VALVES

VALVE DEFINITION
VALVES ARE MECHANICAL SPECIFICALLY DESIGNED TO: DIRECT START STOP MIX REGULATE FLOW, PRESSURE OR TEMPERATURE OF A PROCESS FLUID DEVICES

 Valves can be designed to handle either LIQUID or GAS applications. Industrial Valves : Size 0.5 Nominal Dia (DN15) to 48 (DN1200). 90% of Valves are 4 (DN100) or smaller in size.

SERVICE
Vacuum to over 13,000 psi (897 bar)

MATERIALS OF CONSTRUCTION
Iron, Steel, Plastic, Brass, Bronze (or) a number of special Alloys

HISTORY
In 1712, Englishman Thomas Newcomen invented a simple Iron Plug Valve, to regulate the flow of steam to the piston The first known application of a Throttling valve. Corliss Steam Engine unveiled in 1876 was designed with Self-acting Control Valves. Invention of Crude oil as an inexpensive and plentiful form of power in early 19th century spawned the creation of Petroleum Refinery, Petrochemicals, Process Industries, Paper, Food, Beverage Industries creating need for various types of valves.

VALVE CLASSIFICATION
a) Function classifications:
ON-OFF (Block valves) Block or allow flow Non-return (Check valves) Allow flow to travel in one direction Throttling (Full open to full close) Regulation of flow (Can be used as ON-OFF also)

b) Application Classification:
General Service valves (Manual or Automated) -46oC to 343oC, Class 150 to 600, Non-corrosive applications. Special service Custom engineered High pressure, high temperature, corrosive/erosive medium. Severe service Valves with special features to handle volatile applications, very high pressure drops, severe cavitation, flashing, choking, beyond 593oC, liquid Sodium applications.

c) According to motion:
Linear motion sliding stem design. Rotary motion through quarter turn or 45o range to open or block the flow.

d) According to Port size:

Full port valves Reduced port valves

Other types of Valves

Block & Bleed valves To prevent intermixing of fluids (Fin Fan cooler, wash water systems) Butterfly valves Water applications (AWWA standards) Blow-off valves Steam systems

TERMS AND DEFINITIONS

ANSI rating class Numerical pressure design class defined in ASME B 16.5 and used for reference purposes. ANSI rating class is designated by the word CLASS followed by a number. Ex: Class 150. Bi-directional valve Valve designed for blocking the fluid in both downstream and upstream direction. Bleed drain or vent. Block valve Gate, Plug or Ball valve that blocks flow to downstream when in closed position

 Locking device Part or an arrangement of parts for securing a valve in the open and (or) closed position. NPS Nominal pipe size. PN Numerical pressure design class as defined in ISO-7005-1. (PN followed by a number). Ex: PN16. Pressure containing parts Parts such as body, bonnet, gland, stem, gasket, bolting designed to contain pipeline fluid. Process wetted parts Parts exposed directly to pipeline fluid.

ABBREVIATIONS
BM Base Metal Carbon Equivalent = {%C+(%Mn/6)+(%Cr+%Mo+%V)/5+(%Ni+ %Cu)/15} Limit: 0.43 Heat analysis, 0.45 Product. Double Block and Bleed Nominal Size Heat Affected Zone Rockwell Hardness

CE

DBB DN HAZ HR

HV MPD MT NDE NPS NP WPS PQR WQR WM PT PWHT

Vickers Hardness Maximum Pressure Differential Magnetic Particle Testing Non-Destructive Examination Nominal Pipe Size Nominal Pressure Welding Procedure Specification Procedure Qualification Record Welder Qualification Record Weld Metal Penetrant Testing Post Weld Heat Treatment

ANSI PRESSURE CLASS

POUNDS OF FORCE PER SQUARE INCH OF SURFACE AREA 150 300 600 900 1500 2500 4500 NOMINAL PRESSURE ALLOWABLE PRESSURE IN BAR 16 40 100 160 250 400 700

VALVE SELECTION
Valve co-efficient or Flow co-efficient
Cv = Flow X m sqrt Sp. Gravity at flowing temperature / pressure drop

Cv = One US gallon (3.78 litres) of 60oF (16oC) water that flows through an opening (valve) during 1 minute with a 1 psi (0.1 bar) pressure drop

END CONNECTIONS
Threaded (1.5 and smaller sizes) (NPT) Flanged End (2 and larger) Integral, separable Welded End (Class 900 and higher) Socket welded (2 and smaller), Butt welded (3 and higher)

PRESSURE CLASSES
Six standard classes 150, 300, 600, 900, 1500 or 2500 As per B 16.34 standard Special classes 15, 4500 Etc. Intermediate classes Ex. 3300 (CS valve for 150oC, 450 bar)

Casting Quality Factors

ASME Codes / B 16.34 Especially for corrosive, high pressure, high temperature applications Level 1 Level 2 Level 3 Level indicates severity levels of imperfections

Casting imperfections include

A Gas porosity B Sand, slag inclusions C Shrinkage D Cracks E Hot tears F Inserts G Mottling

Examination of Steel castings are done as per

ASME Sec:VIII Div:1 Mandatory Appendix:7 ANSI B 16.5 ANSI B 16.34

Radiographic examination standards

Thickness Up to 2 (51 mm) 2 4.5 (51-114 mm) 4.5 12 (114mm305mm) Above 12 RT spots Standard ASTM E 446 (Std Reference Radiographs) ASTM E 186 (Std Reference Radiographs) ASTM E 280 (Std Reference Radiographs) ASTM E 280 / UT exam is done As per sketch in B 16.34 standards

VALVE MANUFACTURING
Valve design Pattern development Establish methoding process with Statistical Quality Control Pilot casting Tests / Acceptance standards Fix quality factors Machining of castings

 Bought out items (other items like stem, gasket, packing, fasteners, hand wheel, disc, yoke, seat ring) Assembly Testing Marking / Punching Despatch VTR / Release note of TPI Spares, valve key Etc.

MATERIAL
Carbon Steel up to 425oC Chrome-Moly Steel Corrosive, H2S environment SS - >535oC, high temperature, corrosive applications A216 WCB (CS), A217 C5 (AS), A351 CF8M, CF3M (SS)

TRIM MATERIAL
API 600 Trim No. Service Stem Body seat ring Body MOC + HF Body MOC + HF Wedge Back seat bush

MP / LP Steam

SS 410 RC22 max

Body MOC + SS 410 RC22 max 13% Cr RC22 max Body SS 316 MOC + SS 316 RC22 RC22 max max

12

Corrosive service

SS 316

HP Steam

Both body seat / wedge is Stellited.

MATERIAL TESTING
Chemical composition basic, alloying elements Mechanical properties UTS, YS, % elongation, hardness Etc. Special properties Impact, high corrosion resistant properties Etc.

Various Heat Treatment processes conducted in valve manufacturing

Normalizing Hardening Annealing Tempering Solution Annealing

EXAMINATIONS
Visual Liquid Penetrant Magnetic particle examination Radiography Ultrasonic examination

TEST PROCEDURE API 600

Gate valve : Shell Backseat Air seat Hydro seat : Shell Backseat Air seat Hydro seat : Shell High pressure closure test Low pressure closure test Low pressure air seat test (optional)

Globe valve

Check valve

REPAIR
Weld repairs should be approved by TPI / Client WPS / PQR / Welder qualifications check NDT Post weld heat treatment Tests as above

Gasket Selection
Purpose : Prevent leakage from joint Prevent leakage to atmosphere Allow function of internal mechanism Material / : CAF, Spiral Wound, Ring Joint type types

PACKING
Any soft material encased in a bonnet or in a body used to seal a valve closure elements stem or shaft is called packing. It is held by a packing follower or guides. Ex: Graffoil, Impregnated Graffoil Etc.

CLOSING ELEMENTS
GATE GLOBE BALL PLUG BUTTERFLY Etc.

TYPES OF OPERATION
MANUAL GEAR OPERATED ACTUATOR OPERATED

COMMON VALVE PROBLEMS

High pressure drop Result in cavitation, flashing, choked flow, high noise levels, vibrations. Water hammer effects Due to sudden stoppage of flow, shock waves are generated, avoid sudden pressure surges. Erosion, Corrosion Defects, leaks (Gland leaks) Operational issues closing, opening Etc.

ACCREDITATIONS
API Monogram API 6D for Gate, Plug, Ball, Check valves ISO 9001 ISO 14000 IBR / EIL, TDC, TPI approvals

Purchasing Issues
Valve data sheet Drawing Specifications QAP Stage / Final inspections Storage, Installation Spares Warranty, Guarantee issues Vendor surveys for enlistment

INSTALLATION
For best performance, it is recommended that Gate, Globe valves are installed in vertical position with the stem operating end at the top, horizontal or at an angle in between. Swing check valves can be installed in vertical or horizontal pipelines. However, in vertical pipelines the flow should always be in the upward direction.

 Swing check valves should never be installed at the outlet of a Reciprocating pump as the pulsating flow will damage internals of the valve. Gate valves have bi-directional capabilities and can be installed in any direction. Globe valves to be installed in the direction of arrow. Check valves are unidirectional. Flow direction and arrow direction should coincide.

OPERATION
GATE VALVES : Should be fully open or fully closed. Throttling will cause wire drawing at seating area leading to damage, leak. Clockwise: close, anticlockwise: open. GLOBE VALVES : Used for throttling. It is advisable not to use Globe valves for flow control below 10% of full opening. Clockwise: close, anticlockwise: open. CHECK VALVES : All are swing type which automatically open by the velocity pressure of flow and close by the gravitational force when flow reverses or stops.

Maintenance Issues
Periodical cleaning, flushing, greasing Check gear box, actuator mechanisms Installation issues Online leak arresting (clamps, cold repairs Etc.)

PARTS
Disc and Seat that directly affect the flow Stem that moves the Disc Body and Bonnet that house the Stem / internal parts Operator that moves the Stem

DESIGN / TESTING CODES

VALVE GATE GLOBE CHECK DESIGN API 600, BS 1414, DIN 3202 TESTING

API 598, ANSI B 16.34, BS 5352 BS 6755, DIN 3230 BS 5352 (Forged) / BS 1868 (Cast)

Other relevant Standards include:

API 6D Petroleum & Natural Gas Industries Pipeline Transportation Systems Pipeline Valves ASME B 16.5 Pipe flanges and flanged fittings (1/2 to 24) ASME B 16.10 Face to face and end to end dimensions of valves ASME B 16.25 Butt welded ends

 ASME B 16.34 Flanged, threaded and welding ends. ASME B 16.47 Large Dia steel flanges (26 to 60) NACE TM 0284 HIC testing NACE MR0175 Sulfide Stress Cracking resistant metallic materials for oil field equipment API 6 FD / API 607 Fire safe testing of valves

PRESERVATION
End caps Water ingress Check prior to installation

Special Applications
NACE MR0175 IBR FORM - III C AWWA Stds. Water applications Custom designed PAREX rotary valves Cryogenic applications very low temperatures : N2, LPG (-180oC)

TRACEABILITY
Manufacturer Name Plate Heat No. / Lot No. / Sl. No. Size / Rating W.O. No. VTR / Release Note of TPI

Famous / Approved Manufacturers

AUDCO KSB FOURESS SANMAR

COST ASPECTS
Size, Rating Additional Features (Gear, Actuator) Special Requirements (NACE, RT Quality) Location of Supplier vs. User Mandatory Requirements

QUESTIONS / VALIDATION:
What is a Valve? What is the purpose of a Valve? What are types of Valves? What are the Design/Testing standards? What NDT are done in manufacturing stage? What is AWWA Std? Where is it applicable? What is Cv? What are Appurtenances for valves? Name any 03. What are different types of ends of valves? What are NACE application Standards? What is an IBR valve? What is the Form No.?

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