INTRODUCTION

Where Pipework is a means of transporting solids, liquids and gases valves are
incorporated in the Pipework to facilitate the starting, stopping and diverting of the
transportation. Valves are also situated in linework such as steam lines, air lines and
water lines, which serve plants and installations with the utilities they require in their
operations.

GENERAL PRINCIPLES

Consider the different type of liquids and gases that flow around plant pipeline. High
pressure, Low pressure, Corrosive, Non-Corrosive, Low and High Viscosities and
Volatilities. If we understand this, then we can see why so may different types and sizes
of valves are in use.

Valves are manufactured from Forged Steel, Alloys, Cast Steel, Cast Iron, Brass,
Plastics etc, the properties of which limit or determine the service for which they are
designed.

Most manufactures have certain standards developed for the design, manufacture and
testing of all types of valves. The basic dimensional standards such as face to face
length, flange and bolt circle dimensions etc, are those of the API or American Petroleum
Institute and this has made it possible to interchange various manufacturers valves.

VALVE CLASSIFICATION

The various types of valve can be sub-divided into the following groups.

- Isolation Valves (Ball, Plug, Butterfly, Gate)

- Regulating Valves (Globe, Needle and Diaphragm)
- Check Valves or Non – Return Valves
- Relief Valves
DESIGN FEATURES OF VALVES

VALVE COMPONENT FUNCTION

Handwheel Provides a means of operating the valve gate

or disc to open and close the valve, the direction of
rotation is indicated on the handwheel, this is normally
clockwise to close and anti-clockwise to open. In smaller
valves of bronze or brass type the handwheel is made of
alloy and is easily broken, this is to protect the spindle etc
from damage if any great pressure is exerted. The
handwheel may be attached to the bush in the yoke or
directly to the valve or spindle.

Yoke This is the joining piece between the two

pillars, sometimes know as the bridge or the collar. The
yoke may be removable or cast with the pillar and bonnet.
It provides even pressure on pillars when handwheel is
operated.

Pillars Brace between bonnet and yoke. They may be

the removable type held in position with nuts,or
the permanent type which are cast with valve bonnet.

Stem and Spindle Provides a means of operating the gate or disc

to open and close the valve. The gate or disc
being attached to the stem which passes
through the bonnet via the stuffing box. The
upper or external part of the stem may be
threaded and is know as the spindle, this part
is operated by the handwheel. Spindle may be
rotated or just raised and lowered, depending
on the type of stem operation, these will be
discussed later. Spindle has square thread for
greater strength.
 The Gland may be held in position and adjusted by two
nuts and bolts, if so adjustments must be made evenly to
prevent gland binding on the stem and to ensure packing
is pulled down evenly. On smaller valves the gland is held
in position with one nut through which the stem passes,
this nut screws direct onto the outside of the stuffing box.

Stuffing Box Provides a means of passing the valve stem through the
bonnet to operate the shut off mechanism and prevent
any leakage of fluid when packing is added. It is normally
incorporated in the bonnet construction, in smaller valves
it can be a separate part screwed onto the bonnet.

Body Provides a means of channelling the liquid or

gas, from the inlet to outlet port, via the shut off
mechanism, which is normally in the shape of a disc. The
body is actually the valve casing, to which connections
are made to pipelines, etc, the ports may be of the
flanged, screwed or welded type.

Bonnet Valve cover, this enables the internals of the

valve to be removed for servicing, it may be a flange type,
this is normal for valves above 2”. For smaller valves it
may be a screw type, in this case it is in the form of a
large nut. At extremes in temperature high/low extended
bonnet valves are used.

Seat Forms a seal with the gate or disc to prevent

fluid flow when valve is closed. There may be one or two
seats in a valve, depending on the type of shut off
mechanism, It is in the shape of a ring and screwed into
the body, enabling valve seats to be renewed when badly
scored. The face is a machine surface to form a good
seal with the gate or disc. In smaller cheap valves, the
valve seat may be part of the body and not removable,
but in larger and more expensive valves seats are always
removable.
Bush Installed in the yoke. Inside the bush is threaded
to match spindle, ie. Square thread. The bush
may be free to rotate or fixed, depending on
the type of stem operation.

Gland and Bush The gland sometimes referred to as the gland

follower, holds the packing in position inside
the stuffing box. By tightening the gland, the
gland bush enters further into stuffing box
squeezing the packing down, this causes it to
expand and form a seal agai

Gate and Discs Forms a seal with the valve seat when in the closed
position. It is attached to the stem of the valve and can be
raised to open or lowered to close. The gate or disc may
be in the vertical or horizontal position depending on the
type of valve.
The basic concept of the ball valve is the use of spherical ball-plug held between
tow lip seal seats. The seats are made from a choice of various synthetic material
such PTFE butadiene-acrylonitrile rubber and a special nylon variant. The inside
diameter of this lip is always slightly larger than the ball-port so that no “growth” of
the seal occurs to prevent operation. Tolerances are controlled so that a
predetermined deflection of the lip seal occurs during assembly, thus giving intimate
contact, irrespective of line pressure. The metal ball closure member is usually hard
chrome-plated, both to resist abrasion and to give long life.

Ball valves are usually manufactured in sizes of ¼” to 8”. Materials of construction

of the main valve assembly are chosen for the design duty of the valve, such as
cast iron, ductile iron, bronze, aluminium, carbon, stainless steel, titanium,
zirconium, tantelum, and many corrosion resisting alloys and plastics.

Pressure ratings are as high as 7,500 p.s.i. and temperatures ordinarily up to

575ºF.

OPERATION OF BALL VALVES

The Ball Valve has always been considered on of the most efficient type of valve
because it provides an unrestricted throughway, ease of operation, and minimum
weight.

Operating is by means of a shouldered stem which engages in a slot in the ball. By

operating the lever, the ball plug is rotated so that its port is in line with the body
ports or at right angles to body ports, ie. Closing them off and preventing any flow.

Some of the outstanding features of the double seal ball valve are as follows:

Complete shut off The well designed lip seals on the flexible seats deflect under
pressure and follow the contour of the ball in the absence of pressure, ensuring a
dead tight seal in both directions of flow.
Minimum maintenance The seats are self-acting and pressure
energised, thus requiring no adjustment or attention in service.
The valve requires no lubrication and only infrequent attention to
the gland.

Very compact size It requires very little head-room and can be

sited at any angle.

Round bore straight-through flow Produces exceptionally low

pressure drop with almost negligible turbulence.

Two-way sealing The design of the seat is such that line

pressure forces the upstream seat on to the ball and the ball on
to the downstream seat, thus providing a “Double Seal” ball
valve.
COCKS AND PLUG VALVES
Cocks
Cocks are the simplest form of all closure devices, giving on – off and throttling
position for flow control. In its simplest form the cock consists of a taper plug capable
of rotation in an enveloping barrel or body.
Cocks do not incorporate the design features peculiar to plug valves for reducing the
friction between the plug face and body seat.
Cocks are suitable for low pressure service on cold liquids, or low pressure air or
steam in its elementary form and of small bore, the principle can be employed for very
high hydraulic pressures with careful attention to design.
Cocks are generally used for controlling low pressure water, oil, acids (with due regard
to materials of construction) slimes, tars of anything that will flow, but care should be
exercised if contemplated for steam use and they should never be used on
superheated steam. Cocks will often meet an application more effectively than an
elaborate screw-down stop valve. One outstanding advantage of the cock is that multi-
port flow can be arranged.
Types of Cock
Plug cock A taper-seated cock in which the plug is
retained in the body by means of a washer, screw and
nut at the smaller end of the plug.
Gland Cock A taper-seated cock in which the plug is
retained in the body by means of a gland and gland
packing.
Compound Gland Cock A cock in which the plug is retained in the
body by the cover, the stuffing box being formed in the
cover.
Packed Cock Any type of cock in which packing material is
inserted to effect a seal between the plug face and the
body seal.
Plug Valves

A form of shut-off device, having a plug, either parallel, taper or spherical in shape, which
can be turned to move its port or ports relative to the body seal ports to control the flow of
fluid and which incorporates design features which reduce friction between the plug face
and the body seat during the turning of the plug and/or seal them against leakage.
The plug is a refinement of the simple cock, suitable for high pressure and temperatures.
A ¼ turn opens or closes the valve. Flow through the valve is smooth, straight and
uninterrupted. Pressure drop across the valve is therefore low. Seating surfaces are fully
protected from the line fluid. In addition to straightway designs, multiport, and steam jacket
types are available.
In lubricated plug valves, the seating surfaces of the plug and its enveloping barrel or body
are lubricated. The lubricant being in stick or cartridge form and introduced into the head
of the plug and forced through appropriately located ducts and grooves which eventually
communicate with the seating surfaces of the valve. The lubricant is forced through these
ducts with the aid of a screw or gun in conjunction with a small ball check valve to prevent
return flow. This pressure lubrication performs four important functions:-
i) it provides a jacking action
ii) it seals the valve
iii) it minimises friction and wear
iv) it protects the seating surface from corrosion and erosion

Types of Plug Valve

Lubricated plug valve A plug valve which incorporates design

features whereby lubricant is injected under pressure
between the plug face and body seats.
Non-lubricated plug valves A plug valve which incorporates
Mechanical design features to reduce the friction
between the plug face and body seat during turning
of the plug. The most common type is:
Lift plug valve in which mechanical means are
provided to lift the plug from the body seat during
turning of the plug.
A butterfly valve consists of a housing in which a shaft passes through. On this the
vane and valve plate are connected.

The top of the housing can adapt various types of shaft actuators, both power or
manually operated. Power, lever and handwheel actuators are interchangeable
without additional parts.

The actuator is connected on the end of the shaft. The valve is in the fully open or
closed position by turning the actuator 90 angular degrees.

To prevent deflection there are bearing built-in at both ends of the shaft.

When the valve is in the wide open position, there is a straight-through flow with
only the small area of the edge-wise surface of the plate and vane causing an
obstruction.

A lever actuator valve for manual operation has a scale for indicating the vane
position and integral stop at each end of the scale. A plate-plunger pin located on
a squeeze type level assembly engages the plate which is notched for on-off
operation.

The packing at both ends of a one-piece shaft eliminates unbalanced forces on

shaft due to static pressure and resultant vane misalignment problems.

A grease asbestos type of packing is normally used to sea-off leakage through the
gland.

Butterfly valves are multi-purpose valves and are applicable to rather low
pressures, say up to 10 kg/cm2. They are characterised by their large capacity and
are less expensive than plug or globe valves.
 HAND WHEEL

LOCK PIN

BONNET
OPERATING
COMPRESSOR AND MECHANISM
FINGER PLATE
FLEXIBLE BODY
DIAPHRAGM

STREAMLINE
PASSAGE
LINED
INTERNALLY

SEAT
This is valve is used on a large scale in the chemical industry where a large amount
of corrosive material is handled.
Diaphragm valves were first developed for compressed air duty nowadays has a
very wide and important range of duties for the control of fluids. The diaphragm
isolates the operating mechanism in the bonnet assembly from the fluid being
handled. This isolation preserves the lubricated part from possible damage by
abrasive or corrosive fluids and is equally effective in preventing contamination of
pipe contents. Diaphragm valve bodies and diaphragms are available in a very wide
range of material to suit any of more than 700 fluids.
Diaphragm valves are made in different designs for different types of service and
can be equally effective for liquids, slugs, slurries, pulps or fluids containing solid
matter in suspension. Diaphragms are now manufactured to suit temperature
conditions ranging from -85°F to 392°F ( -65°C to 200°C). Even certain steam
services can be tackled subject to pressure limitations. Diaphragm valves find a
wide use in chemical engineering.
Diaphragm valves consist of a mechanism, which enables a diaphragm to be
screwed down onto a seat by means of a so-called compressor. The flexible
diaphragm isolates the operating mechanisms from the liquid flowing through the
valve and therefore there is no gland.
Two diaphragms are used and the most common ones used on the chemical plants
are Teflon and rubber.
The outer portion of the diaphragms also forms the body to bonnet joint, thus
sealing off the fluid from the moving parts. Teflon is normally the diaphragm in
contact with the fluid, the rubber being topside of this against the compressor.
Operation
The stem action of these valves is normally inside screw, non-rising stem, where
the handwheel is attached to a non-rising stem, which is attached to a finger plate
mounted in the valve for guidance of the compressor, the compressor and
diaphragm rising on the stem when the valve is opened.

The operation of this valve is simple the handwheel is rotated to close the valve,
this forces the compressor to which the diaphragm are attached on to the weir at
the base of base of the valve, thus sealing off the fluid.

Summarising the diaphragm valves has the following features:

a) flexible diaphragm
b) absence of gland
c) operating mechanisms insulated from fluid stream
d) a streamline flow

The bodies of these valves can be made from a variety of materials.

Finally, it is easy to line the valve internally in order to increase chemical or

abrasion resistance.
These valves are widely used where uninterrupted flow is required and are
suitable for general purposes on such services as steam, water, oil, gas and many
other fluids. They should not be used in throttling service and should only be used
either fully open or fully close.

A gate valve provides a straight through passage for the flow of fluid. The body
ends are in line and the gate is moved between the body seats by a stem whose
axis is at right angles to that of the body ends. Gate valves may be:

a) Inside screw - In which the actuating thread of the stem is

contained inside the valve. This may take three
forms:
i) Inside screw, rising stem, where the handwheel is
attached to a non-rising stem, the gate rising on the stem
when the valve is opened.

ii) Inside screw, non-rising stem, where the

handwheel is attached to a non-rising stem, the
gate rising on the stem when the valve is opened.

iii) Inside screw, rising spindle, rising stem, where

the handwheel is attached to a rising spindle, and the
stem rises within and with the spindle when the valve is
open.

b) Outside screw - In which the actuating thread of the stem is

exterior to the bonnet. This may take three forms:

i) Outside screw, stem rising with handwheel.

Where the handwheel is attached to the stem and rises
with it when the valve is opened.
 ii) Outside screw, stem rising through handwheel.
Where the handwheel is attached to a yoke sleeve or
bridge and through which the stem rises when the valve
is opened.
iii) Outside screw, non-rising spindle, rising stem.
Where the handwheel is attached to a non-rising spindle
and the stem rises when the valve is opened.

Types of Gate Valve

Wedge Gate Valve - A valve in which closure, ie. Affected by the wedge
action between the gate and body seats. A wedge gate
valve may take the following forms:

a) Solid wedge - In which the gate is in one piece, either solid or cored.
b) Split wedge - In which the gate is in two pieces.

The solid wedge disc has the advantage of strength and being a single part, is not
liable to vibrate or chatter in service, thereby reducing wear to a minimum. The
solid wedge gate valve can be installed in any position without danger of the disc
jamming due to misalignment of parts.

Soft-seals can be installed in solid wedge gate valves, these comprise of non-
metallic rings which are fitted in the body seats, or in the wedge, giving tight
closure backed by contact of metal-to-metal surfaces for searching and corrosive
fluids.

Double Disc Gate Valve - A valve in which the gate consists of two discs which
are forced apart by a spreading mechanism at the pont of closure against both
parallel body seats, thus ensuring an effective sealing of the valve without the
assistance of the fluid pressure.
Parallel Slide Valve - A valve in which the gate consists of one or two discs,
without spreading a mechanism, which slide between parallel body seats, effective
closure being obtained by the fluid forcing the downstream disc face against the
body seat.

HOPKINSONS PARALLEL SLIDE VALVE

The merits of parallel slide valves have been recognised as a general purpose
stop valve and for conditions where the flow through the valve may be in either
direction. It is usually used as an isolating valve on steam service.

Principle Features of the Parallel Slide Valve

Action: The outstanding feature of this valve is that it

Achieves shut off without the aid of wedging action. No
mechanical stress is exerted between the discs and the valve is
not subjected to dangerous strains in opening or closing.

A light spring keeps the discs in close contact with

the seats when the valve is not under pressure. When the valve
is closed and under pressure the disc at the outlet is held in
contact with its seat by liquid or vapour pressure.

When the valve is being opened, the discs slide over the seat
faces until completely clear of the bore, thus giving and
unobstructed passage through the valve and reducing pressure
drop to a minimum. The slide valve action also removes any dirt
and foreign matter the faces.
IDENTIFICATION Muliturn Valve That Effects Closure
By Means Of One Or More Flexible
Elements, Such As Diaphragms
Or Rubber Tubes ,That Can Be Passed
Together To Cut Off Flow.
RECOMMENDED 1- For On-off Service.
2- For Throttling Service.
3- For Moderate Temperatures.
4- Where Pressure Drop Through
Valve Is Low.
5- For Services Requiring Low Maint.
APPLICATIONS 1- Slurries, Mining Slurries,
2- Liquids With Large Amounts Of
Suspended Solids,
3- Systems That Covey Solids,
4- Foods, And
5- Pharmaceuticals.
ADVANTAGES 1- Low 2- Low Maintenance.
3- No Internal Obstruction Or Pockets To Cause Clogging.
4- Non Corrosive And Abrasion- resistant
Cost 5- Simple Design.

DISADVANTAGES 1- Limited Vacuum Application

2- Difficult To Size.
VARIATIONS 1- Exposed Sleeve Or Body,
2- Encased Metallic Sleeve Or Body
MATERIALS Rubber, White Rubber
Hypalon, neoprene, Whit Neoprene
Bunna-n, Bunna-S
Viton-A, Silicon, TFE
SPECIAL INSTALLATION Large Sizes May Require Supports
AND MAINTENANCE Above Or Below The Line If Pipe
Supports Are Inadequate.
INSTRUCTIONS
ORDERING 1- Sleeve Material
SPECIFICATIONS 2- Exposed Or Encased Sleeve
3- Operating Pressure.
4- Operating Temperature.
INTERNAL BELLOWS SEAL
GATE AND GLOBE VALVES

These valves are unique in design having a built in internal bellows seal
designed so that the process pressure is applied externally on the bellows
this combined with the compression/decompression action of the bellows
when opening or closing the valve forms a positive seal within the valve
body, conventional gland packing is provided to give a secondary seal
system.

These valves are normally used on steam tracing. Steam is very

searching and a wire drawing effect is caused on any surface across
which it is escaping, the bellows assembly eliminates this problem.

NOTE: The gate valve spindle stays approximately ¼ proud when the
gate is fully closed against the seat.

It can be seen from the points discussed that the gate valve is simple but
effective, one of the main advantages is the very low pressure drop when
the valve is fully open, this being due to the straight through passage.
 VALVE POSITION
INDICATOR
HAND WHEEL

SPINDLE

BRIDGE
BODY
FLANGE

DISC
SEAT
NEEDLE VALVES

Needle valves consist of housing in which a sharp pointed needle plug passes
through the gland and can be screwed down on its seat.

A screw type of gland may be applied to screw the teflon or asbestos packing
into the gland stuffing box. This is to seal off leakage of gas or liquid along the
spindle.

A screw cap is used to prevent dirt getting into the tread of the gland.

A needle valve has the same principle characteristics as the globe valve and is
mainly used to control small amounts of gas or liquid flows through the valve. It is
normally used on gas sample cylinders and also on by-passes of gas or chemical
injection pumps. This valve is seldom operated in fully-open position, but
basically only for throttling purposes. These are normally used where the flow
has to be controlled at fine limits.

There are two types of needle valve:

i) Straight through flow

- process control

ii) 90 Angle Type

- generally used on gas cylinders for sampling gas/liquid
streams.

OBLIQUE OR KESTNER GLOBE VALVE

Is a valve generally having a spherical body in which the body ends are in line
with each other and in which the axis of the stem is oblique to that of the body
ends.

Mainly used on highly corrosive duty.

Form the points discussed, it can be seen that a screw-down stop valve creates a
higher-pressure drop than a gate valve, this is due to the construction and up and
over flow of the fluid through the valve. It has been found that these valves give
better isolation than gate valves but these valves should not be chosen just for this
reason, remember the increased pressure drop. The main advantage of this valve
is the control of flow, nearly all control valves will be found to have this type of
body and valve seating, with slight modifications.

The following chart will give some ideas of comparison in pressure drop between
gate valves and globe valves. For example a 2” gate valve wide open is equivalent
to adding 1-ft pipe. If this were changed to a globe valve in the wide-open position,
it would be equivalent to adding 54 ft of piping. It can be seen that if fitted in pump
discharge, etc the pressure downstream of the valve would reduce and could
cause further problems.

Fitting Nominal pipe diameter inches

2” 2 ½” 3” 4” 6” 8” 10” 12”
Gate Valve: Length of feet of pipe to be added
¾ closed 140 165 200 280 400 540 700 800
½ closed 33 38 50 65 100 130 160 190
¼ closed 7 8 10 13 19 26 33 39
Open 1 1 2 2 3 4 6 7
Globe valve open 54 62 82 110 170 220 288 330
Angle valve open 27 32 41 55 82 110 140 165
Ball plug valve 9 8½ 11½ 22 36 42
CONTROL AND NON-SHUT OFF VALVES
PNEUMATIC AUTOMATIC CONTROL VALVES

Valves of the type shown are used in process plants for the automatic control of
flows, levels, pressures and temperatures by changing the opening of the valve,
and thus the flow through it.

A control valve consists of an operator and a valve body. The operator provides the
power to vary the position of the valve plug inside the body. The valve body is a
pressure-tight fitting, screwed or flanged to the process line.

The moveable plug serves to control the net flow area through this valve. The plug
is connected to the operator by a stem, which slides through a stuffing box.

The equipment which measures the flow, level, pressure, or temperature being
controlled sends out an air pressure signal, which varies usually in the range 3 to 15
p.s.i. The air signal is applied above the diaphragm. An increasing air signal will
push the operator stem downwards against the force exerted by the spring on the
diaphragm plate. As a result of the downward movement, the net area through
which the flow passes will decrease gradually.

The plug starts moving when 3 p.s.i. is applied to the diaphragm, and touches the
seat when 15 p.s.i. is applied.

An increase in air pressure is required to close the valve and a reduction to open
the valve hence the name “Air off to open” (AFVO).

The plug is constructed so that it can be removed from the valve stem, and refitted
in reverse. The body can also be reversed. The action of the valve is thus reversed

Air failure valve open (AFVO) or air failure valve closed (AFVC) are selected
following consideration of plant requirements so that valves “fail safe” in event of air
failure.

This reversal is sometimes accomplished by fitting the spring on top of the

diaphragm and introducing the air signal to the underside of the diaphragm.
The valve is double-seated so that the static pressure and dynamic axial
forces on the valve plug are balanced. This reduces the forces to be
overcome by the operator to frictional resistance in the gland. However, with
double-seated valves, a complete shut-off is impossible, and this must be
accomplished by a “back-up” valve. The gland packing on the valve stem is
frequently lubricated using a special lubricator, which introduces grease
under pressure into the gland through a lantern ring.

Single Seat Control Valves

Single seat valves are sometimes used in small sizes, or where an absolute
shut off is required.
MOTORISED GATE VALVE

The motorised valves are basically identical to the manually operated

valves, except that the operation of opening and closing the valve is now
performed by a motor..

The motor is built integrally with the handwheel and is connected via a
worm gear drive to the valve spindle. Torque or speed characteristics are
carefully matched. Interchangeable motors give a wide range of output
speeds.

When the electric power is available the motor takes over the function of
the handwheel or any other type of manually operated device. However,
when power is off the auto lever automatically disconnects the drive, so
thatthe valve can be hand operated.

The actuators (motor plus handwheel) can be applied with an integral

reversing motor.

The system of control can be operated as package unit (local control) or in the
control
 SCREWCAP

GASKET
SPRING

PISTON TYPE
BODY SEAT RING DISK

BODY
 CAP

GASKET

BALL DISK

BODY SEAT RING

BODY
No. Parts Name No. Parts Name No. Parts Name
1 Body 6 Seat 11 Gasket
2 Disc 7 Stud 12 Body
3 Bolt 8 Nut 13 Support
4 Nut 9 O-ring 14 Bolt
5 Drain Valve 10 O-ring 15 Nut
CHECK OR NON RETURN VALVES

A check valve in which the check mechanism incorporates a disk, piston or ball
which lifts along an axis in line with the axis of the body seat. Lift type check
valves are described according to the type of check mechanism, as follows:

NOTE: A check or N.R.V. is seldom fully tight – normal isolation procedures

should be enforced on suspension of flow

Swing Check Valves are available in straight body design and y-pattern design. The
disk is suspended from the body by means of a hinge pin and seals against the seat
which is integral with the body. These valves are typically used in sizes 2 inches and
over. Swing check valves can be installed in both horizontal and vertical position. They
are not suitable for pulsating flow.
Closure response of swing check valve is slower compared to lift check valve due to
longer disc travel and inertia of disk.

Piston Check valves are generally used to protect pumps or similar equipment,
allowing the flow only in one direction and preventing flow reversal due to back
pressure. The piston check valves are designed with globe valve bodies, producing an
increased drop pressure in the pipeline. This design provides a tight seal as well as a
fast reaction to the closure impulse. Metal seated check valves may not provide drop
tight sealing when used in gas system or fluid system with low back flow pressure or
fluids containing particles.

The ball check valve is one of the few check valves that works well in both water
and wastewater applications. Ball check valves are simple in operation and commonly
used on small pumps and in low head systems. Consider adding an optional roll-bar to
the piping system for safety; ball check valves have the highest tendency to slam due
to the ball's high inertia long stroke. When ball check valves encounter high pressures
and dynamics, severe slamming may result.

Tilting Disk Check Valves fit between two flanges and provide a compact
installation for large diameter applications. These valves can be installed in horizontal
and vertical lines. They provide a quick closing response and are particularly suited for
pulsating flows with compressible fluids.
NO PART NAME NO PART NAME
1 BODY 6 L-BOLT (EYE-BOLT)
2 DISC BODY
7
3 CLAPPER SEAL SEAT
4 PIN 8 DISC BEARING
5 PLUG
Wafer Type Check Valve has short face-to-face dimensions and low weight allows
a simple space saving installation between the companion flanges. The valves are
suitable to mounting between weld neck or slip on type companion flanges of
different standards.
They are specially developed for applications where a low-pressure loss is essential.
Opening and closing of the valve will take place at an extremely low-pressure
difference over the valve disc. The eccentric disc shaft combination with the disc seat
guarantees a positive shut off returning media. Wafer check valves are becoming the
preferred type of check valve for most applications, due to their compact design and
relatively low cost.

Single Disc Check Valve (Wafer Type Disc Check Valve) consists of four main
components: the body, a disc, a star guide and a spring. The Disc check valves are
opened by the pressure of fluid and closed through compression spring as soon as
flow stops thus preventing reverse flow.
The design of Wafer Design, Sandwich Type Single Disc Spring Loaded Check Valves
allows them to be installed between any flanges of different standard and in any
position; including vertical pipelines where the fluid flows downwards.

Dual Plate, Wafer Check Valve employs two-spring-loaded plates hinged on a

central hinge pin. When the flow decreases, the plates close by the action of torsion
spring before flow reversal takes place. All features put together make the Dual Plate
Check Valve as the most efficient & versatile design. It is also referred to as SILENT
CHECK VALVE. It is much easier to install between standard gaskets and line flanges,
and therefore is more cost effective to install and to maintain. Its design complies
with API 594 and API 6D, testing with API 598. It is also called as Butterfly Check
Valve.
RELIEF VALVES

A relief valve is an automatic pressure relieving device actuated by the

static pressure upstream of the valve and which opens in proportion to the
increase in pressure over the opening pressure.
SAFETY – Guidelines

Safety and relief valves are selected for specific duties – and are identified by a
reference number on the body tag. A relief valves must only be used on that.
They should NEVER be used for any other duty.

Locking Isolation Block Valves in the Open Position

Safety and relief valves should be installed directly onto equipment they are
designed to protect, the discharge routed directly to a vent or vent system
capable of handling the maximum discharge flow and released pressure. In some
instances block valves have been installed in the upstream and downstream
sides of relief valves, the use of these relief valves in stringently controlled. The
block valves must be fully open and chain locked or Castell locked in the
operating position.

Vents

Steam systems may have a localised vent pipe on the discharge of the relief
safety valve, the pipe aligned vertically. In order to eliminate the build up of
condenste in this vent line and consequent increase in the set pressure of the
valve, a small hole is drilled into the low point allowing the water to drain. Rust
scale can block this hole allowing hot condensate to accumulate, should the relief
valve operate this condensate will be blow out creating occasional check should
be carried out to ensure the drain hole is not plugged.
POTENTIAL HAZARDS OF INCORRECT VALVE OPERATIONS AND THE
STEPS TO AVOID THEM

1. The operation of valves and pipelines forms a major part of an operator’s

task. The following points should be observed if the task is to be done
safety and efficiently.

2. Manual operation is normally done using a handwheel or a handle.

Valves should be opened slowly to prevent sudden increases in
temperature or pressure, which could damage equipment.

3. Gate valves should not be used for restricting the flow or

throttling flow. The increased velocity can erode the valve.

4. Valve stem packing must be checked regularly for leakage.

5. Lubricated valves should be serviced regularly.

6. Excessive force should not be used to close a valve; otherwise the valve
seat could be damaged. Instead open valve a little and try to flush particles
that may be resting on the seat.

7. Non-return valves fail in the open or closed positions. If the valve on the
discharge of a pump fails “open” this can cause serious damage to the
pump when it is shutdown. In this case and particularly when left on
standby, the fluid flow can reverse and cause the pump to rotate in the
wrong direction.
 The shaft of a standby pump must always be checked to ensure that it is
stationary.

8. Damaged Iagging should be reported for maintenance. Operators should

not stand on lagged pipes.

9. The pipe movement should be checked when bringing a pipe into or out of
hot service.
Do not allow valve packing to leak as this can erode the valve stem. It can
also have a negative environmental impact.

10. Line heaters should be checked regularly and reported if faulty.

11. Leaking flanges must be reported immediately. If the leak is bad the
pipework may have to be isolated quickly.

12. Check direction of flow is in line with the markings on the valve. Ease of
access to a valve is important.

13. If the valve is in a difficult location it should be reported.

14. Care must be taken to ensure that all dirt which may have accumulated in
a valve during storage or initial installation is removed by flushing.

15. Impingement of high velocity fluids carrying abrasive solid particles can
cause serious damage.

16. Always make sure filters remain in line.

17. Valves that are not operated frequently and may remain open or closed for
long periods. Should be moved about once/month.
18. When gate valves are partially closed they can vibrate causing noise and
possible damage. Only use for throttling in an emergency and if needed to
be used in this position regularly it should be reported and a more
appropriate valve fitted.

19. Normally valves open by turning the handle wheel in an anti clockwise
direction. Normally however direction of rotation is marked on the wheel.

20. When a fully open position always backoff close a small amount ¼ - ½ turn
to stop valve sticking.

21. Wheel keys can cause high stresses on the valve. They should be used
with care.
PREVENTIVE AND ROUTINE PROCEDURES

A plant operator is responsible for checking valves and stuffing boxes as well as
greasing nipples and gear trains as part of his normal activities.

Valves should be checked for: -

1) Excessive nose or vibration,

2) Fluid passing a valve when it is closed,
3) Misaligned, bent or broken stems,
4) Leaking stuffing boxes,
5) Adequate lubricant,
6) Cracks and distortions,
7) Missing or damaged levers or handwheels.

If any of these conditions are observed they should be reported to supervision

immediately