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VALVES

Cost of valves can be up to 20 to 30% of the piping cost for a plant, depending on the process. The cost of valve
of any particular type and size can vary by 100%, depending on its internal construction. Thus the selection of
valves is extremely important for the economics, as well as operation, of process plants. The Process Engineer
assumes the overall responsibility of establishing process design parameters of temperature, pressure, flow, start-
up and shut-down procedures. The size of a valve is determined by the size of its ends which connect to the pipe
(Generally specififed by NB). Port size may be smaller in case of some Ball Valves. Depending on the size of
the required valve and availability, selection of stem type can be based on:

Whether it is undesirable for the conveyed fluid to be in contact with the thread bearing surface.

Whether an exposed screw is liable to be damaged by abrasive atmospheric dust.

Whether it is necessary to see whether the valve is open or closed. In addition to these most other valves
have a simple rotary stem. Rotary, Ball, Plug, and Butterfly valves have a rotary stem which is moved by a
permanent lever, or tool applied to a square boss at the end of the stem.

Parts of Valves

1. Body: The selection of material to fabricate the interior of the valve body is important. It depends on
process chemicals flowing through the valve. There is often a choice with regard to the body and trim
(moving parts like stem, seat and plug), and some valves may be obtained with the entire interior of the
body lined with corrosion-resistant material. Valves are connected to pipe, fittings or vessels by their body
ends, which may be flanged, screwed, butt or socket weld type, or finished for hose or sleeve coupling.
Jacketed valves are also available.

2. Disc, Seat and Port: These components are used directly for stopping and
regulating the flow. The moving part directly affecting the flow is termed as
disc, regardless of its shape. The non-moving part it bears on, is termed as the
seat. The port is the maximum internal opening for flow (that is, when the valve
is fully open). Discs may be actuated by conveyed fluid or moved by stem
having a linear, rotary or helical movement. The stem can be moved manually or
driven hydraulically, pneumatically or electrically, under remote or automatic
control, or mechanically by weighted lever, springs etc.

3. Stem: There are two types of screwed stems, the rising stem and non-rising stem. These are moved by
hand-wheel. Rising Stem generally for gate and globe valves) are made either with inside screw (IS) or
outside screw (OS). The OS type has a yoke on the bonnet and the assembly is referred to as outside screw
and yoke (OS and Y). The hand-wheel can either rise with the stem, or the stem can rise through the hand
wheel. Non-rising stem valves are of Gate type. The hand wheel and the stem are in the same position
whether the valve is open or closed. The screw is inside the bonnet and in contact with conveyed fluid. A
Floor Stand is a stem extension for use with both types of stem, where it is necessary to operate a valve
through a floor or platform. Alternately, rods fitted with universal joints may be used to bring a valve hand
wheel within an operator's reach. Depending on the size of the required valve and availability, selection of
stem type can be based on:

Whether it is undesirable for the conveyed fluid to be in contact with the threatened bearing
surfaces.

Whether an exposed screw is liable to be damaged by abrasive atmospheric dust.

Whether it is necessary to use if the valve is open or closed.

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In addition to the preceding types of stem used with gate and globe valves, most other valves have a
simple rotary stem. Ball, plug and butterfly valves have a rotary stem which is moved by a permanent
lever, or tool applied to a square boss at the end of the stem.

4. Bonnet: There are three

basic types of attachments
for valve bonnets: screwed
(including union), bolted
and breech lock. A
screwed bonnet may
occasionally stick
and turn when a
valve is opened.
Although sticking is
less of a problem
with the union type
bonnet, valves with
screwed bonnets are
best reserved for
services presenting
no hazard to personnel. Union bonnets are more suitable for small valves requiring frequent dismantling
than the simple screwed type. The bolted bonnet has largely displaced screwed and union bonnet valves in
hydrocarbon applications. A U-bolt or clamp type bonnet is offered on some small gate valves for
moderate pressures, to facilitate frequent cleaning and inspection. The pressure seal is a variation of bolted
bonnet used for high pressure valves, usually combined with OS and Y construction. It makes use of line
pressure to tighten and seal an internal metal ring or gasket against the body. A critical factor for valves
used for process chemicals is the lubrication of the stem. Care needs to be taken for selection of packing,
gland design and choice of lubricant. As an option the bonnet may include a Lantern Ring which serves
two purposes, either to act as a collection point to drain off any hazardous seepages, or as a point where
lubricant can be injected. The breech lock is a heavier infrequently used and more expensive construction,
also for high pressure use, and involves seal welding of the bonnet with the body.

5. Seal: In most stem operated valves, whether the stem has rotary or linear movement, packing or seals are
used between stem and bonnet (or body). If high vacuum or corrosive, flammable or toxic fluid is to be
handled, the disc or stem may be sealed by metal bellows, or by a flexible diaphragm (the later is termed
pack-less construction).A gasket is used as seal between a bolted bonnet and valve body. Flanged valves
use gaskets to seal against the line flanges. Butterfly valves may extend the resilient seat to also serve as
line gaskets. The pressure-seal bonnet joint utilizes the pressure of conveyed fluids to tighten the seal.

6. Operator: This is a device which opens or closes a valve. Different devices are available.

Manual Operators

Hand lever: It is used to actuate the stems of small butterfly, ball, plug valves and cocks.
Wrench operation is used for cocks and small plug valves.

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Hand Wheel: It is the most common means of rotating the stem on the
majority of popular smaller valves such as gate, globe and diaphragm.
Additional operating torque for gate and globe valves is offered by
hammer blow or impact hand wheels which may be substituted for
normal hand wheels, if easier operation is needed but where gearing is
unnecessary.

Chain: It is used where a hand wheel would be out of reach. The

stem is fitted with a chain wheel or wrench (for lever operated
valves) and loop of the chain is brought within one meter of
working floor level. Universal type chain wheels which attach the
regular hand wheel have been blamed for accidents, in corrosive
atmospheres, where an infrequently operated valve has stuck, the
attaching bolts have been known to fail. This problem does not
arise with the chain-wheel that replaces the regular valve hand-
wheel.

Gear: These are used to reduce the operating torque. For

manual operation, it consists of a hand wheel operated gear
train actuating the valve stem. As a guide, gear operators
should be considered for valves of 350 mm NB and larger up
to 300#, 200 mm NB and larger up to 600#, 150 mm NB and
larger up to 1500# and 100 mm NB and larger for higher
ratings.

Powered Operators

Electric Geared Motor: The valve stem is moved by Geared

Motor. This is useful for operating large valves in remote
areas.

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Solenoid: These can be used for fast acting check valves, and
with on/off valves in light-duty instrumentation applications.

Pneumatic and Hydraulic: These may be used where

flammable vapor is likely to be present. They are of following
forms:

Cylinder with double acting piston, driven by air, water,

oil or other liquids, which usually actuates the stem
directly.

Air motor which actuates the stem through gearing.

Commonly these motors are piston type and radial
cylinder type.

A double acting vane with limited rotary movement in a sector casing, which actuates
the stem directly.

Squeeze type.

Gate Valve: There are different types of gate valves.

1. Plug Gate Valves: This valve has round tapered disc which moves up and down. Suitable for
throttling and full flow use, but only available in smaller sizes.

2. Single Disc Parallel Seat Gate Valve: Unlike single seat valve described above, this valve affords
closure with flow in either direction. Stresses on stem and bonnet are lower than wedge gate valves.
It is primarily used for liquid hydrocarbons and gases.

3. Single Disc Single Seat Gate Valve or Slide Valve: It is used for handling paper and pulp slurry
and other fibrous suspensions, and for low pressure gases. It will not function properly with inflow
on the seat side. It is suitable for regulating if tight closure is not required.

4. Double Disc (Split Wedge) Gate Valve: In this the discs wedge against inclined seats without use
of a spreader. Other features are same as parallel seat. It allows the disc to rotate, distributing wear.

5. Double Disc Parallel Seat Gate Valve: It has two parallel discs which are forced on closure,
against parallel seats by a spreader. It is used for liquids and gases at normal temperatures. It is not
suitable for regulation. To prevent jamming, it is installed vertically.

6. Solid Wedge Gate Valve: It has either solid or flexible wedge disc. In addition to on/off service,
these valves can be used for regulating usually in sizes of 150 mm NB and larger, but it will make
noise unless disc is fully guided throughout travel. Suitable for most liquids and gases.

Sizes of 150# Gate Valves

Size NB Length Diameter Flange Handle Height
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Thickness Dia
40 165 127 14.3 152 330
50 178 152.5 16 203 360
65 190.5 178 17.5 203 415
80 203 190.5 19 254 425
100 229 229 24 254 510
125 254 254 24 305 595
150 267 279.5 25.4 305 685
200 292 343 28.6 305 773
250 330 406.5 30.5 408 940
300 356 483 32 457 1030
350 381 533.5 36 457 1270
400 406.5 597 36.5 508 1450
450 432 635 40 508 1600
500 457 698.5 43 610 1810
600 508 813 48 610 2170

MATERIALS OF CONSTRUCTION

BODY
CARBON STEEL
CARBON STEEL FORGED A-105
CARBON STEEL CAST A-216 Gr WCB
0.15% MOLY STEEL CAST A-217 Gr WCI
Cr. MOLY STEEL CAST A-217 Gr WC6, WC9
4.6% Cr. MOLY STEEL CAST A-217 Gr C5
8.1% Cr. MOLY STEEL CAST A-217 Gr C12
LOW CARBON STEEL CAST A-352 Gr LCB
LOW CARBON MOLY STEEL CAST A-352 Gr LC-1
3.5 NICKEL STEEL CAST A-352 Gr LC-3

STAINLESS STEEL
18-8 S CAST A-351 Gr CF8
18-8 S MOLYCAST A-351 Gr CF8M
18-8 S LOW CARBON A-351 Gr CF3
18-8 S LOW CARBON WITH MOLY A-351 Gr CF3M
18-8 S Cb CAST A-351 Gr CF8C
1.25 Cr 0.5 MOLY FORGED A-182 GrF11
11.5-13.5 Cr STEEL FORGED A-182 Gr FC
HEAT RESISTING 25-12 CAST A-297 Gr MH
HEAT RESISTING 25-20 CAST A-297 Gr MK
HEAT RESISTING 25-30 CAST A-297 Gr MT

NICKEL ALLOY
NICKEL CAST A-296 CZ 100
MONEL CAST A-296 M35W
HATELLOY B CAST A-296 N12M
HASTELLOY C CAST A-296m M CW-12M

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MANUFACTURING STANDARDS: BS:1414/API-600/API-6D/ANSI B-16.34

FACE TO FACE AS PER ANSI B 16.10
ENDS FLANGED & DRILLED AS PER ANSI B 16.5 RF
TESTED AS PER BS:5146, API 598
AVAILABLE IN CLASS 900, 1500
AVAILABLE WITH ACTUATOR OPERATOR
AVAILABLE WITH EXTENSION STEM
Test Pressure Kg/cm2
Hydrostatic Air
Class
Body Seat & Back Seat Seat
150 30 22 6
300 76 55 6
600 150 110 6

Sizes of 300# Gate Valves

Flange Handle
Size NB Length Diameter Height
Thickness Dia
40 190.5 156 21 152 390
50 216 165 22 203 370
65 241.5 190.5 25.4 203 440
80 282.5 210 29 254 445
100 305 254 32 254 520
125 381 279.5 35 305 570
150 403.5 317.5 36.5 356 740
200 419 381 41.6 406 910
250 457.5 444.5 48 458 1100
300 502 521 51 508 1200
350 762 584.5 54 559 1415
400 838.5 648 57.5 610 1540
450 914.5 711.5 60.5 813 1670
500 991 775 63.5 965 1910
600 1143 914.5 70 1508 Gear

Sizes of 600# Gate Valves

Flange Handle
Size NB Length Diameter Height
Thickness Dia
40 241.5 156 28.6 203 380
50 292 165 32 203 445
65 330 190.5 35 254 475
80 356 210 38 254 490
100 432 273 44.5 305 615
125 508 330.5 51 406 765

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150 559 356 54 457 840

200 660.5 419 62 508 950
250 787.5 508 70 610 1290
300 838.5 559 73 406 Gear
350 889 603.5 76.5 508 Gear
400 991 686 82.5 508 Gear
450 1093 743 89 508 Gear
500 1194 813 95.5 508 Gear

Plug Valve: It has a cylindrical or tapered plug in the body. Its

advantage is that it is compact and a quarter turn valve. The tapered
plug tends to jam and requires high operating torque. This is
overcome to some extent by low-friction teflon seat or by lubrication
(with the drawback that it may contaminate the conveyed fluid). It is
mainly used for water, oil, slurries or gases as quick closing valve.

Globe Valve: There are different types of Globe Valves.

1. Blow Off Valve: It confirms to boiler codes. Y and angle types are often used. It is
used to remove air and other gases from boilers. It is manually operated.

2. Double Disc Globe Valve: It features two discs bearing on separate seats spaced
apart on a single shaft, which frees the operator from stresses set up by the conveyed
fluid pressing into the valve. It is principally used on control valves and pressure
regulators for steam and other gases. Tight shut-off is not possible.

3. Composition Disc Globe Valve: It is suitable for coarse regulation and tight shut off. Replacable
composition disc construction is similar to that of a faucet. Grit will imbed in the soft disc
preventing seat damage and ensuring good closure. Close regulating will rapidly damage the seat.

4. Wye Body Globe Valve: It has in-line ports and stem emerging at about 45o, hence the name Y. It is
preferred for erosive fluids due to smoother flow patterns.

5. Plug Type Disc Globe Valve: It is used for severe regulating service with gritty liquids, such as
boiler feed water, and for blow-off service. It is less subjected to wear under close regulation than
the regular seated valve.

6. Regular Disc Globe Valve: This is unsuitable for close regulation as disc and seat have narrow
(almost line) contact.

7. Angle Valve: This is globe valve with body ends at right angles, saving the use of a 90o elbow.
However, higher stress may prevent its use.

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8. Straight Globe Valve: These are used for regulating service. For line sizes over 150 mm NB,
choice for flow control may go for gate or butterfly valve. The direction of flow around disc is in
upward direction.

Sizes of 150# Globe Valves

Flange Handle
Size NB Length Diameter Height
Thickness Dia
25 127 108 11.1 152 260
40 165 127 14.3 152 300
50 203 152.5 16 203 330
65 216 178 17.5 203 334
80 241.5 190.5 19 254 395
100 292 229 24 305 470
125 356 254 24 305 510
150 406.5 279.5 25.4 356 570
200 495.5 343 28.6 406 642
250 622.5 406.5 30.5 406 768
300 698.5 483 32 508 770
350 787.5 533.5 35 508 920
400 914.5 597 36.5 508 1010
450 978 635 40 559 1062
500 978 698.5 43 559 1220

Sizes of 300# Globe Valves

Flange Handle
Size NB Length Diameter Height
Thickness Dia
25 203 124 17.5 152 295
40 229 156 21 203 310
50 267 165 22.2 203 325
65 292 190.5 25.4 254 330
80 317.5 210 28.6 254 450
100 356 254 32 305 515
125 400 279.5 35 356 530
150 444.5 317.5 36.5 356 600
200 559 381 41.5 356 730
250 622.5 444.5 48 406 840
300 711.5 521 51 508 1005

Sizes of 600# Globe Valves

Flange Handle
Size NB Length Diameter Height
Thickness Dia
25 216 124 24 152 295
40 241.5 156 28.6 203 310

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50 292 165 32 203 325

65 330 190.5 35 254 381
80 356 210 38 254 485
100 432 273 44.5 305 623
125 508 330.5 51 356 660
150 559 356 54 356 778
200 660.5 419 62 406 828
250 787.5 508 70 508 942

Needle Valve: It is small valve used for flow control and for dosing liquids
and gases. Resistance to flow is precisely controlled by a relatively larger
seat area and the adjustment afforded by fine threading of the stem.

Squeeze Valve: It is well suited to regulating the flow of difficult liquids,

slurries and powders. Maximum closure is about 80%, which limits the
range of regulation, unless the variation of this type of valve with a central
core (seat) is used, offering full closure.

Pinch Valve: It is also suited to regulating flow of difficult liquids, slurries and powders. Complete
closure is possible, but tends to rapidly wear the flexible tube, unless it is of special design.

Ball Valve: Its advantages are low operating torque, availability

in large sizes, rotary 90o stem movement, compactness, and in-
line ability to replace of all wearing parts in some designs.
Possible disadvantages are that liquid is trapped within the body
(and within the ball on closure), and that compensation of wear is
affected only by resilient material behind the seats. The later is
avoided in single seat eccentric version, which has the ball
slightly offset so that it presses into the seat, on closure. Principal
uses are for water, oil, slurries, gases and vacuum. Valve is
available with a ball having a shaped port for regulation. It can
have full port or reduced port.

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Butterfly Valves: This offers advantage of rotary stem movement (90o or less), compactness and absence
of pocketing. It is available in all sizes, and can be produced in chemical-
resistant and hygienic forms. The valves are used for gases, liquids,
slurries, powders and vacuum. The usual resilient plastic seat has a
temperature limitation, but tight closure at high temperatures is available
with the version having metal ring seal around the disc. If the valve is
flanged, it may be held between flanges of any type. Slip-on and screwed
flanges do not form a proper seal with some wafer types of the valve, in
which the resilient seat is extended to serve also as line gaskets.

Check Valve: There are different types of check valves.

1. Wafer Check Valve: It effects closures by two semi-circular doors, both hinged to
a central post in a ring-shaped body which is installed between flanges. It is
frequently used for non-fouling liquids, as it is compact and relatively low cost. A
single disc type is also available.

2. Ball Check Valve: It is suitable for most services. The valve can handle
gases, vapors and liquids, including those forming gummy deposits. The
ball sits by gravity and / or back pressure, and is free to rotate, which
distributes wear and aids in keeping contacting surfaces clean.

3. Stop Check Valve: Its principal use is in steam lines, with steam generation
by multiple boilers. It can be kept closed automatically or manually.

4. Piston Check Valve: It changes the flow in 90o, and it also has a lifting disc. It has less pounding
with frequent changes in flow direction. Spring loaded can operate in any orientation. It is not
suitable for gritty liquids.

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5. Lift Check Valve: In this the disc is guided and it rises upward with
fluid pressure, and closes by gravity. It can be installed horizontally
or vertically if spring is provided to push the disc back.

6. Tilting Disc Valve: It is suitable where frequent flow reversal occurs. Valve
closes rapidly with better closure and less slamming than the swing check
valve, which it somewhat resembles. It can be installed vertically with
upward flow or horizontally.

7. Swing Check Valve: The regular swing check valve is not

suitable if there is frequent flow reversal as pounding and
wearing of disc occurs. For gritty liquids, a composition disc
is advisable to reduce damage to the seat. It may be mounted
vertically with upward flow or horizontally.

8. Foot Valve: It is typically used to maintain a column of water on suction side of a pump. The valve
is basically a lift-check valve with an integrated strainer.

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Sizes of 150# Check Valves

Flange
Size NB Length Diameter Height
Thickness
40 165 127 14.3 112
50 203 152.5 16 138
65 216 178 17.5 160
80 241.5 190.5 19 170
100 292 229 24 185
125 330 254 24 215
150 356 279.5 25.4 245
200 495.5 343 28.6 305
250 622.5 406.5 30.5 340
300 698.5 483 32 400
350 787.5 533.5 36 450
400 864 597 36.5 470
450 978 635 40 525
500 978 698.5 43 559
600 1296 813 48 650

Sizes of 300# Check Valves

Size NB Length Diameter Flange Height

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Thickness
40 241.5 155.5 21 140
50 267 165 22.5 160
65 292 190.5 25.4 180
80 317.5 210 29 200
100 356 254 32 225
125 400 279.5 35 250
150 444.5 317.5 36.5 265
200 533.5 381 41.5 325
250 622.5 444.5 48 390
300 711.5 521 51 465
350 838.5 584.5 54 470
400 864 648 57.5 500
450 978 711.5 60.5 580
500 1016 775 63.5 675
600 1346 914.5 70 775

Sizes of 600# Check Valves

Flange
Size NB Length Diameter Height
Thickness
40 241.5 155.5 28.6 160
50 292 165 32 170
65 330 190.5 35 190
80 356 210 38 200
100 432 273 44.5 235
125 508 330.5 51 285
150 559 356 54 325
200 660.5 419 62 425
250 787.5 508 70 500
300 838.5 559 73 500
350 889 603.5 76.5 590
400 991 686 82.5 655
450 1092.5 743 89 680
500 1194 813 95.5 785

Diverting Valves: Two types of diverting valves are made. Both switch flow from a line into one of two
outlets. One type is of Y pattern has a hinged disc at the junction which closes one of the two outlets, and
is used to handle powders and other solids. The second type handles liquids only, and has no moving parts.
Flow is switched by two pneumatic control lines. It is available up to 150 mm NB.

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Multi Port Valves: It is used largely on hydraulic and pneumatic

control circuits and sometimes used directly in process piping. These
valves have rotary ball or plug type discs with one or more ports
arranged to switch flow.

Safety Valve: There are different types of safety valves.

1. Ball Float Valve: These automatic valves are used in

steam traps to remove condensate water from the
system, to remove air from liquid systems and as
vacuum breaker or breather valves. It is widely used
to control liquid level in Cooling Water tank.

2. Safety Relief Valve (Temperature Safety Valve): It relives excess pressure of either gas or liquid
which may suddenly develop a vapor phase due to rapid and uncontrolled heating from chemical
reaction in liquid-laden vessels. It lifts up due to sudden change in temperature in the valve.

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3. Relief Valve: It is used to relieve excess pressure in

liquids or steam, in situations, where full flow
discharge is not required, when release of small
volume of liquid would rapidly lower pressure. It is
mounted vertically. Its outlet is of bigger size than
inlet because volumn of fluid in outlet is much
higher than inlet, due to reduction in pressure.

Line Blind Valve: This is a positive shut-off device which basically consists of a flanged assembly,
sandwitching a spectacle plate or blind. It is used where spectacle blind needs to be installed and removed
frequently.

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Flush Bottom Valve: It is usually installed on the bottom of the tanks

and vessels. These are usually globe type valves, designed to minimize
pocketing, primarily for convenient discharging of liquids with
suspended solids in it from the low point of a tank. The regulating part is
like inverted bucket and it sits deep in the bottom nozzle. It goes into the
vessel, when opened. It is used for slurry material in the vessel.

Sampling Valve: A valve usually of needle or globe pattern, placed in a branch line for
the purpose of drawing off samples of process materials through a branch. Sampling from
very high pressure lines is best done through a double valved collecting vessel. A cooling
arrangement may be needed for sampling from high temperature lines.

Control Valve: It automatically regulates pressure and / or flow rate, and are available for any pressure. If
there are different system pressures, in a plant up to and including 300#, sometimes all control valves
chosen will be rated at 300# for inter-changability. The size of control valve is usually chosen to be
smaller than size of the pipe line, to avoid throttling and consequent rapid wear of the seat. Globe pattern
valves are normally used for control, and their ends are usually flanged for ease of maintenance. The disc
is moved by hydraulic, pneumatic, electrical or mechanical actuator.

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Pressure Regulating Valve: These are control valves of globe type,

which adjust downstream pressure of liquid or gas (including steam or
vapor) to a lower desired value called set pressure.

Diaphragm Valve: It is used for regulating flow of slurries and corrosive liquids and for vacuum. The
term diaphragm valve is also applied to valves which have a diaphragm seal between stem and body.

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Breather Valve: A special self acting valve installed on storage tanks,

long distance pipe lines etc., to release air or gas accumulated inside.

Jacketed Valve:

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