Instr 12207 Control Valves, Actuators and Positioners

Control Valves, Actuators and Positioners
Module 12207
Instrument Trainee Task Module 12207
CONTROL VALVES, ACTUATORS, AND- POSITIONERS-------------------Objectives

Upon completion of this module, the trainee will be able to: 1. Define and discuss principles of operation and construction of various control valves. 2. Define and discuss the principles of operation and construction of various actuators. 3. Define and discuss principles of operation of various positioners. 4. Define and discuss variables measured and used as inputs to various types of positioners. . Discuss valve selection criteria! and identify various control valves! actuators! and positioners usin" specification sheets! pictures! or samples.
#rere$uisites
%uccessful completion of the follo&in" 'as( Module)s* is re$uired before be"innin" study of this 'as( Module+ ,--./ -ore -urricula0 ,--./ 'as( Module 12201! Craft-Related Mathematics; ,--./ 'as( Module 12202! Instrumentation Drawings and Documents II; ,--./ 'as( Module 12203! Principles of Welding; ,--./ 'as( Module 12204! Process Control Theory.
/e$uired %tudent Materials

1. %tudent Module 2. /e$uired %afety .$uipment
1nstrument 'rainee 'as( Module 12207
-ourse Map 1nformation

'his course map sho&s all of the Wheels of earning tas( modules in the second level of the 1nstrument curricula. 'he su""ested trainin" order be"ins at the bottom and proceeds up. %(ill levels increase as a trainee advances on the course map. 'he trainin" order may be adjusted by the local 'rainin" #ro"ram %ponsor.
-ourse Map+ 1nstrument! 2evel 2 2.3.2 2 -OM#.2'.
-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207
TABLE OF CONTENTS Section Topic Page 1.0.0 2.0.0 2.1.0 2.1.1 2.1.2 2.1." 2.1.$ 2.1.' 2.1.6 ".0.0 ".1.0 ".1.1 ".1.2 ".1." ".1.$ ".1.' ".1.6 ".1.7 ".1.. ".1.& ".1.10 ".2.0 $.0.0 $.1.0 $.1.1 $.1.2 $.1." $.1.$ $.1.' '.0.0 '.1.0 '.2.0 '.".0 '.".1 '.".2 '."." '.".$ '.".' Introduction to Control Valves, Actuators, and Positioners 6 Principles of Operation and Construction of Various Control Valves 7 Glo e Valves ..7 Gate Valves 12 !nife Valves 22 #all Valves ..26 Plu% Valves .2& #utterfl( Valves .."' )eedle Valves $1 Principles of Operation and Construction of Various Actuators .$$ Valve Actuator *er+s ... $$ ,ail Open $$ ,ail Closed . $$ ,ail As Positioned . $' ,ail -afe . $' -prin% to Open . $' -prin% to Close . $' Air to Open $6 Air to Close $6 /pstrea+ $7 0o1nstrea+ .. $. 2e%ulators and 2educers $. Principles of Operation and Construction of Various Positioners ..'' Valve Operators and Positioners '' 3(draulic Operators . '' Pneu+atic Operators .. '6 4otor Operators '& -olenoid Operators .. 60 4anual Operators . 60 Valve -election, *(pes, and Applications . 62 Valve -election . 62 Valve *(pes and Applications . 6$ Valve 4ar5in%s and )a+eplate Infor+ation . 6$ 2atin% 0esi%nation 6' *ri+ Identification .. 66 -i6e 0esi%nation 66 *7read 4ar5in%s 67 Valve -c7e+atic -(+ ols 6.
'rade 'erms 1ntroduced 1n 'his Module

Actuator: 'he part of a re"ulatin" valve that converts electrical or fluid ener"y to mechanical ener"y to position the valve. Angle valve: 4 type of "lobe valve in &hich the pipe openin"s are at ri"ht an"les. ANSI: 4merican ,ational %tandards 1nstitute. ASTM: 4merican %ociety for 'estin" Materials. Ball valve: 4 type of plu" valve havin" a spherical disc. Bellows: 4 fle6ible! thin7&alled! corru"ated cylinder &hich e6pands and contracts under differential pressure situations. Bonnet: 'he part of a valve containin" the valve stem and pac(in". Butterfly valve: 4 $uarter7turn valve havin" a plate7li(e disc &hich stops flo& by the outside area of the disc sealin" a"ainst the inside of the valve body. Check valve: 4 valve that allo&s flo& in one direction only. CWP: -old &or(in" pressure. Deformat on: 4 chan"e in the shape of a material or component due to an applied force. D a!hragm actuator: 4 valve actuator in &hich pressure e6erted on the diaphra"m is used to position the valve stem. D sc: #art of a valve used to control the flo& of system fluid. "ate valve: 4 valve havin" a strai"ht7throu"h flo& desi"n &hich e6hibits very little resistance to flo&+ normally used for open8shut applications. "lo#e valve: 4 valve in &hich flo& is al&ays parallel to the stem as it "oes past the seat. I$ent f cat on !late: 4 metal plate or disc located on a valve! sho&in" the manufacturer9s name and the desi"n information for the valve. %a!! ng: 'he removal of matin" surface defects usin" an abrasive compound. % ft: 'he actual travel of the disc a&ay from the closed position &hen a
valve is relievin". Pack ng: Material used to ma(e a dynamic seal! preventin" system fluid lea(a"e around a valve stem.
Plug valve: 4 $uarter7turn valve havin" a ported disc. Safety&'el ef valve: 4 type of pressure relief valve that can be used as a safety valve or a relief valve. Seat: 'he part of a valve a"ainst &hich the disc presses to stop flo& throu"h the valve. Throttl ng: 'he re"ulation of flo& throu"h a valve. Tor(ue: 4 t&istin" force used to apply a clampin" force to a mechanical joint. )alve #o$y: 'he part of a valve containin" the passa"es for fluid flo&! valve seat! and inlet and outlet connections. )alve stem: 'he part of a valve &hich raises! lo&ers! or turns the valve disc. )alve tr m: 'he internal components of a valve &hich are e6posed to the flo&in" fluid. We$ge: 4 term for the disc in a "ate valve. *oke #ush ng: 'he bearin" bet&een the valve stem and the valve yo(e.
1.0.0 1,'/OD:-'1O, 'O -O,'/O2 3423.%! 4-':4'O/%! 4,D #O%1'1O,./%

4s an instrument trainee! you &ill encounter many different types of fluid transport systems. 'hese9 systems may be as simple as potable &ater plumbin" or as comple6 as petrochemical process pipin" systems. /e"ardless of the desi"n! they &ill all have at least one thin" in common0 there &ill be some type of control valve! valve actuator, or positioner in the system. 3alves are necessary in these systems to start! stop! and control or throttle flo&. 'hey are essential to isolate hi"h ener"y or ha;ardous fluids from the atmosphere. 4ctuators for these valves provide a means of automatic operation as a result of some type of system input! i.e.! pressure! flo&! or temperature. 4ny discussion of valves and actuators &ould be incomplete &ithout considerin" the use and operation of valve positioners. 'hese devices are essential in cases &hen remote operability of a valve is re$uired due to inaccessibility for manual operation. 'hey also provide a means of operatin" e6tremely lar"e valves a"ainst hi"h differential pressures usin"
pneumatics or hydraulics as an ener"y source.
2.0.0 #/1,-1#2.% O< O#./4'1O, 4,D -O,%'/:-'1O, O< 34/1O:% -O,'/O2 3423.%
4 valve is a controlled restriction )in a pipe system* &ith some means of operatin" it. .6amples of its basic principles of operation include &hen a surface is pressed a"ainst an openin"! as one closes a door or &hen a surface moves across an openin"! as one closes a &indo&. =ith one of the surfaces overlappin" the other! a ti"ht seal is formed. 3alves! as sho&n in !igure "# are used for three principles+ 'o control the volume or amount of flo& 'o control the direction of flo& 'o control the pressure at &hich a system operates.
<i"ure 1. 3alve <unctions
2.1.0 >2O?. 3423.%

Globe valves are used to stop! start and re"ulate fluid flo&.. 'hey are indispensable elements of po&er plant systems and are commonly used as the standard a"ainst &hich alternative valve types are jud"ed. 4s sho&n in !igure $# the "lobe valve disc can be totally removed from the flo& path or it can completely close the flo& path. 'he essential principle of "lobe valve operation is the perpendicular movement of the disc a&ay from the seat. 'his causes the annular space bet&een disc and seat rin" to. "radually close as the valve is closed. 'his characteristic "ives the "lobe valve "ood throttling ability &hich permits its use in re"ulatin" flo&. 'herefore! the "lobe valve is used not only for start7stop functions but also for flo& re"ulatin" functions. 1t is "enerally easier to obtain very lo& seat lea(a"e &ith a "lobe valve as compared to a gate valve. This is because the disc to seat rin" contact is more at ri"ht an"les &hich permits the force of closin" to ti"htly seat the disc.
<i"ure 2. >lobe 3alve
>lobe valves can be arran"ed such that the disc closes a"ainst the direction of fluid flo& or such that the disc closes in the same direction of fluid flo&. =hen the disc closes a"ainst the direction of flo&! the (inetic ener"y of the fluid impedes closin" but aids openin" of the valve. =hen the disc closes in the same direction as flo&! the (inetic ener"y of the fluid aids closin" but impedes openin" of the valve. 'his characteristic ma(es the "lobe valve preferable to the "ate valve &hen $uic(7actin" stop valves are necessary. 4lon" &ith its inherent and obvious advanta"es! the "lobe valve has a fe& dra&bac(s. 4lthou"h valve desi"ners can partly or entirely eliminate any or even all of the dra&bac(s for specific services! the corrective measures are e6pensive and often narro& the valve scope of service. 'he most evident shortcomin" of the simple "lobe valve is the hi"h head loss from the t&o or more ri"ht7an"le turns of flo&in" fluid. Obstructions and discontinuities in the flo& path add to the loss. @i"h pressure losses in the "lobe valve can add up to thousands of dollars a year for lar"e hi"h7pressure lines. 'he fluid7dynamic effects from the pulsation! impacts! and pressure drops in traditional "lobe valves can
dama"e trim and stem packing, and actuators! as &ell as cause troublesome noise. 1n addition! lar"e si;es re$uire considerable po&er to operate! thus necessitatin" "earin"! levers! etc. 4nother dra&bac( is the lar"e openin" needed for assembly of the disc. >lobe valves are often heavier than other valves of the same flo& ratin". 'hen! too! the cantilever mountin" of the disc on its stem is a potential trouble source. .ach of these shortcomin"s yields to analysis and in"enuity! but only at a price in dollars! space! and &ei"ht. 'he angle valve of !igure % is another and simpler modification of the basic "lobe form. =ith the ends at ri"ht an"les! the diaphra"m can be a simple flat plate. <luid can flo& throu"h &ith only a sin"le A0 de"ree turn! dischar"in" more symmetrically than the dischar"e from an ordinary "lobe. 1nstallation advanta"es also may su""est the an"le valve. 1t can replace an elbo&! for e6ample.
,i%ure ". An%led Glo e Valve <or moderate conditions of pressure! temperature! and flo&! the an"le valve closely resembles the ordinary "lobe. Many manufacturers have interchan"eable trim and bonnets for the t&o body styles! &ith the body differin" only in the outlet end. 'he an"le valve9s dischar"e conditions are so favorable from fluid7dynamics and erosion standpoints that many hi"h7 technolo"y control valves have the confi"uration. 2i(e valve bodies! there are also many variations of disc and seat arran"ements for "lobe valves. 'he three basic types are sho&n in !igure &.
<i"ure 4. %eat8Disc 4rran"ements
'he ball7shaped disc! !igure &'# fits on a tapered! flat7surfaced seat and is! usually used on relatively lo&7pressure! lo&7temperature systems. 1t is "enerally used in a fully open or shut position! but it may be employed for moderate throttlin" of a flo&. !igure &( sho&s one of the proven modifications of seat8disc desi"n! a hard non7metallic insert rin" on the disc to ma(e closure ti"hter on steam and hot &ater. 'he composition disc is resistant to erosion and is sufficiently resilient and cut7resistant to close on solid particles &ithout serious permanent dama"e. 'he composition disc is rene&able. 1t is available in a variety of materials that are desi"ned for different types of service! such as hi"h7 and lo&7 temperature &ater! air! or steam. 'he seatin" surface is often formed by a rubber B0B rin" or &asher. 'he plu"7type disc! !igure &C# provides the best throttlin" service because of its confi"uration. 1t also offers ma6imum resistance to "allin"! &ire dra&in"! and erosion. #lu"7type discs are available in a variety of specific confi"urations! but in "eneral they all have a relatively lon" tapered confi"uration. .ach of the variations have specific types of applications and certain fundamental characteristics. !igure ) sho&s the various types.
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<i"ure . >lobe 3alve #lu"s
'he e$ual percenta"e plu"! as its name indicates! is used for e$ual percenta"e flo& characteristic for predetermined valve performance. .$ual increments of valve lift "ive e$ual percenta"e increases in flo&. 2inear flo& plu"s are used for linear flo& characteristics &ith hi"h pressure drops. B3B port plu"s provide linear flo& characteristics &ith medium and lo& pressure drops. 'his type of desi"n also prevents &ire dra&in" durin" lo& flo& periods by restrictin" the flo&! &hen the valve is only partially open! throu"h the orifices in the B3B plu". ,eedle plu"s are used primarily for instrumentation applications and are seldom available in valves over 1 inch in si;e. 'hese plu"s provide hi"h pressure drops and lo& flo&s. 'he threads on the stem are usually very fine0 conse$uently! the openin" bet&een the disc and seat does not chan"e rapidly &ith stem rise. 'his permits closer re"ulation of flo&. 4ll of the plu" confi"urations are available in either a conventional "lobe valve desi"n or the an"le valve desi"n. Only &hen the needle plu" is used is the valve name chan"ed )needle valve*. 1n all other cases the valves are still referred to as "lobe valves &ith a specific type of disc. >lobe and an"le valves should ordinarily be installed so that the pressure is under the disc. 'his promotes easy operation. 1t also helps to protect the pac(in" and eliminates a certain amount of erosive action on the seat and disc faces. @o&ever! &hen hi"h temperature steam is the medium bein" controlled! and the valve is closed &ith the pressure under the disc! the
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valve stem, &hich is no& out of the fluid! contracts on coolin". 'his action tends to lift the disc off the seat, causin" lea(s &hich eventually result in &ire dra&in" on seat and disc faces. 'herefore! in hi"h7temperature steam service! "lobe valves may be installed so that the pressure is above the disc.
2.1.1 >ate 3alves

>ate valves are used to start or stop fluid flo&! but not to re"ulate or throttle flo&. 'he name "ate is derived from the appearance of the disc in the flo& stream! &hich is similar to a "ate. !igure * sho&s a "ate valve. 'he disc is completely removed from the flo& stream &hen a "ate valve is fully open. 'his characteristic offers virtually no resistance to flo& &hen the valve is open and! hence! there is little pressure drop across an open "ate valve. =hen the valve is fully closed! a disc to seal rin" contact surface e6ists for 3C0D and "ood sealin" is provided. 7 =ith proper matin" of disc to seal rin"! very little or no lea(a"e occurs across the disc &hen the "ate valve is closed. On openin" of the "ate valve! the flo& path is enlar"ed in a hi"hly non7linear manner &ith respect to percent of openin". 'his means that flo& rate does not chan"e evenly &ith stem travel. 4lso the partially open "ate disc tends to vibrate from the fluid flo&. Most of the flo& chan"e occurs near shutoff &ith a relatively hi"h fluid velocity causin" disc and seat &ear and eventual lea(a"e if used to re"ulate flo&. <or these reasons! "ate valves are not used to re"ulate or throttle flo&.
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<i"ure C. >ate 3alve
'he primary consideration in the application of a "ate valve &ith relation to a "lobe valve is that the "ate valve represents much less flo& restriction than the "lobe valve. 'his reduced flo& restriction is the result of strai"ht7throu"h body construction and the desi"n of the disc. 4 "ate valve can be used for a &ide variety of fluids and provides a ti"ht seal &hen closed. 'he major disadvanta"es to the use of a "ate valve! as opposed to a "lobe valve! are as follo&s+ 1. 2. 3. 4. 1t is not "ood for throttlin" applications. 1t is prone to vibration in the partially open state. 1t is more subject to seat and disc &ear than a "lobe valve. /epairs! such as lapping and "rindin"! are "enerally more difficult to accomplish.
>ate valves are available &ith a variety of fluid control elements. -lassification of "ate valves is usually made by the type of fluid control element used. 'hese elements are available as+
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%olid wedge <le6ible &ed"e %plit &ed"e Double disc )parallel disc*
%olid! fle6ible! and split &ed"es! !igure +# are employed in valves havin" inclined seats! &hile the double discs are used in valves havin" parallel seats. /e"ardless of the style of &ed"e or disc used! they are all replaceable. 1n services &here solids or hi"h velocity may cause rapid erosion of the seat or disc! these components should have a hi"h surface hardness and replaceable seats as &ellasdiscs. 91f the seats are not replaceable! any dama"e &ould re$uire removal of the valve for refacin" of the seat or refacin" of the seat in place. 3alves bein" used in corrosive service should al&ays be specified &ith rene&able seats.
<i"ure 7. =ed"e 'ypes
'he solid! or sin"le &ed"e type! sho&n in !igure , is the most commonly used disc because of its simplicity and stren"th. 4 valve &ith this type of &ed"e may be installed in any position! and it is suitable for almost all fluids0 it is most practical for turbulent flo&.
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<i"ure E. %olid or! %in"le =ed"e
-han"e for inade$uate fle6ibility &ith a solid &ed"e disc has spurred alternatives. 'he fle6ible &ed"e! !igure -# is a one7piece disc &ith a cut around the perimeter to improve ability to match error or chan"e in an"le bet&een the seats. 'he cut varies in si;e! shape! and depth. 4 shallo& narro&! cut "ives little fle6ibility but retains stren"th. 4 deeper and &ider cut )or cast7in7recess* leaves little material at the center! allo&in" more fle6ibility but perhaps compromisin" stren"th and ris(in" permanent set. 4 correct profile of the disc half in the fle6ible7&ed"e desi"n can "ive uniform deflection properties at the disc ed"e! so that the &ed"in" force applied in seatin" &ill force the disc seatin" surface uniformly and ti"htly a"ainst the seat. >ate valves used in steam systems have fle6ible "ates. 'he reason for usin" a fle6ible "ate is to prevent bindin" of the "ate &ithin the valve &hen the valve is in the closed position. =hen steam lines are heated! they &ill e6pand! causin" some distortion of valve bodies. 1f a solid "ate fits snu"ly bet&een the seat of a valve in a cold steam system! &hen the system is heated and pipes elon"ate! the seats &ill compress a"ainst the "ate &ed"in" the "ate bet&een them and clampin" the valve shut. 'his problem is overcome by usin" a fle6ible "ate!. &hose desi"n allo&s the "ate to fle6 as the valve seat compresses it! thereby preventin" clampin".
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<i"ure A. <le6ible =ed"e
'he major problem associated &ith fle6ible "ates is that &ater tends to collect in the body nec(0 then! under certain conditions the admission of steam may cause the valve body nec( to rupture! the bonnet to lift off! 'or the seat rin" to collapse. 'o prevent this! it is essential that correct &armin" up procedures are follo&ed. 4lso! some very lar"e "ate valves have a three7position vent and bypass valve installed. 'his valve allo&s ventin" of the bonnet either upstream or do&nstream of the valve and has a position for bypassin" the valve. %plit &ed"es! as sho&n in !igure ".# are of the ball and soc(et desi"n &hich are adjustin" and self ali"nin" to both seatin" surfaces. 'he disc is free to adjust itself to the seatin" surface if one7half of the disc is sli"htly out of ali"nment because of forei"n matter lod"ed bet&een the disc half and the seat rin". 'his type of &ed"e )disc* is suitable for handlin" non7 condensin" "ases and li$uids at normal temperatures! particularly corrosive li$uids. <reedom of movement of the discs in the carrier prevents bindin" even thou"h the valve may have been closed &hen hot and later contracted due to coolin". 'his type of valve should be installed &ith the stem in the vertical position.
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<i"ure 10. %plit =ed"e
'he parallel disc! !igure "", &as also desi"ned to prevent valve bindin" due to thermal transients. ?oth lo&7pressure iron valves and hi"h pressure steel types have this disc. #rinciple of operation is that &ed"e surfaces bet&een the parallel faced disc halves are caused to press to"ether under stem thrust and spread apart the discs to seal a"ainst the seats. 'he tapered &ed"es may be part of the disc halves or may be separate elements. 'he lo&er &ed"e must bottom out on a rib at the valve bottom so that the stem can develop seatin" force. 1n one! version! <i"ure 12! the &ed"e contact surfaces are curved to (eep the point of contact close to the optimum. 1n other parallel7disc "ates! !igures "% and "&! the t&o halves do not move apart under &ed"e action. 1nstead! the upstream pressure holds the do&nstream disc a"ainst the seat. 4 carrier rin" lifts the discs! and a sprin" or sprin"s hold the discs apart and seated &hen there is no upstream pressure. 4nother desi"n found on parallel "ate discs provides for sealin" only one port. 1n these desi"ns! the hi"h pressure side pushes the disc open )relievin" disc* on the hi"h pressure side but forces the disc closed on the lo& pressure side! see !igure "). =ith such desi"ns! the amount of seat lea(a"e tends to decrease as differential pressure across the seat increases. 'hese valves &ill usually have a flo& direction mar(in" &hich &ill sho&
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&hich side is the hi"h pressure )relievin"* side. -are should be ta(en to ensure these valves are not installed bac(&ards in the system.
<i"ure 11. #arallel Disc >ate 3alve
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<i"ure 12. #arallel Disc
%ome parallel7disc "ate valves used in hi"h7pressure systems are sometimes &ith an inte"ral bonnet vent8bypass line. 4 three7&ay valve is used to position the line to bypass to e$uali;e pressure across the discs prior to openin". =hen the "ate valve is closed! the three7&ay valve is positioned! to vent the bonnet to one side or the other. 'his prevents moisture from accumulatin" in the bonnet. 'he three7&ay valve is positioned to the hi"h pressure side of the "ate valve )&hen the "ate valve is closed* to ensure that flo& does not bypass the isolation valve. 'he hi"h pressure acts a"ainst sprin" compression and forces one "ate off of its seat. 'he three7&ay valve vents this flo& bac( to the pressure source.
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<i"ure 13. %prin" 2oaded #arallel Disc >ate 3alve
<i"ure 14. #arallel Disc >ate 3alve
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<i"ure 1 . /elievin" Disc >ate 3alve
>ate valves are classified as either risin" stem or non7risin" stem valves. On the non7risin" stem "ate valve sho&n in !igure "*# the stem is threaded on the lo&er end into the "ate. 4s the hand&heel on the stem is rotated the "ate travels up or do&n the stem on the threads &hile the stem remains vertically stationary. 'his type valve &ill almost al&ays
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have a pointer type indicator threaded onto the upper end of the stem to indicate valve position. 'he non7risin" stem ),/%* confi"uration places the stem threads inside the valve! out of contact &ith the environment! and also assures that the stem merely rotates in the pac(in"! &ithout much dan"er of carryin" dirt into the pac(in" from outside or inside. /isin" stem )/%* "ate valves! !igure "+# are desi"ned so that the stem is raised out of the flo& path &hen the valve is open. /isin" stem "ate valves come in t&o basic desi"ns. %ome have a stem that rise above )throu"h* the hand&heel &hile others have a stem that is threaded to the bonnet! !igure ",. 1n this case! the hand&heel rises &ith the stem. %eats for "ate valves are either provided inte"ral &ith the valve body! or in a seat rin" type of construction. %eat rin" construction provides seats &hich are either threaded into position or pressed into position and seal7 &elded to the valve body. 'he latter form of construction is recommended for hi"her temperature service. 1nte"ral seats! !igure "+# provide a seat. of the same material of construction as the valve body &hile the pressed7in or scre&ed7in seats permit variation. /in"s &ith hard facin"s may be supplied for the applications &here they are re$uired. %mall for"ed steel "ate valves may have hard7faced seats pressed into the body. 1n some series! this +type .of valve!! in si;es from 182 to 2 inch is rated for 2 00 psi" steam service. 1n lar"e "ate valves! discs are often of the solid7&ed"e type! &ith seat rin"s scre&ed in! &elded9 in! or pressed in %cre&ed7in rin"s are considered replaceable since they may be removed and ne& seal rin"s installed.
2.1.2 Fnife 3alves

4 special type of "ate valve is the (nife "ate of !igure "-. 'his valve serves in slurry and &aste+ lines and in other lo& pressure applications. 'he sharp ed"e of the disc bottom is easily.forced closed in contact &ith a metal or elastomer seat. Open! the disc is in the air! after passin" throu"h a full7&idth pac(in" bo6. Fnife valves have a disc able to cut throu"h deposits and flo&7stream solids such as resin slurry. 'hey! li(e most "ate valves! can be positioned by manual! electrical! pneumatic and hydraulic actuation.
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<i"ure 1C. ,on7/isin" %tem >ate 3alve
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<i"ure 17. /isin" %tem >ate 3alve
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<i"ure 1E. /isin" %tem >ate 3alve G %tem 'hrou"h ?onnet
<i"ure 1A. Fnife 3alve
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2.1.3 ?all 3alves

Ball valves,- as the name implies! are stop valves that use a ball to stop or start the flo& of fluid. 'he ball performs 9the same function as the disc in the "lobe valve. =hen the valve handle is operated to open the 9 valve! the ball rotates to a point &here the hole throu"h the ball is in line &ith the valve body inlet and outlet. =hen the valve is shut! &hich re$uires only a A0 rotation of the hand&heel for most valves! the ball is rotated so that the hole is perpendicular to the flo& openin"s of the valve body and flo& is stopped. Most ball valves are of the $uic(7actin" type )re$uirin" only a A0D turn to operate the valve either completely open or closed*! but many are planetary "ear operated. 'his type of "earin" allo&s the use 9of a relatively small hand&heel and operatin" force to operate a fairly lar"e valve. 'he "earin" does! ho&ever! increase the operatin" time for the valve. Figure 20 sho&s the major components of a ball valve. 'he ball valve! in "eneral! is the least e6pensive of any valve confi"uration. 1n early desi"ns havin" metal7to7metal seatin" the valves could not "ive bubble7ti"ht sealin" and &ere not fire safe. =ith the development of elastomeric materials and &ith advances in the plastics industries! the ori"inal metallic seats have been replaced &ith materials such as fluorinated polymers! nylon! neoprene! and buna7,. ?all valves also have lo& maintenance costs.
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<i"ure 20. ?all 3alve -omponents
1n addition to $uic(! $uarter7turn on7off operation! ball valves are compact! re$uire no lubrication! and "ive ti"ht sealin" &ith lo& torque. =ith a soft seat on both sides of the ball! most balls valves "ive e$ually effective sealin" of flo& in either direction. Many desi"ns permit adjustment for &ear. %ince conventional ball valves have relatively poor throttlin" characteristics! they are not "enerally satisfactory for this service. 1n a throttlin" position the partially e6posed seat rapidly erodes because of the impin"ement of hi"h7velocity flo&. @o&ever! a ball valve has been developed &ith a spherical surface7coated plu" &hich is off to one side in the open position and &hich rotates into the flo& passa"e until it bloc(s the flo& path completely. %eatin" is accomplished by the eccentric movement of the plu". 'he valve re$uires no lubrication and can be used for throttlin" service. ?all valves are desi"ned on the simple principle of floatin" a polished ball bet&een t&o plastic seatin" surfaces permittin" free turnin" of the ball. %ince the plastic are subject to deformation under load! some means must be provided to hold the ball a"ainst at least one seat. ,ormally this is accomplished throu"h sprin" pressure! differential line pressure! or a combination of both. Figure 21 sho&s a combination of line pressure and a sprin" on the ball.
<i"ure 21. ?all 3alve =ith %lanted %eals
?all valves are available in the venturi! Figure 22, reduced and full port
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patterns. 'he latter has a ball &ith a bore e$ual to the inside diameter of the pipe. ?alls are usually metallic in metallic bodies &ith trim )seats* produced from elastomeric materials. 4lso! all7plastic desi"ns are available. %eats are replaceable! as are the balls.
<i"ure 22. 3enturi 'ype ?all 3alve
?all valves are available in top entry! Figure 23, and split body )end entry* types! Figure 24. 1n the former! the ball and seats are inserted throu"h the top! &hile in the latter! the ball and seats are inserted from the ends.
28
<i"ure 23. 'op .ntry ?all 3alve
<i"ure 24. %plit ?ody ?all 3alve
'he resilient seats for ball valves are made from various elastomeric materials. 'he most common seat materials are '<. )vir"in*! filled '<.! ,ylon! ?una7,! ,eoprene! and combinations of these materials. ?ecause of the elastomeric materials these valves cannot be used at elevated temperatures. 'ypical ma6imum operatin" temperatures at full pressure ratin" of the valves are sho&n in <i"ure 2 for various seat materials. 'o overcome this disadvanta"e! a "raphite seat has been developed &hich &ill permit operation up to 1000D<.
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%eat Material 'emperatures '<.)3ir"in* <illed '<. ?una7, ,eoprene
Operatin" 4 0H< 400H< 1E0H< 1E0H<
<i"ure 2 . Ma6imum Operatin" 'emperature for %eat Materials
-are must be used in the selection of the seat material to insure that it is compatible &ith the materials bein" handled by the valve! as &ell as its temperature limitation.
2.1.4 #lu" 3alves

#lu" calves are used to stop97or start fluid flo&. 'he name! is derived from the shape of the dis( &hich resembles7!a plu". 4 plu" valve is sho&n ins !igure $*. 'he simplest form of a plu" valve is the petcoc( sho&n in !igure $+.
<i"ure 2C. #lu" 3alve
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<i"ure 27. #etcoc(
'he body of a plu" valve i s, machined to receive the tapered or cylindrical plu". 'he disc is a solid plu" &ith a bored. passa"e at the ri"ht an"le to the lon"itudinal a6is of the plu". 1n9 the open position! the passa"e in the plu" lines up9 &ith the inlet and outlet ports of the +valve body. =hen the plu" is turned A00 from the open position! the solid part of the plu" bloc(s the ports and stops fluid flo&. #lu" valves are available in either a lubricated or non7lubricated desi"n and &ith a variety of styles of port 7openin"s throu"h the plu" as &ell as a number of plu" desi"ns. 4n important. characteristic of the plu" valve is its easy adaption to multiport construction. Multiport valves are &idely used. 'heir installation simplifies pipin"! and they provide a much more convenient operation than multiple "ate valves &ould. 'hey also eliminate pipe fittin"s. 'he use of a multiport valve eliminates the need of t&o! three! or even four conventional shut7off valves! dependin" upon the number of ports in the plu" valve. #lu" valves are normally used only for on7off operations! particularly &here fre$uent operation of the valve is necessary+ 'hese valves are not normally recommended for throttlin" service because! li(e the "ate valve! a "reat percenta"e of flo& chan"e occurs near shut7off at hi"h velocity. @o&ever! a diamond7shaped port has been developed for throttlin" service. Multiport valves are particularly advanta"eous on transfer lines and for divertin" services. 4 sin"le multiport valve may be installed in lieu of three or four "ate valves! or other type of shut7off valves. One &ord of caution is that many of the multiport confi"urations do not permit complete shut7off of flo&. 1n most cases one flo& path is al&ays open. 'hese valves are
31
intended to divert the flo& to one line &hile shuttin" off flo& from the other lines. 1f complete shut7off of flo& is a re$uirement! it is necessary that a style of multiport valve be used &hich permits this! or a secondary valve should be installed on the main feed line ahead of the multiport valve to permit complete shut7off of flo&. 1t should also be noted that in some multiport confi"urations! flo& to more than one port simultaneously is also possible. >reat care should be ta(en in specifyin" the particular port arran"ement re$uired to "uarantee that proper operation &ill be possible. #lu"s are either round or cylindrical &ith a taper. 'hey may have various types of port openin"s! Figure 28, each &ith a varyin" de"ree of free area relative to the correspondin" pipe si;e.
1. /ectan"ular port is the standard shaped port &ith a minimum of 70 percent of the area of the correspondin" si;e of standard pipe. 2. /ound port means that the valve has a full round openin" throu"h the plu" and body! of the same shape as standard pipe. <ull port means that the area throu"h the valve is e$ual to or "reater than the area of standard pipe. %tandard openin" means that the area throu"h the valve is less than the area of standard pipe! and therefore these valves should be used only &here restriction of flo& is unimportant.
<i"ure 2E. #lu" 3alve 7 #ort 'ypes
3.
Diamond port means that the openin" throu"h the plu" is diamond7 shaped. 'his has been desi"ned for throttlin" service. 4ll diamond port valves are venturi restricted flo& type.
-learances and lea(a"e prevention are the chief considerations in plu" valves. Many plu" valves are of all7metal construction. 1n these versions! the narro& "ap around the plu" can allo& lea(a"e. 1f the "ap is reduced by
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sin(in" the taper plu" deeper into the body! actuation tor$ue &ill climb rapidly and "allin" can occur. 2ubrication remedies this. 4 !series of "rooves around the port openin"s! in the plu" or body! issupplied &ith "rease prior to actuation! not only to lubricate the plu" motion but also to seatil_ the "ap! see !igure. $-. >rease! injected into a fittin" at stem top travels do&n throu"h a check valve in the passa"e&ay and then past the plu" top to the "rooves on the plu" and!! do&n to a &ell belo& the plu". 'he lubricant must be compatible &ith the temperature and nature of the fluid! of course. T e most common fluids controlled by plu" valves are "ases and li$uid hydrocarbons. %ome &ater lines have these valves too! if lubricant contamination is not a serious dan"er. 'his type 7can "o to7247 inch !si;e! &ith pressure capability of C000 psi". %teel or iron bodies are available. 'he plu" can be9 cylindrical or tapered. 'he correct choice of lubricant is e6tremely important for successful lubricated plu" valve performance. 1n addition to providin" ade$uate lubrication to the valve! the lubricant must not react chemically &ith they material passin" throu"h the valve nor must the lubricant contaminate the material passin" throu"h the valve because of solubility. 4ll manufacturers of lubricated plu" valves have developed a series of lubricants &hich are compatible &ith a &ide ran"e of media. 'heir recommendation should be follo&ed as to &hich lubricant is best suited for the service. 'o overcome the disadvanta"es of the lubricated plu" valves! in so far as their need of lubrication! t&o basic types of non7lubricated plu" valves &ere developed. 'he non7lubricated valve may be either a lift7type or have an elastomer sleeve or plu" coatin" that eliminates the need to lubricate the space bet&een the plu" and seat.
33
<i"ure 2A. 2ubricated 'aper #lu" 3alve
2ift7type valves provide a means of mechanically liftin" the tapered plu" sli"htly to desi"nate it from its seatin" surface to permit easy rotation. 'he mechanical liftin" can be accomplished throu"h either a cam! as sho&n in Figure 30 or by means of an e6ternal lever
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<i"ure 30. -am7Operated and ,on72ubricated #lu" 3alve
4 typical non7lubricated plu" valve &ith an elastomer sleeve is sho&n in Figure 31. 1n this particular valve a sleeve of '<. completely surrounds the plu". 1t is retained and loc(ed in place by the metal body. 'his results in a continuous primary seal bein" maintained bet&een the sleeve and the plu" at all times! both &hile the plu" is rotated and &hen the valve is in either the open or closed position. 'he '<. sleeve is durable and essentially .inert to all but a fe& rarely encountered chemicals. 1t also has a lo& coefficient of friction and therefore is self7lubricatin". =hen installin" plu" valves! care should be ta(en to allo& room for the operation of the handle )lever! &rench*. 'he handle is usually lon"er than the valve! and it rotates to a position parallel to the pipe from a position A0 de"rees to the pipe. 2ubricants are available in stic( form! and in bul(. %tic( lubrication is usually employed &hen a small number of valves are in service or &hen they are &idely scattered throu"hout the plant. @o&ever for a lar"e number of valves "un lubrication is the most convenient and economical solution. 4ll valves are usually shipped &ith an assembly lubricant. 'his assembly lubricant should be removed by completely relubricatin" &ith the proper lubricant before bein" put into service.
35
<i"ure 31. 'ypical ,on72ubricated #lu" 3alve &ith .lastometer %leeve
/e"ular periodic lubrication is a must for best results. .6treme care should be ta(en to prevent any forei"n matter from enterin" the plu" &hen insertin" ne& lubricant.
2.1.
?utterfly 3alves
Butterfly valves, !igure %$# possess many advanta"es over "ate! "lobe! plu"! and ball valves in a variety of installations! particularly in the lar"er si;es. %avin"s in &ei"ht! space! and cost are the most obvious advanta"es. Maintenance costs are lo& since there is a minimum number of movin" parts and there are no poc(ets to trap fluids. ?utterfly valves are especially! &ell suited for the handlin" of lar"e flo&s of li$uids or "ases at relatively lo& pressures and for the handlin" of slurries or li$uids &ith lar"e amounts of suspended solids.
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<i"ure 32. ?utterfly 3alve
'his type of valve is suitable for throttlin" as &ell as open7closed applications. Operation is easy and $uic( because a A0 de"ree rotation of the handle moves the flo& control element from the fully closed to the fully opened position. 'hese valves may also be e$uipped for automatic operation. ?utterfly valves are built on the principle of a pipe damper. 'he flo& control element is a disc of appro6imately the same diameter as the inside diameter of the adjoinin" pipe! &hich rotates on either a vertical or hori;ontal a6is. =hen the disc lies parallel to the pipin" run! the valve is fully opened! and &hen the disc approaches the perpendicular position! the valve is shut. 1ntermediate positions! for throttlin" purposes! can be secured in place by handle7loc(in" devices. %toppa"e of flo& is accomplished by the valve disc sealin" a"ainst a seat &hich is on the inside diameter periphery of the valve body. Ori"inally a metal disc &as used to seal a"ainst a metal seat. 'his arran"ement did not provide a lea(7ti"ht closure but did provide sufficient closure in such applications as po&er plant &ater distribution lines. 3alves of this desi"n are still available. =ith the advent of the ne&er elastomeric materials most butterfly valves are no& produced &ith an elastomeric seat a"ainst &hich the disc seals. 4n e6ample of this is the plants circulatin" &ater pump dischar"e valves! as sho&n in !igure %%. 'his arran"ement does provide a lea(7ti"ht closure.
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<i"ure 33. -irculatin" =ater #ump Dischar"e 3alve
<i"ure 34 sho&s a seat rin" arran"ement &hich utili;e a clamp7rin" arran"ement )4* and a bac(in" rin" used on a serrated ed"e rubber rin" )?*. 'hese desi"ns prevent the e6trusion of the O7rin". <i"ure 3 sho&s additional seat rin" desi"ns.
<i"ure 34. ?utterfly 3alve %eat 4rran"ements
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,i%ure "'. -eat 2in% 0esi%ns ?ody construction varies. 'he most economical is the &afer type &hich simply fits bet&een t&o pipeline flan"es. 4nother type of lu" &afer valve is held in place bet&een t&o pipe flan"es by bolts that join the t&o flan"es and pass throu"h holes in the valveIs outer casin". 3alves are also available &ith conventional flan"ed ends for boltin" to pipe flan"es and in a scre&ed end construction. <i"ure 3C sho&s these valve body desi"ns.
,i%ure "6. ,lan%ed and ,-cre1ed #utterfl( Valves 'he stem and disc for a Jbutterfly valve are separate pieces. 'he disc is bored to receive the stem. '&o methods are fused7to ! secure the disc to the stem so that the disc rotates as the stem is turned. 1n the first method the disc is simply bored throu"h and the disc secured to the stem by means of bolts or pins &hich pass throu"h Bthe stem and disc as sho&n in !igure %+. The alternate method! also sho&n in !igure %+ involves borin" the disc as before! then broachin" the upper stem bore to fit a s$uared or he67shaped stem. 'his method allo&s the disc to BfloatB
39
and see( its center in 9 the seat. :niform sealin" is accomplished and e6ternal stem fasteners are eliminated. 'his is advanta"eous in the case of covered discs and in corrosive applications. 1n order for the disc to be held in the proper position! the stem must e6tend beyond the bottom of the disc and be fitted into a bushin" in the bottom of the valve body. One or t&o similar bushin"s are also necessary alon" the upper portion of the stem as &ell. 'hese bushin"s must either be resistant to the media bein" handled or they must be sealed so that the corrosive media cannot come into contact &ith them. ?oth methods are employed! dependin" upon the valve manufacturer.
<i"ure 37. %tem8Disc 4rran"ement
%tem seals are effected either &ith pac(in" in a conventional stuffin" bo6 or by means of O7rin" seals. %ome valve manufacturers! particularly those speciali;in" in the handlin" of corrosive materials! effect a stem seal on the inside of the valve so that no material bein" handled by the valve can come into contact &ith the valve stem. 1f a stuffin" bo6 or e6ternal O7rin" seal is employed! the material passin" throu"h the valve &ill come into contact &ith the valve stem. ?utterfly valves can be operated manually by lever )handle*! hand&heel! or chain&heel. !igure 3E. sho&s a lever actuator. 4 steel or ductile iron handle &ith a sprin" loaded loc(in" tri""er is secured to the stem. 'he position indicator has increments for variable control bet&een 0 and A0 de"rees non7adjustable travel stops. :sually lever actuators are not recommended on valves above 10 or 12 inches in si;e because of the hi"h tor$ue re$uired for operation. 4 hand&heel actuator is sho&n in !igure %-. 4 totally enclosed scre& and lever mechanism imparts hand&heel movement to the butterfly valve disc for variable settin"s bet&een full open and full closed positions. 'he disc position indicator consists of shaft mounted pointer and cast7in.
40
increment scale on housin" cover plate. 'his type of actuation is recommended for hi"h tor$ue conditions and corrosive atmospheres. 1t should be noted that this type of actuator is self loc(in" in any position. .6tension handles and floor stand hand&heels may ! also be used on these hand&heel actuators. -hain&heel actuators are modifications of the hand&heel actuators in &hich the chain&heel operator has been incorporated into the assembly rather than usin" the hand&heel itself. 1n addition to manual operation! butterfly valves may also be operated by means or air or fluid po&er and electricity. 4vailable for this type of operation are cylinder actuators! diaphragm actuators, piston actuators and electric actuators.
<i"ure 3E. 2ever 4ctuated ?utterfly 3alve
41
<i"ure 3A. @and&heel 4ctuated ?utterfly 3alve
Operatin" tor$ues re$uired for specific valves and services should al&ays be chec(ed &ith the valve manufacturer before si;in" the automatic operatin" accessory. Most manufacturers &ill supply the valve &ith the automatic operation if specified.
2.1.C ,eedle 3alves

,eedle valves! as sho&n in !igure &.# are used for ma(in" relatively fine adjustments in the amount of fluid allo&ed to pass throu"h an openin". 'he distin"uishin" characteristic of a needle valve is the lon"! taperin"! needle7li(e point on the end of the valve stem. 'his BneedleB acts as a dis(. 'he lon"er part of the needle is smaller than the orifice in the valve seat! and therefore passes throu"h it before the needle seats. 'his arran"ement permits a very "radual increase or decrease in the si;e of the openin" and thus allo&s a more precise control of flo& than could be obtained &ith an ordinary "lobe valve. ,eedle valves are often used as component parts of other! more complicated valves. <or e6ample! they are used in some types of reducin" valves. Most constant7pressure pump "overnors have needle valves to minimi;e the effects of fluctuations in pump dischar"e pressure. ,eedle valves are also used in some components of automatic combustion control systems &here very precise flo& re"ulation is necessary.
42
<i"ure 40. ,eedle 3alve
?ar7stoc( bodies are common and! in "lobe types! a ball s&ivelin" in the stem end! !igure 41! &ill "ive the necessary rotatability for seatin" &ithout dama"e.
43
<i"ure 41. ?ar7%toc( 1nstrument 3alve
'he meterin" valves7 sho&n in !igure &$ are used for e6tremely fine flo& control.. 'he thin disc8orifice allo&s for linear flo& characteristics. 'herefore! the number of hand&heel turns can be directly correlated to the amount of flo&. 'he valve on the left has a micrometer handle to assist in valve positionin". 'he valve stems have 40 threads per inch for fine control. 'hese valves also have t&o different styles of stem pac(in"! an 07rin" &ith '<. bac(in" rin"s and a '<. pac(in" cylinder. 'he valves are e$uipped &ith replaceable seats for ease of maintenance.
44
<i"ure 42. Meterin" 3alve
3.0.0 #/1,-1#2.% O< O#./4'1O, 4,D -O,%'/:-'1O, O< 34/1O:% 4-':4'O/% 3.1.0 3423. 4-':4'O/ './M%
4s stated earlier0 valves serve to stop! start! or to re"ulate fluid flo&. 'o facilitate these basic functions!. various operators or actuators are used in conjunction &ith valves. <or the purpose of describin" ho& valves and their actuators operate durin" normal or abnormal conditions! various "eneral terms are used. Other terms are used to depict the orientation of a valve &ith relation to other components. 'his section &ill e6plain these types of terms.
3.1.1 <ail Open

'he term fail open# &hen used to describe a valve or valve operator! means that &hen the controllin" medium is lost! the valve &ill automatically open. 4 common valve operator that provides this feature is a pneumatic sprin" and diaphra"m operator. 4ir supplied on one side of the diaphra"m serves to move the valve in the closed direction. :pon loss of the controllin" air supply! a!sprin"! &hich is an inte"ral part of the operator! forces the valve to move to the open position.
3.1.2 <ail -losed

'he term fail closed# &hen used to describe a valve or valve operator! is similar to the fail open term above! only that the sprin" is positioned to effect closin" the valve upon loss of control air. 1t may be stated! then! that the term fail closed means that! upon loss of the controllin" medium! the valve is positioned automatically to the closed position.
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3.1.3 <ail 4s #ositioned

!ail as positioned simply means that! upon loss of the controllin" medium! the valve remains in the same position it &as in prior to the loss. 4 common e6ample &ould be a motor7operated valve. 2oss of the electrical po&er supply &ould cause the valve to be left in the position it &as in at the time of the po&er loss.
3.1.4 <ail %afe

'he term fail safe means that! upon loss of the controllin" medium! the valve is driven to its safe position. %afe position may be open! closed! or as is! dependin" upon the position re$uired to place the system in a safe confi"uration.
3.1.
%prin" to Open
/pring to open is a phrase that describes the effect that sprin" force has on a valve operator. 'he sprin" is positioned to open the valve and some other operatin" force must be used to shut the valve. !igure &% sho&s a r sprin" to open valve operator.
<i"ure 43. %prin" to Open 3alve Operator
1n this valve! the sprin" e6erts an up&ard force on the stem to open the valve. 4ir pressure is used to shut the valve.
3.1.C %prin" to -lose

1n a sprin" to close valve operator! the sprin" is used to move the valve to the closed position. 'he sprin" e6erts a force that moves the stem do&n to close the valve. 4ir pressure is used to open the valve. !igure && sho&s a sprin" to close valve operator.
46
3.1.7 4ir to Open

4ir to open valve operators use air pressure to open the valve and sprin" force to shut the valve. !igure && sho&s a sprin" to close valve operator! but it is also an air to open operator. !igure &) is an air to open valve operator that uses the sprin" force to e6ert an up&ard force to close the valve. 1t could also be referred to as a spring to close valve operator.
<i"ure 44. %prin" to -lose 3alve Operator
3.1.E 4ir to -lose

'ir to close valve operators use air to move the valve to its closed position. !igure &* is an e6ample of an air to close type operator. 'he air pressure e6erts an up&ard force on the diaphra"m to close the valve. %prin" force opposes the force induced by the air pressure. 'his operator could also be referred to as a spring to open operator.
47
<i"ure 4 . 4ir Open 3alve Operator
<i"ure 4C. 4ir to -lose 3alve Operator
3.1.A :pstream
'he term upstream is used to describe the location of a component &ith re"ard to another component &ithin a fluid system. 'o say a component is located upstream means the component is located in the direction opposite the flo& &ith relation to another component.
48
3.1.10
Do&nstream
Do&nstream is e6actly the opposite of upstream. 1t could be said that a do&nstream component is located in the direction of flo& &ith relation to a "iven component.
3.2.0 /.>:24'O/% 4,D /.D:-./%

1f fluids are clean and if flo& is reasonably constant! &ithout sudden and fre$uent chan"es! then the small! automatic control system &hich is the re"ulator can be an ine6pensive! simple! and reliable solution to a control problem. /e"ulators can control do&nstream pressure! temperature! or flo& rate &hile the upstream pressure varies &idely. -ontrol of upstream pressure is also possible. -ontrol by a re"ulator is not as close as it &ould be in a more e6tensive system of control valve! actuator! and controller! but the controlled variable can be remar(ably! constant over the full flo& ran"e! if necessary! and to a lesser accuracy over a ran"e of upstream pressure chan"e. 'he sin"le7sta"e re"ulator balances do&nstream pressure a"ainst outside7set sprin" force! on a metal diaphra"m to open or close the valve disc! !igure &+. Diaphra"m motion is restricted so capacities are limited. %team flo& of 1000 1bm8hr is close to the ma6imum for this sin"le7sta"e re"ulator. %ensitivity to upstream pressure and flo& is hi"her than for the t&o7sta"e re"ulator. 1n this! &hat amounts to a small sin"le7sta"e re"ulator controls flo& 9to a piston that has enou"h area to operate a lar"e main valve. 4 very small movement of the pilot valve ma(es a lar"e chan"e in main7valve position. 'he error or droop of the sin"le7sta"e element is not as pronounced in the controlled valve of the main valve. 1n other versions of t&o7sta"e re"ulators! the first sta"e is remote from a lar"e main valve &ith a capacity of several hundred thousand pounds an hour of steam. 3ery small t&o7sta"e re"ulators for air! on the other hand! may have capacities of only a fe& cfm. 4 lar"e sin"le7sta"e re"ulator resemblin" a ca"e control valve &ith diaphra"m and sprin" actuator! !igure &,! can reduce pressure or maintain bac(7pressure. 'he pressure7sensin" line runs from the main line either do&nstream or upstream! to the top of the heavy7&all diaphra"m case. #ressures up to 2 0 psi" for small7diameter actuators are common. 'he flo& rate controller of !igure &- operates on some&hat different principles. 4 (nob at top rotates a sleeve to reduce the si;e of a slot7 shaped meterin" orifice cut in the &all of a stationary ca"e surroundin" the outlet tube. =hen the supply pressure rises! the impeller moves to close the outlet valve ports and decrease pressure do&nstream of the orifice. 'his action restores flo& rate to the set valve. <lo&s of 00 "pm of &ater are &ithin the capacity of this re"ulator! this is ample for coolin"7&ater flo&s in the po&er plant.
49
<i"ure 47. %in"le7%ta"e #ressure /e"ulator
50
<i"ure 4E. diaphram 4ctuated #ressure /e"ulator
51
<i"ure 4A. <lo& /e"ulator
<or re"ulation of temperature in coolin" systems! temperature re"ulators are used to control flo& to a heat e6chan"er! !igure ).. 'he temperature re"ulator consists of a valve and a thermostatic control unit mounted 7on the valve. 'he thermostatic control unit consists of t&o parts7the temperature7control element and the control assembly.
52
<i"ure 0. 'emperature /e"ulator
'he temperature7control element consists of a bellows connected by a fle6ible armored tube to a bulb mounted in the coolin"7&ater line. 'he temperature7control element is essentially t&o sealed chambers. One chamber is formed by the bello&s and cap! sealed to"ether at the bottom! and the other chamber is in the bulb. 'he entire system )e6cept for a small space at the top of the bulb* is filled &ith a mi6ture of ether and alcohol! &hich vapori;es at a lo& temperature. =hen the bulb is heated! the li$uid e6pands! forcin" the li$uid out of the bulb and throu"h the tube0 the bello&s is moved do&n&ard and operates the valve.
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'he control assembly consists of a sprin" loaded mechanical lin(a"e &hich connects the temperature7control element to the valve stem. 'he force produced by the coil sprin" in the control assembly balances the force of the vapor pressure in the temperature7control element. 'hus! the do&n&ard force of the vapor pressure in the temperature7control element. 'hus! the do&n&ard force of the temperature7control element is balanced at any point by the up&ard force of the sprin". 'he valve can then be set to hold the temperature of the coolin" &ater &ithin the allo&ed limits. /educin" valves are automatic valves used to reduce some supply pressure to a specified lo&er dischar"e pressure. 4 reducin" valve can be set for any desired dischar"e pressure &ithin a desi"n limits of the valve. 4fter the valve is set! the reduced pressure should be maintained re"ardless of chan"es in the supply pressure! as lon" as the supply pressure is &ithin the desi"n limits of the valve! and the amount of reduced pressure fluid re$uired! as lon" as the amount re$uired is &ithin the capacity ratin" of the valve. 'he dischar"e pressure of a reducin" valve &ill al&ays vary to a certain e6tent! dependin" upon the particular valve desi"n. 'his variation occurs in response to variations in inlet pressure and flo& demand. 'he ran"e over &hich the dischar"e pressure &ill vary is called the accuracy re"ulation of the valve. 'he sprin"7loaded reducin" valve sho&n in !igure )"# is a type &hich is commonly used for "eneral purpose steam service. 'he valve consists of the main reverse seated valve &ith a piston on stop of its. valve .stem! a reverse seated controllin" or au6iliary! valve! a controllin" diaphra"m! and an adjustin" sprin". @i"h pressure! steam enters9 the! valve on the inlet side and acts a"ainst the main valve disc! tendin" to close the main. valve. @o&ever! hi"h pressure steam is also bled throu"h ports to he au6iliary! valve! &hich. controls the admission of hi"h pressure steam to the top of the main valve piston. 'he piston has a lar"er surface area than the main valve disc0 therefore! a relatively small amount. of hi"h pressure steam actin" on the top of the main valve piston &ill+ tend to open the main valve! thus allo&in" steam at a reduced pressure to flo& out the dischar"e side. 'he (ey to operation of this reducin" valve is the openin" of the au6iliary valve to allo& the hi"h pressure steam to "et to the top of the main valve piston. 'he controllin" diaphra"m transmits a !0pressure do&n&ard upon the au6iliary valve stem! and this tends to open the valve. @o&ever! reduced pressure steam is bled bac( to the chamber beneath the diaphra"m0 and this steam e6erts a pressure. up&ard on the diaphra"m! &hich tends to close the au6iliary valve. 'he position of the au6iliary valve is determined by the position of the controllin" diaphra"m. 'he position of the diaphra"m at any "iven moment is determined by the relative stren"th of t&o opposin" forces+ )1* the do&n&ard force e6erted by the adjustin" sprin"! and )2* the up&ard force e6erted on the underside of the diaphra"m by the reduced pressure steam. 'hese t&o forces are continually see(in" to reach a state of balance! and! because of this! the dischar"e pressure of the steam is constant! as lon" as the
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amount of steam used is &ithin the capacity of the valve.
<i"ure 1. %prin" 2oaded /educin" 3alve
4ir7controlled reducers! !igure )$# operate on the principle that the pressure of an enclosed "as varies inversely as its volume. 4 reduction in volume results in an immediate increase in pressure! and an increase in volume results in an immediate decrease in pressure. 4 relatively small chan"e in the lar"e volume &ithin the dome loadin" chamber produces only a sli"ht pressure variation! &hile the sli"htest variation in the small volume &ithin the actuatin" chamber creates an enormous chan"e in pressure. 'he! restrictin" orifice connectin" these0 t&o chambers "overn the rate of pressure e$uali;ation by retardin" the flo& of "as from one chamber to the other.
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<i"ure 2. #neumatic #ressure -ontrolled /educin" 3alve
4.0.0 #/1,-1#2.% O< O#./4'1O, 4,D -O,%'/:-'1O, O< 34/1O:% #O%1'1O,./%

'he purpose of value operators )also called valve actuators or positioners* is to move the valve stem and the disc in and out of the valve seatin" area. 'his movement effects the openin"! closin"! or throttlin" action &hich the valve itself is intended to perform.
4.1.0 3423. O#./4'O/% 4,D #O%1'1O,./%

4lmost all valves must be physically operated by some type of operator or actuator. Many different types of operators are manufactured! but they all fall into one of several "eneral cate"ories. 'hese cate"ories are+
4.1.1 @ydraulic Operators

@ydraulic valve operators convert li$uid fluid pressure into valve motion. 'he fluid is normally &ater or oil. <luid pressure acts on a duple6 piston that is connected to the valve stem. 'he re$uired len"th of stem travel and seatin" thrust is obtained by varyin" cylinder si;e. :nits usually have hand pumps for manual operation &hen it is necessary to bypass the central po&er system. 'he system can provide the ultimate in actuator performance+ e6ceptional stiffness! fast stro(in" speeds! very hi"h thrust! and unparalleled dynamic response. 3ery lar"e valves! such as in condenser coolin" &ater systems! are often hydraulically operated
56
because of the amount of force available from a relatively small operator. 4 hydraulic operator is sho&n in !igure )%.
<i"ure 3. @ydraulic Operator
4.1.2 #neumatic Operators

'here are 7t&o basic ne imatic actuator desi"ns. One uses a sprin" and a diaphra"m! the other uses a piston and a cylinder. 'here are other (inds! as &ell as many9 variations of the basic pneumatic types. 'he diaphra"m actuator consists of a fluid7po&ered device in &hich the fluid acts upon a fle6ible member! the diaphra"m! to provide linear motion to the stem. 'he pneumatic sprin" and diaphra"m actuator is a very common! e6tremely reliable desi"n. 1t offers both lo& cost and hi"h reliability. 'he advanta"e of the sprin" and diaphra"m actuator is its fail7 safe action on loss of si"nal pressure. 'he actuators are available for either fail7open or fail7closed action. 'hey have fe& movin" parts and are e6tremely reliable and simple to maintain. !igure )& sho&s a typical sprin" and diaphra"m operator.
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<i"ure 4. %prin" and Diaphra"m Operator
'he piston pneumatic actuator consists of a fluid7po&ered device in &hich the fluid acts on a moveable cylindrical member! the piston! to provide linear motion to the actuator stem. #neumatic piston actuators are normally used &hen thrust and tor$ue re$uirements e6ceed the capability of sprin" and diaphra"m actuators. 'hey are also &ell7suited for use &ith valves &hich have lon" stro(es. #iston actuators normally &or( &ith supply pressures from 0 to 1 0 psi. 4lthou"h these actuators can be e$uipped &ith sprin" return! this construction has limited capabilities. #iston actuators used for throttlin" control re$uire a double7 actin" positioner that &ill simultaneously load and unload opposite sides of the piston. 'he pneumatic piston is often used &hen compact! hi"h thrust actuators are re$uired. !igure )) sho&s a typical piston7type pneumatic operator. #neumatic operators may be used &ith valves to control various parameters in fluid systems. #ressure! temperature! level! or flo& control may be accomplished by use of pneumatic valve operators. .lectropneumatic positioners are used in combination &ith either sin"le or double actin" actuators to provide accurate throttlin" of control valves. 'hey provide valve position proportional to a pneumatic or a D.-. current input si"nal.
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<i"ure
. #iston #neumatic Operator
!igure )* is a schematic of the operational components of a typical positioner. /efer to this fi"ure for the follo&in" e6planation of the positioner operation.
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<i"ure C. 'ypical #ositioner %chematic
4.1.3 Motor Operators

Motor operators translate a remote electric si"nal into valve motion. %ince the operator &on9t have to operate it in person! the valve can be located &herever the desi"ner li(es. 'he electric si"nal can be manual! from a pushbutton! or automatic! electrically interloc(ed &ith machinery operation. 1n motor7actuated valves! !igure )+# the motor is usually a small! hi"hspeed type. 4 "ear train then reduces the speed and increases the tor$ue to obtain a ti"ht closure.
<i"ure 7. Motor Operated 3alve
Motor7operated valves may be used for controllin" various parameters in fluid systems. 'hey may be used to control pressure! temperature! level! or flo&.
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4.1.4 %olenoid Operators

%olenoid7operated valves use a remote electrical si"nal to position valves! but it is a fastactin" type motion. 'he solenoid is a device that uses electrical ener"y to create a ma"netic field in a coil that attracts a core to effect openin" the valve. %olenoid valves are normally smaller si;e valves. 'hey are commonly used in comple6 control systems needin" a multiplicity of small! fast7actin" control valves. !igure ), sho&s a typical solenoid7operated valve.
<i"ure E. %olenoid7Operated 3alve
4.1.
Manual Operators
Manual valve operators ran"e from a simple hand&heel to other more novel desi"ns. =here bindin" could occur! some valve hand&heels are e$uipped &ith a hand&heel that moves freely for a portion of its travel and then ma(es solid contact &ith another &heel that is attached to the stem. 'his is used to hammer the valve from its bound position. ?indin" can occur &hen there is a hi"h differential pressure across the valve. =here valves are located hi"h and out of normal reach in the overhead! a chain operator may be used. 1t is simply a chain that rotates the hand&heel similar to the operation of a chain hoist.
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On some lar"er valves! manually operated "ear heads are fitted on the valve bonnet or yo(e. 'his allo&s the operator to use the mechanical advanta"e inherent to "ear drives. 'hese &ould! of course! re$uire more revolutions to cycle the valve so these units may be fitted &ith a rin" and pinion "ear that allo& for faster cyclin". !igure )- sho&s a hand&heel &ith this type setup.
<i"ure A. @and&heel =ith /in" and #inion >ear
4 portable air motor may be used to shorten the cyclin" time of the valve. 1t is hand held to the pinion "ear and turns the pinion and rin" "ear! thus operatin" the valve. 4lthou"h not normally a desi"n function! manually operated valves may be used to control various parameters of a fluid system. 'hey may be used in throttle valves for the control of temperature! pressure! level! or flo&.
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.0.0 3423. %.2.-'1O,! 'K#.%! 4,D 4##21-4'1O,%

?ecause of the diverse nature of valves &ith valve types overlappin" in each other! both in desi"n and application! &e need to loo( at the selection process for pic(in" a particular valve. 1n this section &e &ill discuss valve selection! valve types! and valve applications.
.1.0 3423. %.2.-'1O,

4lthou"h valve selection may appear to be rather simple there are many factors &hich must be ta(en into consideration. >uessin" or settlin" for just any valve is ris(y at best. :nfortunately cost is $uitee often an overridin" factor! althou"h e6perience has sho&n that sparin" e6pense no&. may result in additional e6pense at a later date. =hen selectin" a valve durin" system desi"n overall system performance is ta(en into consideration. Luestions &hich must be as(ed include+ =hat temperature &ill the system be operatin" atM 4re there any internal parts &hich &ould be adversely affected! by the temperatureM 3alves &hich are desi"ned for hi"h temperature steam systems are not necessarily suited for e6treme lo& temperatures! &hich may be found in a li$uid nitro"en system. =hat pressure )or vacuum*0 &ill this valve be operated inM @o& does the temperature affect the valves pressure ratin"M %ystem inte"rity is a major concern on any system. 'he valve must be rated at or above the ma6imum system pressure anticipated. Due to valve desi"n! pac(in" construction or end attachments the valve is often considered a &ea( point in the system. 4re there any si;in" constraintsM 1t seems rather obvious that a t&o inch valve &ould not be installed in a ten inch pipe but &hat may not be that obvious is ho& does the yo(e si;e! hand&heel or operator si;e fi"ure in. 4re &e in a ti"ht spot &here a risin" stem "ate valve &ill not be able to open fullyM =ill the operator e6tend into a &al( &ay and create a safety ha;ardM 3alve manufacturers provide dimensional tables to aid in valve selections. =ill this valve be used for on7off or throttle applicationM 'hrottle valves are "enerally of the. "lobe valve type althou"h in some applications a ball valve or butterfly valve may be used. =hat type of erosion &ill the valve be e6posed toM =ill it re$uire hardened seats and discsM =ill it be throttled close to its seat and need a special pressure drop valveM =hat (ind of pressure drop is allo&edM >lobe valves e6hibit the lar"est pressure drop or head loss characteristics &hereas a ball valve &ould e6hibit the least. =hat (ind of differential pressure &ill this valve be operated a"ainstM =ill this differential pressure be used to seat or unseat the valveM =ill the hi"h differential pressure deform the body or disc and bind the valveM =ill this also re$uire a bypass valve. @o& &ill this valve be connected to the systemM =ill it be &elded! scre&ed or flan"edM %hould it be butt7&elded or soc(et &eldedM :nion threaded or pipe threadedM %hould the flan"es be raised! flat! phono"raphic! male8female or ton"ue and "rooveM
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=hat type environment must this be installed inM 1s it a dirty environment &here an e6posed stem &ould score the yoke bushing and cause premature failureM Or is it a clean environment &here different stem lubricant should be usedM =hat (ind of fluid is bein" handledM 1s it ha;ardous such that pac(in" lea(a"e may be detrimentalM 1s it corrosive to the pac(in" or even the valve itselfM =hat9s the life e6pectancy re$uiredM =ill it re$uire fre$uent maintenanceM 1f so! is it easily repairable or does the man7hour labor re$uirements justify replacement instead of repairM Of course there are many other $uestions &hich may be re$uired. Once these are ans&ered a suitable valve may be selected. 1f an installed valve is to be replaced then a valve identical to the one removed should be reinstalled. 1f that valve is no lon"er bein" manufactured or the manufacturer is no lon"er in business then valve selection should be made in the same fashion as a ne& application e6cept that valve9 dimensions9 are "oin" to be the limitin" factor &ithout the &or(9 re$uired for pipin" alteration+ %everal $uestions9 that should be as(ed ho&ever are 4re the system parameters the same as &hen desi"ned or has the system intent chan"edM @ave any problems been noted since system fabrication that could be remedied by installin" a different desi"n valve at this timeM =hat type operator shbuld9the ne& valve be fitted &ith or is the ne& valve compatible &ith the installed operatorM
.2.0 3423. 'K#.% 4,D 4##21-4'1O,%

4s &e have noted from valve selection! there are many factors that determine the application and8or type of valve to be used! some of the factors include+ the temperature at &hich the system &ill be operatin". the pressure that the system &ill be operatin" at or the si;in" constraints. (ind of fluid that is in the system. type of environment in &hich the valve &ill have to operate. type of operator the valve &ill use.
=e also (no& that the type of valve used is determined by the application of the valve. 3alve types are+ stop valves! chec( valves! and special7 purpose valves such as safety/relief valves. <or the purpose of this module! &e are "oin" to study stop valves and chec( valves.
.3.0 3423. M4/F1,>% 4,D ,4M.#24'. 1,<O/M4'1O,

#rior to the advent of the present system of valve and flan"e codin"! manufacturers had their o&n systems. =ith the development of components rated at hi"her temperatures and pressures! alon" &ith more strin"ent re"ulations! a standard &as needed. 'he Manufacturers %tandardi;ation %ociety )M%%* first developed %#72 in 1A34. 1n 1A7E! %#7 2 &as revised to incorporate all the chan"es that had developed since
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1A34. 'o preclude errors in crossreferencin"! the 4merican ,ational %tandards 1nstitute 0'1/I2 and the 4merican %ociety for 'estin" Materials 0'/TM2 have adopted the M%% mar(in" system. 'he t&o mar(in"s you are most familiar &ith are the flo& direction arro& and the brid"e&all mar(in"s! sho&n in !igure *.. 'he brid"e&all mar(in" is used e6tensively on "lobe valves and the flo& direction arro& can be used on any type of valve. =ith a "lobe valve! flo& normally enters +under the9 disc0 ho&ever! in some applications it may be specified for flo& to enter on the top side of the disc. 'his is especially true in linear flo& throttle and needle valves. 1t is important! to.9 note that brid"e&all mar(in"s do not sho& direction of flo&! but rather ho& the stern and pac(in" are situated in respect to the inlet and outlet ports.
<i"ure C0. 3alve Mar(in"s
,o mar(in"s for flo& are normally used on "ate!. plu"! butterfly! or ball valves. 1f a "ate valve has a flo& arro&! it is because the "ate valve has a double "ate. Double "ate type valves are capable of relievin" fluid pressure in the event that a hi"h pressure difference e6ists across the shut "ate. %tandard practice is for the outlet7side "ate to relieve to the inlet side. 'his type of valve is used for specific applications0 therefore! system plans should be consulted for correct valve orientation. 'here are normally t&o identification sets+ one permanently embossed! &elded or cast into the valve body! and the other a valve identification plate# !igure *". 'ypically as a minimum! the follo&in" information &ill be included &ithin the t&o sets+ 1. 2. 3. 4. . C. /atin" desi"nation mar(in"s. Material desi"nation mar(in"s. Melt identification mar(in"s. 'rim identification mar(in"s )if applicable*. %i;e mar(in"s. 'hread identification mar(in"s )if applicable*.
=e &ill also discuss the omission of mar(in"s and component mar(in"
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re$uirements.
<i"ure C1. 4ctuator ,ameplate
.3.1 /atin" Desi"nation

'he ratin" desi"nation of a valve "ives us the pressure and temperature ratin" as &ell as the type of service. !igure *$ sho&s service desi"nations commonly used.
CORRESPOND TO SWP (steam working pressure) SP WSP S steam pressure working steam pressure steam
CORRESPOND TO CWP (cold working pressure) WO OW! WO! !"P WWP W water oil pressure oil water gas pressure water oil gas pressure gas li#uid pressure working water pressure water pressure
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'he ratin" desi"nation for products may be desi"nated by the class numbers alone! e.".! a steam pressure ratin" or! a pressure class desi"nation. 'he ratin" desi"nation for products that conform to reco"ni;ed standards but are not suitable for the full ran"e of pressures or temperatures of those. standards may be mar(ed as appropriate and also sho& the numbers and! letters representin" the pressure ratin" at the limitin" conditions. 'he ratin" desi"nation for products that do not conform to reco"ni;ed 7 national product !standards may77be sho&n+ by numbers and letters representin" the! pressure ratin"s at ma6imum and minimum temperatures. 1f desired! the ratin" desi"nation9 may be sho&n as the ma6imum pressure follo&ed! by 3 !"3 and the allo&ed pressure9 at the ma6imum temperature )for e6ample! 2000 -=# 72 8A2 <*. Other typical desi"nations are "iven as the first letter of the system they are desi"nated for+
<i"ure C2. 3alve /atin" Desi"nations
.3.2 'rim 1dentification

'rim identification mar(in" is re$uired on the identification plate for all flan"ed7end and butt &eldin" end steel or flan"ed7end ductile iron body valves havin" trim material that is different than the body material. %ymbols for materials are the same0 the identification plate may be mar(ed &ith the &ord trim follo&ed by the appropriate material symbol. 'rim identification mar(in" for "ate! "lobe! an"le! and cross valves or valves &ith similar desi"n characteristics shall consist of three symbols. 'he first shall indicate the material of the stem! the second the material of the disc or &ed"e face! and the third shall indicate the material of the seat face. 'he symbol may be preceded by the &ords B%'.M!B BD1%-!B B%.4'!B or used alone. 1f used alone! the symbols must appear in the order "iven. #lu"! ball! and butterfly valves or other $uarter7turn valves re$uire no trim identification mar(in" unless the plu"! disc! closure member! or the stem or both are different material than the body. 1n such cases! trim identification symbols on the nameplate &ill first indicate the material of the stem and second the material of the plu"! ball! disc! or closure member. 'hose valves &ith seatin" or sealin" material different than the body material shall add a third symbol to indicate the material of the seat. 1n these cases! symbol identification shall be preceded by the &ords B%'.M!B BD1%-B )or B#2:>!B B?422!B or B>4'.!B as appropriate* and the9 &ord B%.4'.B 1f used alone! the symbols must appear in the order "iven.
.3.3 %i;e Desi"nation

%i;e mar(in"s &ill be in accordance &ith the product7referenced mar(in"9re$uirements. <or si;e desi"nation for9 products9 desi"ned &ith a sin"le nominal pipe si;e of the connectin" ends! the &ord BnominalB indicates Jthe numerical identification associated &ith pipe si;e. 1t does
67
not necessarily correspond to the valve! pipe! or fittin" inside diameter. #roducts havin" internal elements &hich are the e$uivalent of one pipe si;e or different than the end9 si;e 9may have dual + mar(in"s unless specified other&ise in a product standard+ :nless these e6ceptions e6ist!9 the first number shall indicate the connectin" end pipe si;e and the second the minimum bore diameter or the pipe si;e correspondin" to the closure si;e! e.".! C 6 4! 4 6 2182! 30 6 24. 4t the manufacturer9s option! triple mar(in" si;e desi"nation may be used for valves. 1f triple si;e desi"nation is used! the first number shall indicate the connectin" end si;e at the other end. <or e6ample! B24 6 20 6 30B on a valve desi"nates a si;e of 24 connection! a si;e 20 nominal center section! and a si;e 30 connection. <ittin"s &ith multiple outlets may be desi"nated at the manufacturer9s option in a Brun 6 run 6 outletB si;e method. <or e6ample! 30 6 30 6 24 on a fittin" desi"nates a product &ith si;e 30 end9 connections and a nominal si;e 24 connection bet&een.
.3.4 'hread Mar(in"s

<ittin"s! flan"es! and valve bodies &hose connectin" ends are threaded as other than 4merican ,ational %tandard #ipe 'hread or 4merican ,ational %tandard @ose 'hread &ill be mar(ed to indicate the type. 'he style or mar(in" may be the manufacturer9s o&n symbol provided that confusion &ith standard symbols is avoided. <ittin"s havin" left7hand threads shall be mar(ed &ith the letters B2@B on the outside &all of the appropriate openin". Mar(in" of products &ith ends threaded for 4#1 casin"! tubin"! or drill pipe shall include )1* nominal si;e! )2* the letters B4#1!B and )3* the thread type symbol as listed in !igure C3.
Name$Description Casing - short round thread Casing - long round thread Casing - buttress thread Casing - extreme-line Line pipe Tubing - non-upset Tubing - external-upset
S%m&ol CSG LCSG BCSG XCSG LP TBG UP TBG
<i"ure C3. .6amples of 'hreaded7'ype %ymbols
Mar(in" of products usin" other pipe threads shall include the follo&in"+ 1. ,ominal pipe! tubin"! drill pipe! or casin" si;e. 2. Outside diameter of pipe! tubin"! drill pipe! or casin". 3. ,ame of thread.
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4. ,umber of threads per inch.
.3.
3alve %chematic %ymbols
'he last and most important aspect of valve identification is the ability to identify different types of valves from9 blueprints and schematics. 1n "eneral! the symbols that denote various control valves! actuators! and positioners are standard symbols as sho&n in !igure *&. @o&ever! in certain cases these symbols &ill vary dependin" on site specific prints. 'he le"end of a typical system print or schematic &ill sho& the symbols that represent all components on the dra&in".
69
<i"ure C4. 'ypical #ipin" %ystem %chematic %ymbols
%:MM4/K
-ontrol valves! actuators! and positioners are inte"ral to the operation and control of fluid flo& systems. .ach device has characteristics &hich ma(e it specially suited for certain applications. 'he applications for &hich they are used vary &idely and include+ fine control of flo&! temperature re"ulation! pressure re"ulation! and flo& isolation. #roper selection of the control valve for a specific system &ill be determined by several factors such as system desi"n pressure and temperature! pipin" si;e! and system flo& conditions. 'hese criteria &ill determine the material of &hich the component &ill be constructed. 4ctuators and positioners serve as ener"y transmission devices that &ill cause valve stem movement. 'hey are desi"ned to use several different ener"y sources to perform their function. 'hese devices provide a means by &hich valves may be operated remotely or operated a"ainst e6tremely hi"h differential pressures. 'he information presented in! this module has provided a detailed description of construction and operation of various control valves! actuators! and positioners. 4s a trainee involved in installation of these components! this information &ill prove invaluable in the proper selection and correct installation of+ any of these valves! actuators! and positioners in a fluid system.
/eferences
<or more advanced study of the topics covered in this tas( module! the
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follo&in" &or(s are su""ested+ Piping 4and5oo6# %i6th .dition! Mc>ra&7@ill! 1nc.! 1AA2.
%.2<7-@.-F 8 #/4-'1-. L:.%'1O,%

1. 2. 3. a. b. c. d. e. f. ". h. )1* 2ist the 3 thin"s that valves are desi"ned to doM 'he most common use of a "lobe valve is toNNNNNNNNNNNNNNNNNflo&. Matchin" .6ercise+ %elect the term belo& &hich most closely matches the statement. 4ctuator ?onnet ?rid"e&all mar(in" >ate valve #ac(in" %eat =ed"e 3alve trim NNNNNNNNNN to NNNNNNNNNN NNNNNNNNNN NNNNNNNNNN 'he internal components of a valve &hich are e6posed the flo&in" fluid. )2* )3* )4* stop ) * the )C* or 4 term for the disc in a "ate valve. Material used to ma(e a dynamic seal! preventin" system fluid lea(a"e around a valve stem. 'he part of a valve a"ainst &hich the disc presses to flo& throu"h the valve. NNNNNNNNNN %ymbol on body of valve sho&in" the relationship of stem to the inlet and outlet parts. NNNNNNNNNN the valve. )7* NNNNNNNNNN 4 valve havin" a strai"ht7throu"h flo& desi"n &hich e6hibits very little resistance to flo&+ normally used for open and shut applications. 'he part of a valve containin" the valve stem and pac(in". 'he part of a re"ulatin" valve that converts electrical fluid ener"y to mechanical ener"y to open and close
)E*
NNNNNNNNNN
71
4.
>iven the follo&in" list of letter desi"nators for valve symbols! fill in the blan(s &ith the correct name of the valve type. )a* 4 )b* > )c* 2 )d* O )e* = )f* D=3 NNNNNNNNNNNNNNNNN NNNNNNNNNNNNNNNNN NNNNNNNNNNNNNNNNN NNNNNNNNNNNNNNNNN NNNNNNNNNNNNNNNNN NNNNNNNNNNNNNNNNN
=hat is a desirable feature of a pneumatic positionerM a. =hen used in combination &ith either a sin"le7 or double7actin" actuator! it provides accurate throttlin" of control valves. b. #rovides a &ide ran"e of proportional outputs to valve controls. c. /elatively ine6pensive first time cost. d. .6tended maintenance7free operation. Motor operators translate a remote electric si"nal into valve motion. a. 'rue. b. <alse. =hat type of motor is commonly used for motor7operated valvesM a. 2ar"e D.-. motor. b. %mall D.-. motor. c. %mall hi"h7speed 4.-. motor. d. 2ar"e hi"h7speed 4.-. motor.
7.
72
#./<O/M4,-. 8 24?O/4'O/K .O./-1%.%

1. 1dentify the internals of a "lobe valve. %tep 1 3erify that the valve is a "lobe valve. %tep 2 ,ame all individual parts. %tep 3 .6plain the function of individual parts. 1dentify internals of a "ate valve. %tep 1 3erify that the valve is a "ate valve. %tep 2 ,ame all individual parts. %tep 3 .6plain the function of individual parts. 1dentify internals of a diaphra"m actuated pressure re"ulator. %tep 1 3erify that the re"ulator is a diaphra"m actuated pressure re"ulator. %tep 2 ,ame all individual parts. %tep 3 .6plain the function of individual parts. 1dentify internals of a piston and cylinder operator. %tep 1 3erify that the operator is a piston and cylinder operator. %tep 2 ,ame all individual parts. %tep 3 .6plain the function of individual parts. 2ocate 9brid"e&all Bmar(in"s on a "lobe valve and determine the! stem and pac(in"! orientation. %tep 1 #oint out brid"e&all mar(in"s on "lobe valve. %tep 2 .6plain &hether pressure &ill be felt on the disc and stem or the pac(in".
2.
3.
4.
C. 1dentify valve actuators and positioners from site specific schematics. %tep 1 %tudy le"end on schematic. %tep 2 9 2abel the type of valve circled on schematic by the instructor. 7. 1dentify variables that apply to positioners.
73

Instr 12207 Control Valves, Actuators and Positioners

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Instr 12207 Control Valves, Actuators and Positioners

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Control Valves, Actuators and Positioners

Instrument Trainee Task Module 12207

CONTROL VALVES, ACTUATORS, AND- POSITIONERS-------------------Objectives

/e$uired %tudent Materials

1nstrument 'rainee 'as( Module 12207

-ourse Map 1nformation

-ourse Map+ 1nstrument! 2evel 2 2.3.2 2 -OM#.2'.

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

1nstrument 'rainee 'as( Module 12207

'rade 'erms 1ntroduced 1n 'his Module

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

1.0.0 1,'/OD:-'1O, 'O -O,'/O2 3423.%! 4-':4'O/%! 4,D #O%1'1O,./%

1nstrument 'rainee 'as( Module 12207

pneumatics or hydraulics as an ener"y source.

<i"ure 1. 3alve <unctions

2.1.0 >2O?. 3423.%

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 2. >lobe 3alve

1nstrument 'rainee 'as( Module 12207

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 4. %eat8Disc 4rran"ements

1nstrument 'rainee 'as( Module 12207

<i"ure . >lobe 3alve #lu"s

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

2.1.1 >ate 3alves

1nstrument 'rainee 'as( Module 12207

<i"ure C. >ate 3alve

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 7. =ed"e 'ypes

1nstrument 'rainee 'as( Module 12207

<i"ure E. %olid or! %in"le =ed"e

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure A. <le6ible =ed"e

1nstrument 'rainee 'as( Module 12207

<i"ure 10. %plit =ed"e

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 11. #arallel Disc >ate 3alve

1nstrument 'rainee 'as( Module 12207

<i"ure 12. #arallel Disc

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 13. %prin" 2oaded #arallel Disc >ate 3alve

<i"ure 14. #arallel Disc >ate 3alve

1nstrument 'rainee 'as( Module 12207

<i"ure 1 . /elievin" Disc >ate 3alve

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

2.1.2 Fnife 3alves

1nstrument 'rainee 'as( Module 12207

<i"ure 1C. ,on7/isin" %tem >ate 3alve

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 17. /isin" %tem >ate 3alve

1nstrument 'rainee 'as( Module 12207

<i"ure 1E. /isin" %tem >ate 3alve G %tem 'hrou"h ?onnet

<i"ure 1A. Fnife 3alve

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

2.1.3 ?all 3alves

1nstrument 'rainee 'as( Module 12207

<i"ure 20. ?all 3alve -omponents

<i"ure 21. ?all 3alve =ith %lanted %eals

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207

<i"ure 22. 3enturi 'ype ?all 3alve

1nstrument 'rainee 'as( Module 12207

<i"ure 23. 'op .ntry ?all 3alve

<i"ure 24. %plit ?ody ?all 3alve

-ontrol 3alves! 4ctuators! and #ositioners 5 Module 12207