Module 11

PIPINGS and VALVES

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 Course Contents
1. Pipe
2. Piping standard
- Nominal pipe diameter
- Schedule number
- Piping standards code
- Tubes
- Fittings and other piping auxiliaries
3. Method of joining sections
- Threaded
- Bell and spigot
- Flanged
- Welded connection
- Fitting
4. Types of flanged joints
5. Expansion joints
6. Blinds
7. Spaces

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 Course Contents
8. Valves
- Types of valves
9. Valves
- Gate valve
- Globe valve
- Diaphragm valve
- Plug valve
- Ball valve
- Butterfly valve
- Needle valve
- Check valve
- Safety valve
10. Function of valve
11. Basic control function of valves

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 Course Contents
10. Application of Valve types
11. Valve ratings
12. Valve operation and maintenance
13. Do’s and don’t for better valve service
14. Pressure relieving devices
- How high pressure develops
- Types of pressure relieving devices
15. Definition of pressure relief terms

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 Pipes

• Piping systems are the arteries and veins of a petrochemical plant

just as they are in the human body. In a petrochemical, piping
systems handle all liquids, solids, gas or vapor.
• Material is frequently stored and handled in the fluid state. Most fluid
cannot be handled in open channels but required closed ducts.
• In ancient these ducts were hollowed logs and later they were made
of section of wood or of pottery.
• Development of iron brought about the manufacture of cast iron and
wrought iron pipes.
• Any structural material now available is used for pipe in application
where its peculiar advantages are most valuable.

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 Piping Standards

Nominal pipe diameter

Pipe sizes are based on the approximate diameter and are reported as
nominal pipe sizes. Although the wall thickness varies depending on
the schedule number, the outside diameter of any pipe having a given
nominal size is constant and independent of the schedule number. This
permits the use of standard fittings and treading tools on pipes of
different schedule numbers

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 Piping Standards

Schedule number
• Pipes were originally classified on the basis of wall thickness
as standard (extra strong, and double extra strong).
• Because of modern industrial demands for more exact spec,
pipes are now specified according to wall thickness by a
standard formula for schedule number designated by the
American Standards Association.
• Schedule number is defined by ASS as: = 1000 Ps/Ss
where Ps = safe working pressure
Ss = safe working fiber stress

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 Piping Standards
Schedule number
• Ten schedule numbers are in use at present.
• These are 10, 20, 40, 60, 80, 100, 120, 140, 160
• For pipe diameters up to 10 in, schedule 40 corresponds to the
former “standard” pipe and schedule 80 corresponds to the
former “extra strong” pipe.

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 Piping Standards

Schedule number
How they came up with the formula?
Bursting pressure of a thin walled cylinder may be estimated from
the following equation:

Pb = 2STtm/Dm where: Pb = bursting pressure

ST = tensile strength
tm = minimum wall thickeness
Dm = mean diameter

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 Piping Standards

Schedule number
A safe working pressure Ps can be evaluated from equation if the
tensile strength is replaced by a safe working fiber stress Ss

Ps = 2Sstm/Dm

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 Piping Standards
Piping standard codes

• The American National Standards Institute (ANSI) and the

American Petroleum Institute (API) have established dimensional
standards for most widely used piping components

• ANSI B31
- List of those standards can be found in the ANSI B31 code
section
- Section also lists specifications for pipe and fitting materials
and testing methods of the American Society for Testing and
Materials (ASTM)
- American Welding Society (AWS) specification
- Standard of the manufacturers Standardization Society of the
Valve and Fitting Industry (MSS)

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 Piping Standards
Piping standard code (con’t)

The design of piping system applied to this project is listed as

ASME B31.3
• ASME stands for American Society of Mechanical Engineer
• ASME 31.3 is actually a section of ANSI B31
• ASME (ANSI) 31.3 is a Standard Number and designation is
Chemical Plant and Petroleum Refinery Piping
• ASME (ANSI) 31.1 scope and application:
- For all piping within the property limits of the facilities engaged
in the processing or handling of chemical, petroleum or related
product unless specifically excluded by the code
• Information on latest issue can be obtain for ASME. 345 East
47th st. New York NY 10017

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 Piping Standard

Tubing
Copper tubing, brass tubing are used extensively in industrial
operations. Other metals, such as nicklel and stainless steel, are also
available in the form of tubing.
Although pipe specifications are based on standard nominal sizes,
tubing specs are based on the actual outside diameter with a
designated wall thickness.
Conventional system, such as the Birmingham wire gauge (BWG) are
used to indicate the wall thickness.

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 Piping Standard

Fittings and other piping auxiliaries

• Fittings, flanges, valves, flow meters, steam traps and many other
auxiliaries are often rated on the basis of the safe operating
pressure as
25 psi – low pressure
125 psi - standard
250 psi – extra heavy
300 to 10,000 - hydraulic

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 Method of Joining Sections

Method of joining sections

The methods of joining sections are generally similar for all
materials. The principal methods involve are
1. Threaded
2. Bell and spigot
3. Flanged
4. Welded connections
5. Fitting

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 Threaded Joints

• Threaded pipe is most commonly encountered in industry because

practically all small sizes of pipe are joined by thismethod, whether
fabricated of steel, wrought iron, cast iron, brass, or plastic.
• This system is simple because the outside diameters of the pipe are
kept constant with a tolerance of 1/64 in. oversize and 1/32 in.
undersize, and the inside diameters of fittings are kept within the
same limits, regardless of materials.
• The tolerance for the wall thickness of the different materials varies
but is usually 12.5 per cent.
• Pipe larger than 12in. Is rarely threaded, and the outside diameter
corresponds to the nominal pipe size.
• Standard lengths of pipe are from 16 to 22 feet.

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 Bell and Spigot Joints

Bell and spigot connected pipe handle more fluid than any other
connection since it is the most practical type of joint in large pipe
sizes when pipes are made of materials other than steel. These
joints are usually calked with oakum and lead but the mechanical
joint is becoming more popular because of the tighter joint, simplicity
of installation, greater latitude of angular displacement and
expansion. These joints may be “locked” with a groove in the spigot
which prevents pulling apart the joint, “roll on” with a rubber gasket
tightened with a bolted ring or “screwed gland”, with a ring gland
drawn up against the gasket when screwed into threads in the bell.

Materials for pipe joined in this manner are usually cast iron, clay,
or concrete, although glass, plastic and cement asbestos are
sometimes employed.
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 Welded Connections

• The modern trend for pipe in sizes above 2 in. is toward more
welded connections. No threading, calking, or bolts is needed, and
no gaskets are required when the system is fused into an unknown
line of material.
• Pipe ends needs no treatment other than scarfing (beveling) and
very few fittings are required if the welder shapes the necessary
pieces from pipe sections.
• Fittings and valves are of steel and are of two types, butt weld and
socket weld. The butt weld fittings are of the same dimension as the
pipe, and the socket weld fittings have enlarged ends similar to
threaded fittings, but the pipe slips into place and is fillet welded.

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 Fittings

Threaded joint fittings

• Couplings – join successive straight length of pipes with no change
in direction or size.
• Reducing couplings – used when size is to be reduced or enlarged.
• Elbows – used when direction is to changed (90 and 45 deg elbows
are available)
• Reducing elbows – used when both size and direction are changed.
• Nipples – because of the mechanical difficulty of cutting sharp
thread, nipples are made in factory in a series of standard lengths
from about 4 pipe diameter in length to close nipples, whose threads
merge from each end of the section.
• Tees and crosses – used if more than 2 branches of piping are to be
connected at the same point.

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 Fittings

Threaded joint fittings (con’t)

• Unions – since most piping must be broken at interval for
maintenance and since standard pipe threads are right hand, thus
making it impossible to use right hand fittings exclusively in
connecting pipe from one fixed point to another fixed point, a union
serves as a connector. The two halves of the union may be
tightened to the pipe section independently, and the final connection
made by tightening the bonnet of the union.
• Reducing bushing – used if size reduction is desired at a tapped
connection.
• Street elbow – used if a simultaneous change in direction and
connection to a tapped outlet is required. (male thread at one end
female thread on the other).

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 Fittings

Threaded joint fittings (con’t)

• Cap – used to close end of a pipe
• Plug/capped nipple – used to close an opening in a piece of
equipment.

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 Fittings

Welded connections
Fittings are of steel and are of 2 types, butt weld and socket weld.
The butt weld fittings are of the same dimension as the pipe, and the
socket weld fittings have enlarged ends similar to threaded to
threaded fittings, but the pipe slips into place and is fillet welded.
Fittings are similar to equivalent threaded type.

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 Fittings

Bell and spigot connections

Fittings [of the same materials as the pipe] are similar in type and
function to those for threaded pipe.

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 Fittings

Compression fittings
• Compression fittings are widely used for small sized tubing at both
low and high pressure. These are convenient and efficient,
particularly if the connection is to be broken.

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 Flanged Joints

Flanged joints are the most common method for joining pipe in sizes
2 inches and above. The use of flanges allows for making the piping
up in sections that are easy to handle and also allows access for
cleaning, draining, etc.
1. Socket welding flanges
2. Slip on welding flanges
3. Threaded flanges
4. Welding neck flanges
5. Lap joint flanges

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 Flanged Joints

Socket welding flanges

• Socket welding flanges are widely used for moderate service,
particularly in the smaller sizes, because of the ease of fit p and
alignment. Although usually welded at the flange hub only, the pipe
end may also be welded without having to reface the flange. The
pipe end weld can be ground to provide a smooth bore.

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 Flanged Joints

Slip-on Welding Flanges

• Slip-on flanges are popular for normal service conditions because of
the ease of fit up and alignment and the greater tolerance
permissible in cutting the pipe to length. Recommended fabrication
practice is to wed at both the flange hub and the pipe end.

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 Flanged Joints

Threaded Flanges
• Threaded flanges are widely used because no welding equipment is
required for assembly and both the pipe and flange can be
completely salvaged upon dismantling. Accurately cut, clean,
tapered pipe threads dimensioned to ANSI A2. 1 Pipe Threads,
assure strong, tight joints.

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 Flanged Joints

Welding Neck Flanges

• Welding neck flanges are designed to be butt welded to the pipe.
The long tampered hub reinforces the flange, permits stress-
relieving, magnafluxing or x-raying the weld, when required, and
removes the flange face from the heat affected zone. These
advantages make welding neck flanges particularly suitable for
severe service involving high pressure, extreme temperatures, or
hazardous fluids.

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 Flanged Joints

Lap Joint Flanges

• Lap joint flanges, while requiring a separate end connector, provide
a joint in which the product does not come in contact with the flange.
In addition, the ability of the flange to rotate simplifies assemble and
alignment of bolting on systems requiring frequent dismantling.
• Screwed flanges must be seal welded after the screwed joint is
made up tight. Threading of pipe above 2” is difficult and this type is
not used too often.
• Slip-on flanges are widely used because of their low cost, ease of fit-
up and alignment, however, they are not too good for service where
the temperature and pressure fluctuate. In some services corrosion
of the internal weld may be a problem.

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 Flanged Joints

Lap Joint Flanges (con’t)

• Welding neck flanges are probably the best all around type of
flange. They are the strongest of all those shown. There are no flow
problems associated with the assembly and the butt joint is the best
method to insure a sound weld.
• Lap joint flanges are good for a combination of alloy pipe and carbon
steel flanges. This combination reduces the cost and usually
reduces the delivery time compared to waiting for solid alloy flanges.
• The gaskets used with flange joints must always be softer than the
flange material because one or the other must be deformed in order
to make a tight joint.

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 Flanged Joints

Lap Joint Flanges (con’t)

• The elastomers include rubber, nylon, plastic, etc. These materials
have a disadvantage in that they can cold flow when squeezed - -
even at room temperature. Thus, it is difficult to maintain a tight joint.
These materials also have a tendency to flow out ant must be
reinforced with cloth or wire mesh if any significant pressure is
involved. Some elastomers are good for no more than 100oF. At this
temperature that will soften and some will actually begin to melt.
Some elastomers are soluble in oil.
• The spiral wound metal gasket with asbestos filler requires special
flange finishing. Tightening of joints using these gaskets normally
requires special attention and will take more time to properly tighten.

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 Expansion Joints

Expansion Joints
• All metals expand with increasing temperature. Steel pipe is no
exception to this rule. Expansion must be considered to
accommodate the change in length in the change from atmospheric
temperature to operating temperature. Expansion joints are used to
absorb the effect of the increased length with temperature. These
can be bends or corrugated expansion joints. The attached piping
must be properly anchored and guided to direct the expansion to
utilize the expansion to utilize the expansion joint most effectively.

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 Blinds

Blinds are a piping item used extensively in the plant. A blind is used
to provide positive isolation in between piping flanges and thus
insure that any leakage that takes place will be to the atmosphere
and not through the pipe.
• Normally, blinds are used to prepare vessels or tanks for entry
and to isolate equipment and piping in order to provide complete
safety in welding.
• Blinds are also used for hydrostatic testing but in this case they
must be of special design in order to handle the test pressures
that will be involved.

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 Spacers

Spacers are required when there is a blind of appreciable thickness

to be used. It is ordinarily impossible to spring the flanges far
enough apart to install a blind of thickness beyond ½ in.
• Under the above conditions a spacer is required to take up the
space occupied by the blind when the equipment is returned to
operating condition.
• Sometimes the blind and the spacer are attached to each other
and in this case it is known as figure 8 or spectacle blind.

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 Valves

• Valves are used for the control of volume and pressure of fluids
moving through piping or in enclosed vessels. They may be
operated automatically or by hand. Type of construction is as varied
as the operations within the plant; each is designed for the service to
be performed.

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 Valves

Types of valves
1. Gate valves
2. Globe valves
3. Diaphragm valves
4. Plug valves
5. Ball valves
6. Butterfly valves
7. Needle valves
8. Check valves
9. Safety valves

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 Valves

Gate valves
• The gate valve is probably the most widely used valve in plant
operations, particularly in the larger sizes of piping installations and
those of the most severe service.
• It consists of a main body and a stem which raises or lowers a “gate”
across the fluid flow. In high pressure installations the gates must be
of heavy construction and are sometimes difficult to open. Some are
motor operated and some have a small by-pass line for equalizing
the pressure on both sides of the gate before opening.
• The rising stem gate valve is used in both water and process piping.
It requires more overall space for installation, but is used to an
advantage in handling corrosive streams that tend to damage stem
threads in other type valves.

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 Valves

Gate valves (cont)

• The non-rising stem gate valve is used extensively in water piping.
Its chief disadvantage is the fact that the degree of opening cannot
be readily determined.
• A gate valve should be used only in service where it can be kept in a
fully opened position. In partially opened positions the gate will
vibrate and mar the seating surfaces, preventing complete closure.
• Wrenches and levers should not be used to exert extra pressure on
valve stems when the gate has become completely seated in
closing. This practice will result in galling and marring of the seat
and disc, making complete closure impossible.

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 Valves

Gate valves
– used to minimize pressure drop in the open position and to
stop flow rather than to regulate it.

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 Valves
Globe valves
• The essential feature of this type valve is a globular body with an
internal, horizontal partition having a circular opening in which is
inserted a ring or seat. The globe or disc seats on this ring to effect
shut-off.
• The valve opening is so arranged that flow through it must make two
90-degree changes of direction. This results in a relatively high
pressure drop, or resistance to flow.
• The globe valve is generally used in small sized piping for throttling
or control. They are used principally in steam or air service where
throttling and a positive shut-off is desirable.
• Installation should be such that flow is up through the seat ring and
against the bottom of the disc or glove. This will prevent opening
difficulties caused by the accumulation of debris above the disc.
This should be avoided.

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 Valves

Globe valves (cont)

• With this type of valve it is important that the valve is installed with
flow passing through it in the correct or required manner. Normally
the flow enters the “S” shaped passage underneath the valve plug.
When the plug lifts, the liquid flows up past the plug and through the
outlet. This method of installation keeps the pressure from the
packing gland when the valve is in the closed position.
• Occasionally the flow is reversed and the inlet pressure flow enters
on top of the seat. This is normally done when it is wished to have
the pressure assist or ensure the closing of the valve. With oils of a
certain type, this is bad practice as, if the oil has a tendency to
congeal, gum will form on the valve stem and prevent the valve plug
and stem from rising.

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 Valves

Globe valves - offer ease in throttling

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 Valves

Diaphragm valves

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 Valve

Diaphragm valves

Diaphragm valves
– limited to 50psi, excellent for fluid containing suspended solids
45
 Valves

Plug valves
• The plug valve, or cock, is a conical plug within a body. Its chief
advantage is in its tight shut off. A one quarter (90 degree) turn of
the plug changes it from a fully closed to a wide open position
• Since the plug tends to stick when used in high temperature and
high pressure service, some types of these valves have been
provided with a means of lubrication through the stem of the cock.
• A rotary life plug valve is non lubricated. In operation, as the stem is
turned, the plug lifts slightly from its seat, rotates to the opposite
position then lowers back into place. This operation can be
performed in about one-fourth to one-half a turn in the smaller sizes.
Large valves require more rotation of the stem.
• The quick opening principle of plug valves makes them impractical
as a means of controlling rate of flow.

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 Valves

Plug valve – for throttling service, little likelihood of leakage when

closed.

47
 Valves

Ball valves
• Ball valves are adaptations of plug valves using ball-shaped discs
instead of conical plugs located within the body. A hole through the
center of this disc provides the straight-through flow which is
characteristic of ball valves. Ball valves are used to shut off or permit
full flow of fluid through the valve.
• Ball valves have all the advantages of plug valves in terms of
excellent flow characteristics - quick opening, straight-through flow,
minimum turbulence, tight closure and compactness - plus the
additional advantage of not requiring any lubrication or sealant.
They achieve tight closure by establishing a controlled squeeze of
the ball against the sear rings which are made of plastic material
such as teflon.

48
 Valve
Ball valves

49
 Valves

Butterfly valves
• The butterfly valve derives its name from the wing-like action of the
disc which operates at right angles to the flow. Ordinarily, they are
not intended for tight shut off, but resilient seats have broadened
their possibilities and they are now frequently advertised as having
“bubble tight” closure.

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 Valves

Butterfly valve

51
 Valves

Needle valves
• Needle valves are designed to give very fine control of flow in small
diameter piping systems. They get their name from their sharp-
pointed conical disc and matching seat. The stem threads are fine
so that more turns of the hand wheel are required to increase or
decrease the opening through the seat.

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 Valves

Needle Valves – offer flow adjustment on small lines

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 Valves

Check valves
• Check valves are automatic in operation. They prevent flow in one
direction, but allow it in the other. These valves should be carefully
checked for direction of flow in lines.
• Swing check valves are unsuitable for use in vertical lines. Note
importance of correct installation of a check valve in relation to the
stream flow. Usually the valve body has features that indicate
correct direction.
• Sometimes an arrow indicates the direction of flow permitted
through the valve. Do not rely upon a check valve to give full shut-off
against a back flow. Only on special occasions, [authorized] will the
check valve be depended upon to prevent back flow of liquid or
other hazardous material when opening lines into other systems or
to the atmosphere. Always use a block valve when possible.

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 Valves

Safety valves
• Safety valves are installed in strategic locations to provide pressure
relief for process equipment subjected to excessive pressure.
• A safety valve consists of six basic parts; spring, spindle or stem,
adjusting screw, disc, nozzle or seat, and body. Safety, or relief,
valves are intended for emergency protection only and should not be
used as an operating valve.
• Frequent “popping” of a relief valve contributes to their failure,
therefore, they should set at 25% above working pressure. For
example, relief valves on the discharge of reciprocating pumps will
relieve with each pump stroke if the set pressure is too low.
Continuous pounding of the disc upon the seat causes damage and
resultant leakage of the valve.

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 Valves

Safety valves (cont)

• Other causes of valve leakage are spring failure and debris on
seating surfaces. Extreme caution should be exercised in tampering
with relief valves while a unit is in operation. The proper place for
reseating a leaking valve is in the shop. Pressure should be reset on
the test rack.
• When pressure builds up in a vessel or line, pressure is also exerted
on the plug. The plug is lifted from its seat and the excess pressure
in immediately released. At the same time, the spring tends to push
back the plug on to its seat. When the spring tension is once again
greater than the vessel pressure then the plug will again reseat.

56
 Pressure Relieving Devices

Conventional Relief Valve

57
 Functions Of Valves

• Piping system, in order to effectively perform the function of

transporting fluids from the point to another, need devices to control
or regulate the flow of fluids. Although devices are available – which
by suitable instrumentation automatically regulate or control the flow
of fluids in response to flow, level, pressure, temperature, or other
control signals – only manually operated devices will be discussed
in this section. Check valves, relief valves, steam traps, drain valves,
etc although not manually operated are also discussed in this
section.
• Manually operated valves are devices which are opened or closed
by turning a hand wheel or moving, rotating or otherwise
manipulating a hand lever or wrench. Gate, globe, plug, ball,
diaphragm and butterfly valves are in this category.

58
 Functions Of Valves

(cont)
• When valves are large size, difficult to operate due to flow
conditions, located in inaccessible positions, require rapid opening
and closing, or need to be operated remotely from a central control
area, mechanical or power actuated operators are frequently
installed on these valves. Gear operators, chain wheels, or electric
motor operators are some of the mechanical or power actuated
operators most often used.
• Each type of valve is designated for a specific purpose to meet
and/or satisfy the following basic control functions desired in a
piping system.

59
 Basic Control Functions Of Valves

• Starting and stopping Flow

To start or stop the fluid flow is the function for which valves are
most generally used. Gate, plug, ball, butterfly and diaphragm
valves effectively perform this function with very little pressure drop
through the valve.
• Regulating and throttling Flow
Regulating or throttling flow is most efficiently performed with globe,
angle, or needle valves. These valves are seldom used in size
above 8 inches because of the difficulty opening and closing the
larger valves against pressure.
Butterfly and diaphragm valves are also effective as regulating or
throttling valves at limited fluid flow characteristics.

60
 Basic Control Function Of Valves

(cont)
• Preventing backflow
Check valves perform the function of checking or preventing
reversal of flow in piping systems. Flow keeps these valves open if
the flow is in the right direction, while gravity and reversal of flow
closes them automatically. Check valves are available in two basic
types - swing and lift checks.
• Relieving Pressure
Relief and safety valves are installed on equipment such as boilers,
vessels, drums, piping systems, etc. which can be seriously
damaged if subject to pressures in excess of the equipment design.
They are usually spring loaded and automatically open to release
pressure which exceeds the limit for which the valve was set.

61
 Application Of Valve Types

Gate valves
• The Principal characteristic of a gate valve is the fact that the
flow through the valve is stopped by sliding a relatively flat
surface, called a gate or disc, across the flow path of the fluid
and started by moving the disc into a chamber in the valve
bonnet out of the flow path. Gate valves are most effective fully
closed or fully opened. When fully opened the fluid flows
through the gate valve in a straight line with very little pressure
drop.

62
 Application Of Valve Types

Globe valves
• Globe valves are named after the globular shape of their body.
They are most suitable for throttling fluid flows because of their type
of seating arrangements, however, they can also be used in fully
shut off and fully open service
• Globe valves seating is parallel to the line of flow with all contact
between seat and disc ending when flow begins.
• The fluid flow through a globe valve follows a changing course
which causes resistance to flow and considerable pressure drop.
However, in order to control the fluid flow we must sacrifice some
pressure drop.

63
 Application Of Valve Types

Angle valves
• Angle valves are similar to the design of globe valve but have less
resistance which results in less pressure drop.
• The angle valve effectively utilizes globe valve seating principle
while providing for a 90 degree turn in piping. It is less resisting to
flow than the globe valve it displaces. Requires fewer joints; saves
make-up time and labor.

64
 Application Of Valve Types

Needle valves
• Needle valves are designed to give very fine control of flow in small
diameter piping systems.
• Generally used in chemical injections to process and delivery lines

65
 Application Of Valve Types

Plug valves
• The plug valve is often referred to as the oldest member of the valve
family, however, this is only true of the non-lubricated type which
may be considered a modification of the simple cock.
• The non-lubricated plug valve is an evolution of the simple plug
cock. All the advantages of the simple plug cock are maintained but
the tendency of the plug to seize or bind has been overcome by
changes in the design and construction of the plug valve. This has
been accomplished by the use of various plastics or other materials
with low friction values for contact or sealing surfaces. As a result of
these changes non-lubricated plug valves are now available for a
much greater range of service conditions.
• Teflon (tetrafluoroethylene) is one of the principle materials with low
friction value being used today for contact surfaces.

66
 Application Of Valve Types

Plug valves (cont’)

Teflon, however, has its own problems in terms of cold flow and
temperature limitations.
• The lubricated plug valve with lubricant or sealant injected into the
valve under pressure to maintain a leak-tight seal and to permit ease
of movement of the plug inside the valve utilizes the lubricant as a
hydraulic jack to raise the plug slightly to reduce the friction during
operation of the plug valve.

67
 Application Of Valve Types

Ball valves
• Ball valves are adaptations of plug valves using ball-shaped discs
instead of conical plugs located within the body. A hole through the
center of this disc provides the straight-through flow which is
characteristic of ball valves. Ball valves are used to shut off or permit
full flow of fluid through the valve.
• Ball valves have all the advantages of plug valves in terms of
excellent flow characteristics - quick opening, straight-through flow,
minimum turbulence, tight closure and compactness - plus the
additional advantage of not requiring any lubrication or sealant.
They achieve tight closure by establishing a controlled squeeze of
the ball against the sear rings which are made of plastic material
such as teflon.

68
 Application Of Valve Types

Ball valves (cont’)

• Because of the sealing of ball valves is accomplished with a ball
shaped disc seating against plastic materials, the temperatures for
which these valves can be used are limited.

69
 Application Of Valve Types

Butterfly valves
• They are widely used in the municipal field for the control of water
flow.
• Butterfly valves are excellent for handling large flow of gases and
liquid at relatively low pressure.
• The butterfly valve in full open position has relatively low pressure
drop and minimum turbulence since the disc position is parallel to
the fluid flow. Some of the advantages of butterfly valves are little
head room required, light in weight, durability, low initial cost and
ease of operation. However, they are limited in pressure and
temperature applications.

70
 Application Of Valve Types

Check valves
• The principal function of a check valve is to automatically prevent
reversal of the direction of the fluid flow. Pressure of the fluid flowing
through the check valve keeps it open – reversal of the flow closes
it. Most manufacturers plainly mark check valves for direction of
flow. The design of check valves are relatively simple and are
available in three basically different types - swing check, lift check,
and ball check.

71
 Application Of Valve Types

Check Valves
• Used to prevent reversal of flow
1. Swing check valve
- Normal design is for use only in horizontal lines
2. Lift check valves
- Vertical lift check valve – for installation in vertical line, where
the flow is normally upward
- Globe check valve – for use in horizontal lines
- Angle check valve – used for installation where a vertical line
with upward flow turn horizontal
3. Tilting disk check valve
- May be installed both horizontally and vertically. Less pressure
drop at low velocity but greater at high velocity. Arrests
slamming.

72
 Application Of Valve Types

Swing check valve

• Swing check valves have a disc, hinged at the top, which seats
against a machined seat in the tilted bridge wall opening. The disc
swings freely in an arc from the fully closed position to one providing
unobstructed flow. The fluid flows through the body in a straight line.
The straight line flow results in low pressure drop because of the
minimum resistance to flow.

73
 Application Of Valve Types

Check Valves

Swing check valve

74
 Application Of Valve Types

Check valves

Tilting disk check valve

75
 Application Of Valve Types

Lift Check Valve

• The lift check valve has a disc equipped with a short guide, usually
above and below, which moves vertically in integral guides in the
cap and bridge wall. Fluid flow moving through the body in a
frequent changing course keeps the valve open.
• When flow stops gravity or reverse of flow direction automatically
closes the valve by forcing the disc against the seat. Lift check
valves provide a tighter seal against back flow than can be achieve
with the swing check valve.
• Lift check valves can only be used in horizontal pipe lines and are
generally used in conjunction with globe and angle valves.

76
 Application Of Valve Types
Check valves

Lift check valve (vertical)

77
 Application Of Valve Types

Check valves

Lift check valve (angle)

78
 Application Of Valve Types

Ball Check Valve

• Ball check valves are similar to lift check valves except that a ball is
used in place of the lift disc for closure purposes. The ball is pushed
away from the seat during fluid flow and closes rapidly when flow
stops or is reversed. This valve has extensive use in piping systems
moving hot oils and can only be used in vertical lines.

79
 Application Of Valve Types

Stop-Check or Non-Return Valve

• A special and more complicated check valve called the stop-check
or non-return valve is essential to the safe operation of a boiler.
Their design must conform to the ASME Boiler Construction Code
for Non-Return Stop valves. The valves are intended to perform four
important functions in boiler steam piping:
1. Act as an automatic non-return valve preventing backflow of
steam from the connected main steam header into the boiler in the
event of failure of that boiler.

80
 Application Of Valve Types

• Stop-Check or Non-Return Valve (cont’)

2. Assist in cutting out a boiler, when ceasing to fire that boiler. In
this case, the disc automatically closes and prevents steam header
pressure from entering the boiler. The valves are equipped with a
hand wheel which permits closing the valves under pressure or, if
already closed automatically, permits holding the disc in the closed
position.
3. Assist in bringing a boiler into service after shutdown. This
operation requires considerable care when performed manually but
is accomplished automatically by a stop-check valve without
pressure fluctuations or disturbance of the water level.

81
 Application Of Valve Types

Stop-Check or Non-Return Valve (cont’)

4. Act as a “safety first” valve by preventing back flow of steam from
the header into a boiler, shut down for inspection or repairs, should
an attendant accidentally open the valve.

Since the valves are equipped with hand wheels it is important to

note that there is no mechanical connection between the disc and
steam. When the stem is raised by the hand wheel, only the boiler
pressure can lift the disc.

82
 Application Of Valve Types

• Water drain valves

Compressed air system, constantly accumulate water and oil. Such
liquids in air lines are a hazard and a hindrance to effective use of
the air system for process uses, tools, machinery, air cylinders, etc.

83
 Application Of Valve Types

Safety valves
• Applications of safety valves will be discussed separately later in
this module under pressure relieving devices.

84
 Application Of Valve Types

Actuators
An actuator, [a transducer according to definition for instrumentation
final control element]) translates the control signal from one form or
level of energy or power to another, e.g. from a pneumatic signal into a
mechanical action which is used to manipulate a process variable.

85
Application Of Valve Types

86
Application Of Valve Types

87
 Valve Ratings

Most valve manufacturers comply with MSS Standard Marking

System SP-25 in the identification of their valves. The following
symbols are generally used:

S - Steam
O - Oil
G - Gas
W - Water
L - Liquid

General purpose valves may show two service ratings. One is a

steam rating, based on a specific pressure/temperature condition.
The second rating is for cold service.

88
 Valves Ratings

• Steam Ratings
Steam ratings are used as a basis for determining the suitability of a
material for a given application. For lower temperatures the safe
working pressure of a material is usually greater that the steam
rating.

• Cold Ratings
Most valves have two service ratings. In addition to the steam
rating, explained above, cold service ratings are usually designated
by the mark WOG, which stands for cold water, oil, or gas, non-
shock.

89
 Valve Ratings

• Steel Ratings are Different

Temperature and pressure are not always the only factors to be
considered, however. Frequently, steel materials are used for their
structural ability to meet unusually severe conditions beyond the
range for which brass or iron are recommended, such as shock,
vibration, line stresses, fire hazard etc.

90
 Valve Ratings

• Steel ratings are different (con’t)

Cast and forged steel valves and fittings bear a mark such as 150,
300, 600 etc. These figures denote the maximum pressure at a
certain maximum temperature for which an item is suited. A certain
600-pound steel valve, for example, may be suitable for 600-pound
pressure at temperatures up to 850oF. But if the temperature
exceeds that point, up to 1000oF., let’s say, the valve is not
recommended for pressures over 170 pounds. This important effect
of temperature makes it imperative to know both pressure and
temperature conditions of a service, and to consult the
manufacturer’s service recommendation tables.

91
 Valve Operation And Maintenance

Variations in Stem Operation of Gate, Globe and Angle Valves

1. Rising stem with outside screw and yoke. In this construction the
stem screw remains outside the valve body whether valve is opened
or closed. Stem threads are not subjected to the effects of fluids in
the line - such as caused by corrosion, erosion, sediment, etc. This
construction also permits convenient lubrication of stem threads.

The rising stem shows at a glance the position of the disc.

Adequate headroom must be provided for the rising stem when the
valve is opened, and the stem should be protected against damage
when raised.

92
 Valve Operation And Maintenance

(con’t)
2. Rising stem with inside screw. This is the simplest and most
common stem construction for gate, globe, and angle valves in the
smaller sizes. The position of the stem indicates the position of
the disc. The stem should be protected against damage when the
valve is open.

3. Non-rising stem with inside screw. Stem does not rise when
disc is raised, but merely turns with handwheel. Ideal where
headroom is limited. Since stem merely turns when operated,
wear on packing is minimized.

93
 Do’s And Don’t For Better Valve Service

1. Don’t expose valves to damaging blows. Valves can’t be abused

and still operate efficiently. A bent stem not only cripples valves, but
may cause a shutdown that results in costly delay and repair.

2. Don’t overlook leaks – big and small. A leak in a valve often can
be remedied simply and in a hurry, if caught in time. Stem leaks
normally can be fixed by slightly tightening the packing nut or gland.

Stuffing box leaks usually can be stopped by merely “pulling” up the

packing nut. On bolted glands, care must be taken to tighten bolts
evenly… as severely coking the gland will bind the stem. If the
stuffing box must be repacked, this repair should be scheduled for
qualified maintenance mechanics.

94
 Do’s And Don’t For Better Valve Service

(con’t)
2. Bonnet and flange leaks can be caused by bolts loosening under
service strain, If tightening the joints doesn’t stop the leak, the
gasket may be damaged and this repair should also be scheduled
for qualified maintenance mechanics.

3. Don’t spare the oil can. Wear on stem packing is due mainly to
the rising and turning motion of the valve stem, combined with
deteriorating effects of service conditions. A few drops of oil on the
stem, now and then, help to reduce friction - - and wear, Don’t
forget to lubricate exposed stem threads.

95
 Do’s And Don’t For Better Valve Service

(con’t)

4. Don’t operate gate valves continuously in a “cracked open”

position because the valve seats will be severely damaged.
Damage to valve seats will cause valve to leak when closed.

5. Do not use large pipe wrenches to close valves.

6. Rising stem valves should be backed off slightly to relieve

tension on the stem.

96
 Pressure-Relieving Devices
How high pressure develops

The possibilities for development of excess pressure exist in nearly

every process plant.
Excess pressure can develop from:
1. explosion
2. chemical reaction
3. reciprocating pumps or compressors
4. process upsets
5. external fire around equipment

• In addition to the possible injury to personnel, the loss of equipment

can be serious and an economic setback
• Most countries have laws specifying the minimum attention
required in the applications of pressure-relieving equipment in
process and steam power plants.

97
 Pressure Relieving Devices

Types of pressure relieving devices

1. Relief valves
2. Safety valves
3. Safety-relief valve
4. Conventional and balance valves
5. Frangible disk (rupture disk)

98
 Pressure Relieving Devices

Relief Valve
• A relief valve is an automatic pressure-relieving device actuated by
the static pressure upstream of the valve, and which opens further
with increase in pressure over the set pressure
• Opening of valve is proportional to the increase in pressure over the
opening pressure
• Used primarily for liquid services
• Rated capacity is usually attained at 25 percent over pressure

99
 Pressure Relieving Devices

Storage Tank and High Pressure Relief Valve

100
 Pressure Relieving Devices

Bellows Relief Valve

101
 Pressure Relieving Devices

Emergency Relief Vent

102
 Pressure Relieving Devices

Safety Valves
• An automatic pressure relieving device actuated by the static
pressure upstream of the valve, and characterized by rapid full
opening or pop action upon opening.
• It is used for steam, gas or vapor service.
• Rated capacity is reached at 3, 10 or 20 percent overpressure,
depending upon applicable code.

103
 Pressure Relieving Devices
Safety-relief valve
• Safety relief valve is an automatic pressure relieving device
actuated by the static pressure upstream of the valve and
characterized by an adjustment to allow either a “pop” or a “non
pop” action and a nozzle type entrance
• Suitable for use as either a safety or relief valve, depending on
application.
• Safety, relief and safety relief valves are installed in strategic
locations to provide pressure relief for process equipment subjected
to excessive pressures. These valves consist of six basic parts:
spring, stem, adjusting screw, disc, nozzle or seat, and body.
• Rated capacity is reached at 3 or 10 percent overpressure,
depending upon code and/or process conditions. Pressure relieving
valves are intended for emergency protection only and should not
be used as an operation valve. Frequent “popping” of a relief or
safety valve contributes to their failure and are therefore set at 25%
- 50% above the working pressure.

104
 Pressure Relieving Devices

Safety-relief valve (con’t)

• For example, relief valves on the discharge of reciprocating pumps
will relieve with each pump stroke if the set pressure is too low.
Continuous pounding of the disc upon the seat causes damage and
resultant leakage of the valve.
• Other causes of valve leakage are spring failure and debris on
seating surfaces.
• Used on steam, gas, vapor and liquid (with adjustments) and is
probably the most general type of valve in petrochemical and
chemical plants

Do not tamper with relief valves while a unit is in operation. The

proper place for reseating a leaking valve is in the shop with pressure
reset on the test rack.

105
 Pressure Relieving Devices

Safety relieve valve

106
 Pressure Relieving Devices

Conventional and balance safety valve

• Conventional safety valves operate satisfactorily only when there is
relatively constant back pressure. Changes in back pressure can
seriously affect its operational pressure and flow capacity
• Balance valves operate satisfactorily under varying back pressure
as this has little influence on performance

107
 Pressure Relieving Devices

Frangible disk (rupture disk)

• A rupture disk is a thin diaphragm (metal, plastic, non metallic) held
between flanges and designed to burst at a predetermined pressure.
• Each bursting requires the installation of a new disk
• Used in corrosive service, and for required bursting pressure not
easily accommodated by the conventional valve.
• Applicable to steam, gas vapor and liquid system

108
 Definition of Pressure Relief Terms

1. Set pressure
• Is the inlet pressure at which the safety or relief valve is adjusted
to open
• This pressure is set regardless of any back pressure on the
discharge of the valve

109
 Definition of Pressure Relief Terms

2. Overpressure
• Pressure increase over the set pressure of the primary relieving
device is over pressure
• It is the same as accumulation when the relieving device is set at
the maximum allowable working pressure of the vessel

110
 Definition of Pressure Relief Terms

3. Accumulation
• Pressure increase over the maximum allowable working pressure
of the vessel during discharge through the safety or relief valve,
expressed as a percent of that pressure.

111
 Definition of Pressure Relief Terms

4. Maximum allowable working pressure

• The maximum allowable working pressure of an unfired pressure
vessel is that pressure determined by code requirements, the
metal material of construction and its operating temperature,
above which the vessel may not be operated
• For a given metal temperature, this pressure is the highest
pressure at which the safety device may be set to open.

112
 Definition of Pressure Relief Terms

5. Operating pressure
• Pressure (gage), to which the vessel is subjected in service
• A processing vessel is usually designed for a maximum allowable
working pressure, which will provide a suitable margin above the
operating pressure to prevent undesirable operation of the relief
device
• Margin is approximately 10 % higher, or 25 psi – which ever is
higher.

113
 Definition of Pressure Relief Terms

6. Blowdown
• The reduction in flowing pressure below the set point required for
a device to close
• Is the difference between the set pressure and the reseating
pressure of a safety or relief valve
• Expressed as percent of the set pressure or psi

114
 Definition of Pressure Relief Terms

7. Back pressure
• Pressure developed on the discharge side of safety valves is back
pressure
• This pressure may be generated by the flowing fluid as it passes
through the relief discharge piping, or it may be an established
pressure as a part of a discharge vent system into which the valve
is discharging
• It may be combination of these two.

115
Vacuum Breaker

116
Electric Solenoid

117
Thermal Valve

118