Valve preventive

maintenance routine
(Valve PMR)

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 VALVE BASICS
What is a valve?
A device that regulates the flow of gases, liquids or loose
materials through an aperture, such as a pipe, by opening,
closing or obstructing a port or passageway

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 VALVE BASICS
Introduction to the Types of Valves
• Because of the diversity of the types of systems, fluids, and
environments in which valves must operate, a vast array of valve types
have been developed. Examples of the common types are the globe
valve, gate valve, ball valve, plug valve, butterfly valve, diaphragm
valve, check valve, pinch valve, and safety valve. Each type of valve has
been designed to meet specific needs.

• Some valves are capable of throttling flow, other valve types can only
stop flow, others work well in corrosive systems, and others handle
high pressure fluids. Each valve type has certain inherent advantages
and disadvantages. Understanding these differences and how they
effect the valve's application or operation is necessary for the
successful operation of a facility.

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 VALVE BASICS
Introduction to the Types of Valves
Although all valves have the same basic components and function to
control flow in some fashion, the method of controlling the flow can
vary dramatically. In general, there are four methods of controlling
flow through a valve
1. Move a disc, or plug into or against an orifice (for example, globe
or needle type valve).
2. Slide a flat, cylindrical, or spherical surface across an orifice (for
example, gate valves).
3. Rotate a disc or ellipse about a shaft extending across the
diameter of an orifice (for example, a butterfly or ball valve).
4. Move a flexible material into the flow passage (for example,
diaphragm and pinch valves).
5. Each method of controlling flow has characteristics that make it
the best choice for a given application of function.

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 VALVE BASICS
How do valves regulate flow?

• Isolates flow: on/off functions

• Controls flow: volume functions
• Checks flow: directional functions

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 VALVE BASICS
Isolating valves

• Isolating valves also called “block valves”

• Possible valve choices for isolating service
–Gate
–Ball
–Butterfly
–Plug

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 VALVE BASICS
Control and regulating valves
• Control valves are prime examples
• Possible valve choices for control and
regulating
–Globe
–Butterfly
–Ball
–Plug

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 VALVE BASICS
Check valves

• Swing check most common

• Many globe valves can be made
“stop check” or non-return
types

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 VALVE BASICS
Check valves

Ball Check Valves

Lift Check Valves Swing Check Valves

Butterfly Check Valves Stop Check Valves Cone Check Valves

 VALVE BASICS
Safety and pressure relief valves

§ Special on/off valves

§ Designed to:
–Open and relieve excess pressure
–Re-close after normal conditions are restored
–Function when normal operating controls fail
§ Not designed to control normal operating
pressure
§ Most critical valve in pressurized systems
§ Referred to as PRVs

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 VALVE BASICS
Safety and pressure relief valves
 VALVE BASICS
Safety and pressure relief valves
Relief and safety valves prevent equipment damage by
relieving accidental over-pressurization of fluid systems.
The main difference between a relief valve and a safety
valve is the extent of opening at the set point pressure.

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 VALVE BASICS

Reducing Valves

Reducing valves automatically

reduce supply pressure to a
preselected pressure as long as the
supply pressure is at least as high
as the selected pressure. As
illustrated in the Figure, the Reducing Valves
principal parts of the reducing valve
are the main valve; an upward-
seating valve that has a piston on
top of its valve stem, an upward-
seating auxiliary (or controlling)
valve, a controlling diaphragm, and
an adjusting spring and screw.
 VALVE BASICS
common valves
• Gate
• Globe
• Ball
• Check
• Butterfly
• Plug
• Diaphragm Valve
• Angle valve
• Needle Valve
• Float valve

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 VALVE BASICS
Gate valves
• Mature design.
• Simple construction with few moving
parts.
• Not recommended for throttling service.
• Relatively easy and inexpensive to
manufacture.
• Easy to repair.
• Heavy design compared to butterfly and
ball valves.

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 VALVE BASICS
Gate valves
Solid Wedge
The solid wedge gate valve shown in
the figure is the most commonly used
disk because of its simplicity and
strength. A valve with this type of wedge
may be installed in any position and it is
suitable for almost all fluids. It is
practical for turbulent flow.

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 VALVE BASICS
Gate valves
Flexible Wedge
The flexible wedge gate valve
illustrated in the Figure is a one-piece
disk with a cut around the perimeter to
improve the ability to match error or
change in the angle between the seats.
The cut varies in size, shape, and depth.
A shallow, narrow cut gives little
flexibility but retains strength. A deeper
and wider cut, or cast-in recess, leaves
little material at the center, which allows
more flexibility but compromises
strength.

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 VALVE BASICS
Gate valves
Split Wedge
Split wedge gate valves, as shown in
Figure , are of the ball and socket
design. These are self-adjusting and self
aligning to both seating surfaces. The
disk is free to adjust itself to the seating
surface if one-half of the disk is slightly
out of alignment because of foreign
matter lodged between the disk half and
the seat ring.

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 VALVE BASICS
Globe valves
• Primarily a regulating or throttling
valve.
• Basic design over 150 years old.
• Called a globe due to round body
shape.
• Poor flow path; much fluid friction.
• Generally not made in very large sizes.
• Usually a unidirectional installation.
• May be made in stop-check
configuration.
• Low repair cost.

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 VALVE BASICS
Globe valves

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 VALVE BASICS
Globe valves

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 VALVE BASICS

Ball valves
• Relatively new valve style (since 1950).
• May be resilient or metal seated.
• Can be used for blocking or regulating
flow.
• Two main designs: floating and
trunnion.
• Resilient seated typically.
–Use Teflon for seat material
–Have lower maximum temperature
rating of about 450oF.
• Compact design.
• Moderate repair cost.

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 VALVE BASICS

Ball valves

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 VALVE BASICS

Plug valves
• Oldest valve design, developed 2000
years ago!
• Available either lubricated or lined.
• Can be used for blocking or regulating
flow.
• Lubricated types used for hydrocarbon
service.
• Lined types popular in chemical
industry.
• In some cases replaced by ball and
butterfly designs.
• Moderately expensive to repair.

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 VALVE BASICS

Butterfly Valves
• Center-hinged swinging disc.
• Low pressure and low temperature
designs are resilient seated, usually
rubber lined.
• Can be used for blocking or regulating
• High performance types are metal
seated.
• Often double and triple “offset” to
reduce closure torque.
• Relatively expensive to repair.

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 VALVE BASICS

Diaphragm Valves
A diaphragm valve is a linear motion valve that is used to
start, regulate, and stop fluid flow. The name is derived
from its flexible disk, which mates with a seat located in the
open area at the top of the valve body to form a seal. A
diaphragm valve is illustrated in the Figure .

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 VALVE BASICS
Needle Valves
A needle valve, as shown in Figure 20,
is used to make relatively fine
adjustments in the amount of fluid
flow. The distinguishing characteristic
of a needle valve is the long, tapered,
needlelike point on the end of the valve
stem. This "needle" acts as a disk. The
longer part of the needle is smaller
than the orifice in the valve seat and
passes through the orifice before the
needle seats.

7/5/2021 27
 VALVE BASICS

Comparison between four types of

common valves

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 VALVE BASICS
Float valves
The float valve is a simple
mechanical liquid level controller.
A float detects changes of
elevation in the liquid free surface
and opens or closes a valve.

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 VALVE BASICS
Pinch valves

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 VALVE BASICS
Classification of valves based on the
type of motion

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 VALVE BASICS
Market segments
• Municipal water and wastewater.
• Home plumbing systems.
• Heating, ventilating and air conditioning
(HVAC).
• Fire protection.
• General industry.
• Power.
• Oil, gas and refining.

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 VALVE BASICS
Power –fossil fuel plants
• Steam generating plants.
• Materials: carbon steel to low alloy.
• Valve sizes: 2" to 16“.
• Operating conditions:
Ø high temperatures,
Ø high pressure

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 VALVE BASICS
Oil, gas and refining

• Largest variety of materials and types

• Materials: steel through super alloy
• Valve types: all
• Valve sizes: ½" through 48"
• Operating conditions:
Ø cryogenic to 1000°F,
Ø low to high pressures
• Media: water , hydrocarbons to
hydrofluoric acid.

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 VALVE BASICS
common valves symbols

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Valve Components

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Valve Components

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 Valve Components

Valve Body

• The body, sometimes called the shell,

is the primary pressure boundary of a
valve. It serves as the principal
element of a valve assembly because
it is the framework that holds
everything together.
• The body, the first pressure boundary
of a valve, resists fluid pressure loads
from connecting piping. It receives
inlet and outlet piping through
threaded, bolted, or welded joints.

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 Valve Components

Valve Body

• Valve bodies are cast or

forged into a variety of
shapes. Although a sphere
or a cylinder would
theoretically be the most
economical shape to resist
fluid pressure when a valve
is open, there are many
other considerations.

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 Valve Components

Bonnet designs

• Screwed or threaded.
• Union bonnet.
• Bolted bonnet, flat gasket.
• Bolted, ring-type joint.
• Welded.
• Pressure seal.

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 Valve Components

Screwed or threaded

• Oldest commercial design.

• Usually on bronze valves.
• Used on some hydraulic
valves.
• Not allowed in most
refineries and petrochemical
plant process service.

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 Valve Components

Bolted bonnet, flat

gasket
• Most popular current design.
• Utilizes a minimum of four bolts.
• Adaptable to many gasket types.
• Not used much for pressure classes
above 1500.
• Higher pressure classes (above
Class 1500) have gone to pressure
seal type bonnets.

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 Valve Components

Bolted ring joint type

• Similar to regular bolted bonnet.
• Uses a carbon steel ring gasket
softer than the body and bonnet
material if possible.
• Useful for higher pressures and
temperatures than flat gasket bolted
bonnets.

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 Valve Components

Pressure seal bonnet

• Invented in early 1940s.

• Much lighter than bolted bonnet.
• Employs a soft wedge-shaped
carbon steel ring, sometimes plated
with silver.
• Newest designs use a stainless-
steel-contained graphite filler.
• Not for pressure classes below 600.
• Require internal pressure to
energize seal.

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 Valve Components

Welded bonnet

• Used in sizes through 24”

before pressure seals were
invented.
• Commonly used on API 602
valves ½" through 2“.
• Used in combination with a
bolted bonnet as a “lip seal”.
• Excellent for fugitive emissions
containment.

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 Valve Components

Common end connections

• Threaded (½" to 2")
• Socket weld (½" to 2")
• Buttweld (generally above 2")
• Flanged (generally above 2")
–Raised face
–Flat face
–Ring-type joint

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 Valve Components

Common end connection – examples

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 Valve Components

Other end connections

• Raised face tongue and

groove.
• Brazed ends.
• Mechanical clamping
–Grayloc
–Victaulic
–Sanitary

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 Valve Components

Handle or actuator
A handle is used to manually control a valve from
outside the valve body. Automatically controlled
valves often do not have handles, but some may have
a handle (or something similar) anyway to manually
override automatic control, such as a stop-check
valve. An actuator is a mechanism or device to
automatically or remotely control a valve from
outside the body.
 Valve Components

Valve Trim
The internal elements of a valve are
collectively referred to as a valve's
trim. The trim typically includes a
disk, seat, stem, and sleeves needed
to guide the stem. A valve's
performance is determined by the
disk and seat interface and the
relation of the disk position to the
seat.
Valve Components

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 Valve Components

Disc
A disc or valve member is a movable obstruction
inside the stationary body that adjustably
restricts flow through the valve. Although
traditionally disc-shaped, discs come in various
shapes. Depending on the type of valve, a disc
can move linearly inside a valve, or rotate on the
stem (as in a butterfly valve), or rotate on a hinge
or trunnion (as in a check valve). A ball is a round
valve member with one or more paths between
ports passing through it.
 Valve Components

Seat

The seat is the interior surface of the body which

contacts the disc to form a leak-tight seal. In
discs that move linearly or swing on a hinge or
trunnion, the disc comes into contact with the
seat only when the valve is shut. In disks that
rotate, the seat is always in contact with the
disk, but the area of contact changes as the disc
is turned. The seat always remains stationary
relative to the body. Seats are classified by
whether they are cut directly into the body, or if
they are made of a different material:
 Valve Components
Seat
Hard seats are integral to the valve body.
Nearly all hard seated metal valves have a small
amount of leakage.
Soft seats are fitted to the valve body and
made of softer materials such as PTFE or various
elastomers such as NBR, EPDM, or FKM
depending on the maximum operating
temperature.
A closed soft seated valve is much less liable to
leak when shut while hard seated valves are
more durable. Gate, globe, and check valves are
usually hard seated while butterfly, ball, plug,
and diaphragm valves are usually soft seated.
 Valve Components
Stem
The stem transmits motion from the handle or
controlling device to the disc. The stem typically
passes through the bonnet when present. In some
cases, the stem and the disc can be combined in
one piece, or the stem and the handle are
combined in one piece.
The motion transmitted by the stem may be a
linear force, a rotational torque, or some
combination of these(Angle valve using torque
reactor pin and Hub Assembly). The valve and
stem can be threaded such that the stem can be
screwed into or out of the valve by turning it in
one direction or the other, thus moving the disc
back or forth inside the body.
 Valve Components
Stem
Packing is often used between the stem and the
bonnet to maintain a seal. Some valves have no
external control and do not need a stem as in
most check valves.
Valves whose disc is between the seat and the
stem and where the stem moves in a direction
into the valve to shut it are normally-seated or
front seated. Valves whose seat is between the
disc and the stem and where the stem moves in a
direction out of the valve to shut it are reverse-
seated or back seated. These terms don't apply to
valves with no stem or valves using rotors.
 Valve Components
Stem
The stem, which connects the actuator and disk, is responsible for
positioning the disk. Stems are typically forged and connected to the
disk by threaded or welded joints. For valve designs requiring stem
packing or sealing to prevent leakage, a fine surface finish of the
stem in the area of the seal is necessary. Typically, a stem is not
considered a pressure boundary part.

Non rising Stems Rising Stems

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 Valve Components
Types of Stems
1- RISING STEM WITH OUTSIDE SCREW AND YOKE

The exterior of the stem is threaded, while the portion of the stem in the
valve is smooth. The stem threads are isolated from the flow medium by
the stem packing. Two different styles of these designs are available;
one with the handwheel attached to the stem, so they can rise together,
and the other with a threaded sleeve that causes the stem to rise
through the handwheel.

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 Valve Components
Types of Stems
2- RISING STEM WITH INSIDE SCREW

The threaded part of the stem is inside the valve body, and the stem
packing along the smooth section that is exposed to the atmosphere
outside. In this case, the stem threads are in contact with the flow
medium. When rotated, the stem and the handwheel to rise together to
open the valve.

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 Valve Components
Types of Stems
3- NON RISING STEM WITH INSIDE SCREW

The threaded part of the stem is inside the valve and does not rise. The
valve disc travels along the stem, like a nut if the stem is rotated. Stem
threads are exposed to the flow medium, and as such, are subjected to
the impact. That is why this model is used when space is limited to allow
linear movement, and the flow medium does not cause erosion,
corrosion or abrasion of the stem material.

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 Valve Components
Types of Stems
4- SLIDING STEM

This valve stem does not rotate or turn. It

slides in and out the valve to open or close
the valve. This design is used in hand-
operated lever rapid opening valves. It is
also used in control valves are operated by
hydraulic or pneumatic cylinders.

5- ROTARY STEM

This is a commonly used model in ball, plug,

and Butterfly valves. A quarter-turn motion
of the stem open or close the valve.

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 Valve Components
Yoke :
A Yoke connects the valve body or bonnet with
the actuating mechanism. The top of the Yoke
holding a Yoke nut, stem nut, or Yoke bushing
and the valve stem passes through it. A Yoke
usually has openings to allow access to the
stuffing box, actuator links, etc.. Structurally, a
Yoke must be strong enough to withstand
forces, moments, and torque developed by the
actuator.

YOKE NUT
A Yoke nut is an internally threaded nut and is
placed in the top of a Yoke by which the stem
passes

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 Valve Components

Valve Actuator
The actuator operates the stem and disk assembly. An actuator may be a
manually operated hand wheel, manual lever, motor operator, solenoid
operator, pneumatic operator, or hydraulic ram. In some designs, the
actuator is supported by the bonnet. In other designs, a yoke mounted to
the bonnet supports the actuator.
 Valve Components

Valve Packing
Most valves use some form of packing to prevent leakage from the space
between the stem and the bonnet. Packing is commonly a fibrous
material (such as flax) or another compound (such as Teflon) that forms a
seal between the internal parts of a valve and the outside where the
stem extends through the body.