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Stopping and starting flow Reduce or increase a flow Controlling the direction of flow Regulating a flow or process pressure Relieve a pipe system of a certain pressure
There are many valve designs, types and models, with a wide range of industrial applications. All satisfy one or more of the functions identified above. Valves are expensive items, and it is important that a correct valve is specified for the function, and must be constructed of the correct material for the process liquid.
CLASSIFICATION OF VALVES
The following are some of the commonly used valve classifications, based on mechanical motion:
Linear Motion Valves. The valves in which the closure member, as in gate, globe, diaphragm, pinch, and lift check valves, moves in a straight line to allow, stop, or throttle the flow. Rotary Motion Valves. When the valve-closure member travels along an angular or circular path, as in butterfly, ball, plug, eccentric- and swing check valves, the valves are called rotary motion valves.
Quarter Turn Valves. Some rotary motion valves require approximately a quarter turn, 0 through 90, motion of the stem to go to fully open from a fully closed position or vice versa.
Classification of valves based on motion Valve types Gate Valve Globe valve Plug valve Ball valve Butterfly valve Swing check valve Linear motion x x x x x x x x x Rotary motion Quarter turn
If you can't explain it simply, you don't understand it well enough. Albert Einstein
x x x x
CLASS RATINGS
Pressure-temperature ratings of valves are designated by class numbers. ASME B16.34, ValvesFlanged, Threaded, and Welding End is one of the most widely used valve standards. It defines three types of classes: standard, special, and limited. ASME B16.34 covers Class 150, 300, 400, 600, 900, 1500, 2500, and 4500 valves.
VALVE BODY
The Valve body is the first boundary of a pressure valve. He serves as the main element of a valve assembly because it is the framework that holds all the parts together. The valve-body ends are designed to connect the valve to the piping or equipment nozzle by different types of end connections, such as butt or socket welded, threaded or flanged. Valve bodies are cast or forged in a variety of forms and each component have a specific function and constructed in a material suitable for that function.
VALVE TRIM
If you can't explain it simply, you don't understand it well enough. Albert Einstein
Valve's trim is a collective name for the replaceable parts, in a valve. A typically valve design includes a disk, seat, stem, and sleeves needed to guide the stem.
VALVE DISK
The disc is the part which allows, throttles, or stops flow, depending on its position. In the case of a plug or a ball valve, the disc is called plug or a ball. The disk is the third most important primary pressure boundary. With the valve closed, full system pressure is applied across the disk, and for this reason, the disk is a pressure related component. Disks are usually forged, and in some designs, hard surfaced to provide good wear properties. Most valves are named, according to the design of their disks.
VALVE SEAT(S)
A valve may have one or more seats. In the case of a globe or a swing-check valve, there is usually one seat, which forms a seal with the disc to stop the flow. In the case of a gate valve, there are two seats; one on the upstream side and the other on the downstream side. A gate valve disc has two seating surfaces that come in contact with the valve seats to form a seal for stopping the flow. The seat ensure the seating surface for the disk. For a good sealing, a fine surface finish from the seating area is necessary. In some designs, the body is machined to serve as the seating surface, in other designs, forged seal rings are threaded or welded to the body. To improve the wear resistance of the seat or seal rings, the surface is often hard faced.
VALVE STEM
The valve stem provides the necessary movement to the disc, plug or the ball for opening or closing the valve, and is responsible for the proper positioning of the disk. It is connected to the valve handwheel, actuator, or the lever at one end and on the other side to the valve disc. In gate or globe valves, linear motion of the disc is needed to open or close the valve, while in plug, ball and butterfly valves, the disc is rotated to open or close the valve. Stems are usually forged, and connected to the disk by threaded or other techniques. To prevent leakage, in the area of the seal, a fine surface finish of the stem is necessary. There are five types of valve stems:
Rising Stem with Outside Screw and Yoke The exterior of the stem is threaded, while the portion of the stem in the valve is smooth. The stem threads are isolated from the flow medium by the stem packing. Two different styles of these designs are available; one with the handwheel attached to the stem, so they can rise together, and the other with a threaded sleeve that causes the stem to rise through the handwheel. This type of valve is indicated by "O. S. & Y." is a common design for NPS 2 and larger valves.
Rising Stem with Inside Screw If you can't explain it simply, you don't understand it well enough. Albert Einstein
The threaded part of the stem is inside the valve body, and the stem packing along the smooth section that is exposed to the atmosphere outside. In this case, the stem threads are in contact with the flow medium. When rotated, the stem and the handwheel to rise together to open the valve.
Nonrising Stem with Inside Screw The threaded part of the stem is inside the valve and does not rise. The valve disc travels along the stem, like a nut if the stem is rotated. Stem threads are exposed to the flow medium, and as such, are subjected to the impact. That is why this model is used when space is limited to allow linear movement, and the flow medium does not cause erosion, corrosion or abrasion of the stem material.
Sliding Stem This valve stem does not rotate or turn. It slides in and out the valve to open or close the valve. This design is used in hand-operated lever rapid opening valves. It is also used in control valves are operated by hydraulic or pneumatic cylinders.
Rotary Stem This is a commonly used model in ball, plug, and butterfly valves. A quarter-turn motion of the stem open or close the valve.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
An important aspect of the life time of a valve is the sealing assembly. Almost all valves, like standard Ball, Globe, Gate, Plug and Butterfly valves have their sealing assembly based upon shear force, friction and tearing. Therefore valve packaging must be properly happen, to prevent damage to the stem and fluid or gas loss. When a packing is too loose, the valve will leak. If the packing is too tight, it will affect the movement and possible damage to the stem.
VALVE YOKE
A Yoke connects the valve body or bonnet with the actuating mechanism. The top of the yoke holding a yoke nut, stem nut, or yoke bushing and the valve stem passes through it. A yoke usually has openings to allow access to the stuffing box, actuator links, etc.. Structurally, a yoke must be strong enough to withstand forces, moments, and torque developed by the actuator.
VALVE ACTUATOR
Hand-operated valves are usually equipped with a handwheel attached to the valve's stem or yoke nut which is rotated clockwise orcounter clockwise to close or open a valve. Globe and Gate Valves are opened and closed in this way. Hand-operated, quarter turn valves, such as Ball, Plug or Butterfly, has a lever for actuate the valve. There are applications where it is not possible or desirable, to actuate the valve manually by handwheel or lever. These applications include:
Large valves that must be operated against high hydrostatic pressure Valves they must be operated from a remote location When the time for opening, closing, throttle or manually controlling the valve is longer, than required by system-design criteria
These valves are usually equipped with an actuator. An actuator in the broadest definition is a device that produces linear and rotary motion of a source of power under the action of a source of control. Basic actuators are used to fully open or fully close a valve. Actuators for controlling or regulating valves are given a positioning signal to move to any intermediate position. There a many different types of actuators, but the following are some of the commonly used valve actuators:
Gear Actuators Electric Motor Actuators Pneumatic Actuators Hydraulic Actuators Solenoid Actuators
If you can't explain it simply, you don't understand it well enough. Albert Einstein
1. Body 2. Bonnet 3. Seat(s) 4. Disk 5. Stem 6. Back seat 7. Packing 8. Gland 9. Gland follower 10. Yoke 11. Stem nut 12. Hand wheel
1. Body 2. Bonnet 3. Seat(s) 4. Disk (blue part is threaded) 5. Stem (gray part is threaded) 6. Thrust bush and washer 7. Packing 8. Gland 9. Gland follower 10. Hand wheel
If you can't explain it simply, you don't understand it well enough. Albert Einstein
Globe Valve
1. Body 2. Bonnet 3. Seat ring 4. Disk 5. Disk locknut 6. Disk washer 7. Stem 8. Back seat 9. Packing 10. Gland 11. Gland follower 12. Set screw 13. Stem nut 14. Hand wheel
If you can't explain it simply, you don't understand it well enough. Albert Einstein
If you can't explain it simply, you don't understand it well enough. Albert Einstein
GATE VALVE
Gate Valves are primarily designed to start or stop flow, and when a straight-line flow of fluid and minimum flow restriction are needed. In service, these valves generally are either fully open or fully closed. The disk of a gate valve is completely removed when the valve is fully open; the disk is fully drawn up into the valve bonnet. This leaves an opening for flow through the valve at the same inside diameter as the pipesystem in which the valve is installed. A gate valve can be used for a wide range of liquids and provides a tight seal when closed. Advantages of using gate valves:
Good shutoff features Gate Valves are bidirectional and therefore they
can be used in two directions Pressure loss through the valve is minimal
They can not be quickly opened or closed Gate Valves are not suitable for regulate or
If you can't explain it simply, you don't understand it well enough. Albert Einstein
10
disc with a cut around the perimeter to improve the ability to correct mistakes or changes in the angle between the seats. The reduction will vary in size, shape and depth. A shallow, narrow cut gives little flexibility recess, but leaves retains little material strength. in the A deeper and wider cut, or cast-in middle, which allows more flexibility, but compromises strength.
wedge
selfaligning to both seats sides. This construction which seats between the tapered seats in the valve body. This type of wedge is suitable for the treatment of non-condensing gases and liquids at normal temperatures, particularly corrosive liquids.
For a valve of the rising stem type, the stem will rise above the handwheel if the valve is opened. This happens, because the stem is threaded and mated with the bushing threads of a yoke. A yoke is an integral part from a rising stem valve and is mounted to the bonnet. For a valve of the non rising stem type, there is no upward stem movement if the valve is opened. The stem is threaded into the disk. As the handwheel on the stem is rotated, the disk travels up or down the stem on the threads while the stem remains vertically stationary. The two links (on the right above) to detailed (large) drawings of both stem types, tell you more, as what I can tell you here.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
11
pressed into position and seal welded to the valve body. The latter form of construction is recommended for higher temperature service. Integral seats provide a seat of the same material of construction as the valve body while the pressedin or threaded-in seats permit variation. Rings with hard facings may be supplied for the application where they are required.
GLOBE VALVE
A globe valves is a linear motion valve and are primarily designed to stop, start and regulate flow. The disk of a globe valve can be totally removed from the flowpath or it can completely close the flowpath. The fundamental principle of the globe valve operation is the perpendicular motion of the disk away from the seat. This ensures that the ring-shaped space between the disk and seat ring gradually close as the valve is closed. This property gives a globe valve reasonably good throttling capability. Therefore, the globe valve can be used for starting and stopping flow and to regulate flow. Advantages of using globe valves:
The major drawbacks to the use of a globe valve are: Higher pressure drop compared to a gate valve Large valve sizes require considerable power or a larger actuator to operate
Z-Body
Y-Body
Angle-Body
If you can't explain it simply, you don't understand it well enough. Albert Einstein
12
There are three primary body designs for globe valves, namely: Z-body, Y-body and Angle body.
Z-body
line.
design
is
the
most
common
body
type,
with
Z-shaped
diaphragm.
The horizontal setting of the seat allows the stem and disk to travel perpendicular to the horizontal
Y-body design is an alternative for the high pressure drop, inherent in globe valves.
Seat and stem are angled at approximately 45 degrees, what gives a straighter flowpath at full opening.
Angle-body
degrees turn.
design
is
modification
of
the
basic
Z-type
globe
valve.
The ends of this globe valve are at an angle of 90 degrees, and fluid flow occurs with a single 90
If you can't explain it simply, you don't understand it well enough. Albert Einstein
13
BALL VALVE
A ball valve is a quarter-turn rotational motion valve that uses a ball-shaped disk to stop or start flow. If the valve is opened, the ball rotates to a point where the hole through the ball is in line with the valve body inlet and outlet. If the valve is closed, the ball is rotated so that the hole is perpendicular to the flow openings of the valve body and the flow is stopped. Advantages of using ball valves:
Quick quarter turn on-off operation Tight sealing with low torque Smaller in size than most other valves
Disadvantages of ball valves: Conventional ball valves have poor throttling properties In slurry or other applications, the suspended particles can settle and become trapped in body cavities causing wear, leakage, or valve failure.
Top entry ball valves allow access to valve internals for maintenance by removal of the valve bonnet-cover. It is not required to be removed valve from the pipe system. Split body ball valves consists of a two parts, where one part is smaller as the other. The ball is inserted in the larger body part, and the smaller body part is assembled by a bolted connection.
The valve ends are available as butt welding, socket welding, flanged, threaded and others.
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sealing ability. The disadvantage of soft-seat materials (elastomeric materials) is, that they are not can be used in high temperatures processes. For example, fluorinated polymer seats can be used for service temperatures from 200 (and larger) to 230C and higher, while graphite seats may be used for temperatures from ? to 500C and higher.
Air, gaseous, and liquid applications Drains and vents in liquid, gaseous, and other fluid services Steam service
PLUG VALVE
A plug valve is a quarter-turn rotational motion valve that use a tapered or cylindrical plug to stop or start flow. In the open position, the plug-passage is in one line with the inlet and outlet ports of the valve body. If the plug 90 is rotated from the open position, the solid part of the plug blocks the port and stops flow. Plug valves are similar to ball valves in operation. Advantages of using plug valves:
Quick quarter turn on-off operation Minimal resistance to flow Smaller in size than most other valves
Disadvantages of plug valves: Requires a large force to actuate, due to high friction. NPS 4 and larger valves requires the use of an actuator. Reduced port, due to tapered plug.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
15
Lubricated plug valves are provided with a cavity in the middle along there axis. This cavity is closed at the bottom and fitted with a sealant-injection fitting at the top. The sealant is injected into the cavity, and a check valve below the injection fitting prevents the sealant from flowing in the reverse direction. The lubricant in effect becomes a structural part of the valve, as it provides aflexible and renewable seat.
Nonlubricated Plug Valves contain an elastomeric body liner or a sleeve, which is installed in the body cavity. The tapered and polished plug acts like a wedge and presses the sleeve against the body. Thus, the nonmetallic sleeve reduces the friction between the plug and the body.
Diamond port plug has a diamond-shaped port through the plug and they are venturi restricted flow types. This design is suitable for throttling service.
Air, gaseous, and vapor services Natural gas piping systems Oil piping systems Vacuum to high-pressure applications
BUTTERFLY VALVE
A butterfly valve is a quarter-turn rotational motion valve, that is used to stop, regulate, and start flow. Butterfly valves are easy and fast to open. A 90 rotation of the handle provides a complete closure or opening of the valve. Large Butterfly valves are usually equipped with a so-called gearbox, where the handwheel by gears is connected to the stem. This simplifies the operation of the valve, but at the expense of speed. If you can't explain it simply, you don't understand it well enough. Albert Einstein
16
Compact design requires considerably less space, compared to other valves Light in weight Quick operation requires less time to open or close Available in very large sizes Low-pressure drop and high-pressure recovery
Disadvantages of butterfly valves Throttling service is limited to low differential pressure Cavitation and choked flow are two potential concerns Disc movement is unguided and affected by flow turbulence
Cooling water, air, gases, fire protection etc. Slurry and similar services Vacuum service High-pressure and high-temperature water and steam services
If you can't explain it simply, you don't understand it well enough. Albert Einstein
17
CHECK VALVE
Check valves are "automatic" valves that open with forward flow and close with reverse flow. The pressure of the fluid passing through a system opens the valve, while any reversal of flow will close the valve. Exact operation will vary depending on the type of check valve mechanism. Most common types of check valves are swing, lift (piston and ball), butterfly, stop and tiltingdisk.
Swing check valve A basic swing check valve consists of a valve body, a bonnet, and a disk that is connected to a hinge. The disk swings away from the valve-seat to allow flow in the forward direction, and returns to valve-seat when upstream flow is stopped, to prevent backflow. The disc in a swing type check valve is unguided as it fully opens or closes. There are many disk and seat designs available, in order to meet the requirements of different applications. The valve allows full, unobstructed flow and automatically closes as pressure decreases. These valves are fully closed when flow reaches zero, in order to prevent backflow. Turbulence and pressure drop in the valve are very low.
Lift check valve The seat design of a lift-check valve is similar to a globe valve. The disc is usually in the form of a piston or a ball. Lift check valves are particularly suitable for high-pressure service where velocity of flow is high. In lift check valves, the disc is precisely guided and fits perfectly into the dashpot. Lift check valves are suitable for installation in horizontal or vertical pipe-lines with upward flow. Flow to lift check valves must always enter below the seat. As the flow enters, the piston or ball is raised within guides from the seat by the pressure of the upward flow. When the flow stops or reverses, the piston or ball is forced onto the seat of the valve by both the backflow and gravity.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
18
Leakage from the valve gland or stuffing box is normally a concern for the maintenance or plant
engineer. This leakage means: a) Loss of material b) Pollution to the atmosphere c) Dangerous for plant employees.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
19
For example, take the case of a steam leakage through the valve gland. At 150 PSI, a clearance of just 0.001" through the gland will mean a leak at the rate of 25 lb/hour. This equates to a loss of USD 1.2 per eight hour shift, or USD 1,100 per year. Similarly, a tiny drop of 0.4 mm diameter per second results in a waste of about 200 litres per year of costly oil or solvent. This leakage can be reduced considerably by using the bellow seal valve. This article will now consider the construction and operation of the bellow seal.
Bellow construction
The bellow cartridge is welded to both the valve bonnet and the valve stem. The bellow cartridge has a number of convolutions and these convolutions become compressed or expanded depending upon the movement of valve stem. (Scientifically speaking the bellow gets compressed when the valve is in the open position and expanded when the valve is in the closed condition). It is important to properly install the valve bodies. The bellow can be sealed to the valves in two different ways. Firstly, the bellow can be welded to the valve stem at the top and the valve body on the bottom. In this case the process fluid is contained inside the bellow or in second method the bellow is welded to the valve stem at the bottom and the body on the top. In this case the process fluid is contained in the annular region between the valve bonnet and bellow (from the outside). The bellow is a critical component and forms the heart of the bellow seal valves. To avoid any twisting of the bellow the valve must have a stem with linear movement only. This can be achieved using a socalled sleeve-nut at the yoke portion of the valve bonnet. A handwheel is fitted onto the sleeve-nut which effectively transfers a rotary motion of the handwheel into a linear motion in the valve stem.
Bellow types
There are two main types of bellow: the Forged Bellow and the Welded Bellow. Formed-type bellows are made from rolling a flat sheet (thin wall foil) into a tube which is then longitudinally fusion welded. This tube is subsequently mechanically or hydrostatically formed into a bellow with rounded and widely spaced folds. The welded leaf type bellow is made by welding washer-like plates of thin metal together at both the inner and outer circumference of the washers - like plates. A welded leaf bellow has more folds per unit length as compared to forged bellows. Thus, for the same stroke length, forged bellows are two to three times longer than their welded leaf counterparts. Reportedly, mechanically forged bellows fail at random spots, while the welded leaf usually fails at or near a weld. To ensure full penetration of bellow ends and end coller welding it is advisable to fabricate using micro plasma welding.
Bellow design
The multi-ply bellow design is preferred for handling higher pressure fluids (generally two or three plies of the metal wall). A two ply bellow can increase its pressure rating by 80% to 100% as If you can't explain it simply, you don't understand it well enough. Albert Einstein
20
compared to a single ply bellow of the same thickness. Alternatively, if a single ply bellow of a thickness equivalent to a pressure rating of a two ply bellow is used, the stroke length is reduced. Thus, a multi-ply bellow design offers a distinct advantage over a single ply bellow. It is clear that the bellow is subject to metal fatigue and this fatigue can induce weld failure. The bellow fatigue life is affected by the material of construction, fabrication technique, stroke length and stroke frequency, in addition to the usual parameters such as fluid temperature and pressure.
Bellow materials
The most popular stainless steel bellow material is AISI 316Ti which contain Titanium to withstand high temperatures. Alternatively, Inconel 600 or Inconel 625 improve fatigue strength and corrosion resistance as compared with stainless steel bellows. Similarly, Hastalloy C-276 offers greater corrosion resistance and fatigue strength than Inconel 625. Fatigue resistance can be improved by using a multiply bellows system and reducing the stroke length; this can significantly increase the bellow service life.
Valve options
The most common valve types to be fitted with bellow seals are the gate and globe designs (see Figure 1).These are very suited for use with bellows due to their internal construction and axial movement of the valve stem. Based on available information, it seems that current bellow seal valves range in size from 3 mm NB to 650 mm NB. Pressure ratings are available in from ANSI 150# to 2500#. Material options for the valves include carbon steel, stainless steel and exotic alloys.
Applications
Heat transfer media: hot oil is commonly used in industries such as synthetic fibres / POY (Partially Oriented Yarn). However, there is always a risk of fire due to hot oil spillage on highly inflammable chemicals. Here, bellow seal valves can stop the leakage. Vacuum / ultra high vacuum: some applications require a vacuum pump to continually extract air from a pipeline. Any conventional valves installed on the pipeline can allow external air to enter the pipeline thorough the valve stuffing box. Hence the bellow seal valve is the only solution to prevent air from passing through the stuffing box. Highly hazardous fluids: for media such as chlorine (see Figure 2), hydrogen, ammonia and phosgene, the bellow seal valve is an ideal design as leakage through the gland is totally eliminated. Nuclear plant, heavy water plant: in instances where radiation leakage is to be prevented at all times, the bellow seal valve is the ultimate choice. Costly fluids: in some applications leaks need to be avoided simply because of the high cost of the fluid. Here, an economic assessment often favours the use of bellow seal valves. Environmental standards: around the world, standards regarding emissions and the environment are getting more stringent day by day. It can therefore be difficult for companies to expand within existing If you can't explain it simply, you don't understand it well enough. Albert Einstein
21
premises. With the use of bellow seal valves, expansion without additional environmental damage is possible.
A/B. Bonnet tendency to move up or down as pressure changes C. System pressure D. Sealing forces due to pressure
The higher the internal pressure, the greater the sealing force. Easy dismantling is made possible
by dropping the bonnet assembly into the body cavity and driving out the four-segmental thrust rings by means of a push pin. Relying on fairly simple design principles, pressure seal valves have proven their capability to handle increasingly demanding fossil and combined-cycle steam isolation applications, as designers
If you can't explain it simply, you don't understand it well enough. Albert Einstein
22
continue to push boiler, HRSG, and piping system pressure/temperature envelopes. Pressure seal valves are typically available in size ranges from 2 inches to 24 inches and ASME B16.34 pressure classes from #600 to #2500, although some manufacturers can accommodate the need for larger diameters and higher ratings for special applications. Pressure seal valves are available in many material qualities such as A105 forged and Gr.WCB cast, alloy F22 forged and Gr.WC9 cast; F11 forged and Gr.WC6 cast, austenitic stainless F316 forged and Gr.CF8M cast; for over 500C, F316H forged and suitable austenitic cast grades. The pressure seal design concept can be traced back to the mid-1900s, when, faced with ever increasing pressures and temperatures (primarily in power applications), valve manufacturers began designing alternatives to the traditional bolted-bonnet approach to sealing the body/bonnet joint. Along with providing a higher level of pressure boundary sealing integrity, many of the pressure seal valve designs weighed significantly less than their bolted bonnet valve counterparts.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
23
Now let's look at the pressure seal joint detailed in Figure 2. Note the differences in the respective body/bonnet joint configurations. Most pressure seal designs incorporate "bonnet take-up bolts" to pull the bonnet up and seal against the pressure seal gasket. This in turn creates a seal between the gasket and the inner diameter (I.D.) of the valve body. A segmented thrust ring maintains the load. The beauty of the pressure seal design is that as system pressure builds, so does the load on the bonnet and, correspondingly, the pressure seal gasket. Therefore, in pressure seal valves, as system pressure increases, the potential for leakage through the body/bonnet joint decreases. This design approach has distinct advantages over bolted bonnet valves in main steam, feedwater, turbine bypass, and other power plant systems requiring valves that can handle the challenges inherent in high-pressure and temperature applications. But over the years, as operating pressures/temperatures increased, and with the advent of peaking plants, this same transient system pressure that aided in sealing also played havoc with pressure seal joint integrity.
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maintained as a function of tight machining tolerances on component parts, means of providing the requisite torque to open/close as a function of gears or actuation, and selection/ application of proper materials for seating surfaces. Cobalt, nickel, and iron-based hardfacing alloys are utilized for optimal wear resistance of the wedge/disc and seat ring seating surfaces. Most commonly used are the CoCr-A (e.g., Stellite) materials. These materials are applied with a variety of processes, including shielded metal arc, gas metal arc, gas tungsten arc, and plasma (transferred) arc. Many pressure seal globe valves are designed having integral hardfaced seats, while the gate valve and check valves typically have hardfaced seat rings that are welded into the valve body.
VALVING TERMINOLOGY
If you have dealt with valving for any length of time, you've probably noticed valve manufacturers are not overly creative with the terms and vernacular used in the business. Take for example, "bolted bonnet valves." The body is bolted to the bonnet to maintain system integrity. For "pressure seal valves," system pressure aids the sealing mechanism. For "stop/check valves," when the valve stem is in the closed position, flow is mechanically stopped, but when in the open position, the disc is free to act to check a reversal of flow. This same principle applies to other terminology used for design, as well as valve types and their component parts.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
25
Face to Face and End to End dimensions of RF valves according to ASME B16.10 class 150
NPS
1/2 3/4 1 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Gate Solid Wedge and Double Disc 108 117 127 140 165 178 190 203 229 254 267 292 330 356 381 406 432 457 508 559 610 610
Gate Conduit
Globe and Lift Check 108 117 127 140 165 203 216 241 292 356 406 495 622 698 787 914
Swing Check
Ball Long Pattern 108 117 127 140 165 178 190 203 229 394 457 533 610 686 762 864 914 1067
Ball Short Pattern 108 117 127 140 165 178 190 203 229 267 292 330 356 381 406
A
140 165 178 190 203 229 254 267 292 330 356 108 117 127 140 165 203 216 241 292 330 356 495 622 698 787 864 978 978 1067 1295 1295 1448 1524
178 190 203 229 267 292 330 356 381 406 432 457 508 508 559 610 660 711 762 813
305 381 394 457 533 610 686 762 864 914 1067
1016 1956
711
If you can't explain it simply, you don't understand it well enough. Albert Einstein
26
Face to Face and End to End dimensions of RF valves according to ASME B16.10 class 300
NPS
1/2 3/4 1 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Gate Solid Wedge Double Disc and Conduit 140 (1) 152 (1) 165 (1) 178 (1) 190 216 241 282 305 381 403 419 457 502 762 838 914 991 1092 1143 1245 1346 1397 1524 1626 1727
Swing Check
Ball Long Pattern 140 152 165 178 190 216 241 282 305 403 502 568 648 762 838 914 991 1092 1143 1245 1346 1397 1524 1626 1727
Ball Short Pattern 140 152 165 178 190 216 241 282 305 403 419 457 502 572 610 660 711 813
A
159 (6) 190 (6) 216 241 282 305 403 419 457 502 762 (4) 838 (4) 914 (4) 991 (4) 1092 (4) 1143 (4) 1245 (4) 1346 (4) 1397 (4) 1524 (4) 1626 (4) 1727 (4) 403 502 568 711 762 838 914 991 1092 1143 1245 1346 1397 1524 1626 1727 152 178 203 216 229 267 292 318 356 400 444 559 622 711 216 229 241 267 292 318 356 400 444 533 622 711 838 864 978 1016 1118 1346 1346 1499 1594
2083
If you can't explain it simply, you don't understand it well enough. Albert Einstein
27
Face to Face and End to End dimensions of RF valves according to ASME B16.10 class 600
NPS
1/2 3/4 1 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Gate Solid Wedge Double Disc and Conduit 140 (1) 152 (1) 165 (1) 178 (1) 190 216 241 282 305 381 403 419 457 502 762 838 914 991 1092 1143 1245 1346 1397 1524 1626 1727
Swing Check
Ball Long Pattern 140 152 165 178 190 216 241 282 305 403 502 568 648 762 838 914 991 1092 1143 1245 1346 1397 1524 1626 1727
Ball Short Pattern 140 152 165 178 190 216 241 282 305 403 419 457 502 572 610 660 711 813
A
159 (6) 190 (6) 216 241 282 305 403 419 457 502 762 (4) 838 (4) 914 (4) 991 (4) 1092 (4) 1143 (4) 1245 (4) 1346 (4) 1397 (4) 1524 (4) 1626 (4) 1727 (4) 403 502 568 711 762 838 914 991 1092 1143 1245 1346 1397 1524 1626 1727 152 178 203 216 229 267 292 318 356 400 444 559 622 711 216 229 241 267 292 318 356 400 444 533 622 711 838 864 978 1016 1118 1346 1346 1499 1594
2083
If you can't explain it simply, you don't understand it well enough. Albert Einstein
28
Face to Face and End to End dimensions of RF valves according to ASME B16.10 class 900
NPS
1/2 3/4 1 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Gate Solid Wedge Double Disc and Conduit Long Pattern 165 (1) 190 (1) 216 229 241 292 330 356 432 508 559 660 787 838 889 991 1092 1194 1295 1397 1448 1549 1651 1778 (2) 1930 (2) 2083 (2)
A
216 (3) 229 (3) 241 292 330 356 432 559 660 787 838 889 991 1092 (4) 1194 (4) 1295 (4) 1397 (4) 1448 (4) 1651 1778 1930 2083 (4) (4) (4) (4) 165 190 216 229 241 292 330 356 432 508 559 660 787 838 889 (5) 991 (5) 1092 (5) 1194 (5) 1295 (5) 1397 (5) 1448 (5) 1600 (5) 1651 (5) 165 190 216 229 241 292 330 356 432 559 660 787 838 889 991 1092 1194 1295 1397 1448 1549 1651 1778 1930 2083
2083 (5)
If you can't explain it simply, you don't understand it well enough. Albert Einstein
29
Face to Face and End to End dimensions of RF valves according to ASME B16.10 class 1500
NPS
3/4 1 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 22 24
A
254 (1) 279 (1) 305 (1) 368 419 381 457 559 610 737 838 965 1029 1130 1219 1321 1549 254 279 305 368 419 381 457 (3) (3) (3) (3) (3) (3) (4) 229 254 279 305 368 419 381 457 559 610 737 838 965 1029 1130 (5) 1219 (5) 1321 (5) 1549 (5) 254 279 305 368 419 381 457 610 737 838 965 1029 1130 1219 1321 1549
If you can't explain it simply, you don't understand it well enough. Albert Einstein
30
Face to Face and End to End dimensions of RF valves according to ASME B16.10 class 2500
NPS
1/2 3/4 1 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 22 24 General notes:
A
254 (1) 279 (1) 305 (1) 368 419 470 546 673 705 832 991 1130 1257 1384 1537 1664 1943 254 279 305 368 419 470 546 (3) (3) (3) (3) (3) (3) (4) 216 (7) 229 254 279 305 368 419 470 546 673 705 832 991 1130 1257 1384 (5) 1537 (5) 1664 (5) 1943 (5)
368 419 470 546 705 832 991 1130 1257 1384
Dimensions are in millimeters unless otherwise indicated. (1) = Solid wedge only. (2) = Double disc and conduit only. (3) = Regular pattern only. (4) = Venturi pattern only. (5) = Swing Check only. (6) = Short pattern only. (7) = Globe and Lift Check only. The face-to-face dimension for flanged valves is the distance between the extreme ends which are the gasket contact surfaces.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
31
End-to-End dimensions apply to flanged valves where the gasket contact surfaces are not located at the extreme ends of the valve. The distance between the extreme ends is described as the endto-end dimension and applies to flanged valves like: Ring Joint, large or small female and large or small groove
If you can't explain it simply, you don't understand it well enough. Albert Einstein
32
If you can't explain it simply, you don't understand it well enough. Albert Einstein
33
Inlet Isolation Valves a. Valves shall be full bore. ASME Section VIII Appendix M recommends the use of full area isolation
(stop) valves. Mandatory paragraph UG-135 (b)(1), of ASME Section VIII, requires that the opening through all pipe and fittings between a pressure vessel and its pressure-relief valve shall have the area of the pressure-relief device inlet. It is therefore recommended that the minimum flow area in the isolation valve be equal to or greater than the inlet area of the pressure-relief valve. The minimum flow area of the isolation valve and the inlet area of the pressurerelief valve can be obtained from the isolation valve manufacturer and the pressure-relief valve manufacturer.
b. Valves shall be suitable for the line service classification. c. Valves shall have the capability of being locked or carsealed open. d. When gate valves are used, they should be installed with stems oriented horizontally or, if this is
not feasible, the stem could be oriented downward to a maximum of 45 from the horizontal to keep the gate from falling off and blocking the flow.
e. A bleed valve should be installed between the isolation valve and the pressure-relief device to
enable the system to be safely depressurized prior to performing maintenance. This bleed valve can If you can't explain it simply, you don't understand it well enough. Albert Einstein
34
also be used to prevent pressure build-up between the pressure-relief device and the closed outlet isolation valve.
f. Consideration should be given to using an interlocking system between the inlet and outlet isolation
valves to assist with proper sequencing.
g. Consideration should be given to painting the isolation valve a special color or providing other
identification. When placing the pressure-relief device into service, it is recommended to gradually open the isolation valve. This ramping up of system pressure can help prevent unwanted opening of a valve seat due to the momentum of the fluid. The inlet valve must be open fully.
Outlet Isolation Valves a. Valves shall be full bore. ASME Section VIII Appendix M recommends the use of full area isolation
(stop) valves. To help minimize the built-up back pressure, it is recommended that the minimum flow area in the outlet isolation valve be equal to or greater than the outlet area of the pressure-relief valve. The minimum flow area of the outlet isolation valve and the outlet area of the pressure-relief valve can be obtained from the isolation valve manufacturer and the pressure-relief valve manufacturer respectively.
b. Valves shall be suitable for line service classification. c. Valves shall have the capability of being locked or carsealed open. This outlet isolation shall never
be closed while the vessel is in operation without using an inlet isolation valve that has first been closed with the space between the inlet isolation valve and the pressure-relief valve adequately depressured.
d. A bleed valve should be installed between the outlet isolation valve and pressure-relief device to
enable the system to be safely depressurized prior to performing maintenance. This bleed valve can also be used to prevent pressure build-up between the pressure-relief device and the closed outlet isolation valve.
e. Consideration should be given to using an interlocking system between the inlet and outlet isolation
valves to assist with proper sequencing.
f. Consideration should be given to painting the isolation valve a special color or providing other
identification. When the outlet isolation valve is used in conjunction with an inlet isolation valve, upon commissioning the pressurerelief device, the outlet isolation valve shall be opened fully prior to the inlet isolation valves.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
35
If you can't explain it simply, you don't understand it well enough. Albert Einstein
36
This causes an incremental change in force which overcompensates for the increase in spring force and causes the valve to open at a rapid rate. At the same time, the direction of the fluid flow is reversed and the momentum effect resulting from the change in flow direction further enhances lift. These effects combine to allow the valve to achieve maximum lift and maximum flow within the allowable overpressure limits. Because of the larger disc area exposed to system pressure after the valve achieves lift, the valve will not close until system pressure has been reduced to some level below the set pressure. The design of the control chamber determines where the closing point will occur. The difference between the set pressure and the closing point pressure is called blowdown and is usually expressed as a percentage of set pressure.
OTHER DESIGNS OF RELIEF VALVES Safety Valve. A safety valve is a pressure relief valve actuated
by inlet static pressure and characterized by rapid opening or pop action. (It is normally used for steam and air services.)
Low-Lift Safety Valve. A low-lift safety valve is a safety valve in which the disc lifts automatically
such that the actual discharge area is determined by the position of the disc.
Full-Lift Safety Valve. A full-lift safety valve is a safety valve in which the disc lifts automatically
such that the actual discharge area is not determined by the position of the disc.
Relief Valve. A relief valve is a pressure relief device actuated by inlet static pressure having a
gradual lift generally proportional to the increase in pressure over opening pressure. It may be provided with an enclosed spring housing suitable for closed discharge system application and is primarily used for liquid service.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
37
Safety Relief Valve. A safety relief valve is a pressure relief valve characterized by rapid opening or
pop action, or by opening in proportion to the increase in pressure over the opening pressure, depending on the application and may be used either for liquid or compressible fluid.
Conventional Safety Relief Valve. A conventional safety relief valve is a pressure relief valve
which has its spring housing vented to the discharge side of the valve. The operational characteristics (opening pressure, closing pressure, and relieving capacity) are directly affected by changes of the back pressure on the valve.
Balanced Safety Relief Valve. A balanced safety relief valve is a pressure relief valve which
incorporates means of minimizing the effect of back pressure on the operational characteristics (opening pressure, closing pressure, and relieving capacity).
Pilot-Operated Pressure Relief Valve. A pilotoperated pressure relief valve is a pressure relief valve
in which the major relieving device is combined with and is controlled by a self-actuated auxiliary pressure relief valve.
Power-Actuated Pressure Relief Valve. A poweractuated pressure relief valve is a pressure relief
valve in which the major relieving device is combined with and controlled by a device requiring an external source of energy.
Vacuum Relief Valve. A vacuum relief valve is a pressure relief device designed to admit fluid to
prevent an excessive internal vacuum; it is designed to reclose and prevent further flow of fluid after normal conditions have been restored.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
38
Terminology
The following definitions are taken from DIN 3320 but it should be noted that many of the terms and associated definitions used are universal and appear in many other standards. Where commonly used terms are not defined in DIN 3320 then ASME PTC25.3 has been used as the source of reference. This list is not exhaustive and is intended as a guide only; it should not be used in place of the relevant current issue standard:
Operating pressure (working pressure) is the gauge pressure existing at normal operating
conditions within the system to be protected.
Set pressure is the gauge pressure at which under operating conditions direct loaded safety
valves commence to lift.
Test pressure is the gauge pressure at which under test stand conditions (atmospheric
backpressure) direct loaded safety valves commence to lift.
Opening pressure is the gauge pressure at which the lift is sufficient to discharge the
predetermined flowing capacity. It is equal to the set pressure plus opening pressure difference.
Reseating pressure is the gauge pressure at which the direct loaded safety valve is re-closed. Built-up backpressure is the gauge pressure built up at the outlet side by blowing. Superimposed backpressure is the gauge pressure on the outlet side of the closed valve. Backpressure is the gauge pressure built up on the outlet side during blowing (built-up
backpressure + superimposed backpressure).
Accumulation is the increase in pressure over the maximum allowable working gauge pressure of
the system to be protected.
Opening pressure difference is the pressure rise over the set pressure necessary for a lift
suitable to permit the predetermined flowing capacity.
Reseating pressure difference is the difference between set pressure and reseating pressure. Functional pressure difference is the sum of opening pressure difference and reseating pressure
difference.
Operating pressure difference is the pressure difference between set pressure and operating
pressure.
Lift is the travel of the disc away from the closed position. Commencement of lift (opening) is the first measurable movement of the disc or the perception
of discharge noise.
Flow area is the cross sectional area upstream or downstream of the body seat calculated from
the minimum diameter which is used to calculate the flow capacity without any deduction for obstructions.
Flow diameter is the minimum geometrical diameter upstream or downstream of the body seat. Nominal size designation of a safety valve is the nominal size of the inlet.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
39
Theoretical flowing capacity is the calculated mass flow from an orifice having a cross sectional
area equal to the flow area of the safety valve without regard to flow losses of the valve.
Actual flowing capacity is the flowing capacity determined by measurement. Certified flowing capacity is actual flowing capacity reduced by 10%. Coefficient of discharge is the ratio of actual to the theoretical discharge capacity. Certified coefficient of discharge is the coefficient of discharge reduced by 10% (also known as
derated coefficient of discharge).
The following terms are not defined in DIN 3320 and are taken from ASME PTC25.3:
Blowdown (reseating pressure difference) - difference between actual popping pressure and
actual reseating pressure, usually expressed as a percentage of set pressure or in pressure units.
Cold differential test pressure the pressure at which a valve is set on a test rig using a test fluid
at ambient temperature. This test pressure includes corrections for service conditions e.g. backpressure or high temperatures.
Flow rating pressure is the inlet static pressure at which the relieving capacity of a pressure
relief device is measured.
Leak test pressure is the specified inlet static pressure at which a quantitative seat leakage test
is performed in accordance with a standard procedure.
Measured relieving capacity is the relieving capacity of a pressure relief device measured at the
flow rating pressure.
Rated relieving capacity is that portion of the measured relieving capacity permitted by the
applicable code or regulation to be used as a basis for the application of a pressure relieving device.
Overpressure is a pressure increase over the set pressure of a pressure relief valve, usually
expressed as a percentage of set pressure.
Popping pressure is the value of increasing static inlet pressure of a pressure relief valve at
which there is a measurable lift, or at which the discharge becomes continuous as determined by seeing, feeling or hearing.
Relieving pressure is set pressure plus overpressure. Simmer is the pressure zone between the set pressure and popping pressure. Maximum operating pressure is the maximum pressure expected during system operation. Maximum allowable working pressure (MAWP) is the maximum gauge pressure permissible at
the top of a completed vessel in its operating position for a designated temperature.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
40
Installation
Many valves are damaged when first placed in service because of failure to clean the connection properly when installed. Before installation, flange faces or threaded connections on both the valve inlet and the vessel and/or line on which the valve is mounted must be thoroughly cleaned of all dirt and foreign material. Because foreign materials that pass into and through safety valves can damage the valve, the systems on which the valves are tested and finally installed must also be inspected and cleaned. New systems in particular are prone to contain foreign objects that inadvertently get trapped during construction and will destroy the seating surface when the valve opens. The system should be thoroughly cleaned before the safety valve is installed. The gaskets used must be dimensionally correct for the specific flanges. The inside diameters must fully clear the safety valve inlet and outlet openings so that the gasket does not restrict flow. For flanged valves, draw down all connection studs or bolts evenly to avoid possible distortion of the valve body. For threaded valves, do not apply a wrench to the valve body. Use the hex flats provided on the inlet bushing. Safety valves are intended to open and close within a narrow pressure range. Valve installations require accurate design both as to inlet and discharge piping. Refer to International, National and Industry Standards for guidelines.
Inlet piping
Connect this valve as direct and close as possible to the vessel being protected. The valve should be mounted vertically in an upright position either directly on a nozzle from the pressure vessel or on a short connection fitting that provides a direct, unobstructed flow between the vessel and the valve. Installing a safety valve in other than this recommended position will adversely affect its operation.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
41
The valve should never be installed on a fitting having a smaller inside diameter than the inlet connection of the valve.
Discharge piping
Discharge piping should be simple and direct. A "broken" connection near the valve outlet is preferred wherever possible. All discharge piping should be run as direct as is practicable to the point of final release for disposal. The valve must discharge to a safe disposal area. Discharge piping must be drained properly to prevent the accumulation of liquids on the downstream side of the safety valve. The weight of the discharge piping should be carried by a separate support and be properly braced to withstand reactive thrust forces when the valve relieves. The valve should also be supported to withstand any swaying or system vibrations. If the valve is discharging into a pressurized system be sure the valve is a "balanced" design. Pressure on the discharge of an "unbalanced" design will adversely affect the valve performance and set pressure. Fittings or pipe having a smaller inside diameter than the valve outlet connections must not be used. The bonnets of balanced bellows safety valves must always be vented to ensure proper functioning of the valve and to provide a telltale in the event of a bellows failure. Do not plug these open vents. When the fluid is flammable, toxic or corrosive, the bonnet vent should be piped to a safe location.
If you can't explain it simply, you don't understand it well enough. Albert Einstein
42