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Cocks & Valves For Marine Installation by - Md. Mazharul Anwar
Cocks & Valves For Marine Installation by - Md. Mazharul Anwar
FOR
MARINE INSTALLATION
[INSTALLATION, OPERATION & MAINTENANCE]
COCKS
What is Cock?
Cocks are used in small-bore pipework and are joined to adjacent pipework by a compression
coupling.
Fig. Cock
Cocks control or interrupt flow. Basically, they have bodies with screwed ends for connection
to the joining pipes and internal passages arranged so that they can be restricted or closed:
this is done by rotating a central plug in relation to a seating surface, usually by an external
lever or wheel.
A cock may be straight-through, right-angled or open-bottomed as required by its situation in
a pipe system, the plug may be tapered or parallel; tightness may be achieved by grinding the
plug to the body or resilient packing material packed tightly into suitably placed grooves in
the body for low or high pressures respectively. If under pressure the cock may be double-
glanded, so that the plug can not blow out, if important e.g. boiler blowdown cocks on ship’s
shell, so constructed that the handle can be removed only when the cock is closed.
Classification of Cocks
Cocks are also used in piping systems for small services in ships. They are classified as:
1. Stop cock
2. Angle cock
3. Ball cock
4. Plug cock
5. Vent cock or Bleed cock
6. Drain cock
7. Blow-down cock
8. Bib cock
9. Piller cock
10. Convert or mixing cock
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VALVES
What is Valve?
Valve is a mechanical device which controls the flow of fluids in any fluid handling system
(or piping system). The fluid controlled can be common liquids, gases and vapors; but they
also can be liquids carrying suspended particles. The control applied to these fluids can take
one or more of the following forms:
Starting or stopping flow
All kind of valves also bodies as cocks furnished with flanged or screwed ends or ends
prepared for clamping or welding for connection to the joining pipes and internal passages
arranged so that they can be restricted or closed, this is done by lowering, raising or rotating a
disk or diaphragm in relation to a seating surface or by controlling the movement of a ball or
plug.
Valve Chests
Valve chests are a series of valves all built into single block or manifold. Various
arrangements of suction and discharge connections are possible with this assembly.
Classification of Valves:
Valves are classified according to their application in the various types of piping circuits or
other services in marine installations.
1. Sea valves
(a) Sea chest valve or Sea suction valves (or Sea injection valves)
(b) Inboard sea valve
(c) Outboard discharge valve
(d) Overboard discharge valve
2. Bilge valves
(a) Bilge suction valve or Bilge injection valve
(b) Inboard bilge valve
(c) Outboard discharge valve
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3. Ballast valves
(a) Inboard ballast valve
(b) Outboard discharge valve
4. Fire valves
(Used in water/water sprinter type fixed installation fire extinguisher piping circuits)
(a) Inboard fire valve
(b) overboard discharge valve
(c) overboard discharge nozzle
5. cargo oil service valves
(a) Inboard cargo oil service valve
(b) Overboard inlet valve
(c) Overboard discharge valve
6. Bunker oil valves
(a) Inboard bunker oil valve
(b) Overboard inlet valve
(c) Overboard discharge valve
Valves are classified on design and construction:
1. Gate valves (or Sluice valves)
(a) Standard port (bore) gate valve
(b) Full port (bore) gate valve
(c) Conventional port (bore) gate valve
(d) Single disk gate valve
(i) Single disk wedge gate valve
(ii) Single disk parallel slide gate valve
(e) Twin or double disk gate valve
(i) Twin disk wedge gate valve
(ii) Twin disk parallel slide gate valve
(f) Soft seal gate valve
(g) Pressure seal gate valve
(h) Metal seated gate valve
(i) Flex gate valve
(j) Solid wedge gate valve
(k) Flexible wedge gate valve
(l) Inside screw type gate valve
(m) Outside screw yoke type gate valve
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6. Ball valves
(a) Standard port (bore) ball valve
(b) Full port (bore) ball valve
(c) Reduced port (bore) ball valve
(d) Simplon ball valve
(Fig. at page No. 9, BSS Special Purpose Valves)
(e) Comanche ball valve
(Fig. At page No. 9, BSS Special Purpose Valves)
(f) Free floating ball valve
(g) Trunnion mounted ball valve
(h) Memory seal ball valve
(Fig. At page No. 56 87, VELAN VALVES)
(i) Metal seated ball valve
(Fig. At page No. 68, VELAN VALVES)
(j) One piece ball valve
(Fig. At page No. 58, 62, VELAN VALVES)
(k) End entry ball valve
(Fig. At page No.56, VELAN VALVES)
(l) Top entry ball valve
(Fig. At page No. 60, VELAN VALVES)
(m) Split body ball valve
(Fig. At page No. 64, 68, VELAN VALVES)
(n) Thread end ball valve
(o) Flange end ball valve
(p) Weld end ball valves
(i) But-weld end ball valve
(ii) Slot-weld end ball valve
7. Plug valves
(a) Parallel plug valve
(b) Tapper plug valve
(c) Standard port plug valve
(d) Full flow port or full port plug valve
(e) Reduced port plug valve
(f) Non transflow port plug valve
(g) Rectangular port plug valve
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SEA VALVES
Fig. Sea valves
1. Sea chest
2. Main Sw CIRC p/ps (Main Sea water circulating pumps, port side)
3. REFRIG p/ps (Refrigeration pumps, port side)
4. GS/FIRE p/ps (General Service / Fire Fighting pumps, port side)
5. Ballast p/ps (Ballast pumps, port side)
6. Bilge p/ps (Bilge pumps, port side)
A. Sea chest valves
B. Inboard sea valves
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GATE VALVES
Gate valves are also designated as sluice valves, broadly used as main suction valves or main
valves and discharge valves in maximum fluid handling systems in a ship.
Fig. Weld end type gate valve Fig. Flange end type gate valve
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Fig. Knife Gate Valve Fig. O’ Port Knife Gate Valve Fig. Diamond Port knife Gate Valve
Fig. The gate valve operates at right angles to a flow either to close
or open a passageway to liquids.
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When using in a location where a great differential pressure occurs across the valve, the valve
may be opened and closed smoothly by assembling a by-pass valve in the line. It is desired to
combine into a valve of large operation in particular. The size of the by-pass valve should be
1/10 or more of the master valve main body. A large force is required to open and close a
large valve. In such a cause, gear-operated type is recommended.
All gate valves is should be preferably mounted vertically. For side mounting or oblique
mounting special design gate valves are required.
There is little evidence of serious failure occurring with gate valves. They appear to be more
robust than other types of valve and are less susceptible to damage. This is largely because
the valve gate or disk is restricted out of the flow of liquid passing through the valve when it
is in the open position. The valves prone, however, to build-up of sludge or scale in the valve
seat, which can prevent the valve from closing properly.
Tests:
Gate valves are hydraulically tested at least with respect to the following items:-
Shell test: Working pressure plus 50%
Seat test: Maximum working pressure
As required, the small aperture (bore) valves may be tested at working pressure plus 100%
(for shell test) and 40% (for seat test), and the medium aperture (bore) valves, at working
pressure plus 80% (for shell test) and 20% (for seat test).
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GLOBE VALVES
Globe valves are also known as mushroom valves. In marine applications globe valves are
selected as regulating valves for any piping circuit (or fluid handling systems).
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Fig. The globe valve is used primarily to control the flow of fluids in one direction.
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Note: 1.
Note: 2.
Generally, Gate valves are constructed with non-rising stem (NRS) but Globe valves are
constructed with rising stem (RS)
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TESTS:
Globe valves are hydraulically tested at least with respect to the following items:-
Shell test: Working pressure + 50%
Seat test: Maximum working pressure
As requirements, the small aperture (bore) valves may be tested at working pressure plus
100% (for shell test) and 40% (for seat test), and the medium aperture (bore) valves, at
working pressure plus 80% (for shell test) and 20% (for seat test).
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BUTTERFLY VALVES
A butterfly valve consists basically of a disk pivoted across the bore of a ring body having the
same radial dimensions as the pipe in which it is fitted. The full-bore straight-through flow
arrangement of this type of valve, especially if combined with a carefully stream lined disk
profile, gives this type of valve excellent flow characteristics, minimal turbulence and low
pressure drop. All types of butterfly valves are easy to install in the pipe line at any altitude.
The three piece and five piece valves are ideal for applications where the medium is
aggressive and frequent maintenance is required as the design enables the body sections to be
removed without dismantling the surrounding pipework. The disk either presents its full face
to the direction of flow, in which case it is closed, or its end profile being rotated through 90◦,
in which case it is fully open. These works are done by quick-acting with low operating
torque, only a quarter turn is needed to fully open or close the valve. Butterfly valves are used
to lesser extent, mostly with large diameter piping. Sizes range from 6 mm to over 1000 mm
bore. These valves are not recommended where the flow velocity exceeds approximately
6m/sec. (20 ft/sec.). Butterfly valve is full-flow, bubble-tight shut-off in size. They are good
for on-off and throttling service and perform well when controlling large flow amounts of
liquids and gas. However, these valves do not normally create a tight seal and must be used in
low-pressure situation or where some leakage is permissible.
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Butterfly valves are used with flow in either direction. Minimal flow loss when the valves are
fully opened. The valve step is fitted horizontally, in principle, but it may be also fitted
vertically. In larger valves, mounting legs can be attached. The valve disk should be closed
during valve piping work. All standard butterfly valves are closed in clockwise turning and
equipped with lever or round wheel. The fully open and fully closed positions are positively
stopped. Where square cap is provided or extension is needed, sudden opening or closing
should be avoided. Otherwise, pulsation and water hammer may occur. The drive unit for
opening and closing the valve is operated by cam. In large valves, bearings are used at both
sides of the stem and in the drive unit, and gears are coupled with the cam in order to
decrease the opening and closing torque. Because of good flow characteristics of butterfly
valves and the simplicity with which it can be opened or closed by remotely controlled
actuators.
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TESTS:
Butterfly valves are at least subjected to the following hydraulic tests in flow direction.
Shell test: Working pressure plus 50%
Disk test: Working pressure plus 50%
Seat test: Maximum working pressure.
As requirements, the small aperture (bore) valves may be tested at working pressure plus
100% (for shell test) and 40% (for seat test), and the medium aperture (bore) valves, at
working pressure plus 80% (for shell test) and 20% (for seat test).
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For regulating or tight shut-off with flow in either direction. These valves sizes from 2″ to 8″.
Lever or gear box operated larger sizes up to 12″.
Maximum working pressure 150 lbf / Inch2 at 15◦ C to 70◦ C on air and gases.
FLOW CHARACTERISTICS
PRESSURE DROP-FLOWRATE
Cadet Butterfly Valves:
The graph below gives flow rates against pressure drop through a fully open valve for water
at 20◦ C (68◦ F).
…………………..Graph (page no. 12, CRANE BUTTERFLY VALVE)………………
TORQUE REQUIREMENTS
Torque plays an important part in the cost, operation and life span of butterfly valves. The
following explains why.
TORQUE CHARACTERISTICS
Bearing friction, seal or seating friction, and fluid dynamic effects on the disk are primary
factors in determining torque requirements for a butterfly valve. These are described below.
1. Bearing friction torque,
2. Seat friction torque,
3. Fluid dynamic torque and
4. Operating torques
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BALL VALVE
Ball valves are suitable for most manual on-off service (starting and stopping flow). A
comprehensive ball valve line to handle a wide variety of liquids and gases at low, medium
and high pressure they are not suitable for throttling because in the partially open position.
Sealing surfaces of the ball are exposed to abrasion by process fluids.
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PLUG VALVE
The flow control element of a plug valve, the plug, is a cylinder or a truncated cone with a
hole through it. The plug rotates about an axis that is perpendicular to the hole and to the
fluid path. The plug is always in the fluid path. However, when the valve is open the hole
aligns with the fluid path, and the fluid passes straight through it. Because this valve is
symmetrical, either end can be the inlet, or thus flow can be from either direction through the
valve. The forms of control for which plug valve is suited for starting and stopping flow and
changing flow direction. Fig. No. … shows a plug valve.
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DIAPHRAM VALVE
Diaphragm valves are designed for application in the chemical, brewing or control
engineering fields. These valves are used in marine application primarily for low pressure
water (200 psi or less) services. They are especially suitable for systems containing
appreciable sand or other solids. The flow control element of a diaphragm valve is a flexible
membrane, called a diaphragm that is deformed to close the fluid path. The diaphragm lines
the side of the fluid path and is pushed across it until the diaphragm seats against the other
side of the fluid path, stopping the flow. The diaphragm isolates the operating mechanism in
the pipeline, ensuring purity of the line fluid and that the operating mechanism is not
corroded by the fluid. Fig. No. ..shows a diaphragm valve. (Fig. At page no. 14, BSS Special
purpose valves)
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PINCH VALVE
These valves are particularly suitable for substances which are difficult for normal types of
valve such as food froducts, pastes, sludges, powders, liquid containing abrasives and
sewage. The standard ranges have diecast aluminium body with an integral cylindrical
moulded rubber sleeve, providing a straight full flow bore. In operation the sleeve is
flattened, on the center point by pinching between tube anvils, the sleeve is the only part of
the sleeve in contact with liquid or materials being dealt with. Maximum working pressure
100 lbf / inch2 for valves up to 4″ and 80 lbf / inch2 for 6″ size. Suitable for temperatures up
to 100◦ C when fitted with neoprene or nitrile sleeve and 60◦ C when fitted with natural
rubber. Not suitable for use on vacuum or partial vacuum service. (Fig. At page no. 14, BSS
Special purpose valves)
SHUT-OFF VALVES
A shut-valve is another name for a check valve or non-return valve. It allows flow in one
direction only. Shut-off valves are automatically actuated. The check valve is a built-in
safeguard to prevent backflow. They are opened and sustained in the open position by the
force of velocity pressure, and closed by the force of gravity. Seating load and resultant
tightness is dependent upon back pressure. The disk and associated moving parts may be in a
constant state of movement if the velocity pressure is not sufficient to hold the valve in a
wide open and stable position. Premature wear and noisy operation or vibration of the
moving parts can be avoided by selecting the size of shut-off valve on the basis of flow
conditions.
Many kinds of shut-off valves are arranged in various pipe lines to prevent reverse flow (or
back flow).
Lifting Check Valves
Lifting check valves “check” flow. They let flow go one way and will not it reverse. The flow
control element of lifting check valve, which can be a disk, piston or ball, moves along the
axis of the fluid path. The force of the fluid causes the flow control element to unseat
automatically, opening and maintaining the fluid path the valve. If the flow stops, the weight
of the flow control element, an auxiliary spring, or both, causes the flow control element to
return to its seated, closed position. In the case of prevented reverse flow, the back-pressure
of the fluid assists in seating the flow control element and makes for a tighter seal.
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Fig. Flange end Spring less free-lifting check valve (or Stop check valve)
Fig. Flange end Springless free-lifting check valve (port angle: 90°)
Stop check valves are fitted in the compartment sarved by a bilge suction line when the pipe
is nearer to the ship then 1/5 th (one fifth) of the ships breath. Such valves are intended to
prevent flooding of the compartment in the event of collision damage.
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These valves are used for bilge systems to prevent back flooding. There are also used as feed
check and boiler stop valves.
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Fig. Flange end swing check valve Fig. Weld end swing check valve
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V = 60
2. Imperial units:
V = 48
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Sizing swing check valves on this basis may often result in the use valves that are smaller
than the pipe in which they are used, necessitating the use of reducers for installation. The
pressure drop will be no greater than that of the larger valve that is only partially open, and
valve life will be greatly extended. The added bonus of course, is the lower cost of the
smaller valve.
There is no tendency for the seating surfaces of swing check valves to gall or scores, because
the disk meets the flat seat squarely without rubbing control upon closing.
Swing check valves are used to prevent reversal of flow in horizontal or vertical pipe lines. In
vertical lines, or for any angle from horizontal to vertical, they can be used for upward flow
only.
By installing a counterweight, sudden flow of fluid is prevented, so that phenomenon of
water hammer may be relaxed. By attaching a rubber piece to the disk seat, the valve excels
in air tightness and resists impact on the valve seat. The valve can be repaired easily by
removing the upper cover.
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TESTS:
All valves are subjected to at least the following hydraulic tests.
Shell test: Working pressure plus 50%.
Seat test: Maximum working pressure.
As required, small aperture (bore) valves may be tested at working pressure plus 40% (for
seat test), and medium aperture (bore) valves at working pressure plus 80% (for shell test)
and plus 20% (for seat test).
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Fig. Safety valve & Pressure relief valve Fig.Pressure relief valve
Under normal conditions a pressure relief valve should operate consistently within reasonable
limits of its set pressure. Incorrect function may be due to the setting, valve seat deposit or
damage. Pressure relief valve seats should be checked whenever the equipments or machines
are overhauled.
Selection of a valve of the correct size and loading is important since they have a narrow
pressure range.
There are two varieties of pressure relief valves:
(a) Safety valve and
(b) Relief valve
They are similar in design and operation but have different
Safety Valve
The safety valve is used with compressible fluids, these are gasses and vapors. A typical safety valve
is shown in Fig. No. --. The valve constants of a disk held closed by a spring loaded stem. Under
normal conditions, the fluid force on the bottom of the disk is balanced by the force of the spring. The
force acting on the bottom of disk will be increased if the fluid pressure increases. If the fluid force
acting on the bottom of disk is equal to the spring force, the disk begins to lift. The compressible fluid
then rapidly expands into what is commonly called a huddling chamber and acts on substantlly
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larger disk area. The resulting increased force greatly overbalances the spring force and fully
opens the valve. With the valve open, the fluid discharges the rough the outlet into the
atmosphere or discharge piping until the fluid pressure in the equipment is reduced to a level
below the pressure at which the valve begin to open. The spring force is then adequate to
overcome the fluid force on the disk and close the valve. The spring compression can be
adjusted to enable the valve to open at the appropriate pressure.
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Relief Valve
The relief valve is used with incompressible fluids, which are liquids. A typical relief valve is
in Fig. Its operation is similar to that if the safety valve. Construction of the relief valve is
simpler than the safety valve. It does not have a huddling chamber
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or adjusting rings, and separate nozzles and levers are uncommon. As in the safety valve,
when the disk lifts off the seat, a larger disk increased opening force; however, there is no
such mechanism in relief valve, so that rapid fluid expansion and subsequent full opening do
not occur. The amount of opening of the relief valve is directly proportional to the increase in
pressure over the opening pressure.
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Fig. 2-valve change-over chest for oil and ballast suctions as arranged when filling or
discharging ballast ------→
AIR VALVES
A valve that performs automatically let air out of or into a liquid-carrying pipe when the
internal pressure drops below atmospheric.
The air valves are used to discharge the air in the pipe to the atmosphere when sending water
in the piping. In particular, when the pipe line is complicated or long, by discharging the air
pressure in water feed piping is lowered so that the water may be passed easily.
Single Chamber Air Valves (SAV)
Generally these are used in piping of small diameter. Either a valve cock is provided beneath
the body, or the valve is directly joined with flange. In the former type, repairing or replacing
of the valve is easier.
Double Chamber Air Valve (DAV)
They are generally used in larger pipes. A screw-down valve is incorporated in the valve. By
shutting the screw-down valve, the parts at both sides can be easily repaired or repl
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Diverter Valve
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Control valves
Fig. Example of diaphragm operated control valves (Fisher Control Valves Ltd.)
(a) direct acting; (c) balanced trim. Design ED
(b) reverse acting; (d) Design EC with full-capacity standard vatve plug for viscous
fluids
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Foot Valve
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Common Symbols
Pipe fittings
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Fig. Single strainers for (left) high pressure water, steam or oil service and (right) low
pressure water or oil service
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The End
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