BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

INTRODUCTION
BHEL started the manufacture of valves at the Tiruchy complex, along with the manufacture of boilers in 1965. The conventional Gate, Globe and Check valves manufactured were initially intended for use in Thermal Power Plants. Subsequently, the design and production capabilities were systematically upgraded to include Safety Valves, Safety Relief Valves, Quick closing Non-return Valves, HPLP Bypass System and Oil Field Equipment. The scope for supply of these valves has been extended to industrial markets such as chemical, petrochemical, fertilizer plants, Refineries, nuclear power plants.

1.1 PRODUCT RANGE:The Valve Plant manufactures Cast and Forged Steel Valves for a variety of applications. The product range under design and manufacture include the following:Gate, Globe and Non-return valves for pressure ratings up-to 4500 class and temperatures up-to 540'C. Safety and Safety Relief Valves with set pressures up to 220 Kg/sqcm and temperature up to 570'C. HPLP Bypass Control System up to 660 MW. Quick Closing Non-Return valves (QCNRVs) up to 600 Class. Soot Blowers Silencers and Water Level Gauges. Oilf Field Equipment including : o o o o Surface Wellheads, X-mas trees up to 15000 psi. Mudline suspension systems up to 10000 psi. Casing support Systems Equipment for Oil Exploration and Production. Coal Bed Methane Well-Head Equipment

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

2.0 CONVENTIONAL VALVES

Valves are mechanical devices designed to direct, allow, disallow, mix or regulate the pressure, flow or temperature of a process fluid. The basic function of a valve is to Isolate Flow as the Value Engineering experts put it in Verb-Noun form. This article is intended to give a over-view of the general valves being manufactured at BHEL and also to help the process Engineer to identify the valve he needs for an application.

Sl. 1 2 3 4 5

Valve Type Gate Valve Globe Valve Swing Check Piston Lift Check Regulating

Valve Category Isolating Valves

Application

Used to isolate the line. i.e. Fully Closed or to stop the flow or fully opened to allow the flow. Non-Return Allows the medium to flow in Valves one direction. When reverse flow occurs, the valve closes. Regulating Valves Used for Flow Quantity Regulation GLOBE VALVE

GATE VALVE

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

2.1

MATERIAL FORM OF VALVE BODY:-

1. FORGED VALVES : Valve sizes of 2 & below are made of forgings. 2. CAST VALVES : Valve sizes of 2 & above are made of castings. 2.2 VALVE SIZES
Valve sizes are identified by its equivalent nominal pipe size (NPS) of the piping on which these valves are mounted. In BHEL, valves are manufactured from 1/4 to 36 of valve sizes. Forged valve category includes 1/4 to 2 and Cast Valve category includes 2 to 36.

2.3 PRESSURE - TEMPERATURE RATING

Maximum permitted pressure of the medium with respect to its temperature are given in the Standard ASME- B16.34 for the corresponding valve body material. These ratings are specified by CLASS NUMBER. The strength of the material reduces with increase in temperature and the permissible pressure also reduces with increase in temperature of the medium.

The class ratings identified in ANSI-B16.34 are as follows: Class 150; Class 300; class 400; class 600; class 900; class 1500; class 2500; class 4500.

Class 800 is non listed rating obtained by interpolating class 600 class 900. Increase in class number indicates higher fluid pressure with respect to material.

Forged valves are available in class 800, class1500 & class 2500. Cast valves are available in class 150; class 300; class 400; class 600; class 1500; class 2500.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

CHECK VALVE GENERAL ARRANGEMENT

2.4 VALVE BODY MATERIAL:

Valve body is made of following materials. Type of material selection depends on the fluid / mediums temperature and /or its corrosive nature. 1. Carbon Steel used upto -425 C / 800 F. 2. Alloy steel used upto 550 C (593 C) / 1100 F 3. Stainless steel used upto 600 C- mostly used for corrosive nature of medium.

Material type Carbon Steel Upto 425 C Alloy Steel Above 425 C Stainless Steel 600 C

(<=2 inch) Forgings A105 F11 - 538 C F22 - 593 C F91 - 649 C (304) / 316

(>=2 inch) Castings WCB / WCC WC6 - 538 C WC9- 593 C C12A - 649 C CF8 CF8M

Composition C-Mn-Si 1 1/4 Cr 1/2 Mo 2 1/4 Cr 1 Mo 9 Cr 1 Mo V 18Cr & 8Ni 16Cr 8Ni 2Mo

.2.5 END CONNECTION

Valve assemblies are mounted on pipe lines by the following means: 1. Socket weld ends 2. Screwed ends 3. Flanged ends 4. Butt welded ends.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

Socket welded & Screwed end type of connections are provided for valve sizes 2& below. Flanged ends and Butt-welded end type of connections are given for valve sizes 2 & above.

2.6 SPECIAL FEATURES :

In addition to the basic features to specify the valve namely Valve type, Size, Material of Construction, Rating, End Connection & Operation, host of special features are available of which few are elaborated below : 2.6.1 OPERATION:Isolating Valves and regulating valves are operated by one of the following methods, which depend on the size of the valve & the system requirement. * 2.6.1.1 Hand wheel operation - generally provided on many of the valves. * 2.6.1.2. Gear operation - higher size valves are provided with gearbox for every operation. * 2.6.1.3. Motor operated - valves are provided with electrical actuators for remote

operation. Higher size valves are generally provided with electrical actuators for ease of operation. * 2.6.1.4. Chain wheel operated - When operating floor level is very much below the valve (axis) chain wheel with chain is provided for operation.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

2.6.1.5.

Extension spindle operation - When the operating floor level is very much

above the valve (axis), a stand with hand wheel or electrical actuator is provided at the operating level & its spindle is connected to valve.

2.6.3 SPECIAL FEATURES : a) Gland sealing arrangement b) Limit Switch arrangement c) Locking Arrangement d) Indicator Arrangement e) By-Pass Valve Arrangement f) Pressure Relieving Arrangement

g) Balance Hole Arrangement h) Drain Hole Arrangement

1 GLAND SEALING ARRANGEMENT: Valve stem (operating element) is connected to Wedge / Disc (closing element) at one end, and connected to handwheel / actuator (actuating element through yoke bush for opening /closing the valve). Disc / Wedge is kept inside the pressure part while the actuating elements are kept outside the pressure part. A Stuffing box is provided at the bonnet of the valve, allows the stem movement & at the same time arrests the medium

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

from leaking to the atmosphere. In this arrangement a little amount of leakage can occur over a period of service of the valve. When the medium is toxic or like NH3, H2S. Such small leaks thro stuffing box is avoided by providing a gland sealing arrangement. Generally a lantern ( a fluid jacket ) is introduced at the middle of the packing s and dissolving medium / water is allowed to circulate. This dissolves the leaking medium, which is connected thro leaking medium, which is removed thro connected piping. When the valve is used in vacuum service, this arrangement eliminates the outside air getting into the valve body.

2 LIMIT SWITCH ARRANGEMENTS: Two limit switches are mounted on a framework, which is connected to the valve yoke. A lever that is connected to the valve stem actuates the respective limit switch, when the valve is in fully opened fully closed position, which in turn gives signal

to the control room for necessary use.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

3 LOCKING ARRANGEMENT:

Wherever the System warrants that the operation of the Valve shoud not be done by unauthorised personnel, locking arrangements are provided to keep the Valve in either open or closed position until operated upon. Hook type for Gate Valves and chain type for other Valves are common.

4 INDICATOR ARRANGEMENT:

When the valve position is to be known in a Handoperated Valve, Indicator Tubes with Open/ Close markings are fitted on top. The dial fitted to stem moves up or down indicating the Valve position.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

5 By-Pass Valve ARRANGEMENT: By-pass valve arrangement is provided in valves to equalize the pressure in both the inlet and outlet of the valve so that the valve can be opened easily. This is also helpful in warming up the outlet pipeline for preventing sudden thermal shock.

6 Pressure-relief ARRANGEMENT:

This is used to prevent pressure build-up in the Bonnet area in the Flexible Wedge Valves. Normally, it is done by connecting a " Valve between the Bonnet top and Inlet/Outlet thereby preventing over pressure in the Bonnet.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

7 Balance Hole Arrangement The purpose of providing a balance hole arrangement is similar to that of providing a PRV. Wherever a PRV cannot be provided and a similar chance of fluid thermal expansion exists, a balance hole is provided by making a small hole in the wedge connect the Bonnet and the inlet/outlet.

8 Drain Hole Arrangement When the system warrants draining of the valve by removing the sediments accumulated during service of the valve, a drain hole is provided at location G (down most part of the valve) with a suitable plug/ pipeline.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

Preventive Maintenance of Valves

All Types of Valves: 1.It shall be ensured that no solid foreign particles are present either in the valves or pipelines before the valves are installed to avoid damage to sealing surfaces. 2. Valves shall be properly stored. The end caps shall be kept in position and shall be removed just before installation only. 3. All the valves shall be serviced during annual shut down by experienced service personnel. 4. The following remedies are available for technicians at site to solve the minor problems. If the problem still persists, Valve services of BHEL shall be contacted Conventional valves: 1. Gland leakage Gland bolts are to be tightened evenly, as soon as leakage is noticed, and arrested. Additional packing shall be added, if necessary (at the next available shut down) If leakage persists, packing shall be replaced with new set of packing. 2. Body bonnet joint leakage.(SW gasket) Tighten the bolts sequentially. If the leakage still persists, replace the SW gasket. Also ensure that the sealing surface is intact.

3. Pressure seal bonnet/ Hinge Pin leak in high pressure valves. In pressure seal design, sealing effect is achieved by the medium pressure only. In order to ensure effective sealing, self sealing bonnet nuts are to be fully tightened in cold condition and to be retightened after achieving full operating pressure. Also bonnet nuts are to be retightened again when maximum operating temperature is achieved as temperature variations can cause relaxation of bonnet nuts. Proper tightening tool shall be used for tightening.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

4. VALVE PASSING Valve passing is mainly because of damaged sealing surfaces, due to entrapment of foreign particle between wedge / disc and body seat. The same is to be attended by lapping of both the body and wedge / disc seat. It is preferable to attend the valves immediately after steam blowing, in case the valves are involved during steam blowing operation 5. Actuator setting: All Motorised Valves are set at BHEL for the required Torque/ Limit values and shall not be disturbed at site. These Values can be altered only by trained personnel when essential. All gate valves of size 100mm and above and pressure rating 1500 CL and above shall be set for POSITION SEATING . i.e, valve closing shall be by CLOSE POSITION limit switch trip only. The close Torque limit shall be connected as back up/parallel connection. Valve Opening shall be by OPEN POSITION Limit switch trip. All other gate , globe and regulating valves shall be set for TORQUE SEATING only. i.e, valve closing shall be by CLOSE TORQUE limit switch trip ony. The close position limit should NOT be connected as back up/parallel connection. Valve Opening shall be by OPEN POSITION Limit switch trip. For all Gate valves the during initial 5% opening, of the valve from its close position, the OPEN TORQUE LIMIT SWITCH should be bypassed to ensure smooth opening of the vale. Thermostat and Over load relay (OLR) should be connected to the motor control circuit. 6. Valve Jamming. Actuator setting are to be done as per the above recommendations and set to the recommended opening and closing torque values ,other wise it can lead to valve jamming. For actuator wiring and torque /position limit switch setting refer wiring diagram 4.V.MISC. 90721 Rev 11 indicated in the O&M. IMPORTANT NOTE : Operation of the valves continuously under leaking/ passing condition can lead to severe damages/erosion on the stuffing box/gland bore area, valve/bonnet sealing surfaces and body, wedge/disc seat sealing surfaces. At this stage simple replacement of packing/self sealing ring/sw gasket and lapping of the seats will not solve the problem. Valve parts like body, bonnet disc, wedge might be required to be reworked (or) replaced, which is a costly and time consuming work. Hence, all the valve leakage/passing should be attended immediately as soon as it is noticed. Similarly, whenever valves are dismantled, serviced and reassembled, new packing & gaskets are to be used for assembly.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

VALVE ACTUATOR SETTING PROCEDURE

Ref: VAL/ACT_SETPROC/Rev:02

1.0 Open Limit switch setting: In open direction the stem movement shall be terminated (stopped) by open limit switch OLS1. While setting the OLS1 the following points shall be taken care. 1. When the actuator supply is tripped by limit switch, the stem will move a little further distance before coming to stop. This distance (say inertia distance) shall be measured by trial and error, as this varies from actuator to actuator. 2. The stem shall not hit the back seat when fully open. The clearance needed from back seat (say Back seat clearance) is given below for various valves.
Valve TOA Valve of 1500C & above and size 21/2 and above Forged Steel Valves - size 2 & below Cast Steel Valves size 2 & above Back seat clearance 8mm 1 mm 3 mm

1.1. Setting procedure: 1. Open the valve with hand wheel such that the stem stops by touching the back seat and no more opening is possible. 2. Rotate the hand wheel in close direction move the valve stem to get the back seat clearance through a distance as indicated above. Mark this point on the stem. 3. Now close the valve little further for a rough inertia distance. Now set the open limit switch (OLS1) at this point. 4. Connect that actuator as per the wiring diagram enclosed. Now adjust the OLS1 to the correct inertia distance by trial, so that the stem stops at back seat clearance mark on the stem. 2.0 Close Limit switch setting: Close limit switches are set for two purpose 1. For tripping the actuator in close direction: 2. For bypassing the OTS during the initial opening. The setting requirements for Position seated valves and torque seated valves are different as given below.
Valve Position seating valves: TOA Gate Valves of 1500C & above and size 4 and above Torque seating valves: All other valves Close trip setting CLS1 setting required Torque Bypass setting CLS1 setting required

CLS1 setting required, but it should not be used in circuit as back up.

CLS1 setting required

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

2.2 Position seated valve: While setting the CLS1 the following points shall be taken care. 1. When the actuator supply is tripped by limit switch, the valve will move a little further distance before coming to stop. This distance (say inertia distance) shall be measured by trial and error , as this varies from actuator to actuator. 2. The valve shall not have metal to metal contact when fully closed. The clearance needed from bottom position (say Close seat clearance) is given below for various valves.
Valve Close seat clearance TOA Valve of 1500C & above and size 4 to 6 5mm TOA Valve of 1500C & above and size 8 to 10 7mm TOA Valve of 1500C & above and size 12 and above 9mm

2.2.1 Setting procedure: 1. Close the valve with hand wheel such that the stem stops and no further movement is possible. 2. In open direction move the stem to get the close seat clearance. Mark this point on the stem. 3. Now open the valve little further for a rough inertia distance. Now set the Close limit switch (CLS1) at this point. 4. Connect that actuator as per the wiring diagram enclosed. Now adjust the CLS1 to the correct inertia distance by trial, so that the valve stops at Close seat clearance mark on the stem. 5. This same CLS1 setting can be used for bypassing the OTS during initial opening. Hence no separate setting of close limit switch is required. 2.3 Torque seated valve: Torque seated valves are closed by torque by torque limit switches. The position limit switches are not used in the closing circuit. Hence the CLS1 is to be set only for bypassing the OTS during initial opening. The distance from close seat to which the CLS1 is set is given below.
Valve Bypass clearance Forged Steel Valves size 2 & below: 2 mm Cast Steel Valves size 2 & above: 5 mm

2.3.1 Setting procedure: 1. Close the valve with hand wheel such that the stem stops on full close and no further movement is possible.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

2. In open direction, rotate the hand wheel to move the valve stem to get the Bypass clearance. Now set the Close limit switch (CLS1) at this point. 3.0 Aux. Limit switch (Intermediate limit switch) setting. Aux. Limit switches are used for indication of end position. They may also be used for any intermediate position indication/interlock as required by customer. It is necessary to set these limit switches at respective end position to avoid any ambiguity at site. 1. Procedure for setting of aux. Limit switch for open direction (OLS2) is same as that of OLS1, and the OLS2 switch is to be set at the same position of OLS1. 2. Procedure for setting of aux. Limit switch for close direction (CLS2) is same as that of CLS1, and the CLS2 switch is to be set at the same position of CLS1. 4.0 Torque switch setting The open torque switch OTS and close torque switch CTS are to be set to the value given in VAD. 5.0 Dial Position Indicator setting. The full close/open position of dial position indicator shall be set at the point where the valve stem comes to a complete stop after being tripped under normal conditions through limit/torque switch in the corresponding direction. EPT if applicable also to be set to the same position as above. The above settings are diagrammatically represented in Set Point diagram enclosed. The test setup for actuators without integral starter shall be as per wiring diagram Suggested wiring diagram for actuator without integral starter enclosed..

Encl: 1. Set point diagram CON:ED:0118 Rev:01 2. Suggested wiring diagram for actuator without integral starter CON:ED:0117 REV:01.

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES

BHARAT HEAVY ELECTRICALS LIMITED WRITE-UP ON CONVENTIONAL VALVES