VALVES

FACTORS INFLUENCING VALVE SELECTION (Coulson and Richardson Vol 1; 6)

The careful selection and design of valves, especially control valves are important. Good flow
control must be achieved, whilst keeping the pressure drop as low as possible.
(1)

Properties of the fluid

Each class (gas, vapour or liquid) introduces ints own problems depending on the degree of
viscosity, density, velocity, pressure, particle size, etc. Factors may vary through systems
or over periods of time. Problems associated with erosion, mixing, temperature changes,
etc. are all to be considered for satisfactory valve selection.

(2)

Materials of construction
Increasing range of materials of construction are available from metal to plastics. Valve
components should be looked at separately, depending on the function and exposure to the
environment. Most common materials of construction are cast iron, steel, stainless steel,
bronze, copper, etc. Plastic valves are increasingly used.

(3)

Types of services
What type of service will the valve have to deliver. Poistive shut-off, flow control, manual or
automatic, high or low pressure, high or low temperature, operating conditions, speed of
operation, location of valve in the system, maintenance and availability.

(4)

Size of the valve

Normally the valve is selected to a suitable pipe size and fluid friction losses. The types of
end fittings are taken into consideration.

(5)

Availability
The availability of the valve in a specific size and materials of construction has an influence
on the valve selected. Valves are not always available in the specific size and materials of
construction that it is required, then alternatives would have to be used.

(6)

Cost
The cost of the valve makes a difference to the valve that is selected. Financial constraints
and budgets will have to be taken into consideration.

SELECTING A VALVE TYPE

When speaking of valves, it's easy to get lost in the terminology. Valve types are used to
describe the mechanical characteristics and geometry (Ex/ gate, ball, globe valves). We'll
use valve control to refer to how the valve travel or stroke (openness) relates to the flow:
1. Equal Percentage : equal increments of valve travel produce an equal percentage in flow
change
2. Linear : valve travel is directly proportional to the valve stoke
3. Quick opening : large increase in flow with a small change in valve stroke
So how do you decide which valve control to use? Here are some rules of thumb for each
one:
1. Equal Percentage (most commonly used valve control)

a. Used in processes where large changes in pressure drop are expected

b. Used in processes where a small percentage of the total pressure drop is permitted by
the valve
c. Used in temperature and pressure control loops
2. Linear
a. Used in liquid level or flow loops
b. Used in systems where the pressure drop across the valve is expected to remain fairly
constant (ie. steady state systems)
3. Quick Opening
a. Used for frequent on-off service
b. Used for processes where "instantly" large flow is needed (ie. safety systems or cooling
water systems)
Now that we've covered the various types of valve control, we'll take a look at the most
common valve types.
Butterfly Valves

Best Suited Control: Linear, Equal percentage

Recommended Uses:

1. Fully open/closed or throttling services

2. Frequent operation
3. Minimal fluid trapping in line
Applications : Liquids, gases, slurries, liquids with suspended

solids

Advantages:

Disadvantages:

1. Low cost and maint.

1. High torque required for control

2. High capacity

2. Prone to cavitation at lower flows

3. Good flow control

4. Low pressure drop

Other Valves
Another type of valve commonly used in conjunction with other valves is called a check
valve. Check valves are designed to restrict the flow to one direction. If the flow reverses
direction, the check valve closes. Relief valves are used to regulate the operating
pressure of incompressible flow. Safety valves are used to release excess pressure in
gases or compressible fluids.

Valves used for chemical processes can be divided into:

Shut-off valves (block valves)

- purpose is to close of the flow
- should give a positive seal in the closed position
- minimum resistance to flow when open
- Gate, plug and ball valves

Control Valves , both manual and automatic, used to regulate flow

- capable of giving smooth control over the full range of flow, from fully open to completely
-

closed.
Basically globe valves with special designs
Globe, butterfly (for gases and vapours)

TYPES OF VALVES AND THEIR APPLICATIONS

TYPE
Gate
Plug
Ball
Globe
Diaphragm
Butterfly
Pinch

APPLICATIONS
Water and gases but not solid particles
Liguids and gases
Steam, liquids, vacuum, oxygen, chlorine and solid particles
Steam
Corrosive fluids, solid particles
Flow control of gases and vapours, not for solid particles
Slurries

VALVE TYPES

Although many different types of valves are used to control the flow of fluids, the basic valve types
can be divided into two general groups: stop valves and check valves.

STOP VALVES

Stop valves are used to shut off or, in some cases, partially shut off the flow of fluid. Stop valves
are controlled by the movement of the valve stem. Stop valves can be divided into four general
categories: globe, gate, butterfly, and ball valves. Plug valves and needle valves may also be
considered stop valves.

GLOBE VALVES
Globe valves are probably the most common valves in existence. The globe valve derives its name
from the globular shape of the valve body. However, positive identification of a globe valve must be
made internally because other valve types may have globular appearing bodies. Globe valve inlet
and outlet openings are arranged in several ways to suit varying requirements of flow. Figure 1
shows the common types of globe valve bodies: straight flow, angle-flow, and cross flow. Globe
valves are used extensively throughout the engineering plant and other parts of the ship in a variety
of systems.

Globe Valves
Best Suited Control: Linear and Equal percentage
Recommended Uses:

1. Throttling service/flow regulation

2. Frequent operation
Applications : Liquids, vapors, gases, corrosive substances, slurries
Advantages:

Disadvantages:

1. Efficient throttling
2. Accurate flow control
3. Available in multiple ports

1. High pressure drop

2. More expensive than other valves

(a) z-body
Figure 1.-Types of globe valve bodies.
Z-body: The essential principle of globe valve operation is the perpendicular movement of the disk
away from the seat. This causes the annular space between the disk and seat ring to gradually
close as the valve is closed.

(b) y-body
This characteristic gives the globe valve good throttling ability, which permits its use in regulating
flow. Therefore, the globe valve may be used for both stopping and starting fluid flow and for
regulating flow.The most evident shortcoming of the simple globe valve is the high head loss from
two or more right angle turns of flowing fluid. Obstructions and discontinuities in the flow path lead
to head loss.
The y-body design is a remedy for the high pressure drop inherent in globe valves. The seat and
stem are angled at approximately 45. The angle yields a straighter flowpath (at full opening)

GATE VALVES
Gate valves are used when a straight-line flow of fluid and minimum restric tion is desired. Gate
valves are so named because the part that either stops or allows flow through the valve acts
somewhat like the opening or closing of a gate and is called, appropriately, the gate. The gate is
usually wedge shaped. When the valve is wide open, the gate is fully drawn up into the valve,
leaving an opening for flow through the valve the same size as the pipe in which the valve is
installed. Therefore, there is little pressure drop or flow restriction through the valve. Gate valves
are not suitable for throttling purposes since the control of flow would be difficult due to valve
design and since the flow of fluid slapping against a partially open gate can cause extensive
damage to the valve. Except as specifically authorized, gate valves should not be used for throttling.

Best Suited Control: Quick Opening

Recommended Uses:

1. Fully open/closed, non-throttling

2. Infrequent operation
3. Minimal fluid trapping in line
Applications: Oil, gas, air, slurries, heavy liquids, steam,

noncondensing gases, and corrosive liquids

Advantages:

Disadvantages:

1. High capacity

1. Poor control

2. Tight shutoff

2. Cavitate at low pressure drops

3. Low cost

3. Cannot be used for throttling

4. Little resistance to flow

The disk of a gate valve is completely removed from the flow stream when the valve is fully open.
This characteristic offers virtually no resistance to flow when the valve is open. Hence, there is little
pressure drop across an open gate valve.

Gate valves are classified as either RISING STEM or NONRISING-STEM valves. On the
nonrising-stem gate valve shown in Figure 2 the stem is threaded on the lower end into the gate.
As the handwheel on the stem is rotated, the gate travels up or down the stem on the threads,
while the stem remains vertically stationary. This type of valve almost always has a pointer-type
indicator threaded onto the upper end of the stem to indicate valve position. The rising-stem gate
valve, shown in figure 2 has the stem attached to the gate; the gate and stem rise and lower
together as the valve is operated.

(a)

(b)

Figure 2.-Cutaway view of a gate valve (a: nonrising-stem type and b: rising-stem type).

Figure 3 Gate Valve

BALL VALVES.
Ball valves, as the name implies, are stop valves that use a ball to stop or start the flow of fluid. The
ball (fig 4) performs the same function as the disk in the globe valve. When the valve handle is
operated to open the valve, the ball rotates to a point where the hole through the ball is in line with
the valve body inlet and outlet. When the valve is shut, which requires only a 90 rotation of the
handwheel for most valves, the ball is rotated so the hole is perpendicular to the flow openings of
the valve body, and flow is stopped.
Best Suited Control: Quick opening, linear

Recommended Uses:

1. Fully open/closed, limited-throttling

2. Higher temperature fluids

Applications: Most liquids, high temperatures,

slurries
Advantages:

Disadvantages:

1. Low cost
2. High capacity

1. Poor throttling characteristics

2. Prone to cavitation

3. Low leakage and maint.

4. Tight sealing with low torque

Figure 4-Typical seawater ball valve.

Figure 5: Typical Ball Valve

Most ball valves are of the quick-acting type (requiring only a 90 turn to operate the valve either
completely open or closed. This type of gearing allows the use of a relatively small handwheel and

operating force to operate a fairly large valve. Ball valves are normally found in the following
systems aboard ship: seawater, sanitary, trim and drain, air, hydraulic, and oil transfer.
A ball valve is generally the least expensive of any valve configuration and has low maintenance costs. In
addition to quick, quarter turn on-off operation, ball valves are compact, require no lubrication, and give tight
sealing with low torque. Conventional ball valves have relatively poor throttling characteristics. In a throttling
position, the partially exposed seat rapidly erodes because of the impingement of high velocity flow.

A dvant ages A ball valve is generally the least expensive of any valve configuration and has low
maintenance costs. In addition to quick, quarter turn on-off operation, ball valves are compact, require no
lubrication, and give tight sealing.
Disadvan tag es Conventional ball valves have relatively poor throttling characteristics.
In a throttling
position, the partially exposed seat rapidly erodes because of the impingement of high velocity flow.

PLUG VALVES

Figure 6 Plug Valve

In the open position, the passage in the plug lines up with the inlet and outlet ports of the valve body. When
the plug is turned 90 from the open position, the solid part of the plug blocks the ports and stops fluid flow.

BUTTERFLY VALVES
The butterfly valve, one type of which is shown in figure 7 may be used in a variety of systems.
These valves can be used effectively in freshwater, saltwater, and chill water systems. The butterfly
valve is light in weight, relatively small, relatively quick-acting, provides positive shut-off, and can be
used for throttling.

Figure 7-Butterfly valve.

The butterfly valve has a body, a resilient seat, a butterfly disk, a stem, packing, a notched
positioning plate, and a handle. The seat is under compression when it is mounted in the valve
body, thus making a seal around the periphery of the disk and both upper and lower points where
the stem passes through the seat. To close or open a butterfly valve, turn the handle only one
quarter turn to rotate the disk 90. Some larger butterfly valves may have a handwheel that
operates through a gearing arrangement to operate the valve. This method is used especially
where space limitation prevents use of a long handle. Butterfly valves are relatively easy to
maintain. Because the seat is replaceable, the valve seat does not require lapping, grinding, or
machine work.
Butterfly valves possess many advantages over gate, globe, plug, and ball valves, especially for large
valve applications. Savings in weight, space, and cost are the most obvious advantages. The maintenance
costs are usually low because there are a minimal number of moving parts and there are no pockets to trap
fluids.
DIAPHRA GM VA LVES

A diaphragm valve is a linear motion valve that is used to start, regulate, and stop fluid flow. The name is
derived from its flexible disk, which mates with a seat located in the open area at the top of the valve body to
form a seal. A diaphragm valve is illustrated in Figure 8.

OPEN

THROTTLING

CLOSED

Figure 8 Straight Through Diaphragm Valve

Diaphragm valves have a flexible diaphragm connected to a compressor by a stud molded into the
diaphragm. The compressor is moved up and down by the valve stem. Hence, the diaphragm lifts when
the compressor is raised. As the compressor is lowered, the diaphragm is pressed against the contoured
bottom in the straight through valve illustrated in Figure 8 or the body weir in the weir-type valve. Diaphragm
valves can also be used for throttling service. The weir-type is the better throttling valve but has a limited
range. Diaphragm valves are particularly suited for the handling of corrosive fluids, fibrous slurries,
radioactive fluids, or other fluids that must remain free from contamination.

Diaphragm Construc tion

The operating mechanism of a diaphragm valve is not exposed to the media within the pipeline. Sticky or
viscous fluids cannot get into the bonnet to interfere with the operating mechanism. Many fluids that would
clog, corrode, or gum up the working parts of most other types of valves will pass through a diaphragm valve
without causing problems. Conversely, lubricants used for the operating mechanism cannot be allowed to
contaminate the fluid being handled. There are no packing glands to maintain and no possibility of stem
leakage. There is a wide choice of available diaphragm materials. Diaphragm life depends upon the nature
of the material handled, temperature, pressure, and frequency of operation. Some elastomeric diaphragm
materials may be unique in their excellent resistance to certain chemicals at high temperatures. However,
the mechanical properties of any elastomeric material will be lowered at the higher temperature with possible
destruction of the diaphragm at high pressure. Consequently, the manufacturer should be consulted when
they are used in elevated temperature applications.

RELIEF AND SAFETY VALVES

Relief and safety valves prevent equipment damage by relieving accidental over-pressurization of fluid
systems. The main difference between a relief valve and a safety valve is the extent of opening at the
setpoint pressure. A relief valve gradually opens as the inlet pressure increases above the setpoint. A relief
valve opens only as necessary to relieve the over-pressure condition. A safety valve rapidly pops fully open
as soon as the pressure setting is reached. A safety valve will stay fully open until the pressure drops below
a reset pressure.

CHECK VALVES

The check valve allows full, unobstructed flow and automatically closes as pressure decreases. These
valves are fully closed when the flow reaches zero and prevent back flow.
Lift check valves are suitable for installation in horizontal or vertical lines with upward flow. They are
recommended for use with steam, air, gas, water, and on vapor lines with high flow velocities.

Figure 9: Swing check valve

Figure 10: lift Check valve

Plug Valves
1. Introduction
Plug valves are the possible the oldest type of control valves in use.
They are the backbone of fluid control for industrial and municipal processing facilities world-wide.
Widely regarded for reliability, economy, and broad range of service applications, plug valve
manufacturers and specifiers alike recognise the unique challenges of many slurry, sludge, and liquid
handling services. Here, selecting the correct design and materials of construction, when abrasive,
corrosive, scale or plugging prone conditions prevail, can be a difficult task further complicated by
unknown or changing process conditions.

2. Concept
- The concept is simple: a rotary cylindrical or tapered plug with an opening through it is inserted
into an open body to block or allow flow selectively , (Fig.1).

Fig. 1

When the plug is rotated, it permits flow through the opening and the fluid conduit;
The plug valve is used primarily for on--off service and some throttling services. It controls flow by
means of a cylindrical or tapered plug with a hole in the center that lines up with the flow path of
the valve to permit flow. A quarter turn in either direction completely blocks the flow path.

2. Operation and maintenance

Operational and maintenance problems arise when the integrity of key valve components (valve
stem, packing, seats, seals, bearings) or lubrication is compromised, or when exposed surfaces that
rub against solids or scale build-up increase the torque required to actuate.
-

These quarter-turn valves move from fully open to fully closed with 90oC rotation of the sealing
member and flow condition is indicated by the position of the control handle or actuator.
They are adaptable to a broad range of services and are available in wide selection of material in
a wide selection of materials, size, end connections, and seating materials.

3. Types Plug Valves

Plug valves are either lubricated or non-lubricated.

3.1 Lubricated plug valves

Plug valves are available in either a lubricated or nonlubricated design. The lubricated valve provides
tight shutoff of hard-to-handle fluids. The plug is designed with grooves, which retain a lubricant to
seal and lubricate the valve and provide a hydraulic jacking force to lift the plug within the body,
thereby reducing force required for rotary operation (see Fig. 2).
The straight passage through the port prevents accumulation of sediment or scale, and when rotated
90o, the valve plug wipes away foreign matter. The opening of the port varies between 40 and 100 per
cent. A full-round port opening design increases the overall plug valve body size.
Lubricated plug valves must be resealed after only a few operations-in some cases after only one
cycle-and are therefore considered high-maintenance valves to be used for infrequent operation.
They do not lend themselves to automation because of the uncertainty of the necessary operating
torque in remote areas where maintenance is not regularly performed and because there are usually
no provisions for mounting hardware

Fig. 2

3.2 No-lubricated plug valves

Because the non-lubricated plug valve requires no lubrication, it is virtually maintenance free and
gives tight shut-off.
This type of valve is quick operation and non-contaminating and therefore handles slurries very

well.

Of the non-lubricated plug valves there are two basic designs, the sleeved and the fully lined.
3.2.1Non-lubricated plug valves
A sleeved plug valve is one in which the plug is surrounded by a conically shaped sleeve of Teflon (see
Fig. 3.2), The sleeve is first fitted into the body and acts as a seat for closure once the plug is installed.
The plug is continually under pressure from the bonnet assembly to maintain sleeve and plug contact.
This means that even in very low-pressure applications the operating torque of a plug valve remains
high. Plug valves are top-entry valves, which means that the closure element (plug) and seats may be
accessed through the top of the valve without removing the valve from the line. Unlike ball valves,
plug valves are generally not available with a wide variety of seat materials, primarily utilising Teflon
and a few derivatives.

Fig. 3. Non-lubricated plug valves use a PTFEsleeve and tapered plug

(Courtesy of The Durion Company)
Some advantages of the sleeved plug valve are tight shutoff at low pressure, sleeve and seat
protection at the port opening to eliminate wear, and, unlike the ball valve, there are no pockets or
cavities around the plug where material may become trapped and cause the valve to seize,
Until recently the plug valve has been considered a manual valve for on-off applications. Some
valve manufacturers have recently introduced characterised plugs with specially shaped port
openings to provide flow control characteristics in modulating service.

3.2.2. Fully lined plug valves.

The second style in which non-lubricated plug valves are available is fully lined (see Fig. 4).
A relatively inexpensive ductile iron body and plug are fully lined and coated with Teflon. This gives the
valve the ability to resist all the aggressive properties of a fluid using iron as the body material. Of
course, if the external environment is equally aggressive, then an alloy or appropriately coated valve
body should be used.
When selecting a fully lined valve, it is important to consider some specific service conditions to
ensure valve performance. Vacuum is an especially severe service for fully lined valves. Not all
manufacturers recommend their valves for vacuum service, but some may use melt processable
thermoplastics that may be molded into dovetail recesses in the body to lock the liner into place (see
Fig.4).
If a lining is thin and is subjected to continuous abrasion, it may be destroyed, thereby exposing the
less corrosion resistant metallic body to the aggressive line fluid.
Some valve manufacturers use an injection molding process to vary and control lining thicknesses to
suit the mechanicalrequirements of the various valve components.

Fig. 4

Fluorocarbon lining is locked into plug valve using dovetail design.

(Courtesy of Xomox Corporation)

4. Materials
Plug valve bodies and closure elements can be supplied in most sizes in the following materials or
combinations of materials:
Alloy 20 (CN7M)
CD4MCu
Hastelloy B (N-12M)
Monel(M-35)
316 stainless steel (CF8M)
304 stainless steel(CF8)

Carbon steel(WCB)
Ductile iron (A395)
Hastelloy C (CW-12M)
Nickel (CZ1OO)
316L stainless steel(CF3M)
304L stainless steel(0F3)

References
(http://www.tpub.com/fireman/69.htm - 15 Sept 2006)
(http://www.tpub.com/content/doe/h1018v2/css/h1018v2_35.htm - 15 Sept 2006)

Rosaler, Robert C., Standard Handbook of Plant Engineering, McGraw-Hill, New York,
1995, pages 10-110 through 10-122
Purcell, Michael K., "Easily Select and Size Control Valves", Chemical Engineering
Progress, March 1999, pages 45-50