Pipeline Valves

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 Table of Contents
1. Introduction to Valves ........................................................................................................... 4
2. Valve Structure ..................................................................................................................... 5
2.1. Valve Body ...................................................................................................................... 5
2.2. Valve Bonnet ................................................................................................................... 5
2.3. Valve Trim ....................................................................................................................... 6
2.4. Valve Disk and Seat ....................................................................................................... 6
2.5. Valve Stem ...................................................................................................................... 7
2.6. Valve Actuator ................................................................................................................ 8
3. Classification of Valves ........................................................................................................ 9
3.1. Class Ratings ................................................................................................................. 9
4. Types of Valves .................................................................................................................... 10
4.1. Gate valves .................................................................................................................... 10
4.1.1. Construction of a Gate valve .................................................................................. 10
4.1.2. Disks of a Gate valve ............................................................................................... 11
4.1.3. Stem of a Gate valve ............................................................................................... 12
4.1.4. Seats of a Gate valve ............................................................................................... 12
4.1.5. Advantages and disadvantages of Gate valves ................................................... 13
4.2. Globe valves ................................................................................................................... 13
4.2.1. Body designs of Globe valves ................................................................................. 13
4.2.2. Disk & Seat & Stem of Globe valves ...................................................................... 15
4.2.3. Construction of a Globe valve ................................................................................. 15
4.2.4. Typical Applications of Globe valves ...................................................................... 16
4.3. Ball valves ....................................................................................................................... 17

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 4.3.1. Materials - Design - Bonnet ...................................................................................... 18
4.3.2. Ball valves applications ............................................................................................ 18
4.3.3. Advantages and disadvantages of Ball valves ...................................................... 18
4.4. Butterfly valves ................................................................................................................ 19
4.4.1. Types of Butterfly valves .......................................................................................... 20
4.4.2. Butterfly valve Seat Construction ............................................................................ 20
4.4.3. Butterfly valve Body Construction .......................................................................... 20
4.4.4. Seat Disk and Stem of a Butterfly valve ................................................................. 21
4.4.5. Typical applications of Butterfly valves ................................................................. 22
4.4.6. Advantages and disadvantages of Ball valves ...................................................... 22
4.5. Check valves ................................................................................................................... 23
4.5.1. Types of Check valves .............................................................................................. 23
4.6. Control valves ................................................................................................................... 25
4.6.1. Principles of Operation .............................................................................................. 25
4.7 Needle Valve .................................................................................................................. 27
4.8 Three-way Valve ............................................................................................................. 28
4.9 Safety Valve .................................................................................................................. 29
4.10 Xmas tree Valve ............................................................................................................. 31
4.11. Valve Actuators ............................................................................................................. 33
4.11.1. Manual Actuators ................................................................................................... 33
4.11.2. Manually-Operated Gearbox .................................................................................... 34
4.11.3. Electric Motor Actuators ........................................................................................... 34
4.11.4. Pneumatic Actuators ............................................................................................... 35
4.11.5. Hydraulic Actuators ................................................................................................. 36
5. Manufacture procedure ......................................................................................................... 37
5.1. Casting Material ......................................................................................................... 42
Attachment1 ......................................................................................................... 44

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1. Introduction to Valves
Valves are mechanical devices that control the flow and pressure within a system or process. They are
essential components of a piping system that conveys liquids, gases, vapors, slurries etc.
Different types of valves are available: gate, globe, plug, ball, butterfly, check, diaphragm, pinch, pressure
relief, control valves, knife, X mas tree valve, needle, 3way valve, etc. Each of these types has a number of
models, each with different features and functional capabilities. Some valves are self-operated while others
manually or with an actuator or pneumatic or hydraulic is operated.

Functions from Valves are:

 Stopping and starting flow
 Reduce or increase a flow
 Controlling the direction of flow
 Regulating a flow or process pressure
 Relieve a pipe system of a certain pressure

Different parts of valves

There are many valve designs, types and models, with a wide range of industrial applications. All satisfy one or
more of the functions identified above. Valves are expensive items, and it is important that a correct valve is
specified for the function, and must be constructed of the correct material for the process liquid.
Regardless of type, all valves have the following basic parts: the body, bonnet, trim (internal elements),
actuator, and packing. The basic parts of a valve are illustrated in the above image.

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2. Valve Structure

2.1. Valve Body

The valve body, sometimes called the shell, is the primary boundary of a pressure valve. He serves as the
main element of a valve assembly because it is the framework that holds all the parts 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.
The valve-body ends are designed to connect the valve to the piping or equipment nozzle by different types of
end connections, such as butt or socket welded, threaded or flanged.
Valve bodies are cast or forged in a variety of forms and each component have a specific function and
constructed in a material suitable for that function.

Valve body and bonnet

2.2. Valve Bonnet

The cover for the opening in the body is the bonnet, and it is the second most important boundary of a pressure
valve. Like valve bodies, bonnets are in many designs and models available.
A bonnet acts as a cover on the valve body, is cast or forged of the same material as the body. It is commonly
connected to the body by a threaded, bolted, or welded joint. During manufacture of the valve, the internal
components, such as stem, disk etc., are put into the body and then the bonnet is attached to hold all parts
together inside.
In all cases, the attachment of the bonnet to the body is considered a pressure boundary. This means that the
weld joint or bolts that connect the bonnet to the body are pressure-retaining parts. Valve bonnets, although a
necessity for most valves, represent a cause for concern. Bonnets can complicate the manufacture of valves,
increase valve size, represent a significant cost portion of valve cost, and are a source for potential leakage.

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2.3. Valve Trim
Valve's trim is a collective name for the replaceable parts, in a valve. A typically Trim design 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. Because of the trim, basic motions and flow control are possible. In rotational motion trim designs, the
disk slides closely past the seat to produce a change in flow opening. In linear motion trim designs, the disk lifts
perpendicularly away from the seat so that an annular orifice appears.

2.4. Valve Disk and Seat(s)

Disk:
The disc is the part which allows, throttles, or stops flow, depending on its position. In the case of a plug or a
ball valve, the disc is called plug or a ball. The disk is the third most important primary pressure boundary. With
the valve closed, full system pressure is applied across the disk, and for this reason, the disk is a pressure
related component.
Disks are usually forged, and in some designs, hard surfaced to provide good wear properties. Most valves are
named, the design of their disks.

Seat(s):
The seat or seal rings provide the seating surface for the disk. A valve may have one or more seats. In the
case of a globe or a swing-check valve, there is usually one seat, which forms a seal with the disc to stop the
flow. In the case of a gate valve, there are two seats; one on the upstream side and the other on the
downstream side. A gate valve disc has two seating surfaces that come in contact with the valve seats to form
a seal for stopping the flow.
To improve the wear-resistance of the seal rings, the surface is often hard-faced by welding and then
machining the contact surface of the seal ring. A fine surface finish of the seating area is necessary for good
sealing when the valve is closed. Seal rings are not usually considered pressure boundary parts because the
body has sufficient wall thickness to withstand design pressure without relying upon the thickness of the seal
rings.

Valve disk and seat

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2.5. Valve Stem
The valve stem provides the necessary movement to the disc, plug or the ball for opening or closing the valve,
and is responsible for the proper positioning of the disk. It is connected to the valve hand wheel, actuator, or
the lever at one end and on the other side to the valve disc. In gate or globe valves, linear motion of the disc is
needed to open or close the valve, while in plug, ball and Butterfly valves, the disc is rotated to open or close
the valve.
Stems are usually forged, and connected to the disk by threaded or other techniques. To prevent leakage, in
the area of the seal, a fine surface finish of the stem is necessary.
There are five types of valve stems:

 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 hand wheel attached to the stem, so they can rise together, and the other with a
threaded sleeve that causes the stem to rise through the hand wheel. This type of valve is indicated by
"O. S. & Y." is a common design for NPS 2 and larger valves.

 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.

 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.

 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.

 Rotary Stem
this is a commonly used model in ball, plug, and Butterfly valves. A quarter-turn motion of the stem opens
or closes the valve.

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2.6. Valve Actuator
Hand-operated valves are usually equipped with a hand wheel attached to the valve's stem or Yoke nut which
is rotated clockwise or counter clockwise to close or open a valve. Globe and gate valves are opened and
closed in this way.
Hand-operated, quarter turn valves, such as Ball, Plug or Butterfly, has a lever for actuate the valve.
There are applications where it is not possible or desirable, to actuate the valve manually by hand wheel or
lever. These applications include:
 Large valves that must be operated against high hydrostatic pressure
 Valves they must be operated from a remote location
 When the time for opening, closing, throttle or manually controlling the valve is longer, than required by
system-design criteria
These valves are usually equipped with an actuator.
An actuator in the broadest definition is a device that produces linear and rotary motion of a source of power
under the action of a source of control.
Basic actuators are used to fully open or fully close a valve. Actuators for controlling or regulating valves are
given a positioning signal to move to any intermediate position. There a many different types of actuators, but
the following are some of the commonly used valve actuators:
 Gear Actuators
 Electric Motor Actuators
 Pneumatic Actuators
 Hydraulic Actuators

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3. Classification of Valves
The following are some of the commonly used valve classifications, based on mechanical motion:
 Linear Motion Valves. The valves in which the closure member, as in gate, globe, diaphragm, pinch, and
lift Check Valves, moves in a straight line to allow, stop, or throttle the flow.
 Rotary Motion Valves. When the valve-closure member travels along an angular or circular path, as in
butterfly, ball, plug, eccentric- and Swing Check Valves, the valves are called rotary motion valves.
 Quarter Turn Valves. Some rotary motion valves require approximately a quarter turn, 0 through 90°,
motion of the stem to go to fully open from a fully closed position or vice versa.

Classification of Valves based on Motion

Valve Types Linear Motion Rotary Motion Quarter Turn

Gate YES NO NO

Globe YES NO NO

Plug NO YES YES

Ball NO YES YES

Butterfly NO YES YES

Swing Check NO YES NO

Diaphragm YES NO NO

Pinch YES NO NO

Safety YES NO NO

Relief YES NO NO

3.1. Class Ratings

Pressure-temperature ratings of valves are designated by class numbers. ASME B16.34, Valves-Flanged,
Threaded, and Welding End is one of the most widely used valve standards. It defines three types of classes:
standard, special, and limited. ASME B16.34 covers Class 150, 300, 400, 600, 900, 1500, 2500, and 4500
valve.

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4. Types of Valves
On this section there are number of basic information from valves.
It can give you an impression, and good understanding of the differences between the various types of valves,
and how these differences affect the valve function. It will help to a proper application of each type of valve
during the design and the proper use of each type of valve during operation.

4.1.Gate valves
Gate valves are primarily designed to start or stop flow, and when a straight-line flow of fluid and minimum flow
restriction is needed. In service, these valves generally are either fully open or fully closed.
The disk of a Gate valve is completely removed when the valve is fully open; the disk is fully drawn up into the
valve Bonnet. This leaves an opening for flow through the valve at the same inside diameter as the pipe system
in which the valve is installed. A Gate valve can be used for a wide range of liquids and provides a tight seal
when closed.

Gate valve

4.1.1. Construction of a Gate valve

Gate valves consist of three main parts: body, bonnet, and trim. The body is generally connected to other
equipment by means of flanged, screwed or welded connections. The bonnet, which containing the moving
parts is attached to the body, usually with bolts to permit maintenance. The valve trim consists of the stem, the
gate, the disc or wedge and the seat rings.

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4.1.2. Disks of a Gate valve
Gate valves are available with different disks or wedges. Ranging of the Gate valves is usually made by the
type of wedge used.
The most common were:
 Solid wedge is the most commonly used disk by its simplicity and strength. A valve with this type of wedge
can be installed in each position and it is suitable for almost all liquids. The solid wedge is a single-piece
solid construction, and is practically for turbulent flow.
 Flexible wedge is a one-piece disc with a cut around the perimeter to improve the ability to correct
mistakes or changes in the angle between the seats. The reduction will vary in size, shape and depth. As
hallow, narrow cut gives little flexibility but retains strength. A deeper and wider cut, or cast-in recess,
leaves little material in the middle, which allows more flexibility, but compromises strength.

 Split wedge is self-adjusting and self aligning to both seats sides. This wedge type consists of two-piece
construction which seats between the tapered seats in the valve body. This type of wedge is suitable for
the treatment of non-condensing gases and liquids at normal temperatures, particularly corrosive liquids.

Most common wedges in Gate valves

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4.1.3. Stem of a Gate valve
The stem, which connects the handwheel and disk with each other, is responsible for the proper positioning of
the disk. Stems are usually forged, and connected to the disk by threaded or other techniques. To prevent
leakage, in the area of the seal, a fine surface finish of the stem is necessary.
Gate valves are classified as either:
 Rising Stem
 Non Rising Stem
For a valve of the Rising Stem type, the stem will rise above the handwheel if the valve is opened. This
happens, because the stem is threaded and mated with the bushing threads of a Yoke. A Yoke is an integral
part from a Rising Stem valve and is mounted to the Bonnet.
For a valve of the non Rising Stem type, there is no upward stem movement if the valve is opened. The stem is
threaded into the disk. As the handwheel on the stem is rotated, the disk travels up or down the stem on the
threads while the stem remains vertically stationary.

Rising Stem Gate valve

4.1.4. Seats of a Gate valve

Seats for Gate valves are either provided integral with the valve body or in a seat ring type of construction. Seat
ring construction provides seats which are either threaded into position or are pressed into position and seal
welded to the valve body. The latter form of construction is recommended for higher temperature service
Integral seats provide a seat of the same material of construction as the valve body while the pressed-in or
threaded-in seats permit variation. Rings with hard facings may be supplied for the application where they are
required.

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4.1.5. Advantages and disadvantages of Gate valves
Advantages:
 Good shut off features
 Gate valves are bidirectional and therefore they can be used in two directions
 Pressure loss through the valve is minimal

Disadvantages:
 They cannot be quickly opened or closed
 Gate valves are not suitable for regulate or throttle flow
 They are sensitive to vibration in the open state

4.2. Globe valves

A Globe valves is a linear motion valve and are primarily designed to stop, start and regulate flow. The disk of a
Globe valve can be totally removed from the flow path or it can completely close the flow path.
Conventional Globe valves may be used for isolation and throttling services. Although these valves exhibit
slightly higher pressure drops than straight=through valves (e.g., gate, plug, ball, etc.), they may be used where
the pressure drop through the valve is not a controlling factor.
Because the entire system pressure exerted on the disc is transferred to the valve stem, the practical size limit
for these valves is NPS 12 (DN 300). Globe valves larger than NPS 12 (DN 300) are an exception rather than
the rule. Larger valves would require that enormous forces be exerted on the stem to open or close the valve
under pressure. Globe valves in sizes up to NPS 48 (DN 1200) have been manufactured and used.
Globe valves are extensively employed to control flow. The range of flow control, pressure drop, and duty must
be considered in the design of the valve to avert premature failure and to assure satisfactory service. Valves
subjected to high-differential pressure-throttling service require specially designed valve trim.
Generally the maximum differential pressure across the valve disc should not exceed 20 percent of the
maximum upstream pressure or 200 psi (1380 kPa), whichever is less. Valves with special trim may be
designed for applications exceeding these differential pressure limits.

4.2.1. Body designs of Globe valves

There are three primary body designs for Globe valves, namely: Tee Pattern or Z-body, Angle Pattern and Wye
Pattern or Y-body body.

Tee Pattern Globe valve design is the most common body type, with a Z-shaped diaphragm. The
horizontal setting of the seat allows the stem and disk to travel perpendicular to the horizontal line. This design
has the lowest coefficient of flow and higher pressure drop. They are used in severe throttling services, such as
in bypass lines around a control valve. Tee-pattern Globe valves may also be used in applications where
pressure drop is not a concern and throttling is required.

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Angle Pattern Globe valves design is a modification of the basic Tee Pattern Globe valve. The ends
of this Globe valve are at an angle of 90 degrees, and fluid flow occurs with a single 90 degrees turn. They
have a slightly lower coefficient of flow than wye-pattern Globe valves. They are used in applications that have
periods of pulsating flow because of their capability to handle the slugging effect of this type of flow.

Wye Pattern Globe valves design, is an alternative for the high pressure drop, inherent in Globe
valves. Seat and stem are angled at approximately 45 degrees, what gives a straighter flowpath at full opening
and offer the least resistance to flow. They can be cracked open for long periods without severe erosion. They
are extensively used for throttling during seasonal or startup operations. They can be rod through to remove
debris when used in drain lines that are normally closed

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4.2.2. Disk & Seat & Stem of Globe valves
Disk: The most common disk designs for Globe valves are: ball disk, composition disk and the plug disk. Ball
disk design is used primarily in low pressure and low temperature systems. It is capable of throttling flow, but in
principle it is applied to stop and start flow.
Composition disk design uses a hard, non-metallic insert ring on the disk, which ensures a tighter closure.
Plug disk design provides better throttling than ball or composition designs. They are available in many different
designs and they are all long and tapered.

Seat: Globe valve seats are either integrated or screwed in to the valve body. Many Globe valves have
backseats inside the Bonnet. A back seat provides a seal between the stem and Bonnet and prevents system
pressure from building against the valve packing, when the valve is fully open. Back seats are often applied in
Globe valves.

Stem: Globe valves use two methods for connecting the disk and the stem: the T-slot and the disk nut
construction. In the T-slot design, the disk slides over the stem, while in the disk nut design, the disk is screwed
into the stem.

4.2.3. Construction of a Globe valve

Globe valves usually have rising stems, and the larger sizes are of the outside screw-and-yoke construction.
Components of the Globe valve are similar to those of the gate valve. This type of valve has seats in a plane
parallel or inclined to the line of flow.
Maintenance of Globe valves is relatively easy, as the discs and seats are readily refurbished or replaced. This
makes Globe valves particularly suitable for services which require frequent valve maintenance. Where valves
are operated manually, the shorter disc travel offers advantages in saving operator time, especially if the valves
are adjusted frequently.
The principal variation in Globe-valve design is in the types of discs employed. Plug-type discs have a long,
tapered configuration with a wide bearing surface. This type of seat provides maximum resistance to the
erosive action of the fluid stream. In the composition disc, the disc has a flat face that is pressed against the
seat opening like a cap. This type of seat arrangement is not as suitable for high differential pressure throttling.
In cast-iron Globe valves, disc and seat rings are usually made of bronze. In steel-Globe valves for temperature
up to 750°F (399°C), the trim is generally made of stainless steel and so provides resistance to seizing and
galling. The mating faces are normally heat-treated to obtain differential hardness values. Other trim materials,
including cobalt-based alloys, are also used.
The seating surface is ground to ensure full-bearing surface contact when the valve is closed. For lower
pressure classes, alignment is maintained by a long disc locknut. For higher pressures, disc guides are cast
into the valve body. The disc turns freely on the stem to prevent galling of the disc face and seat ring. The stem
bears against a hardened thrust plate, eliminating galling of the stem and disc at the point of contact.

4.2.4. Typical Applications of Globe valves

The following are some of the typical applications of Globe valves:
 Cooling water systems where flow needs to be regulated
 Fuel oil system where flow is regulated and leak tightness is of importance
 High-point vents and low-point drains when leak tightness and safety are major considerations
 Feed water, chemical feed, condenser air extraction, and extraction drain systems
 Boiler vents and drains, main steam vents and drains, and heater drains
 Turbine seals and drains
 Turbine lube oil system and others

4.2.5. Advantages and disadvantages of Globe valves

 Advantages: Good shut off capability
 Moderate to good throttling capability
 Shorter stroke (compared to a gate valve)
 Available in tee, wye, and angle patterns, each offering unique capabilities
 Easy to machine or resurface the seats
 With disc not attached to the stem, valve can be used as a stop-check valve

Disadvantages:
 Higher pressure drop (compared to a gate valve)
 Requires greater force or a larger actuator to seat the valve (with pressure under the seat)
 Throttling flow under the seat and shutoff flow over the seat

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4.3. Ball valves
A Ball valve is a quarter-turn rotational motion valve that uses a ball-shaped disk to stop or start flow. If the
valve is opened, the ball rotates to a point where the hole through the ball is in line with the valve body inlet and
outlet. If the valve is closed, the ball is rotated so that the hole is perpendicular to the flow openings of the valve
body and the flow is stopped.

Ball Valve

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4.3.1. Materials - Design - Bonnet
Materials
Balls are usually made of several metallic, while the seats are from soft materials like Teflon, Neoprene, and
combinations of these materials. The use of soft-seat materials imparts excellent sealing ability. The
disadvantage of soft-seat materials (elastomeric materials) is that they can’t be used in high temperatures
processes, so other material shall be used to recover this problem.
For example, fluorinated polymer seats can be used for service temperatures from −200° (and larger) to 230°C
and higher, while graphite seats may be used for temperatures −50° to 500°C and higher.

Stem design
The stem in a Ball valve is not attached to the ball. Usually it has a rectangular portion at the ball, and that fits
into a slot cut into the ball. The enlargement permits rotation of the ball as the valve is opened or closed.

Ball valve Bonnet

The Bonnet of a Ball valve is fastens to the body, which holds the stem assembly and ball in place. Adjustment
of the Bonnet permits compression of the packing, which supplies the stem seal. Packing material for Ball valve
stems is usually Teflon® or Teflon-filled or O-rings instead of packing.

4.3.2. Ball valves applications

The following are some typical applications of Ball valves:
 Air, gaseous, and liquid applications
 Drains and vents in liquid, gaseous, and other fluid services
 Steam service

4.3.3. Advantages and disadvantages of Ball valves

Advantages:
 Quick quarter turn on-off operation
 Tight sealing with low torque
 Smaller in size than most other valves

Disadvantages:
 Conventional Ball valves have poor throttling properties
 In slurry or other applications, the suspended particles can settle and become trapped in body cavities
causing wear, leakage, or valve failure.

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4.4. Butterfly valves
A Butterfly valve is a quarter-turn rotational motion valve that is used to stop, regulate, and start flow.
Butterfly valves are easy and fast to open. A 90° rotation of the handle provides a complete closure or opening
of the valve. Large Butterfly valves are usually equipped with a so-called gearbox, where the hand wheel by
gears is connected to the stem. This simplifies the operation of the valve, but at the expense of speed.

Butterfly Valve

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4.4.1. Types of Butterfly valves
Butterfly valves have a short circular body, a round disc, metal-to-metal or soft seats, top and bottom shaft
bearings, and a stuffing box. The construction of a Butterfly valve body varies. A commonly used design is the
wafer type that fits between two flanges. Another type, the lug wafer design, is held in place between two
flanges by bolts that join the two flanges and pass through holes in the valve's outer casing. Butterfly valves are
even available with flanged, threaded and butt welding ends, but they are not often applied.
Butterfly valves possess many advantages over gate, globe, plug, and ball valves, especially for large valve
applications. Savings in weight, space, and cost are the most obvious advantages. The maintenance costs are
usually low because there are a minimal number of moving parts and there are no pockets to trap fluids.
Butterfly valves are especially well-suited for the handling of large flows of liquids or gases at relatively low
pressures and for the handling of slurries or liquids with large amounts of suspended solids.
Butterfly valves are built on the principle of a pipe damper. The flow control element is a disk of approximately
the same diameter as the inside diameter of the adjoining pipe, which rotates on either a vertical or horizontal
axis. When the disk lies parallel to the piping run, the valve is fully opened. When the disk approaches the
perpendicular position, the valve is shut. Intermediate positions, for throttling purposes, can be secured in place
by handle-locking devices.

4.4.2. Butterfly valve Seat Construction

Stoppage of flow is accomplished by the valve disk sealing against a seat that is on the inside diameter
periphery of the valve body. Many Butterfly valves have an elastomeric seat against which the disk seals. Other
Butterfly valves have a seal ring arrangement that uses a clamp-ring and backing-ring on a serrated edged
rubber ring. This design prevents extrusion of the O-rings.
In early designs, a metal disk was used to seal against a metal seat. This arrangement did not provide a leak-
tight closure, but did provide sufficient closure in some applications (i.e., water distribution lines).

4.4.3. Butterfly valve Body Construction

Butterfly valve body construction varies. The most economical is the wafer type that fits between two pipeline
flanges. Another type, the lug wafer design, is held in place between two pipe flanges by bolts that join the two
flanges and pass through holes in the valve's outer casing. Butterfly valves are available with conventional
flanged ends for bolting to pipe flanges, and in a threaded end construction.

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4.4.4. Seat Disk and Stem of a Butterfly valve
The stem and disk for a Butterfly valve are separate pieces. The disk is bored to receive the stem. Two
methods are used to secure the disk to the stem so that the disk rotates as the stem is turned. In the first
method, the disk is bored through and secured to the stem with bolts or pins. The alternate method involves
boring the disk as before, then shaping the upper stem bore to fit a squared or hex-shaped stem. This method
allows the disk to "float" and seek its center in the seat. Uniform sealing is accomplished and external stem
fasteners are eliminated. This method of assembly is advantageous in the case of covered disks and in
corrosive applications.
In order for the disk to be held in the proper position, the stem must extend beyond the bottom of the disk and
fit into a bushing in the bottom of the valve body. One or two similar bushings are along the upper portion of the
stem as well. These bushings must be either resistant to the media being handled or sealed so that the
corrosive media cannot come into contact with them.
Stem seals are accomplished either with packing in a conventional stuffing box or by means of O-ring seals.
Some valve manufacturers, particularly those specializing in the handling of corrosive materials, place a stem
seal on the inside of the valve so that no material being handled by the valve can come into contact with the
valve stem. If a stuffing box or external O-ring is employed, the fluid passing through the valve will come into
contact with the valve stem.

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4.4.5. Typical applications of Butterfly valves
A Butterfly valve can be used in many different fluid services and they perform well in slurry applications. The
following are some typical applications of Butterfly valves:
 Cooling water, air, gases, fire protection etc.
 Slurry and similar services
 Vacuum service
 High-pressure and high-temperature water and steam services

4.4.6. Advantages and disadvantages of Butterfly valves

Advantages of Butterfly valves:
 Compact design requires considerably less space, compared to other valves
 Light in weight
 Quick operation requires less time to open or close
 Available in very large sizes
 Low-pressure drop and high-pressure recovery

Disadvantages of Butterfly valves:

 Throttling service is limited to low differential pressure
 Cavitations and choked flow are two potential concerns
 Disc movement is unguided and affected by flow turbulence

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4.5. Check valves
Check valves are "automatic" valves that open with forward flow and close with reverse flow. The pressure of
the fluid passing through a system opens the valve, while any reversal of flow will close the valve. Exact
operation will vary depending on the type of Check valve mechanism. Most common types of Check valves are
swing, lift (piston and ball), butterfly, stop and tilting-disk.

4.5.1. Types of Check valves

4.5.1.1. Swing Check valve
A basic swing Check valve consists of a valve body, a bonnet, and a disk that is connected to a hinge. The disk
swings away from the valve-seat to allow flow in the forward direction, and returns to valve-seat when upstream
flow is stopped, to prevent backflow.
The disc in a swing type Check valve is unguided as it fully opens or closes. There are many disk and seat
designs available, in order to meet the requirements of different applications. The valve allows full,
unobstructed flow and automatically closes as pressure decreases. These valves are fully closed when flow
reaches zero, in order to prevent backflow. Turbulence and pressure drop in the valve are very low.

Swing Check valve

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4.5.1.2. Lift Check valve
The seat design of a lift-Check valve is similar to a Globe valve. The disc is usually in the form of a piston or a
ball.
Lift Check valves are particularly suitable for high-pressure service where velocity of flow is high. In lift check
valves, the disc is precisely guided and fits perfectly into the dashpot. Lift Check valves are suitable for
installation in horizontal or vertical pipe-lines with upward flow.
Flow to lift Check valves must always enter below the seat. As the flow enters, the piston or ball is raised within
guides from the seat by the pressure of the upward flow. When the flow stops or reverses, the piston or ball is
forced onto the seat of the valve by both the backflow and gravity.

Lift Check valve

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4.6. Control Valves
Process plants consist of hundreds, or even thousands, of control loops all networked together to produce a
product to be offered for sale. Each of these control loops is designed to keep some important process variable
such as pressure, flow, level, temperature, etc. within a required operating range to ensure the quality of the
end product. Each of these loops receives and internally creates disturbances that detrimentally affect the
process variable, and interaction from other loops in the network provides disturbances that influence the
process variable.
To reduce the effect of these load disturbances, sensors and transmitters collect information about the process
variable and its relationship to some desired set point. A controller then processes this information and decides
what must be done to get the process variable back to where it should be after a load disturbance occurs.
When all the measuring, comparing, and calculating are done, some type of final control element must
implement the strategy selected by the controller.

4.6.1.Principles of Operation
The most common final control element in the process control industries is the control valve. The control valve
manipulates a flowing fluid, such as gas, steam, water, or chemical compounds, to compensate for the load
disturbance and keep the regulated process variable as close as possible to the desired set point.
Control valves may be the most important, but sometimes the most neglected, part of a control loop. The
reason is usually the instrument engineer's unfamiliarity with the many facets, terminologies, and areas of
engineering disciplines such as fluid mechanics, metallurgy, noise control, and piping and vessel design that
can be involved depending on the severity of service conditions.
Any control loop usually consists of a sensor of the process condition, a transmitter and a controller that
compares the "process variable" received from the transmitter with the "set point," i.e., the desired process
condition. The controller, in turn, sends a corrective signal to the "final control element," the last part of the loop
and the "muscle" of the process control system. While the sensors of the process variables are the eyes,
the controller the brain, then the final control element is the hands of the control loop. This makes it the most
important, alas sometimes the least understood, part of an automatic control system. This comes about, in part,
due to our strong attachment to electronic systems and computers causing some neglect in the proper
understanding and proper use of the all important hardware.

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 Control Valve

Globe valves are normally used for control, and their ends are usually flanged for ease of maintenance.
Depending on their type of supply, the disk is moved by a hydraulic, pneumatic, electrical or mechanical
actuator. The valve modulates flow through movement of a valve plug in relation to the port(s) located within
the valve body.

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. 4.6. Needle Valves
A needle valve is a type of valve having a small port and a threaded, needle-shaped plunger. It allows precise
regulation of flow, although it is generally only capable of relatively low flow rates.

Needle Valves

An instrument needle valve uses a tapered pin to gradually open a space for fine control of flow. The flow can
be controlled and regulated with the use of a spindle. A needle valve has a relatively small orifice with a long,
tapered seat, and a needle-shaped plunger on the end of a screw, which exactly fits the seat.
As the screw is turned and the plunger retracted, flow between the seat and the plunger is possible; however,
until the plunger is completely retracted, the fluid flow is significantly impeded. Since it takes many turns of the
fine-threaded screw to retract the plunger, precise regulation of the flow rate is possible.
Needle valves are usually used in flow-metering applications, especially when a constant, calibrated, low flow
rate must be maintained for some time, such as the idle fuel flow in a carburetor.
Note that the float valve of a carburetor (controlling the fuel level within the carburetor) is not a needle valve,
although it is commonly described as one. It uses a bluntly conical needle, but it seats against a square-edged
seat rather than a matching cone. The intention here is to obtain a well-defined seat between two narrow
mating surfaces, giving firm shutoff of the flow from only a light float pressure.
Since flow rates are low and many turns of the valve stem are required to completely open or close, needle
valves are not used for simple shutoff applications.

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4.7. Three-way Valves
Valves with three ports serve many different functions. A few of the possibilities are listed here.

Three-way ball valves come with a T- or L- shaped fluid passageways inside the rotor. The T valve might be
used to permit connection of one inlet to either or both outlets or connection of the two outlets. The L valve
could be used to permit disconnection of both or connection of either but not both of two inlets to one outlet.

Shuttle valves automatically connect the higher pressure inlet to the outlet while (in some configurations)
preventing flow from one inlet to the other.

Single handle mixer valves produce a variable mixture of hot and cold water at a variable flow rate under
control of a single handle.

Thermostatic mixing valves mix hot and cold water to produce a constant temperature in the presence of
variable pressures and temperatures on the two input ports.

Three-way Valves

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4.8. Safety Valves
The primary purpose of a safety valve is the protection of life, property and environment. A safety valve is
designed to open and relieve excess pressure from vessels or equipment and to reclose and prevent the
further release of fluid after normal conditions have been restored.
A safety valve is a safety device and in many cases the last line of defense. It is important to ensure that the
safety valve is capable to operate at all times and under all circumstances. A safety valve is not a process
valve or pressure regulator and should not be misused as such. It should have to operate for one purpose only:
overpressure protection.

Reasons for Excess Pressure:

There are a number of reasons why the pressure in a vessel or system can exceed a predetermined limit. API
Standard 521/ISO 23251 Sect. 4 provides a detailed guideline about causes of overpressure. The most
common are:

 Blocked discharge
 Exposure to external fire, often referred to as “Fire Case”
 Thermal expansion
 Chemical reaction
 Heat exchanger tube rupture
 Cooling system failure

Each of the above listed events may occur individually and separately from the other. They may also take place
simultaneously. Each cause of overpressure also will create a different mass or volume flow to be discharged,
e.g. small mass flow for thermal expansion and large mass flow in case of a chemical reaction. It is the user’s
responsibility to determine a worst case scenario for the sizing and selection of a suitable pressure relief
device.

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Main Types of Safety Valves:

There are two main types of safety valves: Spring loaded safety valves and pilot operated safety valves.

Spring loaded safety valve

Pilot operated safety valve

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4.9. Xmas Tree Valve
In petroleum and natural gas extraction, a Christmas tree, or "tree" is an assembly of valves, spools, and
fittings used for an oil well, gas well, water injection well, water disposal well, gas injection well, condensate
well and other types of wells. It was named for its crude resemblance to a decorated tree. Christmas trees are
used on both surface and subsea wells. It is common to identify the type of tree as either "subsea tree" or
"surface tree". Each of these classifications has a number of variations.

Xmas Tree Valve

The primary function of a tree is to control the flow, usually oil or gas, out of the well. (A tree may also be used
to control the injection of gas or water into a non-producing well in order to enhance production rates of oil from
other wells.) When the well and facilities are ready to produce and receive oil or gas, tree valves are opened
and the formation fluids are allowed to go through a flow line. This leads to a processing facility, storage depot
and/or other pipeline eventually leading to a refinery or distribution center (for gas).

Subsea and surface trees have a large variety of valve configurations and combinations of manual and/or
actuated (hydraulic or pneumatic) valves. Examples are identified in API Specifications 6A and 17D.

A basic surface tree consists of two or three manual valves (usually gate valves because of their flow
characteristics, i.e. low restriction to the flow of fluid when fully open).

A typical sophisticated surface tree will have at least four or five valves, normally arranged in a crucifix type
pattern (hence the endurance of the term "Christmas tree"). The two lower valves are called the master valves
(upper and lower respectively). Master valves are normally in the fully open position and are never opened or
closed when the well is flowing (except in an emergency) to prevent erosion of the valve sealing surfaces. The
lower master valve will normally be manually operated, while the upper master valve is often hydraulically
actuated, allowing it to be used as a means of remotely shutting in the well in the event of emergency. An

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actuated wing valve is normally used to shut in the well when flowing, thus preserving the master valves for
positive shut off for maintenance purposes. Hydraulic operated wing valves are usually built to be fail safe
closed, meaning they require active hydraulic pressure to stay open. This feature means that if control fluid fails
the well will automatically shut itself in without operator action.

The right hand valve is often called the flow wing valve or the production wing valve, because it is in the flow
path the hydrocarbons take to production facilities (or the path water or gas will take from production to the well
in the case of injection wells).

The left hand valve is often called the kill wing valve (KWV). It is primarily used for injection of fluids such as
corrosion inhibitors or methanol to prevent hydrate formation. In the North Sea, it is called the non-active side
arm (NASA). It is typically manually operated.

The valve at the top is called the swab valve and lies in the path used for well interventions like wireline and
coiled tubing. For such operations, a lubricator is rigged up onto the top of the tree and the wire or coil is
lowered through the lubricator, past the swab valve and into the well. This valve is typically manually operated.

Some trees have a second swab valve; the two arranged one on top of the other. The intention is to allow
rigging down equipment from the top of the tree with the well flowing while still preserving the Two-barrier rule.
With only a single swab valve, the upper master valve is usually closed to act as the second barrier, forcing the
well to be shut in for a day during rig down operations. However, avoiding delaying production for a day is
usually too small a gain to be worth the extra expense of having a Christmas tree with a second swab valve.

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4.10. Valve Actuators
Valve actuators are selected based upon a number of factors including torque necessary to operate the valve
and the need for automatic actuation. Types of actuators include manual hand wheel, manual lever, electrical
motor, pneumatic, solenoid, hydraulic piston, and self-actuated. All actuators except manual hand wheel and
lever are adaptable to automatic actuation.

4.10.1. Manual, Fixed, and Hammer Actuators

Manual actuators are capable of placing the valve in any position but do not permit automatic operation. The
most common type mechanical actuator is the hand wheel. This type includes hand wheels fixed to the stem,
hammer hand wheels, and hand wheels connected to the stem through gears.

Hand wheels Fixed to Stem

As illustrated in the image on the right hand wheels fixed to the stem provide only the mechanical advantage of
the wheel. When these valves are exposed to high operating temperatures, valve binding makes operation
difficult.

Hammer Hand wheel

As illustrated in the image, the hammer hand wheel moves freely through a portion of its turn and then hits
against a lug on a secondary wheel. The secondary wheel is attached to the valve stem. With this
arrangement, the valve can be pounded shut for tight closure or pounded open if it is stuck shut.

Manual valve actuator

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4.10.2. Manually-Operated Gearbox
If additional mechanical advantage is necessary for a manually-operated valve, the valve bonnet is fitted with
manually-operated gear heads as illustrated in the image. A special wrench or hand wheel attached to the
pinion shaft permits one individual to operate the valve when two individuals might be needed without the gear
advantage. Because several turns of the pinion are necessary to produce one turn of the valve stem, the
operating time of large valves is exceptionally long. The use of portable air motors connected to the pinion shaft
decreases the valve operating time.

Manually-operated gearbox

4.10.3. Electric Motor Actuators

Electric motors permit manual, semi-automatic, and automatic operation of the valve. Motors are used mostly
for open-close functions, although they are adaptable to positioning the valve to any point opening as illustrated
in the image below. The motor is usually a, reversible, high speed type connected through a gear train to
reduce the motor speed and thereby increase the torque at the stem. Direction of motor rotation determines
direction of disk motion.
The electrical actuation can be semi-automatic, as when the motor is started by a control system. A hand
wheel, which can be engaged to the gear train, provides for manual operating of the valve. Limit switches are
normally provided to stop the motor automatically at full open and full closed valve positions. Limit switches are
operated either physically by position of the valve or torsion ally by torque of the motor.

Electric motor actuators

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4.10.4. Pneumatic Actuators
Pneumatic actuators as illustrated in the image below provide for automatic or semiautomatic valve operation.
These actuators translate an air signal into valve stem motion by air pressure acting on a diaphragm or piston
connected to the stem. Pneumatic actuators are used in throttle valves for open-close positioning where fast
action is required. When air pressure closes the valve and spring action opens the valve, the actuator is termed
direct acting. When air pressure opens the valve and spring action closes the valve, the actuator is termed
reverse acting. Duplex actuators have air supplied to both sides of the diaphragm. The differential pressure
across the diaphragm positions the valve stem. Automatic operation is provided when the air signals are
automatically controlled by circuitry. Semi-automatic operation is provided by manual switches in the circuitry to
the air control valves.

Pneumatic actuators

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4.10.5. Hydraulic Actuators
Hydraulic actuators provide for semi-automatic or automatic positioning of the valve, similar to the pneumatic
actuators. These actuators use a piston to convert a signal pressure into valve stem motion. Hydraulic fluids
fed to either side of the piston while the other side is drained or bled. Water or oil is used as the hydraulic fluid.
Solenoid valves are typically used for automatic control of the hydraulic fluid to direct either opening or closing
of the valve. Manual valves can also be used for controlling the hydraulic fluid; thus providing semi-automatic
operation.

Hydraulic actuators

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4.11. Manufacturing
In this section the method and steps to manufacturing of common valves are described.
Casting: the casting process is used of Intermediate frequency electric furnace capable of melting for
component with different analysis. The main materials which are used in casting are different grade of cast iron,
different type of steels and bronze.

Casting process

37
Machining: after forming the different part of valve body the machining will be done based upon valve standard
and drawings. The manual and CNC machines in this step are used.

Machining Process
Welding and forming: with various equipment such as cutting CNC, welding equipment using Co2, rotary
tables of different sizes, different rollers to roll out sheets with different thickness dimensions.

Welding Process

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Grinding and sandblasting: finishing the body is done using grinding and sand blasting to achieve required
body.

Grinding Process

Painting and coating: painting of valves is done using electrostatic powder.

Coating process

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Assembly: in this step different part of valves will be attached together based upon the valve drawing.

Assembly process

40
Shop Test: Leak test, hydrostatic test, tensile test and other standard test shall be done in shop to ensure the
accurate performance of valves.

Shop test

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 4.11.1. Casting Materials
ASTM
Common
Casting Service
DESCRIPTION
SPEC

Carbon Steel ASTM A216 Non-corrosive applications including water, oil and gases at temperatures
Grade WCB between -20°F (-30°C) and +800°F (+425°C)

Low Temp ASTM A352 Low temperature applications to -50°F (-46°C). Not for use above +650°F
Carbon Steel Grade LCB (+340°C).

Low Temp ASTM A352 Low temperature applications to -75°F (-59°C). Not for use above +650°F
Carbon Steel Grade LC1 (+340°C).

Low Temp ASTM A352 Low temperature applications to -100°F (-73°C). Not for use above +650°F
Carbon Steel Grade LC2 (+340°C).

3½% Nickel ASTM A352 Low temperature applications to -150°F (-101°C). Not for use above +650°F
Steel Grade LC3 (+340°C).

1¼% Chrome ASTM A217 Non-corrosive applications including water, oil and gases at temperatures
1/2% Moly Steel Grade WC6 between -20°F (-30°C) and +1100°F (+593°C).

2¼% Chrome ASTM A217 Non-corrosive applications including water, oil and gases at temperatures
Grade C9 between -20°F (-30°C) and +1100°F (+593°C).

5% Chrome ASTM A217 Mild corrosive or erosive applications as well as non-corrosive applications at
1/2% Moly Grade C5 temperatures between -20°F (-30°C) and +1200°F (+649°C).

9% Chrome ASTM A217 Mild corrosive or erosive applications as well as non-corrosive applications at
1% Moly Grade C12 temperatures between -20°F (-30°C) and +1200°F (+649°C).

12% Chrome ASTM A487 Corrosive application at temperatures between -20°F (-30°C) and +900°F
Steel Grade CA6NM (+482°C).

12% Chrome ASTM A217 Corrosive application at temperatures up to +1300°F (+704°C)

Grade CA15

316SS ASTM A351 Corrosive or either extremely low or high temperature non-corrosive services
Grade CF8M between -450°F (-268°C) and +1200°F (+649°C). Above +800°F (+425°C)
specify carbon content of 0.04% or greater.

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