion but also to seal the gap. Grease injection into a fitting at stem top travels down through a check valve in the passage way and then past the plug top to the grooves on the plug and down to a well below the plug.
Lesson 4
Page 2
Fig. 4-2. Plug Valve In some older types of taper plug valves without lubricant, mechanisms to jack the plug up slightly before turning serve to break corrosion and give clearance for turning. After actuation, the mechanism is released to set the plug firmly. Developments in plastics, principally TFE and nylon, have extended the plug valves range. If the service is under the temperature limit for TFE, a lining sleeve or shell of TFE in a plug valve can solve the sealing problem for the metal plug. Friction of TFE on a metal plug is low enough to allow easy actuation. The lining method has certain restrictions and calls for certain design measures not necessary in metal-to-metal sealing.
Lesson 4
Page 3
1.2
LUBRICANT-SEAL VALVES
In lubricant seal valves, channels for the admission of the lubricant surround the ports to insure positive sealing against internal or external leakage. The lubricant pressure developed by a turn of the lubricant screw or injection of lubricant with a pressure gun exerts a powerful hydraulic jacking action on the plug, momentarily lifting it from the seat and making it easy to turn. Since the lubricant pressure is greater than the line pressure, it is virtually impossible for solids to lodge between the valve body and plug. The lubricant must be compatible with the temperature and nature of the fluid of course. The most common fluids controlled by plug valves are gases and liquid hydrocarbons. Some water lines have these valves, too, if lubricant contamination is not a serious danger. This type can go to 24 in. size, with pressure capability psig in sizes to 16 in. Steel or iron bodies are available. The plug can be cylindrical or tapered. The functions of pressure lubrication in plug valves are : 1. 2. Hydraulic action, keeping the plug in free working condition Maintenance of positive seal against internal and external leakage. Free turning even of the largest sizes and against heavy differential pressure, and Protection of working surfaces from wear and corrosion. This principle of pressure lubrication makes it possible to take full advantage of the inherent simplicity, compactness, and positive rotary action of the tapered plug valve. DESIGN FEATURES
3.
4.
1.3
The basic design of plug valves Fig. 4-4 is similar to the old fashioned wooden spigot. Full flow is obtained when the opening in the tapered plug faces in the direction of flow. When the plug is rotated a quarter of a turn, flow is stopped. The body and tapered plug represent the essential features in plug valves. Careful design of the internal contours of the valve produces maximum flow efficiency.
Lesson 4
Page 4
Fig. 4-4. Plug valve with lubricant system, as specified in API Standard 600. The hole, or port, in the tapered plug is generally rectangular. However, valves are also available with round port design. Major valve patterns or types are identified as regular, venturi, short, round port, and multi port. The regular pattern employs the tapered form of port opening, the area of which is from 70 to 100 per cent of the internal pipe area. In some cases, the face-to-face lengths are greater than those of standard gate valves. The venturi pattern, available in flanged sizes 6 in. and larger, provides streamlined flow and thus permits reduction in the port size. The port opening area is approximately 35 per cent of the internal pipe area. The short pattern has face-to-face lengths that conform with 150 and 300 lb steel gate valves. The round port full-bore pattern has a circular port through the plug and body efficiency is equal to or greater than that of gate valves of the same size. Use of multi port valves 4-5 is advantageous in many installations because it provides simplification of piping and convenience in operation. One 3-way or 4-way multi port valve may be used in place of two, three, or four straightway valves. Major types of plug valves involve lubricated and non-lubricated designs. Lubricant seal plug valves are less subject to seizing or wear
Lesson 4
Page 5
and may exhibit somewhat greater resistance to corrosion in some service environments. Non-lubricated plug valves are used where maintenance must be kept to a minimum. Both types of valves provides a bubble tight closure and are of compact size.
Fig. 4-5. Multi port valves These valves generally can be readily repaired or cleaned without necessitating removal of the body from the piping system. They are available for pressure service from vacuum to 10,000 psi and temperatures from -50 to 1500 F. 1.4 BALL VALVES
In the past , the use of ball valves 4-6 has been rather limited as bubble tight service was not possible because of problems in the sealing ability of metal-to-metal seats. In recent years, the use of plastics, such as nylon, delrin, synthetic rubbers, and fluorinated polymers for seating, has substantially increased the use of ball valves. With fluorinated polymer seats, ball valves are used for service temperatures ranging from 450 to 500 I. With graphite seats, temperatures as high as 1000 F are possible. Ball valves, similar to plug valves, are quick opening, needing only a quarter turn from full open to full close. To open the valve, the ball is rotated so that the through port lines up with the seat openings. When the valve is closed, line pressure forces the ball against the downstream seat, in an action similar to that of a gate valve. Ball valves are non-sticking, and they provide tight closure. They also exhibit a negligible pressure drop because of their smooth, full-opening port. These valves are easy to repair, and maintenance costs are low. Major components of the ball valve are the body, spherical plug, and seats. Ball valves are made in three general patterns venturi port, full
Lesson 4
Page 6
port, and reduced port. The full-port valve has an inside diameter equal to the inside diameter of the pipe. The reduced port generally involves one pipe size smaller than the line size. Stem sealing is by bolted packing glands and O-ring seals.
Fig. 4-6. Ball Valve Components
Lesson 4
Page 7
Below in Fig. 4-7 and Fig. 4-8 we can see a Ball valve in the open and closed position.
Fig. 4-7. Ball valve in closed position
Fig. 4-8. Ball valve in open position The seats of these valves are often made for plastic coated or self sealing materials. Although providing a good seal at low pressures, they are not usually found in high pressure steam systems. They are very good in systems carrying dirty materials such as mud or slurry. Another advantage is that fluid can flow through the valve in either direction.
Lesson 4
Page 8
Fig. 4-9. Variations of Ball valves design 1.5 BUTTERFLY VALVES
Butterfly valves of extremely simple design, which are used to control and regulate flow. They are characterized by fast operation and low differential pressure drop. They required only a quarter turn from closed to full open position. Butterfly valves are not intended for pressure-tight service. A typical flanged butterfly valve is illustrated in Fig. 4-11. The disc is attached to the stem, and used primarily for isolation of flow. In addition to shut off function, butterfly valves can be used for throttling application not frequently because poor throttling characteristics. The disc is always the same diameter as the piping on which the valve is attached.
Lesson 4
Page 9
Fig. 4-11. Typical butterfly valve When the operating lever is in line with the piping, the valve is open. When the valve operator is perpendicular to the piping, the valve is closed. Most Butterfly valves are constructed with a resilient, natural rubber seat that provide a firm fit and a tight seal when the disc close on it. The sealing area must be resilient, but a rigid back up is usually provided, either of non-metallic type as metal ridges on the body rings or as encapsulated metal rings in a rubber seat ring. Butterfly valves must be removed from a system for all repairs except packing. Since butterfly valves generally hold a single ring of packing, adjustment are rarely made.
Lesson 4
Page 10
1.6
VALVE SEAT DESIGN
Depending upon the type of valve, the valve seat may consist of a bonded resilient liner, a mechanically fastened resilient liner, an inerttype reinforced resilient liner a mechanically fastened resilient seal or an integral Fig. 4-12.
Fig. 4-12 The seats of butterfly valves are often made from a resilient natural gum rubber to provide a good seal. They are commonly used for controlling the petrol/air mixture in the carburetor of your car. Larger butterfly valves are servo assisted by electric motors, hydraulics, diaphragms etc. because they are difficult to move against the flow of the fluid. The disc is always the same diameter as the piping to which it is attached. This gives the advantage of a smoother flow and less pressure drop. The combination of seating geometry and seal material alloys this type of eccentric butterfly to close very tightly on liquids and gas at pressures as high as 3750 psig. This ability has led the manufactures of the spherical-seat eccentric butterfly with TFE seats to call it high performance. Flexibility of the ring varies from design to design. In fig. 4-13 A is comparatively in flexible. The B and C profiles are more flexible.. In any profile, a ring of TFE filled with glass fiber or graphite is inherently less flexible than a ring of unfilled TFE. For ring protection against debris and extrusion as the disc nears its seat, rings tend to be recessed in grooves between retainer and body.
Lesson 4
Page 11
Work continues on metal and graphite seat rings for high temperatures. Sometimes the rings are assisted by TFE rings to give superior tightness at low temperatures, keeping the metal rings for sealing during a high-temperature excursion. The metal seat rings have complicated profiles to give flexibility and ability to survive closure on hard foreign bodies. Fluid pressure assists sealing and often there is a double contact on the disc. Fig. 4-13. Below shows a butterfly valve in the open position.
Fig. 4-13 The position of the butterfly valve disc can easily be seen. The operating lever is in line with the pipe when it is open, and perpendicular or across the pipe when closed. This is also usually the case with plug and ball valves
Lesson 4
Page 12
Diaphragm Valves, Pinch Valves
LESSON
5
LECTURE
Objectives
DIAPHRAGM VALVES, PINCH VALVES
At the end of this lesson, the trainee will be able to demonstrate an understanding of Diaphragm valves, Pinch valves and Instrument valves. 1 DIAPHRAGM VALVES Most valves depend on a controlled geometry and rigid materials for closure. The diaphragm valve operates on an entirely different basis: A highly flexible and extensible Elastomer sheet forced down into a rigid edge, the seat, causes closure. If the valve body, including the seating area, is rigid plastic or a metal with corrosion-resistant Elastomer lining, then the diaphragm valve has an important potential advantage - high resistance to corrosive liquids. This is its chief application, naturally, in water-treatment work and for liquids that might be contaminated by metal contact. The cushioning effect of the Elastomer diaphragm also tends to protect it as it seals tightly on large and small foreign solids in the stream. Slurries and waste water are therefore other applications. The body configuration of Fig. 5-1 causes friction loss and disturbs flow paths more than the straight-through type of Fig. 5-2. This can be a factor in slurry and suspended-solids service. On the other hand, the straight-through type is not recommended for vacuum lines.
Fig. 5-1a
Fig. 5-2a
Lesson 5
Page 1
Fig. 5-1b. Fig. 5-2b 2 VALVE DESIGN Two basic body designs are used for diaphragm valves: 1. The straight - through has no obstructions where the diaphragm seats. Fig. 5-1. The weir has a raised surface where the diaphragm seats on the valve body Fig. 5-2.
2.
The weakness of the diaphragm valve is in its Elastomer diaphragm, which can crack from repeated flexing or be torn by sharp-edged foreign bodies in the fluid. Special design attention goes to the diaphragm itself and to the actuator head that forces the diaphragm into closure. The contact between head and diaphragm must be uniform to prevent localized damage to the diaphragm. This head, also called compressor, may have radial flanges that pass through cutouts between supporting prongs in a finger plate. Breakage of the diaphragm, whether from flexing, cutting or impact of the fluid and particle load as the liquid makes the sharp turn over the center weir, will admit fluid to the bonnet space, corroding the actuating elements. A vent plug in the bonnet allows check for the presence of leakage. Replacement of a defective diaphragm is not difficult, but
Lesson 5
Page 2
often corrosion in the bonnet will require more extensive repairs. Stem sealing by packing or O-rings is also advisable to prevent escape of corrosive agents to the outside. One drawback of the weir-type diaphragm valve is inability to drain a horizontal line through it directly. Turning the valve until the stem is about 20 deg. Above the horizontal greatly improves draining ability. The straight-through-flow design Fig. 5-1, however, can drain even when the stem is straight up. The wide choice of metals and Elastomer for bodies and of Elastomer for diaphragms allows the diaphragm valve to meet all power plants chemical needs. Temperature limits range from about 180 F for natural rubber and Buna N to as high as 350 F for weir-type TFE diaphragms with Elastomer backing and 400 F for all TFE diaphragms. For abrasive service, the diaphragm can be gum rubber or ethylene propylene. The body lining need not be as flexible as the diaphragm. Materials like ethylene tetra fluro ethylene (ETFE), polypropylene, polyvinyl chloride, and poly vinyl iodine chloride are choices. Although most diaphragm valve designs are not intended for precision throttling, they can maintain good throttling qualities, and some types have relatively low pressure-deep features. 3 VARIATIONS OF THE DIAPHRAGM VALVE Two specialized variations of the diaphragm valve are good for throttling characteristic. 1. The Pinch Valve is equipped with a flexible tube that goes through the valve body and forms flange gaskets between the valve and the connecting pipe Fig. 5-3. Due to the smooth straight flow path through a pinch valve, there is minimum pressure drop across the valve. Closure occur through squeezing together of Elastomer walls over a wide area, rather than against a narrow metal ridge. The ability of the pinch valve to handle abrasive and slurries has given it wide application in such power plants services as such disposal, flue-gas desulfurization, waste water, water treatment and, in future, fuelslurry handling.
Lesson 5
Page 3
Fig. 5-3. Pinch Valve Cutaway. 5-4. Boot Valve The heat of the simplest form of pinch valve is a flanged Elastomer tube Fig. 5-6 mounted in a split flanged casting connected to a compressed-air line. The tube is reinforced by fabric plies which are carried outward over the flanges. In the open state, the valve, bolted between pipe flanges, transmits fluids just as if it were part of the piping. Admission of compressed air to the valve body pinches the tube into an oval shape at the center and finally shuts off flow at the center and finally shuts off flow completely. All pinch valves close over a long contact area, so that the seating surfaces can envelop even large objects without leaking or being cut. 2. The Boot Valve Its similar to the Pinch Valve Fig. 5-4, but there are two compressors that flex the boot to open and close, and also provide throttling action. The double compressor is used with each side of the boot flexing to close the valve, wear on each side reduced-thus giving added life to the valve.
Lesson 5
Page 4
Check Valves
LESSON
6
LECTURE
Objectives
CHECK VALVES
At the end of this lesson, the trainee will be able to demonstrate an understanding of Check valves. 1 CHECK VALVES Up to here, all valves described have been actuated from outside the pressure envelope. Not only can they be opened and closed by direct force at any desired time, but in addition, the human supervisor can verify the position by sight or by test of the actuation means. The elementary check valve lacks these characteristics. Its functioning is entirely within the pressure envelope, its opening and closing are governed by flow direction, with the human supervisor powerless to intervene; and also unable to sense the position of the disc. In addition, check-valve reliability must be high. Failure to close and prevent backflow even once in a valves life could cause vast damage. For a check valve, reliability is broader than for other valve types. Not only must the valve close, it also must close according to the desired position/time relationship. A check valve that closes suddenly and late can destroy itself, along with considerable piping and supports. The pressure drop through an open check valve is a source of energy loss. Cost evaluation of the valve should include this effect, although energy loss will not be as significant in the overall a picture as reliability and shockless closure. A satisfactory check valve should therefore: open easily and completely to pass flow with little pressure drop or disturbance to flow patterns; resist damage to seat disc and disc hanging or guiding means in all flow conditions during valve life; close quickly, without valve injury or water hammer, at the instant or flow stoppage. This adds up to a demanding design effort, and success has been sporadic. How tightly a check valve should be required to seat depends on the service. Often, some leakage is permissible. Discharge lines of pumps are an example. As long as flow is not enough to rotate the impeller or rapidly empty an overhead tank, the valve will be satisfactory. On the other hand, if the check valve is supposed to isolate a machine for maintenance, a leak can prevent work from being done and in the long
Lesson 6
Page 1
Check Valves
run make a separate isolation valve necessary. The repair work called for in keeping check valves tight is part of the life costs. The continuing difficulties with check valves have forced many changes in and ingenious additions to the basic elements. Examples of additions are internal and external dashpots, exercise mechanisms, aspirator tubes, spring or power-assisted closure, and position detection. Two basic disc motions for conventional check valves are perpendicular lift from the seat (lift) and pivoted lift (swing) which is nearly perpendicular when the disc is near the seat. Another motion is rotation of an eccentrically mounted butterfly disc seating in a slated seat (tilting disc). 2 CHECK VALVES DESIGN AND TYPE 1. 2. 3. Swing Check Lift Check Ball Check used to prevent back flow.
2.1
SWING CHECK VALVE
The only moving part is a disc assembly that is attached to the body by a pivot pin. The disc is raised when system pressure is greater than the weight of the disc. Fig. 6-1 used mainly in horizontal piping. The pivotpin mounting leaves the disc assembly free to swing toward and away from the valve seat. Swing checks commonly are in horizontal lines with pivot above the seat. When there is no flow through the valve the disc is positioned so that the valve is closed. Liquid or gas flows only when there is a difference pressure between two points. If the pressure is higher at A than B the direction of the flow is from A to B.
Lesson 6 Page 2
Check Valves
In the swing check valve, the hinge pin may be located internally or externally. ON low pressure systems the hinge will be connected externally; on high pressure systems, the hinge pin will usually be internally connected. The opening or closing of a swing check valve is automatic.
Fig. 6-1. Swing Check Valve A swing disc must largely clear out of the fluid path when open but must still have a readily accessible space above it to convert backflow to pressure and closing torque in case torsion springs or disc weight cannot close the disc. Swing-check valves have failed because of this. The leverage of fluid forces on the cantilevered disc, too, tends to wear the pivot and hinge. Spinning of the disc by asymmetric turbulence of fluid can harm lift checks, especially in non-lubricating fluids, although the danger is not as serious as it is for swing checks. Disc and stem wear can break off stems or cause hang-up, so stops to limit rotation may be necessary. Spinning of the disc by fluid forces has injured many swing-check valves. Some times the disc stem has worn completely through, allowing the disc to float down stream. Anti-rotation pins can prevent this. An important modification of the swing disc check is the dual-disc which two D-shaped pieces pivot about a vertical pin and seat on flat D-shaped seats, which can be Elastomer for moderate temperatures. These dual disc valves, with flaps pressured on by a torsion spring, can close with low chock, because the flaps are directly in the pipe center and are fully exposed to fluid backflow force to assist closure if the spring action is too slow.
Lesson 6
Page 3
Check Valves
Fig. 6-2 & 6-3 Swing-Type Check Valve 2.2 LIFT CHECK VALVES
Lift check valves used in horizontal and vertical piping good for high pressure and velocity. The line of flow through a lift check valve is similar to the line of flow through globe valve. The direction of the flow is always from under the disc. Fig. 6-5. The lift check valve allows flows in only one direction. When flow occurs from A to B, it raises the disc. As flow stops, gravity pulls the disc into the seating, and the back flow assist also. Seat surfaces in lift checks can be flat or conical. Lift is low and must never be so high that back flowing water cannot reach the disc top to create closing pressure in case the disc stocks open. A light helical spring may assist closing.
Lesson 6
Page 4
Check Valves
Fig. 6-4 & 6-5 Lift- type check Valve The lift type must have disc guiding of one sort or another. For larger discs for low to moderate pressure Fig. 6-5 sleeve on the disc top envelops a pin protruding from the bonnet, and a pin on the disc under surface slides in a guide bushing supported by arms integral with the seat ring. The lift check valve works CORRECTLY when installed in the HORIZONTAL position. An other design allows to use a lift check valve is a vertical position. The Stop check valve resembles a modified globe valve, but when the stem is raised, the disc operates like that of lift type check valve.
Lesson 6
Page 5
Check Valves
Fig. 6-6 & 6-7 Stop Check Valve In large check valves, the danger of water hammer damage from sudden closure after back flow has started has given impetus to internal dashpots Fig. 6-7. Closure-speed choice bases on waterhammer calculations, often done from computer programs. 2.3 BALL CHECK VALVES
The ball valve is also a check valve used mainly for heavy liquids. The line of flow through such a valve is in a straight line. The part of the valve that controls the opening is a ball. When flow occurs, the ball is raised by the pressure of the flow. The Fig. 6-8. Check is for vertical up flow, but the principle adapts to horizontal flow, too, resulting in a globe-like body with flow upward through the seat and out through the holes in a ball-guide cage.
Fig. 6-8. Ball Valve
Lesson 6
Page 6
Piston Valves
LESSON
7
LECTURE
Objectives
PISTON VALVES
At the end of this lesson, the trainee will be able to demonstrate an understanding of Piston valves. 1 PISTON VALVES Interior partitioning of the valve is the same as in the preceding types. The cut-off member is a hollow cylindrical piston sliding between two sealing rings screwed into the body. The piston is provided with openings which go up and down in front of the outlet hole, thus permitting variation of flaw section Fig. 7-1 show valve components.
Fig. 7-1. List of Piston Valve components The piston is of chrome steel and perfectly machined; the sealing rings are often of self lubricating Teflon. So that lubrication is unnecessary. At the beginning of opening a displacement uncovers a small flow section, permitting precise control of low rates of flow. For each profile the manufacturer supplies the curve of the variation of flow as a function of the height of lift of the disc. Most automatic valves are of the double disc type.
Lesson 7
Page 1
Piston Valves
The double disc design can be used to equalize the pressure across the disc and it can be varied to change flow characteristics through the valve or to change the operation of the valve, such as by decreasing the response time of the valves action. Often, double disc valves used for flow control will be designed for special flow characteristics.
Fig. 7-2. Piston Balance Valve showing double disc arrangement When a single disc valve is put into operation, all pressure drop across the valve is exerted on the area of the valve seat. This force of pressure must be over come by the valve actuator see Fig. 7-2. To overcome this problem, certain valves are designed with a double disc arrangement. This design is especially serviceable where system pressure is very high or where constant adjustment must be made to control a flow through the valve. A piston balance valve allows the force exerted across the seating area to be as equal as possible, while being directed in opposite direction. The double disc arrangement has the flow coming from the left. In the closed position, the fluid pressure would press against the bottom of
Lesson 7 Page 2
Piston Valves
the top disc and against the top of the bottom disc equalizing flow pressure. Even when the valve is open, there is an equalizing force which gives the valve a smooth operation. When the standard valve is fully closed, there is of course, zero flow. As the valve is opened, flow begins to increase rapidly through it. When the valve is open, there is almost no additional increase as the valve is opened all the way. When fine flow control required, such as during controlled chemical additions or for boiler feed flow, a precise control of flow through the valve as it open is required. This control can be achieved by a valve designed to have linear flow characteristics. An example of this type of valve is one designed with a double disc arrangement and used for the control of water going to a boiler.
Lesson 7
Page 3
Valve Maintenance
LESSON
8
LECTURE
Objectives
VALVE MAINTENANCE
At the end of this lesson, the trainee will be able to demonstrate an understanding of Valve Maintenance and Valve Packing. 1 VALVE DISASSEMBLY 1.1 PREPARATION FOR DISASSEMBLY
After checking that the valve is isolated and tagged out, the first step in disassembly is a thorough cleaning of the outside of the valve. This cleaning task is important; it minimizes the amount of foreign matter that gets into the valve and piping system. Later, before reassembly all foreign matter will have to be removed from the inside of the valve. It is much easier to remove dirt from the outside of the valve now than to clean it from the inside before reassembly. Cleaning methods vary with the valve and operating conditions. Wire brushing is usually sufficient, but it may be necessary to wipe away any loose material with a clean rag. In some cases, the outside of the valve may have to be washed. The most important areas to clean are the flange mating surfaces and the area around the gland follower. In this section, the valve to be disassembled is a regular globe valve, which is common to industrial plant use. Fig. 8-1 illustrates the parts of the Gate valve to be described during disassembly.
Fig. 8-1. Gate Valve
Lesson 8
Page 1
Valve Maintenance
1.2
REMOVAL
The first step is to loosen the put on the handwheel (Fig. 8-2). Then the gland nuts (Fig. 8-3). On both sides and the bonnet nuts (Fig. 8-2) are loosened. It is easier to loosen these nuts now than when the bonnet is separated from the valve body. Next, the gland nuts are unscrewed and removed to relieve pressure on the packing (Fig. 8-3). Then the bonnet nuts are taken off 8-3. This will allow for the removal of the handwheel and bonnet assembly.
Fig. 8-2. Loosening the Nuts
Fig. 8-3. Removing the Nuts
After the gasket is removed, the handwheel is rotated in the closed direction as far as possible. Now the nut and handwheel are taken off of the valve. The valve stem is rotated until it is out of the bonnet. This can be done manually or with the aid of a wrench. If a wrench is used, care must be taken not to damage the stem. A soft-faced wrench is good to use, or a piece of soft material held between the wrench and the stem will protect the stem. The stretch is applied between the disc and the back seat of the valve. Accidental scratching of the stem with the wrench is not good, but it will not cause leakage when the valve is reinstalled, since this part of the stem does not come in contact with the packing. However, if the wrench is applied above the back seat or on a threaded portion of the stem, significant damage could result. A leak could develop or the stem could become difficult to rotate, making the valve inoperable. The packing gland will come off as the stem is rotated out of the bonnet. When the stem is out, the packing can be removed. It is taken out with a packing removal tool, or if the valve is small, the packing may easily come out by turning the bonnet over and pushing it out of the stuffing box. Fig. 8-4 illustrates the use of a packing removal tool.
Lesson 8
Page 2
Valve Maintenance
Fig. 8-4. Packing Removal After the packing is removed, the bonnet and the stuffing box can be cleaned and inspected. The body and bonnet are checked for steam cuts and pits. If any are found, they should be repaired through lapping if the damage is minor. Deep cuts or pits may have to be machined on a lathe before lapping can be done. 2 LAPPING, SPOTTING-N, AND GRINDING-IN The processes of lapping, spotting-in, and grinding-in are part of routine valve maintenance. Most minor cuts and pits can be removed through lapping and grinding-in; the spotting-in test should always be performed to check the mating of the valve seating area. 2.1 LAPPING
To lap the seating surface of the bonnet, small amount of lapping compound is first applied on the lapping block . Usually, the process is begun with a coarse grade of compound, changing gradually to a fine grade to achieve a smooth, polished surface at the seating area. After applying compound to the lapping block, the bonnet is rotated in a figure-eight motion, as illustrated in Fig. 8-4, with care taken not to exert excessive pressure on the bonnet. In lapping, the weight of the part usually provides adequate pressure to smooth the surface. Frequently, the bonnet seating surface is checked by wiping the compound from it and inspecting it. The process is repeated until the seating surface is smooth.
Lesson 8
Page 3
Valve Maintenance
Fig. 8-4. Lapping Motion For example, if too much metal is taken from the seating surface of the bonnet or body of a valve, the gasket that fits between them will not be compressed sufficiently. Leakage will result when the valve is put back into service. Deep cuts or pits that cannot be removed by lapping may be filled in by welding and then machined on a lathe. However, maintenance personnel must usually decide if such action is worth the time that must be invested. In some cases, it may be cheaper to replace the valve. After refurbishing the seating surfaces of the bonnet and body, the valve disc and seat are inspected for proper seating. On inspection, if the disc and seat are seating properly, there will be a clearly defined area to indicate this. If not, it is quite likely that the disc has not been seating properly, if at all, and that the valve has been leaking.
2.2
SPOTTING-IN
A more accurate way to inspect the disc and seat for positive seating is through the method of spotting-in. Many discs rotate freely on the stem. This gives the disc a self-seating feature and provides a good seal when the valve is closed. However, during spotting-in, the disc must not be allowed to rotate. To prevent rotation, a piece of shim stock can be used to hold the disc in place and prevent its movement. The shim stock should be positioned between the stem and the disc. Another way to prevent the disc from rotating is to take the disc out of the stem, put a piece of shim stock between the disc and the bottom of the stem, and then reassemble the disc. To spot-in a valve seat, a thin coating of Prussian blue is applied evenly to the surface of the disc. It is important to use a type of blueing that is non-drying. Before applying the blueing, the seat and disc must
Lesson 8 Page 4
Valve Maintenance
be cleaned. A light grinding-in or lapping can be used to accomplish this cleaning. 2.3 GRINDING-IN
Imperfections to the disc or seat will require that the part either be repaired or replaced. Some valves are equipped with replaceable parts. In this case, it may be more economical to replace the disc and seat then to repair them. However, if minor imperfections are found, it is best to make repairs. One method for repairing minor damage to the seating area of a disc or seat is called grinding-in. Grinding-in is accomplished by applying a small amount of lapping compound to the disc. The disc is placed on the seat and rotated back and fourth, using a light downward pressure. The disc is moved forward one-quarter turn occasionally to ensure even grinding-in. Lapping compound should be changed frequently, and finer grades should be used as lapping progresses. A flat-surfaced disc, like the one on the gate valve illustrated in Fig. 85, is repaired in a different fashion. A lapping block can be used to remove minor imperfections. Lapping compound is applied to the block, and the disc is then placed on the block. The disc is rotated in a figureeight motion, using the same light downward pressure as before.
Fig. 8-5. Gate Valve Disc The disc should be checked frequently during the grinding-in process. The compound is removed, and then the disc is inspected. After the lapping compound is wiped from the block and disc, the disc is rotated on the bare metal block in a figure-eight as before. Dark areas on the surface indicate areas where the disc is not seating properly. When lapping or grinding-in has been completed, the seat and the disc should be spotted-in. Then the shim stock (if used) should be removed from between the disc and the stem.
Lesson 8 Page 5
Valve Maintenance
Briefly, then, the lapping and grinding-in processes are as follows: When the original disc is rotated against the original valve seat, the process is called grinding-in. When the disc is rotated against another surface, such as the block, or a lapping tool is rotated against the disc, it is called lapping. However, both processes use lapping compound to smooth out minor imperfections to the seating surfaces. The following important points should be kept in mind when lapping or grinding in a valve: a. b. c. d. e. f. g. h. 3 Never bear heavily on the lap or valve disc. Never bear sideways. Always use clean lapping compound. Spread the compound evenly and lightly. Never lap or grind-in more than necessary. Rotate to change the relationship of the disc or lap with the seat frequently. Always grind-in the disc to the seat after lapping or cutting on a lathe. Always spot-in the seat and disc after grinding-in.
VALVE PART MAINTENANCE In addition to the processes used to inspect and repair the seating areas of valve parts, other types of maintenance should be performed on a disassembled valve. The stem bushing should be inspected for wear and damage. Normally, on a rising stem valve, the threads of the stem rotate on the threads of the bushing to open and close the valve. For this reason, the stem bushing receives a great amount of wear as the valve is operated. If the bushing threads are allowed to wear out on a rising stem valve, the valve will no longer close. System pressure will force it open, and the valve operator will not be able to close the valve. Thus, the bushing threads should be carefully checked for wear. If they are found to be worn, it is best to replace the bushing. to do this, a file, grinder, or hacksaw may be required, since the bushing is usually tackwelded in place. After the tack-weld is removed, the bushing can be turned with a wrench and taken out. The bushing threads are different from the stem threads, but, on a disassembled valve, the bushing can be replaced by using this method. If the valve is in place while the bonnet bushing is being replaced, the stem would be rotated at the same time the bushing is removed and threaded into the bonnet. Otherwise, the stem and bushing threads would bind; this would damage the threads and prevent the installation of a new bushing.
Lesson 8
Page 6
Valve Maintenance
The valve stem is inspected next. It must be straight. A bent stem can cause excessive and rapid wear to the valve packing. Just a slight bend in the stem can render a valve inoperable, and can prevent the packing from sealing properly, which would result in leakage. The stem is placed on a lathe or V-block, as illustrated in Fig. 8-6, where the total run-out is checked with a dial indicator. The dial indicator is arranged to so that it is in contact with the stem. As the stem is rotated, the run-out is indicated on the dial. If the dial remains constant on zero, the stem is straight. If it is not straight, the dial will indicate the degree of deviation. If the stem is bent, it must be straightened or replaced.
Dial Indicator
V-Block
Stem
Fig. 8-6. Stem Inspection While the valve is fully disassembled, all threaded surfaces should be cleaned thoroughly with a wire brush. The bolts and studs threads should be chased with a thread chaser. Finally, the flanges should be carefully inspected. The flanges of both the valve and the pipe should be cleaned with a wire brush before inspection. A putty knife may be needed to scrape material that is hard to remove. Care must be taken, however, to avoid making nicks or gauges on the flange surfaces with the scraper, as that could result in leakage when the valve is placed back in service. While the valve is out of the system, maintenance can be performed to the exterior surfaces. Sandblasting and then painting external surfaces will help to preserve the valve.
Lesson 8
Page 7
Valve Maintenance
VALVE REASSEMBLY When cleaning and inspection have been completed, the valve is ready to be reassembled. An important part of reassembly, after all repairs have been made, is proper lubrication. All moving and threaded parts should be well lubricated during valve reassembly. Many lubricants, both wet and dry, are available, and the proper type must be used for each surface . The manufacturer's instructions should be checked to determine which lubricant is correct for a particular valve. The first stem in reassembly is to put the stem through the bonnet, and then slide the packing gland over the stem (Fig. 8-7). Then the stem is carefully threaded through the yoke bushing until the valve is in the fully open position.
Fig. 8-7. Reassembly, of the Stem and Packing Gland A gasket is set on the body seating surface. Then the stem, bonnet, and packing gland assembly is placed on the valve body. It is important that a new gasket be used each time a valve is reassembled following maintenance. Previously compressed gaskets will not provide a proper seal once they are removed from the valve. The body-to-bonnet bolts are set in and tightened evenly to compress the new gasket uniformly. A cross-torque pattern is used to tighten the body-to-bonnet bolts. In this type of pattern, one bolt is tightened, and then the bolt opposite to that bolt is tightened. Then, a bolt next to the first bolt is tightened, and then the bolt opposite it. The pattern is continued until all bolts are torque to their proper valves. The valve manufacturer's manual will indicate the proper torque valve.
Lesson 8
Page 8
Valve Maintenance
In reassembling a valve, it is important that the disc be kept in the fully open position. This prevents the disc from being driven into the seat, which could cause damage to the seating surfaces or bend the valve stem. In addition, the bonnet must seat squarely on the body of the valve as the bonnet bolts are torque. After the bonnet is installed, the valve is repacked. Finally, if the stem bushing is equipped with a grease fitting, the valve stem should be greased. The valve is now fully reassembled. When a valve is damaged severely enough to warrant replacement, several points must be considered in choosing a new one. The replacement valve must be the same type as the damaged valve and must be rated for the same kind of service. The flanges on a new valve must be the same size and type as those of the damaged valve in order to fit with the piping of the system. The flanges must also have the same face-to-face clearance and hole alignment. 5 PARTICULAR MAINTENANCE PROCEDURES The maintenance procedures discussed thus far concerning valve disassembly, re-packing, repairing, and reassembly are basically the same for all types of valves. There are certain procedures, however, that the performed only on a certain type of valve. 6 VALVE PACKING 6.1 INTRODUCTION TO PACKING
Packing is a tough rope-like material which is commonly impregnated with a lubricant. It is used to prevent leaks of liquids and gases around a valve stem and bonnet. Usually, packing is contained in an assembly called a packing gland. Fig. 8-8 shows a typical valve packing gland assembly.
Lesson 8
Page 9
Valve Maintenance
Fig. 8-8. A typical valve packing gland assembly To produce a seal around moving parts, packing is cut into rings. These rings are wrapped around a valve stem. They are then fitted into a cavity in the packing gland called a stuffing box. Fig. 8-9 shows packing rings fitted into a valve stuffing box.
Lesson 8
Page 10
Valve Maintenance
Fig.8-9. Packing Rings Fitted into a Valve Stuffing Box Once the packing rings have been fitted and seated in a stuffing box, they are compressed by a gland follower. The gland follower causes the packing to put pressure on a valve stem. This produces a seal. Fig. 8-10 shows packing being compressed by a gland follower.
Fig. 8-10. Packing Being Compressed by a Gland Follower.
Lesson 8
Page 11
Valve Maintenance
For packing to work correctly, it must be checked regularly. The packing will need regular adjustment to take up wear caused by shaft or the opening and closing of a valve. 7 PACKING MATERIALS Valves are just one item in which packing is used. Nearly all machines that have shafts or stems passing through their casings or housings use packing. Because there are many uses for packing, it is manufactured in a wide range of materials and sizes shown in Fig. 811.
Fig. 8-11. Range of Typical Valve Packing Materials Packing is manufactured from fibrous materials such as flax, cotton, and asbestos. Packing is also made from metals such as lead, aluminum, babbitt, and plastics like Teflon, nylon and kevlar. These materials are usually constructed to from a continuous square or round-shaped strand. The packing is sometimes impregnated with a lubricant like graphite or mineral oil. 7.1 FIBER PACKING
Fiber packing is manufactured in many different forms as shown. Interlocking braid and braid over braid is very strong. It is suitable for use where there is high pressure. Square braid and twisted packing is very flexible and is usually used on reciprocating shafts.
Lesson 8
Page 12
Valve Maintenance
Fig. 8-12. Examples of Fiber Packing Fiber packing is also woven into cloth which may be wrapped or laminated between layers or rubber, plastic, and graphite
Fig. 8-13. Fiber Packing woven into Cloth 7.2 METAL PACKING
Metal packing is made in crimped or spiral wound form. It may have a hollow core. Because of their low melting points, lead and babbitt packing are used for temperatures below 450 C. Aluminum foil is used for temperatures above 450 C.
Lesson 8
Page 13
Valve Maintenance
Fig. 8-14. Crimped and Spiral Wound Metal Packing 7.3 PLASTIC PACKING
Plastic and other synthetic packing materials are usually manufactured in performed "Vs" called chevrons and also in solid rings.
Fig. 8-15. Examples of Plastic Packing As previously stated, there are many types of packing materials and many uses for them. The packing material reference table, shown below, will assist in the correct selection of packing materials for various applications. 8 IN-SERVICE INSPECTION Valves are inspected while in service to determine if the components function properly under routine operating conditions. When inspecting a valve, it may be necessary to perform minor adjustments, such as adjusting the packing or the operator, to keep the valve in good operating condition.
Lesson 8
Page 14
Valve Maintenance
Particular attention should be given to the stuffing box and flanges to check for leaks in the packing or gaskets. When defects are found that cannot be corrected immediately, they must be reported so that necessary action can be taken. 9 REASONS FOR MAINTENANCE Depending on facility procedures, repair of a valve may be required because of failure or loss of efficiency. Efficiency can be lost due to stem leaks, stem binding, improper operator adjustment, leaking while the disc is closed against the seat, leaks in flange mating surfaces, or other defects. Valves are not usually disassembled for periodic maintenance. In most instances, valves are not taken out of service until a loss of operating efficiency is noted. Of course, failure of a valve may require a complete overhaul. When performing maintenance, the manufacturer's instructions should be reviewed before proceeding with any disassembly work. 10 PACKING REMOVAL The first step in removing worn or damaged packing from a valve is to lockout and isolate the valve from all process flow. The next step is to slacken and remove the gland follower nuts as shown in Fig. 8-16 Depending on the type of valve, the gland follower nuts may be threaded onto dogs, in which case they may be swung aside.
Fig. 8-16. Gland Follower Nuts being Removed After the gland follower nuts have been removed, the gland follower can be positioned and wired next to the yoke. If the gland follower is of a split type, it can be removed completely.
Lesson 8
Page 15
Valve Maintenance
The next step is to remove the packing gland as shown in Fig. 8-17. The packing gland is also positioned and wired next to the gland follower and/or yoke. In many applications, the packing gland is part of the gland follower.
Fig. 8-17. Wiring a Packing Gland Next to Gland Follower To remove the packing from the valve stuffing box, a flexible packing extractor is used as shown in Fig. 8-18.
Fig. 8-18. Flexible Packing Extractor The spiral end of the extractor is inserted and screwed into a packing ring. When the extractor has been firmly screwed into a packing ring it is then removed as shown in Fig. 8-19. All remaining packing rings are removed in the same way.
Lesson 8
Page 16
Valve Maintenance
Fig. 8-19. Packing Ring Being Removed from a valve Stuffing box 11 PACKING INSTALLATION 11.1 MANUFACTURE OF VALVE PACKING RINGS
The first step is manufacturing packing rings is to determine the size and number of packing rings needed to repack a stuffing box and the type of packing material to be used. The type of packing material to be used will depend on the type of liquid or gas flowing through the piping system. The size and number of packing rings can be determined by referring to the manufacturer's specifications (information sheet supplied with the valve). These are usually kept in the plant maintenance office records. If the information sheets are not available, it will be necessary to measure the valve stuffing box to determine the size and number of packing rings. The packing ring size is determined by measuring the gap between the stuffing box wall and the stem outside diameter using a rule, as shown in Fig. 8-20 or inside calipers. The measurement should be recorded so that it is not forgotten.
Lesson 8
Page 17
Valve Maintenance
Fig. 8-20. Measuring a Valve Stuffing Box to Determine Packing size The next step is to determine the number of packing rings needed. This is done by measuring the depth of the stuffing box using a flexible rule. If there is limited space and a rule cannot be used, the measurement can be taken by inserting a piece of wire into the stuffing box. Use your thumb to mark the depth as shown in Fig. 8-21. When the wire has been removed, the distance from your thumb to the end of the wire can be measured with a rule. This measurement should also be recorded so that it is not forgotten.
Fig. 8-21. Measuring the Depth of a Valve Stuffing Box
Lesson 8
Page 18
Valve Maintenance
EXAMPLE OF RECORDED MEASUREMENTS Size of packing, width 1/4" Depth of stuffing box 1-5/16" Determine the size and number of packing rings as follows: Size, width of packing ring = 1/4" Number of Packing Rings = Depth of Stuffing Box Size of Packing
Number of Packing Rings =
1- 5 / 16" "
Number of Packing Rings =
To repack the stuffing box, 5 packing rings need to be cut from 1/4" thick packing.
11.2
MANUFACTURE BUTT JOINT PACKING RINGS
After the size and number of packing rings required to repack a valve has been determined, select the correct packing material. This will be determined by the type of liquid or gas flowing through the piping system. When the correct packing material has been selected, the next step is to manufacture the packing rings. Packing rings are cut on a mandrel. This is a piece of round bar which is the same diameter as the valve stem. The packing material is wrapped around the mandrel the correct number of times, i.e.: 5 times if 5 packing rings are required. The packing material is held in position on the mandrel. A sharp knife is then used to cut the packing material lengthwise as shown in Fig. 8-22. The packing material must be cut in a straight line along the mandrel.
Lesson 8
Page 19
Valve Maintenance
Fig. 8-22. Cutting Butt Joint Packing Rings on a Mandrel
11.3
MANUFACTURE SKIVE (45 RINGS
ANGLE) JOINT PACKING
After the size and number of packing rings required to repack a pump has been determined, select the correct packing material. This will be determined by the type of liquid or gas flowing through the piping system. When the correct packing material has been selected, the next step is to manufacture the packing rings. Packing rings are cut on a mandrel. This is a piece of round bar which is the same diameter as the valve stem. The packing material is wrapped around the mandrel the correct number of timeis 5 times if 5 packing rings are required. The packing material is held in position on the mandrel. A sharp knife is then used to cut the packing material lengthwise at an angle of 45 as shown in Fig. 8-23.
Lesson 8
Page 20
Valve Maintenance
Fig. 8-23. Cutting A Skive (45 Angle) Joint Packing Rings on a Mandrel 11.4 INSTALL PACKING
Before packing can be installed in a valve packing gland assembly, the stuffing box, stem and packing gland should be cleaned using a solvent. If dirt or sand is allowed to get into the stuffing box, it will cause damage to the stem and packing. After cleaning, the stem and packing gland should be inspected for damage and wear. To install the packing, a packing ring is placed around the stem as shown in Fig. 8-24.
Fig. 8-24. A Packing Ring being placed around a Valve Stem The packing ring is then pushed down and seated in the bottom of the stuffing box using the packing gland.
Lesson 8
Page 21
Valve Maintenance
On larger valves, a split bushing can be used to install and seat the packing rings. Fig. 8-25 shows a packing gland being used to install and seat a packing ring.
8-25. A Packing gland Being used to install and seat a Packing Ring When the first packing ring has been seated correctly, the packing gland is removed from the stuffing box. The remaining packing glands can be installed and seated using the same steps. But before doing so, they must be placed so that their butted ends face a different direction (staggered) from that of the previous packing ring. If the butted ends of all the packing rings were placed in a straight line, the liquid or gas flowing through the valve would leak through the gap./
Fig. 8-26. Angle Method of Staggering Packing Rings.(Butted Ends are Staggered at 90)
Lesson 8
Page 22
Valve Maintenance
Fig. 8-27. Alternative Method of Staggering Packing Rings When the last packing ring has been installed and seated, the packing gland, gland follower dogs, and gland follower are replaced. The gland follower nuts are then nipped down equally, while the valve hand wheel is turned. This is done so that the packing is not over compressed so as to cause the stem a seize.
Lesson 8
Page 23
Valve Maintenance
12
Valve Troubleshooting Table

Possible Problem
Leakage
Possible Causes
Gaskets Packing Loosen Bolts ( Bonnet, Flange Packing) Groove in Flange Seat Disc Packing over tight Thread Dirt & Scale Incorrect flow direction Stem damaged by improper maintenance procedures Piping and valve flanges are misaligned Gasket degradation due to exposure to high temperature Bent or damaged shafts/stems resulting in sticking or binding Plug and cage galling from overheating or selection of incompatible materials Stem and guide bushing galling Grit, debris, or welding slag preventing proper plug movement Buildup of viscous, sticky, or coking fluids impeding plug movement Undersized actuator I/P calibration underranged Incorrect flow direction Undersized actuator Bent, galled, or missing components interfering with proper operation Plug frozen by debris between plug and cage, stem and bushing, or plug and seat Excessive actuator force has welded plug into seat Plug slamming (from dynamic instability) has welded plug into seat Galling caused by high temperature Welding slag introduced during installation or during subsequent upstream retrofit or maintenance has bound components Mechanical obstruction to plug movement, e.g.: welding slag, pipeline debris
Corrective Action
Replace Adjust or replace Retighten Repair by welding or replace Repair or replace Repair or replace loosen Rethread and clean Clean Correct flow direction Replace Reinstall valve Replace with compatible materials Disassembly and repair Disassembly and repair. Replace with compatible trim. Disassembly and repair Disassemble, clean, and repair Select compatible valve style Replace Calibrate Correct flow direction Install stiffer spring or larger actuator Disassembly and repair Disassembly and repair Disassembly and repair Check flow direction, valve type, valve ratings Replace sticking components with compatible components Disassemble, clean, and repair
Passing Hard to operate
Disassemble, clean, and repair
Lesson 8
Page 24
Safety Valve
LESSON
9
LECTURE
Objectives
SAFETY VALVE
At the end of this lesson, the trainee will be able to demonstrate an understanding of Safety Valves. 1 PRESSURE Is a force per unit area. (1pound per sq.in.) (PSI) = .143 or kilo Pascal. 7 k Pascal = 1 PSI. 2 RUPTURE DISC Is a piece of metal on other material that is designed to rupture at a predetermined pressure: As per (Figure 9 1 and 9 2).
FIG: 9 1 2.1 Rebuckling or Reverse buckling
FIG: 9-2
another type of rupture disc is two piece component; one piece is the disc and the other is a frame that holds a sharp knife point. As per (Figure 9-3).
Lesson 9
Page 1
Safety Valve
FIG: 9-3 Rebuckling Disc Notice: 1. A rupture in a system will occur at the weakest point in that system. A rupture disc can protect a system from pressure damage because the rupture disc is the weakest point in a system, so it will rupture before any other part of the system is damage by excess pressure. Rupture disc may be connected to discharge piping to ensure the safe removal of pressurized fluid in the event of a rupture. When a rupture disc is replaced, the new disc must have the same pressure rating as the original disc. Advantages of rupture disc a) b) c) d) e) 2.3 1. Simple. Light weight. Fast opening. Relatively inexpensive. No maintenance.
2.
3.
4.
2.2
Disadvantages of rupture disc The major disadvantage of rupture discs is that they must be replaced when they rupture and this required shut down the system. When a rupture disc is used in a vacuum system, a support device is needed to hold the disc in place and prevent atmospheric press. A support device can be used to keep the rupture disc bulging out word. The rupture disc and the support
2.
Lesson 9
Page 2
Safety Valve
device fit into a holder that can be bolted in place between two flanges. As per (Figure 9-4).
FIG: 9 4 Rupture Disc Built- In Support
FIG: 9 5 Parts of a Typical Relief Valve
Lesson 9
Page 3
Safety Valve
Relief Valve To relieve excess pressure in a system. As per (Figure 9 5). Advantages of relief valve over rupture disc are: 1. 2. They close when system pressure returns to normal levels. They can be adjusted as necessary to maintain a very accurate set point.
Notice: Relief valves are used primarily on systems that handle pressurized liquids. The spring washer forms a flat surface on the top of the spring. The flat surface ensure even contact between the spring and the adjusting screw. The position of the adjusting screw is changed to adjust the tension of the spring. As the pressure increase over the set pressure, the valve disc will continue to lift, until it has risen as far as it can go. That point is called the fully open position of the valve. Accumulation of the valve
3.1
Is the difference between the pressure at which the disc begins to lift and the pressure at which the valve is fully open position. (Start open at 20 psi, full open at 25 psi, accumulation of the valve 5 psi). Lift or Travel: is the distance that the disc moves from the closed position to the fully open position. A relief valve remains in fully open position until the excess pressure in the system has been relieved. Difference between liquids and Gases: 1. 2. Volume. Compressibility. Gas take up much more space (volume) then liquid do, and the molecule of a gaseous substance can be squeezed closer together (compressed), while the molecules of a liquid can not.
Example: If one cubic inch of water (liquid) is boiled, the amount of steam (gas) that is produced will fill a space of over 1500 cubic inches, if press does not increase.
Lesson 9
Page 4
Safety Valve
FIG: 9 6 valve seat It is important that the mating surface of the disc and nozzle seat fit together perfectly. This will prevent the valve from leaking under pressure. It is also important that the seat is wide enough to carry the bearing load from the spring and narrow enough to eliminate simmer. For most safety relief valves of this type, the seat width is between .030 and .037. Set at width can be accurately measured using a measuring magnifier. The measuring magnifier is placed against the nozzle seat as shown in the (Figure 9 6) shows what you will see when you look through the eye piece of the magnifier.
Huddling Chamber Safety Valves As per (Figure 9-7) safety valves can be classified according to the way that they open and the number of adjusting rings that they contain. Figure 9 7 is cut way drawing of Huddling Chamber Safety Valve. The spindle is threaded past the disc threads so that it sits on the disc and acts like a ball joint. When the spindle is fully threaded into the disc the thread of the spindle are disengaged from the thread of the disc. In the position, normal vibrations of the valve can not separate the spindle from the disc or the disc from the seat. The disc of the huddling chamber safety valve is shaped quite differently from the disc of a relief valve. The safety valve disc has a lip that is not exposed to system pressure when the valve is closed. The disc in a huddling chamber safety valve is also called a feather.
Lesson 9
Page 5
Safety Valve
FIG: 9 7 4.1 Operation of Huddling Chamber Safety Valve The center portion of the disc in a huddling chamber safety valve is called pressure-sensing area. If the valve is set to open at 20 psi, the disc will begin to left off the seat when that pressure is reached. When this happens, the lip of the disc which was not previously exposed to system pressure, suddenly is exposed to system pressure. This larger area of the disc exposed to the same a mount of system pressure (20 psi) so there is more total force exerted on the bottom of the disc. Force = pressure X Area there for, an increase in area results in a increase in force, while pressure remains the same. The increased force causes the disc to pop open to a bout a 60% open position.
Lesson 9
Page 6
Safety Valve
At this point two force hold the disc at 60% open position: 1. System pressure. 2. The velocity of the escaping steam striking the disc.
In terms of relieving excess pressure, if one cubic foot water must be released to relieve one psi of pressure in water system, then 1500 cubic feet of steam would have to released from a steam system of the same size and pressure to relieve same a mount of pressure one psi. There are two major reasons for not using relief valve on gas steam systems: 1. A relief valve open gradually. It does not open juicily enough to let out the large volume of gas or steam that is needed to relieve excess pressure in the system. The possibility of damage to the valve seat and disc. When a relief valve first begins to open the space between the valve disc and its seat is extremely small. The velocity of the steam or gas escaping through that small space could actually cut the metal. This damage called steam cut Wire drawn in contrast, the initial popping action of the safety valve instantly provides a relatively wide escape route for excess gas or steam. Because the escape route is wide, the velocity of the escaping fluid is relatively low. By reducing the velocity of the gas or steam in this way, the popping action of the safety valve minimizes the steam cutting that would occurs if the disc were exposed to a high velocity flow of steam. If the system pressure continues to increase the velocity of the escaping steam will also increase and the two forces will lift the disc even higher. After the initial popping to the 60% open position, the valve open more gradually (if system press. continues to increase) until it reached the fully open position. The valve does not close until the system press drops a predetermined a mount below the set point (20 psi). then the valve snaps shut quickly due to the shape of the disc, to cut off the flow of steam and thus minimize steam cutting. This occurs at about the 20% open position, as the force of the escaping steam is lost. A small cushion of steam trapped in the huddling chamber of the valve keeps the disc and the seat from slamming together hard enough to be damaged.
2.
Lesson 9
Page 7
Safety Valve
4.2
The basic concepts of safety valve operation:
Popping pressure: Is the pressure at which the valve will pop open. Can be adjusted by adjusting screw. Simmering: When the press. in a system reaches the popping press. of a safety valve, the disc begins to rise off its seat. The valve does not pop open immediately, because the press. has no time to act on the lip of the disc. The condition in which the disc has lifted only slightly is called simmering. In most cases, simmering lasts for only a fraction of a second, until system press. acts on the lip of the disc and the valve pop open. Positive seating: When system press. drops below the popping press, the spring is able to snap the valve shut. When the disc is firmly in place against its seat, the valve is said to have positive seating. Positive seating is important, because it means that the valve will not leak. Blowdown or blowback: The difference between the popping press. of a valve and its positive seating press. is called Blowdown or Blowback. Can be adjusted by adjusting ring. Chattering: If the valve has a popping press. of 20 psi and also a positive seating press. of 20 psi. In this example, the blowdown is 0. After the excess press. is relieved, system press. start to drop. When it reaches 20 psi, the valve does not know whether it should remain closed or pop open again. The disc is likely jump up and down its seat until press. either increase enough to pop the valve open or decrease enough to keep it closed. This condition is known as chattering, because of the sound made by the disc as it moves up and down. Chattering can damage the disc and the seat, so it must be prevented. Chattering is prevented by blowdown, which insure that the popping press. and the position seating press. are different. [Abnormal rapid reciprocating movement of the disc on the seat] 4.3 For one Ring Safety Valve Adjustment The adjusting ring: When the adjusting ring is in the raised position, the escaping steam is directed right at the disc. The velocity of the escaping steam exerts a great deal of upward force, because most of the steam is aimed at the disc. This means that system press, must drop will below the popping press, of the valve before the spring can force the disc back onto its seat. Therefore, raising the adjusting ring increase the blowdown of the valve.
Lesson 9
Page 8
Safety Valve
If the adjusting ring is lowered, the escaping steam is not aimed directly at the disc with the adjusting ring in the lowered position, the valve will close against higher system pressure than it did when the ring was raised. As a result, the blowdown of the valve decrease.
The function of the adjusting ring, then, is to adjust the blewdown of the valve. The higher the ring, the higher the blowdown the lower the ring, the lower the blowdown.
FIG: 9 8 4.4 THE TWO-RING HUDDLING Chamber Safety Valve:
Have two adjusting rings see (Figure 9-8). An upper ring for: 1. 2. Adjusts the blowdown of the valve. Directs the escaping steam away from the disc.
The lower ring for: 1. 2. Directs the escaping system at the disc. Traps a cushion of steam to soften the metal to metal contact as the valve closes.
Lesson 9
Page 9
Safety Valve
The upper adjusting ring adjusts the blowdown of the valve by adjusting the size has a wide, straight path to the outlet. With the ring raised, little of the escaping steam acts on the disc, so the valve can close at higher system press. (The valve thus has a smaller blowdown). The a mount that the upper ring is raised is important, if the ring is raised too much, it might allow so much steam to escape without acting on the disc that the valve might not able to lift all the way.
If the upper adjusting ring is lowered, the escape route for the steam is narrowed, so more of the steam will act on the disc. Lowering the upper ring also directs the steam downward and thus creates a force called reactive force. Reactive force : is a type of force that is equal to the original force, but opposite in direction. Thus, the force of the pressurized gas or steam that is directed downward by the upper ring will exert an up ward force on the disc. When the upper ring is in its lower position, the combination of the narrowed escape route and the reactive force results in a greater blow down of the valve. The lower adjusting ring aims the escaping steam directly at the disc to insure a clean forceful popping action. If set too high the space will be too narrow. Steam will not be able to escape through the narrow space, and the blow down will be increased. There is also possibility that the disc hit the lower ring. If the lower ring set too low much of the steam escape with out hitting the disc. As a result the valve might simmer too long before popping open, or it might not pop open at all. The second function of the lower adjusting ring is to trap a cushion of steam that softens the metal to metal contact between the disc and the seat when the valve closes. If the lower ring is set too low, no cushion of steam is formed. After the rings have been properly set, they are locked in place, by tightening the ring pins that protrude through the valve body.
Lesson 9
Page 10
Safety Valve
FIG: 9 9 5 SAFETY-RELIEF VALVES As per (Figure 9 9). Is a valve that is suitable for use as either a safety or relief valve, depending on the application. Safety valves are commonly used in refineries, on system that contain liquid vapor mixture, and in some low pressure steam system. The valve shown in (Figure 9 9) is a safety relief valve that acts as a safety valve with the adjusting rings in one position and as a relief valves with the ring in another position. The construction is very similar to that of the nozzle reaction safety valve. The valve has a nozzle shaped and upper and lower adjusting rings. The valve set up for service as a safety valve by adjusting the lower ring to direct fluid against the disc, which will cause the valve to pop open. In this position, the lower ring will also trap a cushion of gas or steam to protect the valve from damage as it close. If the valve is to be used as a relief valve, the bottom-adjusting ring must be lowered so that fluid is not directed against the disc. That adjustment will allow the disc to open gradually instead of popping open.
Lesson 9
Page 11
Safety Valve
Adjustments to safety relief valves are made by the valve manufacture before the valves are sent to the plant for installation.
Plant maintenance personnel do not normally make the adjustment that converts safety relief valves from one type to the other.
FIG: 9 10 5.1 PILOT-ACTUATED RELIEF Valves
Are valves that have a separate sensing device that reacts to excess pressure conditions. This arrangement allows excess press. to be detected in one part of a system (such as a steam line) while the valve protects another port of the system (such as the boiler). Pilot actuated relief valves are also called power actuated pressure relief valve (P.A relief valves), electromatic relief valves, and pressure matic relief valves. The valve consists of two major components: As per (Figure 9 10). 1. The valve it self. 2. A separate pilot device that senses changes in press. and initiates the valve opening sequence
Lesson 9
Page 12
Safety Valve
Electrical relay
Pressuresensing tube Disc Solenoid Spring A pilot valve
Outlet
Seat Disc Clearance
Valve Body
Inlet
FIG: 9 11 The valve component of a typical pilot actuated relief valve, is shown in (Figure 9 - 11). The spring in this valve is below the disc, the disc opens down ward, allowing the steam to escape through the outlet at the upper past of the valve body. The valve also has a disc guide, which is a sleeve that aligns the disc.
As shown in (Figure 9 11) there is a small opening between the disc guide and the disc that allows system fluid to pass through from the inlet to the bottom of the main disc. Because of this feature, system pressure is exerted on both the top and bottom of the disc during normal system operation. If system puss. Increase, it increase on both sides of the disc. The valve will not open however, because the press. on the top of the disc counterbalance the pressure on the bottom. The opening of a pilot actuated relief valve is initiated by a separate pilot device, such as the one shown in (Figure 9 11). The pilot device consists of: 1. 2. 3. 4. A pressuresensing tube. An electrical relay. A solenoid. A pilot valve.
The pilot device is set to open at a predetermined pressure. Increase in system pressure is detected by the press. sensing tube. When system press. reaches the predetermined level, the pressure sensing tube activates the electrical relay. The electrical relay closes an electrical circuit and energizes the solenoid. The solenoid then lifts the pilot valve, and the excess pressure is relieved.
The excess pressure that is relieved by the pilot valve comes from below the disc in the main valve. (The amount of press. that the pilot valve is capable of relieving is greater than the amount that could leak between the disc and the disc guide). When this press. is relieved, the
Lesson 9
Page 13
Safety Valve
only press, remaining on the disc is the pressure that is above it. With no press. below the disc to counterbalance it, the pressure above the disc easily overcomes the spring tension, so the valve opens to release system fluid through the out let above the disc. When system press, returns to normal, the pilot valve close. Pressure then builds up again below the main valve disc and helps the spring to hold the disc closed. Pilot actuated relief valve are used on gas and steam systems, like safety valves, they pop open and they have a predetermined a mount of blowdown to prevent chattering. Pilot actuated relief valves are often used on systems that use safety valves in such instance, the pilot actuated relief valves are set to open at lower system press. than the safety valves. This type of arrangement saves wear and tear on safety valves and prevents the costly shutdowns that would be required for safety valves repairs. By law, safety valves cannot be isolated from the systems that they protect, because of the damage that might occur if the systems were operated with out protection. There fore, whenever a safety valve is damaged, its system must be shut down while repairs are made. Pilot actuated valves, however, can be isolated from a system, because they are not part of the system safeguards. These valves can be used and then repaired, if necessary, with out having to shut down the system.
Troubleshooting
FIG: 9 - 12
Lesson 9
Page 14
Safety Valve
External inspection of this type of valve usually in valves checking the following: 1. 2. The lock wire on the adjusting ring pin. Signs of leakage a round the Yoke or bonnet bolts and the discharge piping bolts. The temperature of the valve and the discharge piping. Condition of the catch tray on the discharge piping. (Figure 9 12). Signs of possible leakage from the discharge piping out let.
3. 4.
5.
If a safety valve is suspected, a stethoscope is used to listen for a hissing or whistling sound. Another way to detect leak through is to go out side and check the exhaust pipe form the valve.
The catch tray on the discharge piping collects condensate that comes down the discharge piping when the valve is open. It should be clean and dry. If not cleaned, then it is possible for condensate, dirt, and corrosion particles coming down into the valve seat disc. There may be some sure signs that the valve is leaking through between the disc and seat. Two possible cause of such leakage are: 1. The valve did not reseat correctly after its last popping. 2. Some kind of forcing material, like ash, dirt or rust particles, is trapped between the seat and the feather. These can be corrected by hand lifting the valve. Hand lifting clears foreign material out of the valve and gives the feather a chance to reseat properly.
The operator must know when a safety valve is to be hand lifted so that he can compensate for the drop in system press. And keep it from take emergency measures to raise press. Or to shut the system down. Such an error would be costly and perhaps dangerous. Hand lifting a safety valve requires some important safety precaution Ear protection, safety goggles or a full-face shield, and gloves should all be worn.
Lesson 9
Page 15
Safety Valve
FIG: 9 13 1. Whenever the valve hand lifting, a great deal of hot, pressurized fluid is released, so the person lifting the valve should be as far a way from the valve as possible. As a safety precaution, a hook and lanyard are connected to lifting lever so that the valve can be lifted from a distant (Figure 9 13). 2. The valve should be held open form only 2 or 3 seconds. If it is held open any longer, the rush of steam could damage the feather. Before any work is started on a safety valve, it is important to get as much information as possible about the valve. Atypical valve nameplate provides these data. Before a valve is disassembled, it should be cleaned to keep the dirt and corrosion particles on the outside of the valve from getting inside the valve and damaging it. To maintain proper set points, the position of the compression screw, the upper adjusting ring, and lower adjusting ring must be precisely measured and recorded before these parts are removed from the safety valve. The parts of safety valve according to the order in which they are removed: 1. 2. 3. 4. 5. 6. 7. Hand lifting assembly. Cap. Lock nut and lifting nut. Compression screw. Yoke nuts and yoke. Spindle and feather. Upper and lower adjusting rings.
Lesson 9
Page 16
Safety Valve
Safety valve parts are cleaned with solvent and a brush or by dipping directly in the solvent. Lapping uses abrasives in the form of a lapping compound to restore damaged surfaces. When a lapping plate is used, the basic lapping motion is figure eight motion. Damage to a valve seat usually appears in the form of cracks or steam cutting. The basic difference between lapping a flat valve seat and lapping a valve seat that is not flat is the shape of the lapping tool. The action that can be taken when a valve seat that is a permanent port of the valve body is severely damage are: 1. Use a special tool to restore the damage surface. 2. Mount the valve in a lathe and remachine the seat.
Extensive maintenance on a valve seat can also change the lift of the valve. Lift adjustment can be made by moving the lift stop collar up (to decrease the lift) or down (to increase the lift). A valve that dose not have a lift stop collar for making lift adjustment might have to be replaced. Adjusting rings are subject to damage in the form of nicks, cracks, and steam cutting, but this does not happen very often. The ring still require careful inspection, however, because any damage might cause them to fail when the valve is put back in service Damage adjusting rings are always replaced. The spindle must also be inspected carefully for cracks and other signs of damage. The end of the spindle that fits into the feather must be smooth and round. Because it acts like a ball and socket joint inside the feather so that the feather can align itself properly with the valve seat with out damaging the seat. Flat spots on that end of the spindle can cause uneven contact and unwanted friction between the spindle and the feather. The correct position of the lower adjusting ring determined by a lapping block laid flat against the valve seat is used as a reference point. The ring is adjusted until there is full contact between the seating surface and the lapping block. The ring is then turned and the notches are courted. The ring is in the proper position when the number of notches equals the number given in the notes made during disassembly.
Lesson 9
Page 17
Safety Valve
The tip of the spindle is lubricated before it is screwed into the feather because lubrication minimizes the friction caused be the side to side motion when the valve is in operation. Perfect contact between the feather and the valve seat is necessary in order to prevent passing (steam leak through the valve between the two port). The exact position of the upper ring is measured first. Witness marks can be made with an indelible marking pen and used as described in the procedure for removing the compression screw. (to avoid damaging the ring, a hammer and a punch are not used to make the witness marks). The measurement can also be taken by laying rigid rule across the lip of the valve body and then placing a second rule vertically with one end-resting flat against the top of the upper ring. The measurement is taken on the vertical rule at the pint where it intersects with the horizontal rule. The measurement must be exact so that the adjusting ring can be replaced in the same position during reassembly. Method for testing the contact between the feather and the valve seat: Apply a thin layer of Prussian blue around the seating surface of the feather and insert it into the valve seat. A thin uniform circle of blue on the valve seat indicates correct fit.
When the compression screw has been turned the exact number of time stated in the notes, its position is checked. The tips of the divider used during disassembly are inserted into the witness marks. If the tips of the divide fit precisely into the marks, position of the compression screw is correct. A safety valve should be tested after reassemble to make sure that it has been reassembled correctly. Popping set point can be adjusted by turning the compression screw. A hydrostatic test is not a test of safety valve, it is a test of the system that the safety valve protect. The purpose of a hydrostatic test is to determine whether or not a system can tolerate excessively high pressure in case of an emergency. Causes of a bent spindle are: 1. Careless handling. 2. Improper gagging.
Lesson 9
Page 18
Safety Valve
Two methods used to test safety valves are: 1. Raise system pressure. 2. Use an auxiliary device to lift the spindle only for popping adjustment.
6.1
Blue Check a Valve Seat
After lapping the valve seat, a blue check should be performed to make sure that the meeting surface of the disc and seat fit together properly. Apply alight, even coat of bluing and set the disc on the valve seat and rotate it a quarter turn (in one direction only remove the disc and check for an unbroken, even blue line around the disc seating area. Gagging procedure: 1. 2. 3. 4. 5. Remove the hand lifting lever. Remove the protective cap from the top of the spindle. Align the gag spindle with the valve spindle. Attach the gag jaws to the yoke. Tighten the gag finger tight only. (A wrench in never used on a gag, it might damage the valve by making the gag too tight a condition called over gagging)
If a leaking safety valve is noted during a hydrostatic test the system pressure reduced and then tightens the gag further. After the hydrostatic test has completed, it is essential to remove the gags from all safety valves because gagged valves can not protect the system from over pressure conditions.
Safety Valve adjustment Blow Down Present = Pop Press - Reset Press 100 = % Poping Press
Upper Ring: to adjust the blow down press.
If Blow down present more than 5% turn upper ring Counter clock to decrease the blowdown present.
If Blow down present less to increase turn clock wise the upper ring
Lesson 9
Page 19
Safety Valve
Lower Ring: to adjust the simmering of the safety valve. To increase or decrease Popping Press. Tight or loose the nut. Each nut flat increase the popping press 2 or 3 bars One flat
Installation of safety valve should be a way 8 to 10 times of the pipe diameter away from bend or elbow.
Use cast iron for lapping of the safety valve (Ring lap )
Never gag the safety valve until the boiler pressure retch 75% or 80% of the normal pressure. Never gag all the S/V during the test leave one with out gag. This one should be with hand lever on it safety.
(1) Blow Down (2) Short Blow Down (3) Long
Ok Blow Down
Pop
Reset
Pop
Reset
Reset
For adjustment of the S/V: 1. Shattering from lower ring. 2. Simmering from lower ring should be left up. 3. Lower ring should be 3 to 5 notches from straight adage of the or Nozzle of the S/V. Straight adage Seat
Hand popping should be done before the test take place to clean the seat and disc and should be done before the set pressure by 7 to 10% of the set pressure. Release nut should be checked for final assembly if the pin in position so it will restrict the movement of the spindle so the valve will not close.
Lesson 9
Page 20
Safety Valve
High pressure S/F adjustment: 1. Popping pressure (open). 2. Set pressure Near 1% (from the name plate). 3. Reset pressure
Blow down = (Pop Pr.) (Reset Pr.)/popping pursuer x 100 = %
Good Blow down = 3 to 5 % of the pop pr.
Percent
% =
Blow Down Pop Pr.
100
To increase the B/D take the upper Ring down. Decrease the B/D take the upper Ring up 10 to 20 notches. Secondary adjustment for B/D if the upper ring not work good for adjustment then adjust caller for adjusting B/D opposite to upper ring (Down to decrease the B/D and up to increase the B/D of the Safety valve).
Lesson 9
Page 21

Basic Valves

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Basic Valves

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Kingdom of Saudi Arabia Saline Water Conversion Corporation

General Directorate Of Training Programs Training Center JUBAIL

VALVES & VALVE MAINTENANCE

Valve & valve maintenance

Opening or closing a circuit. Controlling of flow.

Valve & valve maintenance

VALVE CLASSIFICATION AND TYPES

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Fig. 1-4. Straight - Through Flow. 2.

Fig. 1-5. Angled Globe Valve.

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Fig. 1-6. Threaded and Welded Seat Attachment

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BODY FLANGED ENDS GASKET BONNET YOKE STEM HAND WHEEL

GATE SEAT RINGS

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Fig. 2-2 Rising Stem

Fig. 2-3. Non-rising stem gate valve 3.1 NON RISING-STEM

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2-6. Solid Split Gate

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Fig. 2-9 Gate valve with lubricant sale system

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Fig 2-10 Gate valves 5.1 IN-SERVICE INSPECTION:

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Fig. 3-4. Ball Shaped Disc. 2.2 THE COMPOSITION DISC :

A. Ball Type disc

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Fig. 3-5. Composition Disc 2.3 THE PLUG-TYPE DISC:

Fig. 3-6. Plug-Type Disc

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THE NEEDLE DISC:

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