Certificate Course on

PIPING ENGINEERING

December 8 .. 21,2004

VALVES

T. N. Gopinath Consultant

Organized by

Piping Engineering Cell Computer Aided Design Centre Indian Institute of Technology, Bombay Pow ai, Mumbai - 400 076

E.stima.tes reveal that a substanrlru. portion, approximately 8- [0%. of the total oa:pital expen.ditwre of (h.e chemical p-rocc5s industry is Q!d for the EfOc,W"Bmen.t of valyes...Jn_terms of the, number of units also, valves exceed ~y otber piping component. Hence, proper

PIPlNG ENGINEERING CELL

VALVES

Functions ofVatves

II

lNTROOUCTION

I

Re,iuladon

The design of'tbe valves are done! ~n, such a way as to perform any of the above fun,ctions. The type of valves 'Used, can 'be: classified in the following, categories.

1.0 ISOLATION'
1.1 Gate V alves
1.2 Balli Valves
[,3 P'llllg Valves
1..4 Piston Valves,
1.S Diaphragm Valves
1..6 B~tterfiy Valves
1.1 Pinch Valves
2:.0 REGULATION
2.1 Globe Valves T. N., GOPI "ATH

thOUght should be' given. for the selection, of valves. The fus.t step in the selection is to dete:rmine exactly whlat function the valve is expected til perftmn after' it bas been installed.

Valves are mstalled ODl equipmenUp~p'mg to perform :i'Uly one of the' following functions~

I

Non-Return.

I

Special Purpose

2.3 Butterfly Valves

2.4 Diaphragm Valves

2.5 P'iston Valves

2.6 Pinch Valves

3.10 NON-RETURN

3,I Check Valves

4.0 :SPECIAL PURPOSE

4.,1 Multi-port Valves

4.2, Flush Bottom V:a]ves,

4.3 Flo.at Valves

4.5 Line Blind V.alves:

4.,6 Knife Gate' Valves

v.alves

PIPING ErNGIN'EERING CELL

Pll'JNG ENGINEERING CELL

oommontypes of valves. API 600 specifi1es Trim: numbers in tabme 3 of the standard. It speoifies tile types ,of m:ateria.~ which can be used lor the parts with its typical ~pecificaJtion and, grade.

3. Trim (_ wo.,.\:l1 ~ ~ ,~I~; The trim is com_pris,ed of Stem, Seat Surfaces" Baek: Seat BUihmg ,and other sman, internal parts, , art ,PJLrmally !Contact tbe surtllce flUId Tile table below indicates trim of

The above classifieatlcn Js based on ftmctions. The valves could also be classified based on the type' of eenstrucrion. Valve manufa'cturers: offer endless vmeties of construetiens. Based. Oil the operation,valves: can be b,road1y classified as eperated valves, and self':' loplera~ed valves" MainIly the cheek valves are self-operated and all other types COme under operated valves.

The v:a1ves: can fUrther be clasmied based on the end connections. End connection means the arran,gement. of att:acbment of 'the valves to the eqll.ipmelflt or to the piping. The types Qf end connections are:

4.,,0 GWl meta]

5 .. 0 Carbon Steel

6.0 Stainless Steel

:8.0 Poly Propylene, t.JH1\.1W-PE,

tJIDdW";HDP£ etc ..

5).10 Special Alloys

Disc g,uid!; Seatrmg

Seat Ring Disc holdel' Side ptug Hotder' rPin Piscnuipio

Stem SeatRmg Disc g,uf Bwhlng

Stem SeaitRims Wedsc run,S; BuslWI,g

W.O Fluoro polymerlElastQmer lined metals

1] .. 0 Glass

1.0 . Screwed ends

TERMS USED FOR VALVES sPECmC'ATION

1. Pressure .. Temper:-atureRatiogs,

. PreS$UI',e ~ Temperature Rating

is the: .maximum aUowable sustained n,on-shock pressure at !:he ClQrresponding tabulated! temperature .. These are listed in ANS,IB 16.34 andANSlB H5.'s.

~~t 1. C.ass

The valve is specified by the pressure rating of the body of the valves. The Ammo,an ,stand ani specifies the follo'Wms: classes.

2.0 Socket weld ends

4. Wetted Pads

~U parts_, which cone in oontact with the se:rvice fhlid, are called th.e wetted ~.

7. Quart'e.r ~ Turn 'Valves

This refers to the valve where the entire operation 'of' valve is achieved by '90 degrees, rum efthe dosing el'ement

J.O Flanged ends

4,0 Butt weld ends

S" 'Wire .DrawiJiJJg

This term, is wed to indicate the' premature erosion. of the valve seat: caused by ~cess~ve velocity between seat and seat disc. An erasion pattern ~s left as if ,I wire had 'been drawn 'between the seat sun aces .. lExcessiv'i! velocity can. occ·ur when the 'valve is not closed tighUy" A WOG (Wiater~Oil~GS!S. relatively' cool liquids) disc, is the best defense against wiredrawing: because its resiJi.ency makes it easier to close tightly .. Discs of harder material are to be closed carefully to' prevent wire drawing, In LPG Service. the wire drawing e,fieet caus,es a threat of anti-refrigeratioa, The ice fh:rmaooo on. the wedge win obstruct mevement theI1cby mcrea.sin~tb:e leak througl), ,seat further. C. ~ ~"1 ~

. ,. v~)

,6,., Straight." Through: Flow

This refers to the valve in which the ,closm.g ,el,eme.ut is retracted entmdy so that there is no restriction of flow,

8. Pressure Dr,op

Pressure drop is the loss of pressurlC through resjstanceacrossthe valve whu,e flows and is expressed. in terms of equivalent length. in pipe diameters,

5.01 Socketted ends

6.0 WMer type ends II

7.0 Buttress ends

Eqw'iI'a]'e:nt
·~!1IfVa1v,e Position lenglh in, pipe
Gate: dia([JI))
fliilly 1,3
opelll,
Globe I.' 340
Angle globe ... 145
Swiqeheek: !o SO
Plug- il!! 18
Re~tarligular
PllI!gPon
Ban - R!egulm 40
port
:Sall- Full pol"! .. 8 The valves: CQwd. also be classified based Oil the' materials: of co:ostmetiQn. There can be .imY number of combinations possible with the: materials: of construction. It is, for the piping leogine,er to select the same in. consultation with the process engineer t.9 suit the: 'process, fluid. The environment in which the valves are installed' is: also to be eonsidered for seieetion of materials of eonstruetion, Hewever; the most commonly avlilable materials are:

2.1 Class, 1.501
2.2 Class 300#:
2.3 Class 400#
2.4 Class 600#
2 .. 5 Class 900#
2.6 Class 1500#
'2..,1 Class 2500#
2.8 Class 800# Jf ""i ~ .!i'W r,.. .~(n..1)
- - - - I .w vd.J~,
.2.9 Class 4500#" ~ ,,~ "'~ ,. Upstream Pressure

This is the pressure of the fluid that eoters the valve, This is sometimes referred to as inlet or ,supply pressure.

1.0 Cast Iron

2.0 Ductile Iron

:3,,0 Breeze

Va-Ins

PIPING ENGINEERING CELL

110. Downstream Pressure

This is the pressure ofthe fluid that is discharged. from the valve. This ts so-metlmesreferred to as, otlitlet or reduced pressure.

. II. . ~ o_.,A li!J,JnrQ

1l,.LDAR l ~~~: ~ ')

S ignifies "Leak Detection And Repair' to ensure thaitthe' fugitive emissions standards of EP'A 'are met. _gWtiv~ emissions are the minute amount IOf e,rocesL media.fEit escape into ~ ~tmosphere, though gland. packing almllg valve stem.

12"LAER

Signifies "Lowest Acbievable Emission Rate", It is the minimum rate of fugitivle emission. which is achieved by dleploymg proper sealing arrangemeat.

Class, I

, A modification 'of any class Il, III or Nvalve'where design intent. is the same as, the basic <Class; but by . agreement between user and supplier. No fest is required.

0.:5% of rated valve capacity

'OJ % of rated

valve capacity

Class II

Classm

Cl'ass]V

0.0]% of rated valve Icapacity

5 x ~O~I mJ p·er minute water per inch of orifice diameter per psi differerrtiaJ

eaassV

Class VI

as per table below

S'i:ZI" NB rnr. per min. Bll1bble pcrmiinutc
I O.tS ~
I.S 0.30 2
2 I OAS J
1.S 0.160 4
3 I 0,'90 6
4 1.10 1.1.
s ,..00 21
8 6.lji 4S Valves

P(PING ENGINEERl.NG CELL

~ <
Q I' QI 10 0 IQ ~~ 0 CD !fI ~ ~
'I"" : ,"I I~' ,_ Ii ,... ".. r "..
I! I. m I ffi I m ~ ~ ~ ~.
. 1:1 b ~
C'li CO)
'e'! C1l ~ .- O!l OJ 0} ,... 01 ~ I uo' 0 In ~ "'! In
~ ,~ ~ !i! ~ ~ ~: ~ ~ .~ E ~I E ~ ~ E
'1:: p: is
.. ~ I I ·1' ~ ~: ~ ~ ~ i .F ~' .~ I
J II I I .,., 'C
.,fg ~
'0
C G I!;;: -
-a- i" l ~ .; as (£!
-
If .,.~ 1:1) (;i
~ ~ ,0 f2w ~
- ""-' _.'\...
('1;,1' C'oiII ~ ~~ 'CD C",i,I e ~ en (!')
CQI ClQI ..... , ,I
..... ...- ~ S! CD .a I ..... .....
<C <C -< ..... U· - Co) ,.... ~ ~
..;( J!' -e ~ <
~ ~ ::::5 ~. ~ i! ~ ~ :&
t;; ~ ii s t;;
001 I, U) ~
'iCC .cc: ..;: ::::!ii '4:: ::::=: <: < N ....

..

Valves

.5

PIPING ENGINEERING CELL

PIPING ENGINEERING CEL,L

C.S. Body SS a) baUPTfE

seat 800# SW

BaU

e.s, Bodly n%Cr. Tlim 800#SW OJobe

CooS. Body ]3% Cr. TJim!!OO# SWGlobe: valve

1.

W'- t ~." a)

Condensale

RECOMMENDATION FOR VALVES

CBEMIC'ALIBULK DRUG P'LANT

b)

sa,

SBRVICB

Size NB

I

Isnlatien

NOl'Hctum

SteamH.P.,

\4" -1 Vi" a) e.s, Body ,steUiwd trim 800#G~obe with SW' ,endS

b) C.S., Body stellitodtrim 800#}!~tGn with SW ends

~) C8Body SS Ball. Spcc:ial P1FE seam. ,800# SW bidl valve

SAME AS LP STEAM

,a) C.S. Body steUitcdtrlm 800iGlobe . with, SW ends

b) C..S .. Body st:e:lli,ted trim 800# Piston, with sw eads

C,S.Body ~Helli~ed !:rim 800# Liftche~k wiuk,sW

Ends

Piston val",es are costlier. Fromthc point of vie,w,of Enerw cllllScrva~ tio:m,'tney a~ O~K..

I 2n~ 12" _

It) C.S.BodY SS a) C.S. Body a)

Ba1I1! PTFE B% Cr.

Scat 800# Trim 800#

Seni Ball SW Globe

b) a.M. Body b) G.N:.

Bl'o~e Irlm Body check

!Bronze With SW I _

Sc'rd Gatel:O Ends Bro~

IS 778 Trin:J Sc:rd b) n 111..1

Globe to OI,.J._j_YI.,.

IS 718

c.s, Body 13% Cr. Trim SOO#Lift

4.

Utilirlc,s llke Watcr~ Ak, I;SBS

bodyuot ReCOHU1lC1l dedm acidic abnGl5ph~r~

Body Bron:zc Trim

2"-12"

a) CSBody stc:llited trim 300#/1.50# Flgd

Glo'be

a) CSBed" SteUited trim 300#llSO~

a) CS Body stclllited trim 3 M#ft5 0# ,FJi81ll s1Ni:ng cheek

ALL VALVES ro as APPROVlmSY ffiR.

check ~o IS 778

Rec(:unmen dation :f~t AirCS Body-Oa]] or Gate for [solatiOQ

a) GIB04y B%Crdisc: 125#;waler lJi'l)c Butterfly Gcar Operator abo've6" N8

f1;gd'Gate with flex Wedg~

b) CS Bod,y 13% C:r'1:l'fm 300#1150# PlgdPislon

a}1 CS Body' 13%ICr. trim

water type cheCk

:a) CIBooy .13% Cr disc 125# wa{e,rtype Buttetfly Gear

2,"- 12"

b) CSBody 13% Crtrim 300iN150# Flgd Fiston

OpcratQf above6"NB

b) CBady 13% b) Cr,or l8% Or

mm 125#

Flgd. Gate' 'tOI

IS 14846

b) CIBody 13%01' 1,8%Cr tri 125j Dad swing check to IS S312

CIBod)' '3% D,t 1.8% Or triml2S# Flgd, Globe

StecamL.P.

2.

W' - ] W'll;) CS; Body B%Cr. Trim 800.# Globe with SW'ted.!l

rb) CS Body

L30/0. o, Trim 800# Pi$t-QD

a)'CSBoo1 13%0, Trim 800# Globe wttl1 SW ends b) CS Body ll%Cr. Trim 800HPistoili WithSW,en~

C.S.Sody 13% Crtrlm, 800# Lift checkWLth SW'Ends

NoIER APP'R REQIJD. FORPR. 0::: ,3.5

Kglcm~g,

Withsw

lends

c) C SBody SS Bidl Special. PTFE se~tS:. SOO# SW b1!ll valve

I c) CS Boo!y 13% Cr b:im 150#Bgd Oldbe

c) CS Body 13% o !rim,150# FI,gd Gate

d;) Cast han.

Body 13% o plug 125 #Fldg Lub. PIllg Valv~

c) CS Body Ij%C!:'~ 150# fJ;gd swine: ~he~k

'12" - 12'"

a) ,CS Body lJ%Cr trim 150# Bgd Gmabe

b) iCS Body 13% Grtrim [50# Plgd Piston

a) OS Body a U%GJ7.Tdm F1e:twedge lSO#Flgd Gate

10)1 CSBon, 13% Crtrim 150Nf'!gd Pis;~Qn

c.s. Body B%Crtrim 150#Llft ehec;kWitl! SW Ends,

Valves

S)

Hot Oil! Beawg Fll!id

PlrrNG E IGINEEIUNG CELL

P,[PING ENGINEERING CELL,

12"-12"

6)

a) eli. Body Sielljted trim Gtaphoil pkg: 8:00# SWOkihe:

b) CS. Bodly B%'uim BOO#SW PistoD, wilh sullatbl,e 5~&iDg rlns:~

a,) C.S.

Body ste:llUcdl trim S,OO#SW lift cheE:k:

So,l.lIentl process (Stajnless Steel)

S'ol1i'en1f Process

(Highly Como~ive)

Wi - 1:2"

a) SS BodySS balllSO# Flds; fulllOOr1l ball valve withPTFEI GFfseats

b) SSBodySS Plug, 1501 Flgd sleeved plug

a) SS body SS triPll 50# Ag,em G~obc

SS Body 5S trim 150~ F]gn swing Icheck

[ill Ductite Iron body

. lined

witO

SuitibiR fity with 'fc'liIlp erawe to be checked

,Solvc;nt! Pn;lCeS$ (Ca1i'bon Steel)

%"_ 1 W' a) C.S. Body Stellited trim Gmpb,()iIl: pk,g 800#SW Globe

b) C,S. Body 13% ttim BOOIilSW PistoIl with suitable :sealing rings

W'-l'Z"

a) C.S.Body B%Cr. trim 150# FlgdGl()bc

31) C'.s.. Body L),% Cr. trim F~gd [Jft check Ya" fO 1 W'wFlgd swing cuck 2" 8i: above:

a} noodle Iron body &plog lin.edwith fluoropoymer plug valve

t;~) Ball valve with suimble' pbstic body and ball

fiUQlO polymer bidJ ,check valve

b) ...... do-

9'

7)

'Valves

a)CSBody ste1Jited trim, graphoil pkrg 300# (Min) lFlgd 'Qa,t:e with 125 -2501 AARBFlgdl fmisb

CSBody steUited trim ,300tt (Min) Flgdswing: cb,ec:K, wi1iA 125 -2S0 AARHFlg,d Finish

a) CS BQi3y stellittd trim Gr:aphoil! pte: 30011 (Min) FlgdGate, with 125 ~ 2S0AABli FlgdFmisb

b)t 'CSDody i3%Q'IriIn 'Ci:nJJpho:il pkg ,300 It (Min) F]gd Piston wUh Suitab1e seating ring and 1.25- lSOAARH Flid finish

b) CS Body

]3 % Crt:riin1 Gripholl pkg 300#(Mm) FJg,d PistGIi with Suitable seafing ring ,w 12:5 -250 MlHFlgd fi.nish

Ball 1o':alv~ 'with CS body Mone:V HasWIoy C ball ,j(.stem,

Q[Q," Valve with CS Body MOfiC) I lli.stallo,}, C trim

Check (Lift I Swing) va1ve CSMDne:ll BastaUoy C !rim

I) C.s. Body' 58 Ball 150Rgd full port 15b,U valve with PTFE/GFT seats

b) eBBody 13% Crplug ISO# f'19d 5leevf;d p'lug seats,

Vilves

~'" ~ 12"

PIPING ENGINEERING CELL

1.0 ISOLATION VAL YES

The isolation valves used in the Process Indus'try are:

1.1 Gate Valves

1.2. Ball Valves

].3 PlugVaivcs

'1,.5 D" L_ Val'

---' mapmBgm. yes

1.6 Butterfly VaJves

1.7 Finch ValveB

or these, the Buttertly, Diaphragm and Piston, Vallves can be used for regulating 'the flow as well. Similarly, the Olobe Valve design cou.d be medified IQ use it fer positive sb'Il't-off purpose-s, The presem trend in in,dustty is to go for: quarter tum 'valves for 'this, duty dueto ease of operation." The: types of vatves in thls eategory are the SaU valves. Plug valves ami Butterfly valves. BaIlmd Plug; valves are also can be used for flow control with sh~ed port of the closing element, More over the design of quarter tum 'valves are inherently better suited for emission control applications. The Iineer stem movement ,of the S'lte and globe valve tends, to open the' path of emissions release and in its dynami,c mode" emissions, lean be "dragged" alonli:: .'"

the stem. - ~,~

fl..., ,~,

rP \2'" ,:rf" '" t,. I c;I:.{jf .:'>

G TE VAL'VES 11'lo.,_\"\' , .. ;v '-.: ~j

1.1. _ A "r" I .. ' "

~\;~ '0

A. typ,ical Gate: valve will have the fcflewing parts. wbic,b could be identified,

IJ.1 Body
1.1..2 Bonnet
IJ,,3 Wedge Valves

servic'6cslike: the nuclear. very high temperatur-e and lethal services, The screwed-on bonnetlunilln bonnet is 'Used fur very low priority application snd :smaU ,size valves"

Wbenval ves :ue lils1l:d for Cryogemc Service extended bomet design is -used. to ta.ke care 0,'( Juge insulation truekness. When used! for v'ezy high temper-at:lme bonnet attached with tins are also used.

1.1.3 W,ed.ge

This, is the part, which facilitates the service by its movement up and! down. The: type,s ,of wedges, are classified as;

.. Solid Plain Wedge

.. Split Wed,ge

When solid disc is wedged init'o the rigid body seat and the valve undergoes temperature changes, tn.e wedge gets j ammecl in the seat. Hence the f1lexilde wedge ,and :Wllit wedge design is developed to overcome this, difficulty.

NO.In18.l1y lb.! solid plain wedge is, referred as solid wedge and the split wedge is referred as flexible wedge. The desi,~ sliglltly alters with the manufacturers, though lfue basis remains th.e same.

The flexible: wedse design. is foUowed. for valve sizes .50 NBand above, Valves 40 NB and below are available: in solid wedge d,esign only, F1exible wedge design is, superior as it will not get jammed during high temperatnre· operations.

The wedge Ti,"lJfLterial, should be at, 'least of the same ql.lanity as: that e,f the 'body. In case of integra)] seat rings the wedge circumference is depesited with superior quality material. fusma1ller valves, die whole wedge: will be manufactured out of superior mate-deJ.

Valves

1.1.1 Body

The body is the part which geES, attached to the vessel or piping. The classification of the body could be dane: depending on the end connections as indi.CIit,ed! earlier. Bodly could also be specified based on the material of construction of the same, This could be cast, ror.s,edl,or fabricated.

The wall thickness, and. end. to lend/face to face dim.ensions of ithe hody shall be as per the RegulatoIy code to which it is designed.

The end! flanges shall be integrally cast ,or forg.ed with the 'body. It can also, be' attached by welding, if .80' specified. The e:nd conneetion shall suit the rating specified. The flanged connection shall be to ANSI B. 16.5 or any of the: flange: standards. The buttwelding end conoectioe shall be tal ANSI B 16.25 .0,[ any other end preparation required, The socket weld/-screw connec:tion shall be to ANSI 13 16.] 1 or any other equivalent standards. The: body can have' awdliary eoanection such as drains, by-pass, eonneedene, etc.

PIliNG ENGmEEIUNG CELt.

1.1.4

Stem

1.1.5

G~:and

t.i.e

Se:at ring

1.1.1

Yoke

1.1.8

Packing

Ll.2 BORDet

The bonnet is dHSHied based loa. the attaehment of the same to the badly. The type of connection norm,aUy ,a,dop;ted are' .BQ[t'eo" Bellow sealed. Screwed-on, Welded~ Union, Pressure sealed etc,

The bolted. connection sha:11 be fianged, J;inale and female" 'tongue and groove or ring type joint. In low pressure rating valve-s, it may be flat faced The bonnet gasket is selected to suie bodybonnet eennecticn, It can. be corrugated flat 5o,lid metal, flat metal jacketed" asbestos filled;, metal ring joint, spiral woun,dasbestos filled. or flat ring compressed asbestos in ease of low pressure rating, Teflon or Teflon filled for corrosive appllearioos.

The Ibc:;llow sealed bonnets can be bol~ed or welded on to the body. 'These' are sefectEd for very critical

1.1.9

Gland Flange

1.1.1.0

Valve Port:

1.1.11

Yloke Bush

1.1.12,

Lantem

t.L13

Back Seat Bushing

1.1.14

Glan.d ~yeboUs, & nuts

1.1.15

Bonnet bolts &, nuts

1.l.16

Hand! Wbeei

1.t1'7

Hand Wheel nut

10

PIPING ENGINEERING CELL

1.1.4 Stem

The steM conaects the' hand wheel and! the: wedge for operations. The design can have rising 'stem. and nonrising, stem.. The stem is operated, ro,tating the stem nut by hand wheel mounted at the top of the yoke.

In, the rising stem design, the stem moves up along with the wedge to epen, This is called the. OS & Y (Outside SCEew and Yoke) type of design. In case of Don-rising stem the wedge, moves up and down and the st.em is stati();n;ary" 'Thls is, called the: inside screw non rising stem design,

Normally. hat stock or forgjng are used fot the eenstnsetion of stem,

].1.:5 Glan~ Gland Oange, Packing Iud Lsotem

There are two types of gland destgns possible, Single piece and Two piece, Intwo-piece design, there will be gland flange and ,I follower. The follower will havei a spherical end. which facilitates; proper aligning of follower and loading on the packing:. In Single piece; the gland and fcllower will 'be integra~. This desill1 is used. mostly in low-pressure valves.

NOIDlally gland follower will be of superior materia] than the gland flange. Gland flanges are made of carbon. steel only. Thei glands are hoUed to the bonnet withglan.d eyebolts La lowpressure: valves.

Thel1egulatory codes specify that the smffing bo,xsnould accommodate minimum six p,acking rings, for class 150 valves. As regards ru,gher rating valves, it should have lantern ring with five ;~kin~ rings above and tw,o packin ' s' . e ow lantem. Lantern is, net provided for class ]50 valvC$. Lantern is provided for' higher ratipg if required. When lantern is provided, the stuffmg box shan be provided with, two, plugged holes, The'

material of lantern shall have corrosion resistance. equal to that of the body.

Normally; the p,acking is of braided asbestos with suitable corrosion, iohibitor. When special packing such ,IS 'Graph oil' is used, the number of packing nngs reqoir,ed will be more, To accommodate more pa'Ciong rings, the 1eng1lh of gland is also modili,ed. 'This, design is called the 'Deep Gland." design, This is used for the high temperarure serviees, Bwt Uris: cannot satisfy the EP A"s fugitive' emission standard of <500 PPM threshold. Hence frequent LDAR will result in excessive expenditure,

1.1.6 Seat Rings

There are two types of designs possib:te in seat rings.· They are the mtegr,al and renewable, In case of renewable seat rings, it may be either threaded. rolled-in lor welded-in, In case loi integral seat rings, the seat material is weJd=depositled directly on to the valve body. The minlmwn, bardness specified by the' eode for this material is 250 HB', wi.th 50 HB minimum diffet"enDal between body and gate seats" the body seat being: harder. Deposition of harder' materials lik.e "S~ellite-6n is also' done for valves used in speci:a1 services,

'The back seat :arrangement is provided to repack the stuffing box when. the gate is in NLLy open position. The stem- shan have an :integm~ conical or spherical backseat, smfa.ce to, seat ag~t the bonnet backseat

1.1.7 YoRe :8Dd Yoke Bush

Yoke may be iinte,graJ with or separate from the bonaetWhen the yoke is in~.egml. [be stem Dut should be rem.ovable with.out removing bonnet. The yokeshould bavethe same material of construction as that. ,of the shell. The Yoke hush is 'normally a. Ni-resi$'t materia]. Thls is to.prevcnt gau.1.ing, of@e st as stem will normally be (If a Ni'ckel :alloy.

Valves

1.1.8 H:lIld wbeel aDd Hand wbeel Nut

The hand wheel is fixed to the stem by a threaded hand wheel nut 'The mow pointin~ the dlrectioa to open the valve will be marked with the WOld "open" or "elose" or "shut'·, unless the size makes it impracticable'. Valves shall be dosed by tum:.mg the band wheel in clockwbe direction. ,

TIre material of construction ofhud wheel shall be malleable iron, Carbon s1ee[, Nodular iron or Ductile! iron. Cast iron is not JII~efened.. The nut shall be of. carbon steel or st~nJess steel.

When, the installed position of the valve is ,$uch that the: hand wheel is not accessible" then the band wheels are replaced by chain wheels: and the vaJv,c is operated. with chams. For Jarg:e ,diameter valve where the operating torque is lUgb., gear a!tangement is p:ro,.td:ed to faeUitateoperation. Mostly, bevel gear equipment is adopted, General reeemmenderioe for speoifying Gear opem~or is:

Valve Rating Class :150 Class 300

Cl~s 600 & above

Size

t4n'NB '& above 12"NB,& above 8'" NB & above

If remote opemtion of the valve is re'llm-ed, then this could be achieved through. motor 'with limit switches" Proper selection ofthe drive unit should be done depending on the services, -

1.1.9 Bolting

NonnBUy high, tensile ,stud 'bolts are used for bonne,t 00ltS and low Icarboo bo,ns, for gland and yoke bolting. Gland bolt~, are normally bln.ged bolts with hexageaal nuts.

1,,1.10 Valve Port

The valve size is specifled bytbe size of the end cOiJDlection or the body

end. The port or the bore is the passage through the valve,

There are two types of port d'es~gns possible: in gate valves, full bore and . reduced bore. In case of fuU bore, the net a;rea of the bore tbrOligh the Seal shall be as nearly practicabIe equal to the nominal pipe size. Fo:r reduced port valves, the port di,wnet'cr is noanally one size less than the size of the end,

The compact design small bore (Yl - 1 ~ inch) g~te valve'S are as per API 1602 or BS 5352. Unless the full bore design is specifically asked for~ manufaclltters supply Ole reduced bore valves, The full bore design gate' valves are also covered in BS 5352 and is designated as, 'std bore i'. Itt fil1l bore design, ~enet area of the bore tbrQ1Il;gh seat shall be equivalent to that of Seh 8:0 pipes ticr class 800 valves and Seh [,60 pipe for class 1 SOil valves, In no case less than 90% of the above figure is acceptable as per code.

1.2 BALL VALVES

The ball valves are nonnal]y used as positive shut off valves, The positive shut off is attained because of the soft seats. Special design is also 13!v,ailable with ball having shaped port (0,1:' re,gulation..Metal seated ball valves are also availab~e for high temperature service. The ball valves: ean be' classified based on:

rz,

,

PIPING ~GINEllUNG CELL

• The port size

The typJ 0:( body eonstruetion

•

•

The construction of ball

D' The eonstruction ,o(stem

Tbe above classification 18 m addition, to the ones based on, the: end oonnectiOml'I' material fo,r t:onstruction and the :pressure classes, Tll,e pressure: temperatu~e ralings of the ball valves are generally established by the mat:erialls of - the seat rings. -The service ~emper,arureB are also limited by the material of'aeat rings.

The 'ball valve offers: minimum resistance to the flow" TheTIB me 'two types of designs available as .far asthe tloW area through the valve is concerned, They are the Full Port design and the:

Regular Pert (Reduced Port) design. In full port valves, the port diameter will be ,equivallem to, the nominal size of the valve, whereas in the regular port valves" the pod diameter will 'be one size smaller than, 'the nominal size. Valves with shaped port: are used for flow control applicatio:ns ..

Based 'DtII the body censtruction 'the valve could be classHied. as:

•

Single' piece design

Two piece design

Three piece design

•

Tbe sbartpattem

•

$I'=' ·b ~ s: 'Inrrt, ee: :1, fL,.- b,.I!t:,~ riPt, ", ',' •

_ l~rfnL lJff4.'l Ad ~ ~I ~

•. Ex!mdod bod~ design. . ft-"- ~ ~ ,.

It Lined Body 't:: ;:;:c.

In the single piece design valve, the body will be castlfo,r:g:ed, as '0.1113 pieoe, The insertion of the ball will be through. the end or through top of the body and is held in position by body insert or bonnet.

The side ~' d. esign restricts tb,e valve" 1.~ eo be afreguiar port orilly. ~-.:;o v...U.. \..., a~ r .

In two-piece design. the body is constructed in two pieces and the ball is held in position by body stud. Th,ere: can be ,fuU port or regular port, design possible in this ceestruetion, In case 'of three-piece construction, the body bas two end pieces and one centrepiece. These are held by body studs.

same' has been explained ,earlier., The ball at: the bottom leocll,ofthe. bodyconid be supPo,rted :fuJly' by Ihe seat or it could! be: trunnion supported. The ball 'can be solid ball or of hollow construction with. I .cavity .. The ,cavity is to be sealed when the: valves, are used in volatile liquid, This design of the ball is; caUed! sealed cavity design.

The eland shall be bolted type' or screwed .. Inte:m.a11y screwed s,tuf'fIDg: box is, not allowed by code. B,eJJoW' sealed bonnet is abo provided in case 0 f valves used in ~etha. services, Two basic bellow seal. designs. are: available. The same is explained' under plug val "lies.

The val vesshall be operated by wrench or by hand wheel with g.ear an_glom,ent. The wrench shall 'be designed so. that it is, p,araUel to the fl.cw passage ,of the, ball, The valve shall be closed by 'tumiQgthe, Wl'leDch orthe nand. wheel in clockwise direction, The lengtb of the wrench. or the diameter of the lland, wbeel shall be suchthat minim,urn force is required to operate the valve underthe maximum differentia] pressure.

When :addedl emission control is required, additional packing and. leal( off port are options that can be added,

Norm,ally all the parts, are metal except the resilient seats, in a ba1ll valve. plastic ValV,BS are also s'e]eoted for corrosive process fl!uids while they operate up to 150 psi and IOO-lSOP'C and also in food industry. To select the best plastic, valve" process data such as number of cycles belfbre faillures is critical. Ball valves limed! with PTFE on tbe body and eeramie ball is used fo:r extreme corrosive fluids.

],3 PLUG VALVES

The plug 'valves, h"kebaU valves, are quart,er tum positive shut off 'valves. Two major types 0'£ plug, valves are in use, They are the lubricated metalseated, plug valves and T·eflc)o sleev,ed piu,g valves. These valves can have flanged, butt-welded, screwed or socket

Valy,es

15

PU'lING E ·GINEE&lNG CELL

are possible" viz., the fire safe design and the non-fire safe design. In 'the fire safe design, ill. secondary metal seat win be prO'vlded so that 'when the soft seat is fully burnt, the hall will shift its position an,d seat against seeondary metal seat MId arrest fu.]] leakage. The modified. design incorporates a double staged stem seat dlesi,gn and a seating system that adjUSts to the line differential. pressure, At low differential pressures the floating ball seats against resilient tip seat, At higher differential pressures" the ball deflects 10 proQucl!! contact aCIQSS the entire s.eatingswiac,e of the s,e'at riDg.

In an actual fue,the lIleat mtensity of the fire could be so different that it is impossible to ensure that elastomer seais are fully damaged during me. If the seats are only pam,ally damaged, the ball CaDJillot take seating ;against the secondary metal seat and hence the valve would leak. Hence, in my op:inilon, none of the sofl-rseated baU valves can be declared fire safe: since the valves are bouad to leak: En case: of partially damaged seats. The manufacturers have come lip 'with metalseated ball valv,es. which are mlly fire sale. Here the resilient seats are replaced by metal seats, Whiieb could even be deposile~ with bigh temperature reSistan't

- -

materials The: fire safe· design should

also ensuretnat any dev,l'lopment of static electricity should be: fuJly discharged by proper design and m.an.ufac:blre'of valve, Such an arrangement, is, called -the ''ADti,''!stati,c'' design. 'This eD.SUlJe8 !Q have a discharge path fro.m ball to, the spindle and from spindle to the valve 'body with an electrical resistance of not greater than 10 ohms when the valve: is new. A typical method of achieving earthed continuity is to provide stainless steel spring-loaded ploog,ern" one fi,itted between the stem tongue and ball and second fitted between stem and! body.

The ban could be of full bore or a reduced bore, The design aspect of the:

PIPING ENG.INEERING CELL

P[PINGENGINEERIN'G CELL

weld ends. The pressure classifieatien is the same as thai!: specified for the gate 'valve's. The raD!te of pressure to which these' valves could be used depends upon me: seat, seals and the lubriGan~. Plug valves with shaped po:rt are used for flow control ,applications.

1.3.1 Metal Sea,t,ed Plug V:alves

In, lubricated plu,g valves" the lubrication of the seating: surface; is by means of lubricant.whi~ is fed into the operating surface of the valve either in the form of mastic ~ticks 0,1' by grease gun. The selection ,of' the' Iubrieant depends upon the service to which the valve: is subjected to. In certain desig:ns, a low friction Poly Ten, Fluoro Ethylene (PTFE) Is impriegnal,cd on the surface structure IOf the valve plug, This is called 'LOMU' lTeatnlent Thisrred'llces the frequency ofval!ve lubrication.

The plug valve: design, :r:efi:rs te tbr-ee ,&ttems consMerilig 'th.e shape or port th:ro'ugh 'the 'valve and the overall length. The,. are the regular patteDJJ, the sho,lt pattern ,and the' venturi pattem.

The regular pattern valves have plug ports generally 1iectangulM in section and have' area substantially equal to fillJ bore of the pipe., The transition lllom the round body to rectangular sean ports is smooth. 'Without sudden alteration in section. which causes turbulence, 'These are used where pipeline losses are to be k.ept minimum.

The short pattern valves have face-to-face dimensions corresponding to wedg,e gate valves. This is, used as an alternative to' gate: valves,

The Venturi Pattern. V alveahave reduced port area. The cbmlge of seetiea through the body throat is so graded as 'to produce a venturi effee:t to restore ,I large percentage of velocity head .IiOSS tbrou.~h the valve and produce a resultant total pressuredrop of relatively low order.

The plug could be installed with, th.etaper towards the bottom end of the body or reverse, When the mstallati,QI!l, is,

with the tapered portion towards the top, it is caned "'inve.rted plug', Nonmlly larger diameter {81m and above) have this design.

An,other design: in, use is, the Pressure: Balanced pilu,g. The benefit ,of the pressure .. balanced design is the elimination of the possibility ,o,f unbalanced forces causing taper locking 'of the plu,g:. Thisi$ achieved by using the live line pressure to replacethe sealan~ pressure, The regular sealant injeeuon is not needed to keep the valve free to tum.

The pressure balance system cons:ists of two holies in the plug connecting the chambers at each end of the pt\lg with the port.wroch Icontains line pressUl}e.

The valve having: pressure balaaced is called dynamically balanced plug. MIs Audco called these types of valves, as 'Super-H' pressure bJilanced, valves. The brerucaw,ay torque required to 'operate these valves are lower than (almost half) that for th.e reduced port bali valves,

Valves

n

'Skilc ellmnotOi stalnJe.Sfeel

Ai::I]iAlfhgQJc;rMf

Stcili'lc:III d,ed~ 'Gi"Ner pi cded

It

+

e:t'

-='"

o

o

o

C'QJet~. ;taIJ'1lB99 steel rep ~. malmble ~iroo

ThruIf' collar, ~alnle!i!Ql!Qfeel tormed ci3ptucgn:Tl. FiFE

IjIU g" .F EiP Di1 flFA, 1M dI dUCI11fli ~orn

Com,parDon of Break,away Torque' Reqwremeot of Valves

8:o;tt. FEP ~ PFA lined dud1leijQn

"fhe following data, has been published by ,8 valve manufacturer 'to mdleate the easmess in operation. IOf tb"e p,ressme balanced :p,lug valve.

BI;~Ug:n' Qb,phrlClgm. PTPE' Jd'tan dbptltagm • ;tal~;tee.

• •

Satan a(:QJctment pleC$1.JIfe el:

bul'tOiiTl. ;teel

~

IBcttUi\i cC!Nt!I lITIol eaQls Iron

Calle!" bah. ,iitaln_ pteel

i8,d1,c:nIi Gc:fjJ#llI1'IeAflcle!/'i' lllilh I

IockniJ. ~Clh_ steel A

In Teflon sleeved plug va[v,cs. the plug and the body in the valve are separated by a PTFE, Sleeve. This sleeve serves as the seat far the valve pluS', thus eliminating the' contact of' two metal surfaces. Here, the turning 'effort is low and. mctIon is avoided. The !:imitation is.

~" .. -~- ~)~ .. ~-i~~-~ - .. ,
I
~'."'.:, II a~) •. ; :1,).- I ':111 \,1,,;~~1
" :;J.1 J~ : ;}J!~ l~ i ~ fll"
_ _ .....-.....lL.,___ ._ - ~ -:L- ~
2" 1S I 86 60
J" 2S4 2M 120'
4" II 5:8 '284 17S
~;' I USS I l~SS 32:S J
8'~ I ]950 I 11.58 600
ma" I - ., .. 910
12" - - 1100 Valve-s,

1,.3.2 Teft.oD SI,eeved rlu,g Valves

the temperature to which thel sleeve can,

I

be subjected to. The sleeved plug valve

also is, a:vmlabfe complying witlt the fire safeatmosphcric seal. They are not manufactu{ed fire safe through. seat, the anti static design as explained fOT ball 'valve is abo po,ssible in Sleeved plug valves.

The sleeved plug valves are also designed with bellow seals to control the emiasien rates, There are, M'O basic bellow seal design, for qumer tum valves .. One' ~:S the ~'goose neck" or the "beat-straw'' design. The ,other is the '~k and l"lIDOn"'type. The rack and pinion type ~in:ta:ins a linear beUow so there Is less stress and no fortmg~ There is, an alternative to bellow dlesign. is available and is, called a "caged' plug VtdV16. In this design, the plug is inserted in another phl,J~, and! it 'provides inherent emission control ,cbars,Cllieristics of 1I:h~ sleeved plug valve wbile bnproving the throttling capabilities and reducing wear :pat,entiaL Plug valves ata also available with, Fluoro polym,er Hned melru body and plug.

1..3.3 "Permaseal" Plug VaJves

These valves are s:inillair to the sleeved plu,g valves but aI'e provided with Teflon :seats instead of,slee,ves as in the case of ball valves, These are designed for on-off applications and can handle clean, vjSCOUlS and corrosive liquids. The construction features, and operation are identical to that of tlte sleeved. plug valves, Graprute seats abo, can be flTiovided! fQlr high temperature service. But this design eanncU provide drip-tigbt shut off:

1.3,,·4, Eccentric Plug Valves:

'These valves are pr-ovided with plliugs, which ,are mounted, ofi:.ccntre. Eccentric

PIPING ENGINEERING CELL

plug valves are used in corrosive and abrasive service for on-off action, Eccentric action plug moves int,,,, and. away from seat 'eliminating- abrasive wear. These are covered uader MSSdSP staadards,

1,.4, PISTON' VAL VIS

:'

t 't

Piston valve-s resemble in censtruction more towards a globe valve and are used for shut off and re,gnlatioIll. These valves provide positive shlllt off. The shut off assemhly comprises of a meta[ p,iston, two resilie:p.t valve rings and a metal lantern bush. The sealing surface consists of the ou~er vertical surface of the piston and the: corresponding inner

Valv~

1''1

PIPING ENGINEE.RING CELL

surfaces of the: s'ealin,g rings,. This provides a large sealing surface compared to globe valves ef conventional design.

Piston valves arre of itWO types, balanced! and unbalanced, Balanced valves are used in, hlgh."pressure services and unbalanced one for mOW~~lIessure

services"

The bonnet is also oOf the same material as that of the body and it is of bolted construction. The pisto.n ali:mg vyith the two resilient seats provideS proper sealing. The upper valve ring seal I til atm.osphere, tbe lower valve ring pro"lides seal aeress the ports, Ths lantem ring serves as th.e distance piece between the two ring,5,.

There' are two types, of piston designs available: Regulating type and the nc:mnalIn regulating type the: bottom put of the' piston is tapered to have filrottling effect The seiling rings are the heart Qf the piston valves, The seaning rings are made from, specially dleve:lopedl high quality elastomer meterial er graphi tel. The materials, are selected dependin,g upon the service conditions viz. The fluid for which the valve is used and its, pressur,e temperature conditions.

Sp:cin,g washers, .lUY fitted under the 'bolDDet outs to ensure that 'the pressme of the bonnet on the valve ring IS kept constant. This along with the r~i1ient ,scdiDg rings produces a spring acden, which. compensates for lany differential Icxpansio,ft that can occur.

There are two types of" ,stem designs av,afiable) tn.!! inside ,screw rising stem and. '~e' ~" S and Y type with rising ~t:em. The hmdwheel is: of rising design. ][n O~ Sand Y ~e'j a stuffing box with a bolted, gland is provided, This design is mainly used. for Thermic fluidiHigh temperature services.

The piston valves are preferred by maintenance people, as they need lesser attention. They call it as 'Fit and

F.orget' typ ... e ~fvalve. . . ~ .A..." ~

1tr 7A. ~._' . '. V1' ~. ~ tv b--"

Ufo ~ IJP.tM-

1.5 DIAPIIR.A:GM V AL,VES

The main p,arts 'of the 'valve can be identified ,as

104.1 Body

'].4,2 BOmlet,

1.4,.3 Pistou
1.4.4 Valve rings
1.4.5 Lautembush
t4.6 Spindle
1..4.7' Gland
1.4.8 F'acking
'] • .4.'9 Hand'Whe~1 1.4.10 Yoke bush

1.4 .. 11 Bonnet stud

1..4.12 GllaDd."eyebolt

The bod}' is normally of cast construction, It can 'have screwed ends" fim:s,ed ends or ibut:t~wclding ends. 'These valves follow the regulatory codes to DIN. There are no API or J\NSI stmldMdIs covering, the piston valves, Th.e end-to-ecd dimenSions are to' DIN' 3202, which is more than agate or globe valve of the same ,size to APY ANSJlBS standards. Of late, the Piston. V:aJves are also made to ANSI B 16,. ] 0 dimensions,. The end conneetions ar,e also available to ANSI/BSstandards.

Diaphragm valves are .mainly used for low-pressure corrosive services as shutoff valves These can also be used as control valves. Here the diaphragm moves liZp and doWlll to operate tbe v:wve.

ValVes

IS

The' valve body can be lined or unlined,

Ljnin,g material is seleCl1c~d tOI suit eorrcsivenature loft&e service fluid.

Di.aphragm valve wi.th plastic body is also! mB,Dmactured.

There are two types of cUapmagm valves available. They are the W:elt' type and 'Straighr flow' type. The most commonly used 'one is the weir type and are popularly known, as the 'Saunders' type. :in tbis !type', the body oonfi~atiQn is such. that isolbtion as 'WeU as control b '1'Jossible.

A typical maphragm valve has the following m~or parts that could be identified. They are:

r, Body

2. Diaphmgm.

3. Bonnet

4. Stem

5. Stem bushing

6,. Co:mpr&ssor

P'IlING ENG,INEERING CELL

7. Hand whee~

8", Bonnet bolting.

'Th.ebody and the bonnet are made: of casting. The material of construction of the body depends upon the: service: Cor which it: is used. The body can also be lined with cozrosien resistant materials like PTFE, G~assJ Rubber, etc. depending upon, the corrosive nature of the fluid or could be entirely made out of

'I ~ • al Th .:I: - •

p, asue maten _, ae diaphragm IS

normallymade Rom an elastic ma~eriall [:ike fTf1.E, or rubber. Tn.e diaphragm presses agaimst the body to give positive shut off. The port, canalso be adjusted by Icontrollin~ the position of diaphragm" which. is being done for control applicatioas. The diaphragm is, secured between 'the bonnet land the body., The compressor attached to the diaphragm facilitates the up and down movements. There are' two types, Cli'! stem designs possible in ia diaphragm. valve. They are the 'Indicating I mId 'Non-indicating' type. In the indicating m>e't the position of the spindle indieates the port opening. The opening and closi~,g of the valve is effected by tbe hand wheel in a. manually operated valve, The material 10f construction of the hand wheelcould be ductile Imane.:abIe iron er even plastic. The booy ends coUld be :fllaJJge~ screwed or butt-welded as required. In case ofldiaphr:a~ valve with lined body, the ends, are always flanged ,and the lining extends to, the flanged surface, -

Tbe use of these valves is restricted .19 th.~y can withstand a maximwn operating pressure of 7 to 10 kg/sq.emg. The dam,age to t11re diaphragm occurs and 'hence the maintenance is more frequent.. On lined val es, spark testis also conducted in addition to the pressure tests. This is, to ensure that the l.i:ning is continuous and no 'holiday" eccurs.

There are no API or ANSI standards: for this 'type: of valves. These

r I

PIP'ING ENGlNEE,)UNG CELL

are covered by British Standard. and MSS-SP Standards.

M SI- s'p .... flO r (ls:. - S; Ire;

There are three types of hody desiBDS possible in. 'a butterfly valve. They are the double flanged type! wafer llllctype:and. wafer type .. In the deubleflanged body design, the disc f~ contained w1,thin the; body and is fitted to the pipeline liloo any other cOllvlentional valve, These types, of valves are: used rarely .3S. the advanta,g,e of sandwich design is not svailable with the same,

In tbe wafer lug type and wafer type, the valves are designee. to ,Plr:nni~ mstaliatiQD betw,een. ANSIIBSlDIN flanges, There are different designs avamlable; in these types. In certain designs, the body is lined witha resilient material Silch as Nitrije rubber. Ethylene Propylene Diene Monomer (EPDM). PTFE .. The metallic disc w~,tb or without coating eOSUJes, plioper sealing against these Ilin'ers. By selecting proper disc material" this type: of valve can. be us,cd for corrosive services, The body co,wd, be' of any material, There is no gasket needed! for· the installation of these v~lyes ...

1.,6 B,UTTERFL,Y VAL YES

Butterfly valves ,arepositi'V0 shut off quarter tum valves, The major parts of the botter£ly valves are:

1. Body

2. Disc

:3. Shaft

5. Disc seat, or seal

6. Shaft seal

7. Shaft bearin,g

8. Handle',

In certain other designs, the body will 'be provided with soft seat instead of'a liner. 'Ih[s seat flexes asainst due sealmg ed,i!! Q1f tb.e ,disc when, the valve is cloeed, The seat is: made of PTFE with certain. reinforcements. This seating' is diesigned, to replace the PTF.E seats when worn out.

Another de,sign is the offset shaft :an4 eccentric disc design, which ilqp,ans: cannmng action to the disc,. In tltis, the stem eemre Iine, the disc oeone line MId the pipe centre lines are offset, This featm,e causes the disc: to. swing completely out of cGntactwifu tile s~at upon opening. eliminating weill points at top and bottom of seat. Oil dosing, the disc moves ti,ghtly into, the tleKibl.e lip for reliable seating around the entire sear,

Valves,

Valves

'2..0

The difference between the wafer lug and wafer type body design is that the former has provision for all the studs to pass through the 'bodly whereas the latter has provision for only iocating bolts. The wafer lug de-sign, is, also called single £lange: design.

As regards the sbafl: is concerned, there -can be a. single shaft: or a main shaft and a stub ,shaft at the 'bottom of the disc; Single .shaft is a 'better design as it minitnizes tb:e deflectioe. The·shaft seafin\ge.8J1 be done with, '0' mag O't sl.1Lffin,g; box and. P;!cking:., These 'Valve designs provide inherent emission control advantages, over rising stem valves.

Valves up to 12" NB are operated. with lever. Th.e lever can have positions to control 'the floiN" Higher di,am,eter valves ,are pro'vided with gear mit and hand wheel. When used. as control valves, these CM: be provided with aetuatora also.

The use of this type cf'valve for high temperatures is limited. by the material used for seats. Only resilient seats 'can provide :posidv,c shut o,ff. MetaJ1jc. seating em also be provided for use at higher tempe:mures but will 'not provide POSitiV'6 shut off.

These valves can !be used for vacuum ,servi.ce.When used Co.!' CI}"Oaemc service" the valve shall be provided with Bxtend,ed ,shaft to clear the. lnsulation,

When used beneath ,8 hopper for solid handling applications, tigllrt shut off is troublesome since partleles jam between valve closure smfac,es,.further, the valve must be: sttclng to lift half the disc against the weight of the solids, in the hopper. The, advantages of these valves are tha:tth.e wear resistant elastomer has a longer life expectancy than the co,nv,entional metallic seated

2.1

PIPlNG ENGINEERING CELL

(even. stellited) valves when used in hi,gh-density mineral slurries. The seating problem in other type of valv,es does no t affect these 'Valves as the ,encmstedsc's.le. will break when the valve: operates and solids flus,b,. .away with the now. The sleeve is the only wetted pan and by selecting the right

- - ..

sleeve material" the valve bod.,. can be

made out of low cost material. As the design calls for no gland, there is 'no fugitive emission and meets the liP A requirements.

]. 7PINCBVAL YES}.,

Pmch valves are also similar to diaphtagm valves,. In Pinch valves, the' bodies provided with sleeves" whicib ,g,et squeezed to control or stop the flow. The s],ce've' could be ofcoll'osio,n I\ssistmt materi:als like Rubber cr PTFE" The body is nottlla:1ly made nom cast iron. These Sire used for special services where service presslBcs, are v1ery low like isolation of the: hose connections etc. in the' chemical process industry. The body is cast and can have flanged Of screwed ends.

O( lat0 manufacturers have dev1eloped these: valves to endure higher pressures and temperatures (01 to [00 bar &' up to: 120°C respectively) for application, in mining and mineral. industry.

These valves are also -not covered under API Of:- .ANSI standards and are manufactured. as per Mmufacturem' :itandariQs.

2.,0 REGULATING VAL VE.S

The valves nO.nllaUy used :in the plant, to regulate/eontrel the flow are:

2.1 Globe Valves:

2.2

N eedle Valves

13., Back seat

f'IPING ENGINEERlNG CELL

2.3 Butterfly Valves

1. Body

25. Anti-Rotation Device

,2. Bonnett

2.l.1 Body

The . construction of toe body dIffer,s uom 'that ofthe ,gate 'valve, The body ports are: ,man&:;ed such that the :flow rus from the underside of the disk. Though the code specifies that, the, globe valves shan be designed suitable fbr mstaUadoll in either direction, of flow. the preferred direction of Bow for globe valV;e shall be from under the disk. Normally the direction of flow is cast or embosse-d on the valve body.

Theteare two typeS! 'Of' port designs possible, the fun port and the reduced port In the' fi.lJl port design the body ports shall be as large as practicable design considerations permit However, in :no case the: net area. of 'the bore through the seat IO! globe shall be less than the 85% of the area of the actual pipe bare. In the: reduced port desisn, the port diameter is normally one size less than that of the connected, 'pipe.

2 .. 5 Piston Valves

,3. Yokle

2.6 Pinch Valves

4. Backup Ring ,5, Thrust Ring

The' features of autterlly.

Diaphragm, Piston and Pinch 'valves were already explained under isolating valves. There are man'}, ideo.tt,caJ features in rthe COl1structi.on of gate! 3il'.Id globe valves, The: f'oreg:omg no~e is in,tended to ex,plam, the comparison between these valves hl gblighting the differences.

&5 5~2~

1$. Gasket

'1. Glamd

B. Stud .and Nut

9'. Plug

10 .. Seat Ring

2 • .1

GLOBE VAL YES A typical globe valve has the following parts, which could be identifi,ed.

12., Plug Nut

14. C~;amp

2.1.2 BODnet

The body bonnet connection fOJ the globe valve is the same as that of gate" vaiv,es.

IS. Oland Bush

16,", (iland Flange

i'i1- 3·D"-k

AI. • . . 15 __ ,

The disk of'the globe valves shall be:

I. Flat, faced type '

18. Cross Bait and. Nut

19. Eye Bolt and Nut

• Plug type

2,0" Y:oke Nut

• Ball type

n, Hand, Wl-leel

" Needle type

22. Hand Wheel Nut

Iii V port type

The flat -faeed type disks are used when the valve is to be used for the positive shut off service, For such

23. GIl1b Screw

24. Grease Nipple

Valves:

, ------- ----

PRING ENGINEERING CELL

valves, disk can be provided! with mil elastomer 'ring or facio,g which will ensure the same. The needle type disks are used when finer :flow eontrol is to be achieved, These" disks can be also of contoured design, as used in flow contro] valves. These pre generally used for precise flow control applications, V port type dlse , is used for throttling ,application.

The disk shall be either loose or integral with stern. n,li mtegral. design is used mainly for the needle t}lpe of disc. The loose plug design, allowsthe same to be renewable. Wbsn in the fuJJly lOP en, posirioo the net area between the (fisk and the seat sball be equal to the area throu,gh the seat.

Bellow seal is the only way to achieve emission control in this type of valve,

,2.1.4 S'tem

In ease of globe valves, the stem is :alw,ays of rising design along with the hand, wheel, The: stem is provided with a disk Ilut at the lower end, The upper end is provided with a hand whee] screwed by stem nut. In case of bellow sealed valves rising stem with Don-rising hand w1l]ee1 is provided similar to that in the case of gate valve.

2.1.5 Gland" Gland Dang'e, P,acking &:

Lante:ro

Design and details same as that of gate valves.

2.1..'6 Seatnn:gs

In case of globe valves of carbon steel, the hard faced, seats ean be directly deposited on the body or the seat rings shall be shoulder seated.

2.1:1 Yoke and Yoke bush.

The eonstructicn of 'the Yoke is the same as, that of the .g;ate valve. The Yoke sleeve of the' gate valve is machine finished on. all surfaces whereas that of the globe' valve sbaU be: screwed 01" .flt1!ed in the position. and! locked in case of rising, stem design.

Valves

P'IPING ENGINEERING CELL

same as that ef the globe valve except for the disk. In globe valves, the disk is like a truncated" pyramid whereas 0,. the needle valves it win. be fun. This racUity eurles finer :How 'control. The' disk [could also be integral with the stem, in which ease the bottom, part of'the stem will. be machined acoordingly.,

2,.1.8 hand Wheel" Hand Wheel Not

Unlik.e in gate valve' the: hand wheel also rises ,sj,ong wtth the ,stem for globe valve. When 'used. as a, 1:0110:101 valve, actuators arc fixed 5;0 that the . stem movement is effected through the same, Incase of' bellow-sealed globe valves, the non-risiing hand wheel des,~gn is, provided ,similar to that of gate valve. This :is to' ensure that the bellows arenot subj ected to torsion.

The above are the major design aspects of the globe valves :and comparison of [the same with that of the gate valves, As regards, the material of construction, end connection etc. are eoneemed, the same shall be: selected by the pipmg engineer based 100 the: service of the tine to which the y,alvcs areused, The environment in which the valve is irlstaned also will have to be considered whlle selecting the material

I-----,A-+-----'

ISoC:5e.et 'IIe1.d Elnds

A. totally different type of eonstraetion is also, used forthc' needle valves of smaller sizes" The bodyl bonnet connectioe will be screwed OoD type mstead of bQI~ed, In place Dr a flaD,ged ,gland with gland bolting. the packing win be po,sitionBd, wi,tha :screwed muon gland nut The stem will be of inside screw arrangement. This makes the valve eompaet,

The body and bennet can be of forged eonstructien or can 'be fabricated from barstock.

There: could be slight vmaneD in desi,gIl from manufacturer to manufacturer; but the basle design features ,IS !pedS.ed are not: altered.

2,.2 NEEDLE VAL YES

The' needle valves, like glebe' valves, are used for flow control. Normally needle valves are used In smane.f sizes and are :p,ro,iijIld.ed, with either screwed or socket weld end The design ,oithe needle valve can be exactly

These valves arc used only tor limited applications. Evc,n thougb the code covers this design" ~ese are mostly made: as per M~lllfacturersl staadard,

2.31 B,UTTERFL V, DIAP:BRA:GM" PI'STON AND PINCH VALVES

The design and. the construction features ,o,f th.e same ue already explaiaed under the head 'Isolation Valves', These valves can pentmn the dual duty of control as weD as isolation ..

3 .. 0 NON - RETURN VALVES OJ, ;S"3SL--

As ithe' name indicates, th.ese valves are used to ensure unidirectioMl flow of fluid!!. Check valves, ,are, mainly divided into two 'types, based on check mechanism.

3[.1 LUll check valves

3 .. 2 Swin,g check Valves!

The: type is selected depending upon the service, size and material of [construction. Nannally, small bore valves (up to 40.mm NB) are selected as lift, chec'k .M.d. big bore as swilJig check due to constructional limitation.

3.1. LIFf CHECK VALVES

These, valves operate by the liffing action (If the disklel,cment.-The differen.t types of lift check v~dves available' ate ~

3;] .. 1 Piston, Uil check

3.1..2 Ball tift. check

301.3 Non .. slam check

PIPING ENGINEERING CELL,

],.1.1 PbtolllliJfi check

Th.e piston lift valve has body similar to that of globe valve, The piston will be in cylindrical form." the lower end of which is shaped to form a seating disk. The: cyIindri,call part fit into the guide making an effective dashpot, When, i't is in fully open position, the net area between the: seating disk and the seat will be equal to the area, through the seats.

The body will be provided with renewable body seat rings like in globe valves, In careen steel valves, therc= can be hard faced seats deposited directly on to, the 'body ..

The piston, tift check valves can only be p,laced. in the horizontal pipeline,

'The lift check valves can also be p.rolVided with sprin~-l'oaded piston. In, this case. a sp:ring of specified tension has, to be placed, between the guide: WId the piston within the cylindrical portion. 11Us type can be placed in any iocatioD.,

],.1.2 BaD lifl check

In ball lift; check, valves the unidirectional flow is achieved. by the movement of ,I ball. There are two designs possible in' this pattern. the horizontal and the, vertical. In. vertical design. the valve should be placed ill such a. way that the flow is always in the upward direction.

These ,check valves are

provided with guid,es to guide the ball .thrc:;mghDut the travel. The travel should t,e such that In fully open position, the net are-a between the ball and the seat shall be at ~eas:t equalto the' area among]] the seat,

The main parts of lift: cheek valves are the foUowin2.

1. Body

2. HaUl/Piston

PIP'ING ENGINEERING CELL

3' Cover

3.2,.1 CODven,tioIlB.1 Swing cheek valves

4.. Seat I

In these types of valves. the eheek mechanism is me disk. which is hinged .. The pressure of the fluid lifts the disk and aUows the flow. The disk

S. Guide

6. Gasket

7. Cover stud nut

The body' sban be' of forged. or 'cast construction and with. socket weldedlscre;wedlflanged 'end.s.in~egran'y 'cast or with welded-en Ranges.

The cover shall! be either bolted 'or welded 'or with 'DDion nuts. The union nuts could be of hexagonal or octagenal shape, The cover material shall be same' as that of'the body.

The seating shall be integral or renewable; The bardness differMce can also 'be: achieved. by weld deposit on :seating surfaces. The renewable seat rin,gs sball be screwed~in type either shoulder seated or bottom seated..

returns tc the seat with its ,Q'WD weight. 'This anow'S tbB valve 'for mounting in horizontal as we]! as vertical position with upward fluid flow" The main parts of the valves are -

3,.1.3, NUN..sLAM: CHECK v At. YES

1. Body

The non-slam check valve is a spring [o:aded lift ,check valve with. a m.odified d,e-sign oithe body" The valve is designed in such a way-that the same can. be sandwiched between the two flanges" Here 'the disc is held in POSid.OD by a SPring-II' which is: housed, in a, housiag cap or yoke.

3. :H:iDge

4. Hinge Bracket

5. Gasket

3,.2 SWING CBECl{ VALVES

6. Cover Stud and Nut

These valves ope.ra:te by the swinging action of the disk. There are two types of swing clileck valves available, They are 'the conventional swin,g ch.eck valves wiili flangedl ends and the wafer type spring: loao.oo check .,alves.

7. Bracket Stud and Nut

8. Disc,

9. Seat Ring

L 0 .. Hinge Pm

11. Disc Pin

12. Washer

The body will be cast with ,9. tapered wedge. seat and will be provided witlh r-enewable seat. rings., The w,aU Ithickness and end to end/face to face dimensions of the body shall be as per the regulatozy code to whi,ch it is, designed. The end f1langesshal] be! mt1egrally cast Of attached by welding, The flanged connection. shall be to ANSI B 16..5 or any other flange standard. The buttwelding Olld! comtectioDl shall be to .ANSI B ]6.25.

The disk will be attached to the body through hln,ge and binge pin and ,SJwings against the same coneelllng the flow. The disk material sham. be, IQf quality at least equel to that of the body.

The cover will be: bolted on to th.e 'body. The bolted. coeaecticn shall 'be raised .facellongue snd groove/male and femalefring type jomt depen,dilili on the pressure: rating of the valtve. The gasket shall be se1,Bcted to suit the ~e of conneetien, It can be corrugated or flat solid metal, ecrrngated or flat meta~ j ackJeted~ asbestos tilled" metal ring joint;; spiral wound asbestos fined.. F'j,a~ ring compressed asbestos is used for mow-~ pressure application. Tefl.o[1 0:[ TefJ:.on filled for corrosive applications. Nonnally high tensile bolts areu,sed fOT cover bolting. In ,cast iron check valves low carbon steel bo~ts aI'e used.

3.2.2 W,afer check valv'es

Th.£ wafer check valves are the fl.angeless swbIg check valves, 'These are eeveredunder the regulatory code API 594., There atl"e two types, 'of wafer check valve des,isns available.

a) Single plate wafer check valve

b) Dual pla.~e wafer check valve

PIPING ENGINEE.RING CELL

The arraagement of smgle plate check valve is somewhat s:imilar to the conven.tional swln'g eaeck valve.IHer'e a. cmcularplate seated ag.ainst the valve body seat by line backpressure or flow reversal acts as a valve closure. This is furthter aided by the provision of spring ..

In dual plate check valves, there: are two spring loaded semi circular plates, The plates are arranged in such a way thatthe spring force acts beyond the eentre of area of each plate ,and the Cured force acts widilil. the same. This filIcrw:n 'causes the heel to open first preventing rubbing of the seat surface prior to

-, . Th' .:.c d ,.

nOIlDIU open.mg. e SlZ.eS: speeinec m

.API 594 are from 2" NB to ·48;11 NB. Manufacturers have developed standards beyond these sizes as, well,

The platesmalll be' made of material at Ieast equal t.O that of the body. The body and plate :s'eating surface can be renewable or imegr.al or with deposited metall. The seat surface could be stelHted or can be of resilient materi.al. In these valves, the ~tems specified under trhn are: th.e ,seating surfaces;. sprin~s, bigge and bearin-B.s" Table 4 of API - .594 gives, trim numbers and the cprrespom.ding material of construction.

Compared to the cODventio:nal check valves, these have less pressure drop across the valve in lar~,er sizes" reduced water hammer and are comp.act.

4.0 SPECIAL-PURPOSE

VALVES

v.alves" which perform duties ,other than the two-way isolation, control and clleck, are classified under the Icategory of special purpose valves. Few of such valves are

4..1 MUlti~port Valves

4.2 Flush Bottom Valves

The types of valves used for this design are the ball O'f 'the plug valves. However, .globepat1:em valves also can. be desip1ed. 'With. suitable dj'se positions to acrulcve the: three-port design.

The advantages of rnalti-pert design valves are-

(1) ReduetioDl in number of valves used,

PlPlNG ENGINEERING ,CEL.L

4.3 Float Valves

The typical applica.tions oftb.e three' way 'llaIDves are-

( m )aUemate ccltImection af the tw'o ,su.pply lIine-s to ,I common delivery ~

4.:5 Line Blind Valves

4.6 Knife .gate Valves

(2) div,ersi,on of flow tQ either 1M two directions,

(3) isolatioD of DDe ofa pair of safety valves. for maintenance purpose,

4.1 MULTI~PORT VAL YES

AIlyvalve. wlUch has, m.O!,6 'than tw'o ports, is c.lassified as M:utti-poft; V.alves .. The mnlti"port valve-s on. certain. services reduce the time: for loperating and the over all costs. There Sl1C three: port valves and four port valves in common use, Five .. port designs. ate alSo available. Two types of three port designs. are available viz. The 'Til port and' the 'LI port. The possible Ilow 'patterns, of these are as below:

1(4) divi.s.tow of BoW' with isolation facility ..

The fl.ow p3ttems ,of ·8 four .. way valve am-

L PORT VAlVE

The typical[ applications. of foul" w.ay valves are:

1(1) R:evasal of pump ~I!lction and delivezy

(2) 13y pass of strainer Of m,~t,rr

(3,) Reversal of .flow tbrou.gh filter, beat ,exchanger or dryer ..

~~.~~

~':=r -E~'=:L

]___[ 'I ~I

t

A most economical. layou" could be

selected from the study of .above flow patterns.

Valves

(2) Quick and 'easy ope~ation.

1(3) Simplil1ication ofpipin.g layout and! 'thus-,eeonomy in fittimgs",

(4) Less risk o,f product mixing by mconect valve -operation,

(5) The stops can be ,mang.ed to arrest the \mI'equlled ilBwpattems and at the same time: make it impossible for desired positions to be ebtained.

Two of the muitje.port valves can. also be inter c.oupled to permit fast muJtipilB operation in the: simplest possible way :and with. minimum manpower.

It is essential for the. designer to specify the exact requirement of flow patlems based O'n th.e piping arrmgerotmt ~o' the manofaeturer. Lack of proper coordinatien wm reselt in a to·tally- different OU'qJut than what is

required.

4.2 FI.USHBOTTOMVALVES

These are special type of valves, which are used. to drain lout the piping, rea.ctors and vessels, These are attached to the vessels Din pad typ~ nozzle, The disks in closed position ma ch with the bottom of the vessel ,or piping leaving no room for hold up or stagnation.

There ate two types of flush

bottom 'V·~lves.

a) Valv'es with: disk ()pe~g into the tmks,.

b) Valves with disk int·t) the valve.

In the first case" the stem pushes the disk into the tank to, main the liquid. This type eannot be used when thereare any internals" which restrict the

PD'ING EN'GINEERING CELL

movement of the disk. The draining of th~ material could be effected completely. In the second. case" the disk: gets _pulled do,wn into 'the valve effecting the dischar:ge ofmaterial

There are two types of disk design available the plug type and the ram~e'.

Normally:, the inlet size: of a standard Hush bottom, v,aJv,e is one size higher than that 'of the outlet size, There are special constructions possib~e with both sizes sam.e. The outlet port lis at an angle telll the inlet port, Normally 4.5 or 60 deFee,sr deviation is provided. The end eenneetions are normally :Banged. H~wev,er, smaller size smnpaeldrai,n valves have been developed with welding: end at inLet to wi.thstand bigher pressures. The: maximum ratmg available ,act present fior flanged valves ~:s ANSI 300 lbs,

'The parts of the flush bottom, valve: are identical to that of a gl'obe valve and the closing and opening actions are also similar, The shut off is, achieved by disk dosing against the body seat The disk could be' Globe type or Ram type,.

Jacketed flush bottom valves Brie also possible if :required. for the service. The: disk and seat also could be riLacmned, to such accuracy teserve the

vacuum duty as, well. -

4.3 PLOAT VALVES

Float valves are used to control the level of' fluid in a reservoir. Only the inlet IOJ the valve is eonnected with the supply pipe:idne and the outlet is: open to the reservoir. 'Ihere will be a floar with lever, which. controls the movement of thepistonI,cgulating the flow"

P'IPING"ENGINEE!RING CELL

These valves are covered under the Indian Standard IS 170l. There are two types. the IIHP"' and Ute jLP' depending upon, the pressure holdin,g capacity of thevalve.

The bocty lever andintemabl aremanufactured out of gunmetal arul the float is ,gfPVC or copper depend.mlg upon the temperature of the' fluid .. 'The lever length could be adj usted to suit the level in thereservoir.

These valves have threaded ends and! are coenected to the: wall of the reservoir with hexago:nalnut. The reservoir 'need not be provided with 8! nozzle, only an op'ening is required, The level afliquid will always be belowinlet oonnection.

.'

!he materia] of construetion of the body 'IS Cast Iron or Gunmetal for the valves.

4.5 LINE BLIND V.ALVES

Lineblind 'valves are used for posnrve shut off and replaces a I'spectacle blind,"., Unlike blind! pla!tes these are easier to operate and Iess expensive tl1an a standar-d vaiv:e,. The most common type of the line blind 'Valve is three~bo'ltlfive bolt line blind valve, Another desip is the s!mgleg;t~ line blind",a.!ve or the 'pulp valve wh]c'b can be power operated! Of' with hand wheel, There also exists a design af visible-wedge: fine blind valve" which provides a fW1 bore opening or positive bhoding inside :1 seat in a three ~u.arter enclosed body, No line residue can spill 'When wedges, are being chang,ed and no line' movement is necessary when spectacles, ar~ chan.ged.

'111' • •

, e maximum Slze of valve

covered under the stand,ard is 50 NB and! special desism nas, to be: done if mSher size valves arerequired, These are called eqttilibnwn float valves.

4.4 FOOT VALVES

Foot. valves, are, a sort of non .. return valves with strainers mounted art the open ,end of the pump' suction pipelines, These are used when the pump has negative suction. The cheek action of the: valve holdsfue primingfl1llid of Ute pump wbiJe 'the pumps are filled before starting. The s.uction strainer helps: to hold the solids while the pump is sucking the fluid.

These vwves are covered under th,elndiam Standard [S 4038", There are two types of check mechanisms available viz. the lift cbcck and the S,w'lng check, The operation of this is, :similar to, the NQn"'.rerum valves .. Valves, are available with either fill'l&,e(j end ,co.nneeo,on or screwed end connection.

Valves

3'1

4.6 KNIFE GATE V AI. VE

These are single seared Ivalves used for slurry services. They are covered under MS,S.-SP-Standards. Being single seated valve it can be used for only unidirectional operations. Sod r:..

tMr~· -

In Its SImplest form, tile sUding

valves 'consist of two s,tationary steel plates each with large' hoLes drilled through it. Atltird plate 's,Hdes lbeMeen stationary p:~ates to perform valve cperatlons, When open this design offers no resistance to flow. The ability of the glte 'to sUp through. the plate effortlessly is, the success of this design. The edge of th.e gate is shaped! to shear the solids and the 'elastomer seal is: used te keep' the solids aWla)' from lentering the space between the plates. when open and to dean the sliding blade wbeQit relracts.

V ALVEINSP'ECTION AND TES.T

IT specified! in the purchase order, Ih.e valves shall be inspected by the Purchaser's inspe,cting authority at tbe place ",1' manufacture before 'despatch. mr not, the m.anufacturer shall supp~y a certificate stating that the valve mid valve parts comply :in all :respects with the relevant standards and regulatOly codes.

Unless additional inspection is specified in tbe purchase order~ inspection 'by the Purcbaser shall be limitied to the following.

1.0 Visual examination of ,any finsshed 'componen.ts at the assembly stage,

.2 .. 0 Visual and dimensional check of !h,e finished valve

3.,0 Wime8'sing of the required and specified optional pressure tests,

P'IPINGENGINEERING CELL

The regulatory eodes referred for 'these tests are ei,tbc~;

I. API - 598- Valve inspection and tes,t.

2,. AP'I ~ 60r] ~ Fire safe testing, of soft-seated valves.

Pressure Tests:

Pressureteets, unless otherwise ,spe{iifie~l, shalll be earned oat on each valve as 10Uo,w5;

1. Shell - hydrostatic (inclusive of body. bennet, ,stu:f.5ng box and cover 'Plate)

For this test, disks, wedges and plugs shall be in Opell! position and ball in the half open position. Check valves: shall have pressure applied to the upstream side. \Vhen valves with, ~ruffing; box are test~ the back seat shall be tested for 1ealcage with valve in Mly open position md stem packing removed or untightened.

2. Seat .. hydrQstatlc,

For gate valves the test is to be conducted to each side of disk. Far globe valves" pressure. is to be pplied under the disk. For cheek vslves, it is Oil the downstream side. For ball valves and plug valves, it is to each ,siae of ballllplug,.

3. Seat- PnelJmati,c

AU gate, globe. plug and ball valves are air seat tested at a minimum ot 80-psig/U)O psigwith liquid. 00 the side, whicb is not under pressure. This test is net required for check val yes.

For valves 'used fo[ vacuum service a low-peessure air test on the seat ,shaill also be carried out

l5'0 3'0 21
300 n 54
-
400 1'00 14
600 15'0 UO
,~OO I 11S HiS
15'001 II 373 .174
:2:5(10 . 621 456
800 210, U2 Note #: 1. The hydros.~tic seal test pressure of soft-seated valves ShaU not exceed, the' body rating or the seat ra,tmg w:hichever is lesser (refer :regulatory C.Qd-e for the valve,s;).

For hydrosta'tic tests, the test fluid shall be wat,er at ambient tempemrur'e unless: the use 0.' another liquid is ,agr,eed. The use of hi,gh_ chloride - c<ontainin,g water ,should be avoided. The water may contain waler-se;hible oil 'or a rust inhibitor.

Fir,e safe test is a destructive test and carried out only in ,exceptional cases when specified. The arnmgement aed test shaU be as pa,r API 1607 or BS 6755.

Valves

Certificate Course on

PIPING ENGINEERING

December 8 • 21. 2004

BASICS OF PIPING DRAWINGS

'T. N .. Gopioath Consultant

Organized by

Piping Engineering Cell Computer Aided Design Centre Indian Institute of Technology, Bombay Powa&, Mumbai ... 400 076

PIPING ENGINEERING CELL

PIP'ING DRAWINGS

TBEBASICS

The dra...vin,g$1 are always, eensidered as the language of' engioeeES. The machine drawing,s Wild the geometrical dmmngs ,are tau~t in the' basic en,gmeering cuaieulwn. ]Piping Engineers; derive basics: frora ihese to represent tlle pipeline routing on, tbe drawing. There are two types (I f' views used in the piping, dra\Vings:

a) Ortho,grapbic- Plans and Elevations

b) P'ie,tonal,- Isometric Views

Pi:p,mg layout is developed in both plan view and elevation vtew and section I details are: added for c:bri:ty wherever-necessary .. These: drawings ,are called the Gen,S'tll. ,~gement o_~'lPip1ng. To, represent a three plane pipq, in two dimensions, of the paper" oertain symbols are foHowed. Most commenly used symbols are in Table 1., Orfho~phic :symbols are available, in ~.em:plates that are 'used for sPeeding up the m.anual draffin,g and. also ith,€! s-ymbol Hb~U)' for cOlmputer drafting.

In complex: piping system. ,especially within . theunitlplant building whe[l~ OrlD:_o, , bi'e views do not illustrate the details, of design,

ietodal view in iso'metricresmtanoD is drawn for ciarity .. Specially printed isometric sheets are availahle with lines drawn vertically and ,at 3'111' cloc'kw~se and 3,(1 cenntereloekwise respectively from the horizontal axis of the paper by the use of

T. N. GOPINATB

which. 3D representation oftbe pipelines can be prepared,

1.0 :PLAN AND ISOMETRIC PRESENTA:TION O'F A PIPING SYSTEM

The plwpose of drawing i:s to gii.¥6 d.etaHed informatil.m so (hat the pipelines could be fabricated and erected 10 ,satisfy the process requirements:. Prior to making the pipi:Jlg dtawings the ,equ.ipmcnl.layout drawings and plot p,lau are prepaed and these drawings are used as, the basis for developing the piping draWing.. So:metimes preliminary piping study is made to, fix the equipmrelll co-ordiJ:lates. 'The other data required for the developm.ent '0,(' fipin,g dlmwimgs are defined in tbe paper 'all ICCEquipment and P'iping,

Layout".

For presentation of unit pip'Dl,g layout tbe~ scale :adopted usuallly are t :25 or 1 :3,3 til and 1:100 [0:[ the pipe rack. There are different sizes 0,( draWing m.eets 8:v:ailablefor lhe preparatiolIl of the dJrawmgs. The Imrum Standard IS I 0111 standardises the: drawing sheets as below:

SlZE OiVERALL DIMENSIONS

in mm (Untrimm,ed)

Ao 841 x 1189

AI :594:l1t 84l

A'I. ,420' 'x 5:94

AJ ,297, x 420

~ 210x 291

PIPING ENGINEERING CE,LL

T!A8:LE- I PIPING SYMBOLS

Sr.

No.

IDESCRIPTIOM

PlAN

EN'D VIIIEW "

1.0

CHANGE or DIRECTION AT 90·

~ .. 1 DOWNW.4)RI)B:END~N:G

1.1.1 I3W elbow

(

) ,

]8

I

11.11.2 SW elbow

l. '1..3 $crd elbow

11.1." f'lgdelbow

1 .2.2. SW elbow

)

} (

'Ie

~r, I No"

2.0

1.0 I C.'HANGE OF DIRECTION 041 90'

nw VIEW 'I

END V.IEW 2

1 o

1.2 ' UPWARD S(NDING

1.2.4 j:'ilgd elbow

a.i DOWINlM"MIDBENDING

2.2 UPWARD BENIDING

) ) ) ),

( t

P'" n-,.. .•

. 'lpmg uuswmgs

CHlAtIIGE or 'OI~:,EC]ION IIOT' OTIHER ,AINGtES

3.1. l' BW Tee

j

(

:3 .OBRAt;CHIN:G

3J o OWNW,lR 0

'\

) 3 ........ E )

('v II

1.1 ,UPWARO IBENDINiG

PIPING ENGINE:ERING CELL

4


Sr .. 1 DESCRIPTION I PLAN II ENO VIEW 1 I IENID VIEW 2 1
No.
3.0 BR'ANCHI NIG I
3.2 UPWAR'IO
3.2.4 Flgd Tee ~ 1
~
3.2.5 Stub ccnnectlen .i. 1
~
3.2.6 I Half Coupling ~ 1
~
4.0 PAR'AULEL LINES --'->-~ ( ,(, 0
) )
I ( ~. 0'
, ,
5.10 CROSS LINES :r: I~ e) ( c
) )
( ( , (2)
) j: ) , j )1
e ( ~
"
16,0. LJ d' ,
IROUlE0. [LBCM ~ D
" (
CD, ,.
j: ~
7.0 ROLLED TE,E t11 ~ 'r'r-.;R~
I .
I
.
'Sr. DESCRIPTION PLAN I END VIEW l END VII[W
No. 1 2
3.0 8RANCIHIHG
3,.1 DOWNWARIQ
3.1.3 Scrd Tee J I ......... I ) t !
< ....... (
I
j I
3.1.4 Flgd 'lee l II'~II ) t t
( (
I
3.1.5 I Stub connection J' r-. ) t !
( "-" {
3.'1,6 Hell Coupling J ,...,. ) t !
t- .._,; r
3.,2 UPWARD
.
3.2.1 BW Tee ..-L 1
I ~ I
"
I 13.2.2 SW Tee ~ 1
I
T-t--0+--1
3.2.,3 Scrd Te'l! ~ 1
1 '~
,
I P·· Dra' Ipm,g . . WlIlIgS,

. ,S

1,,0 BOW TO START 'THE PIPING, GA 1

3.1 The pipinS drawings should be

dcve!,opcd, m sueh a way that wi the process requirements ,arc met wiUL

The dirnensi(1na~ details of the title block are specified underthe mman Standard IS 11,66S,. The drawing sheet is divided along the length and tbe 'breadth in, equal spaces. The lon~tudina:t_ blooks are identified by alphabets and those along the breadth numeric lilly . 'These cO'-Qrmnates 3ft used to locate the area 0]], the drawmg., The difection of the north, is taken either ,towanlsright or left on top of'the drawing sheet. This clliection is loept constant in aU the areas covered in the plant. so also i:s the scale 0,( the drawing.,

PIPING 'ENGINEE,RING CELL

PIPING ENGINEERING CELL

Piping General Arrangement is, nonnall¥ 2.4 drawn, on Ao, size sheet. U the area to be covered is ,sma.Il then AI size sheet i§l also

used. P~piDg ,group' produces a, ''KEY PLANt.

the plot plan on it small scale (1:500, 1 :7,50 or

1: 1000), wm,ch can be ,accommodated on ,am 2.5 A. size drawing, sheet as per scale :and dividing

the area of the site into SIIlaUer M'eas identified

by 'key letters or numbeD. This is addled to the pi,P,mng drawing for reference purposes, The, subject area a.f' the particular dravrin,g is, batcbed, [or shaded.

I
Sr ..
D'iESCRllPllON II I' I
Nio. PUN ENID V'~EW I END VIEW 2
a..a VALVES
8.1 I Hend 'Whl Opera*ed
ee
Iflgdl Valve with ~~U~ ~
ve.rticol hand whee! ~'[glK
8.2 Lever ,op.eraled
V'Clllv[e 'r-1J;K 6
n¥~
I'"
8.-3 Hanel wheel operQlted I
BIN VOII'Y·I with ~ ~. i0
rolled h(lll'lld whee,1
II
I
I
9.0 CONCENTRIC REDUCER <I x b
~ ~ ®
100 ECCENTRI'C REr)IJCER'
~ .~ @
I FSUV FSO 2...1 Ohtam the drawings numbers and lill in the title bloc~ with the drawin,g :nwnber and tiUe at the bottom n,ght hand comer

,oBbe Sheet. 3;2

2.2 Place the north: mow at the top lcftlrl,gnt. baad, comet of the Sheet, to indicate p,iant.

mo~. -

2.3 Do not p[]an drawing in the; area: above 'the title block 'of ,drawing, as this is allotted fOJ general notes, -number and 'title of referenc,e drawin__gs, brief description of changes [during revision and the bill of materials wherever applicable.

PipiBg Drawings

Process [equipment and piping bave priority on the Pip,ing. GA~ The piping drawings am stattedafller fixing 'positions of the [equipments.

Equipment layout is l1eproduced o,n the Pipm,g GA to its ,scale and drawn on the reverse side in case of manual drafting .. In case of CAD sepante layer is rased .. The majorprlmary beams ad seoGndary beams ar~e also shown if area: covered is indoor.

2.6 Pertinent backgroWld details wbich. gO¥em piping . 11Quting. such as floor drains, HV AC ducting, ,electrical and inshitllment cable trays., ete, are ,aJSO drawn in taint OD the reve.tSB.

.2.7 Utility stations ,Me also establisllIed SOl that the most ccmv,enient utilityllIeader routing; can be ,canleCi out.

:to DEVELOPMENT OF PIPING

GENERAL ARRANGE:MENT

DRAWING

It is not ,always possible fOTthe: p~in~ dnlwin,g to fonow exactly the topc.aI amm.g,emem. of the P &. IDs. Sometimes lines must be 'routed with different j'lIlIlction, sequence and line numbers and, subsequently the list may be ciumged.

3.3 lP'erf01mance andl economics have to be considered in parallel while deciding the routing.

3 .. 4 Piping is. represented by single lines up t~) 8! size: of 1 S:ONH aDd double lines for sizes 200MB. and above. This

7

rUING ENGINEERING CELL

insulation" tnlcin,g requiremectsj etc.

:

" "

MArCIHLINI AREA - 1 !

·--- .. -.----~~--···---------·----l

~

,I

I

l 'N

"

:l ~

1 oi!(

[ I~

! ~

1

:[ ~ I ~ ! ~ I ~

MATCHlI!'IE MEA - i· i

.--- .. -----~----.-----~-~~- ---1

is: to save the time of drafting and to 3.14: Each line should be ideatified by line avoid. confusion.. numher and should also show the

In s:m.gle line repres:entation only the

eemre line of the pipeline, is dmwn using . 3.,1 S Lines, if required, shaD be br-okem to

solid tine an,d lD deuble line show the required details of hldden

representation the actual size to seale is lines without drawing other views,

drawn with ceuW liine marked In chamdotted lines.

3.5

3.6 Line D1!lIIlbers are shown :agamst each line exactly in the same way as repllescnted in .. the: P'&I. diagrams.

3.7' ThechaQge in specifiC-atioil should! be ,shown 'in tine with P&I diagram. This change is usuaUy' indioated immediately to the' downstream of dle valve', flan.ge or equipment

3,.8 Valves should be drawn 'to scale with identification number from the PlAID marked. tkereo:n ..

.3.9 Draw y,3!ive, hand whee~~ to seale 'With stem ful1y Imctended. If it is: lever operated, tIlen the mo,vement of handle position Shoutdbe m~ed

3.1.0 If a valve is chain operated, note 'dile distance: ,of the ,chain tom 'the operating floor.

:3.1] Shew location '0,( eacb instrument; eonnection with encircled inlstrum,eDt number takeu from P&ID"

1.12. Si:m.il.ar all'Sligemcmt shall bel shown as typical detail oreovered in a sep3.1'ate company ,standard :1lS Instrument Hookup drawm.gs.

3.13 Draw plan view of each floor 'of the plan~:md these vi.ews should indi~ate how the ~ayout. willl 10,,1<: like between floors as seen from top.

Piping Drawings

covered! by a note,

Hi

3.16 Do, not draw de:tails that can. he

"

1.17 Draw plan to a larger scale for any part needing m.OR' details and identify it as "Detail 'A"';j' etc.

3.18 Draw p,ut isometric ~etches Of pari elev,MlollS to clarifY complex piptDIG or pipimg bj,dden in the p,lau view.

3.19 Full sections through: the plant m~ybe avoided if isometric drawings are drawn (or ilh.e: lines. Pact secti.o'lls: where reqWred shall be sb.own to clear the: :hidden details in plan.

3,.20 Sections in tlle:plan views are identified by nmnbers say 1-1,2-;" ,etc.. :md details by ,alphabets, e.g.

REFERE:NCE ORAWINIOS :

CENERAl. NOTES :

:tREY:NO I m IDIlsC~PTlCit 1 D.'Te I eio!KQ I ~p~

I ORGoMO. ![!ltv. muploI\I'I' NMI!: a

·oru..WM (IT PRClE:!:T : II-

I mu : G.A.ORiO""IhC; Qf I

~~~--r-~~~~-~~r"~-~~~~~

API'D Ill!' II., II

115tH:ET: i OF" i!1

.Z

1 '

FIG. 1 : TYPICAL GENERAL .ARRANGE:MENT OF PXPJNC

8:

iPiping Drawm.gs,

9

PIPING ENGINEERING CELL

<t EL 10J.040M

J

Ia)

350)(300 CON. RED.

l

J

35'0)(200 tee.REO FSU(typ)

I

____ , __ $-----% DIS.

! 'P 1 l

I

I

I

i sue

,

DlST. COLUMN

P2

!

Ii D!§., $ --

I

I

t i

ct. sue

I

BOTIOM P'l~MPS

2000

ALL IJIMENSIONS, 'INI MIlA

2 . I

FIG .. 2: TYPICAL 'GENERAL A.RRANGE:MENT OF PIPING

Pipin,g Dmwm,gs

.. ,

~I

00

,,..::.1

e

PIPIN'G· ENGINEERING CELL

N

FlG.3:: TYPICAL :PlPINGISOMETRlC DRAWING-

,Iii

]0

PIPING ENGINEERING CELL

,4,.0 ISOMETRIC URAlVINGS OR IS0.5

., I ~iping iSDm~trlcs are three

dimensIonal representation '0'''' piping 00 two dimensional of drawing ,sheet Am isometric dr,awing eovers a cQmpl~ete .line as per the line list OOmlecting one piece or ]eqUipment to 3ll,other. It should show :aU -~nfClrmation necessary for th,e '.fabrication and erection.

Isos are not. drawn to scale but should be' proportional for 'easy unde:rst:an.di.ng. :Dimens.ians are given relative to centreline of :piping ...

Isometric drawing s.lilould aIDso, include the following illfomll!titm':

, I I

Pipin,g;Drawings,

"IPING ENGINE,ERlNG CELL

5.0 SPOOLS

Wh.en the :p[p'ing ~s, sh.op fab.ricate~ the isometric cira:wi.mgs, are developed further to Icre:ue spool drawings. A spool is an, assembly of fittings, flanges and· pipes that may be' prefabsicated, It does, not .im.c~ud,ebolts. Gaskets~ valves or instruments. A sJWol sheet is; an. orthographic drawing: ofa spool dmwn ei,ther .from pipin,g GA orfirom an iso sheet., Each spool sheet shows lonlX-.-Qne 'we of snool and

5:. ID Imtntcts, welder t.OI fabricate the spool

5:.2 Lists the: cut ~engtbs 'of pipe,fittings and flanges etc. needed to make the spool

IMPROPER NORTH (lRI,ENT~TION

4.2 Dimensicns :and ,an,gles.,

4.3 Reier-ence nllIIlber of P' &: IDs,. GA Drawings, line aumbers, dir-ecdon. ,ot llow J insulation and! traQ'm;g.

4.4 Equipment location and equipment

4 .. 1 P~an~. North. - The: direction should be so idCDtificatiOn.

selected! as to faciJitate easyc-hec'kmg ,of

GA with:Iso 4.5 Give Ilo.:zzle id.entification OD the

,connected equipment

IPLAN

N

Piping Drawings

I I
Ib I
J -~ ~
I 5.3 Gives material of constructllon and any

:special treatment of ruu:sb,ed piping 6.4

5.4 Indicates bow many speols of the sa:m.e

type are: reql.tiNd,

4.6 Give the details, of .flange OD the equipment if the: specification is, different ftom th.e connecting, pipin,g~

4.7 Si~e and type: of every val"veJ Direction, of operation,

Spool nutnbers are given to make the identilicati,otl easy.. Iso meets are identified with line number it liepresems,. Both: the: spool and the ,spool sheet can, be id,entified by :£11 number or letter usm,g the iso sheet number as prefix.

StrQight run pipes over 6 m are usuaUy not included in a spool" as such lengths, may be welded in fhe system during erection in the field. The size of a spoG,W is limited, by the av~able means oftmnsport.

6.0 DIMENSIONING OF DRAWINGS

_ i

6.1 Sufficient dimensions to be: given far

positioning: eqmpment and, for

erectin,g piping,

6,.2 Duplicating dimmsio,ns in different views sho11.1d be arvoided. as this may l'iad tD' emJrs if changes are made'. R!eserve bo:I:iz.ontal dimensions, for 'the ]:11m view.

6.3 If single pipe: is, to be positioned or a -pipe connected - to Bozzle is to be: indicat~thensbQw the centre line ehwatio:1l and mark as ~.

6.:5 In case of several pipes an ill pipe raok" . show the 'Top of Support'" Icl,cvatioQ and mark p, 'IDS IEL.

16.6 In lease oflburied pipeLm.m in trench; :s.how elevation of bottom of pipes,

6'.7 In case of drains: and seweI:S, the Invert Elevation. 0.1 the inside ,orl' the pipe is.maiked as IE. ~

6.8

Centre tin.cs of the, eqwpment and pipelines shall be located with reference to the building, column centre Imes or the: co-ordinates which can be eonsidler;:d as a reference base ..

4,.8 Size and ,number ,o,f,con£rol valve,

4.9 Location" orientation and number of each equipmemt.

4.10 Field weld .. preferred in ,all directions to take cue ot site vlaria.fions~ Canalso be covered with: a general note ..

As a general practice Carbon ,steel pipms: 40NB an.d below are 'field fabriclIlted", All Alloy Steel and CaIOOn. Steel spools SO NB and above are: normally "shop, Cabri.cated". Large diam.eter piping, being more diffieun to handle, more economically produced, m womhop'.,

6,,9

"1M. di· b.A' th 1:-

J. J.I.e ·stanceetween e uaes shaD

be: dimeusioned centre line: 00, eelltre line.

4 .. 11

d

arrangemeDt:~n;o;:n .. _r. ---......---'~

4.12 .!BUl ofMateriaJ.

4.1.3 Requirements, of ,stress, relieving. seal we~ldingl pickling, coating. etc,

PIP'ING ENGINEERING ,CELL

6.10 The hori2oDtalllomes on the eqwpmen1i s:bal!J be located from c'entre to fiang,e face in plan. For vertical nozzles: show Face' oflllange elevation (FO!F).

6" I l For valves, instruments and IlonstmdMd eqJwpmetlim, :show the dimensions from flange face lo' flange fac.e.

6.21 F'ox field run pipml, giver only those d:imensio,QS whicb are necessary to route pip,mg clear of equipmcnts and otber ~bstructions., Locate only those items whioh are important 'to the process.

PIPING ENGINEERING CELL

.IS For foundation, the Top of Gm'ut (TOG) elevation is shoWIL

,6r.2l) Do no~, ,omit significant dimension, oth,er than, fitting make' UPI.

6 .. W (5 Show dim.ensions outside, the ,c:lt:a\vm view _, do not cut piictutres.

6. rn 7 Draw dimensien line unbroken, with fine: line. Write dimension just aboVe the horizontal line. For verticaJ lines: write sideways.

810

7.~ Title of the drawing.,

7 . .2 Orl,entation - North arrow against plot: plan.

1.3 Inclusion of graphic scale (if dra:wiqs, is to be redaeed),

7 . .4 Co-onfinates of 'eqmpments against equipment layout.

1.S Equipment .numbers: :and Itheir appearance On thep:iping .draWing.

7'.6 COlHCt identification on all lines in. aU 'views.

1.7 Line' specification chauges ..

1.8, Re:feren-ce drawing: numbers and! files. 6.22 Underline out of scale dimeasions or

mark, as mrS. 1 .. 9 ComBcmess,of:a11dimensions.. - ~

6.12 F)Mlgoo valves are locat:ed.wifu 6.1.8: The dimension

dimension to Bange: faces. Noo .. jflanged IQll1inated

valves are dimensioned to their centres oblique dashes,

orstems,

6.1.3 Fer flanged joints show a small gap, between. dimensio,nliines to mdlicate gasket. :FIan,ged joints can also, 'be sbown wi~Olllt; ,gasket but cover the same with a general Dote and mclude gasket :thiicl@J.css in the valve or equipm.ent dimensions.

tf--· ------i~[X1 ~I ---Ie ~ x .. G !

6.14 F,ol" Finished Floor (Fi.l) the ,tdevation ,shall be the high pomt of the floor.

P·· n_' 1,piD,g ...,14:wungs

lines can 'be with arrow heads or'

6.23 Do Bot terminate dimensions, a~, screwed 7.10 Whether representatl'OD is

or weldedjoiDts. made in line with the symbols or not.

6.19 If series 'o,fdimension. is to be sbo~ strin.s them together. Show overall dimension of the strimg of dlmensioDS. Avoid one of the breaku, dimcnsiotm to omitlqletition ,and erroT duriD,g changes.

7.0 CHECKING OF PlPlN'G DRA'WINGS

cocrectly standard

7.11

Loeation and i.dentifieadon of aU instruments, Requirements 'of upstream I downstream. :straight [eJlgths.

Chectiug shall be doee only on the print or the check plot 0:( the drawings and by coloUNd pencils/peDS.,

A.

7.12 Insulati.on requirements las per P'&:IDs.

Corrected areas: and dimmsions are

mad::ed yeno,w"

..:s.

Areas and dimensions which aIiC 00' be deleted are marlced green.

7.13 Piping ammgement 3:gamst P(lID requirements such as gravity flow, seals, etc.

7.14 p,ossible interference,

7,15 Correctness of scale .in case of' GeneraJJ Arrangement DrawmG$.

7.16 Wheth£t'

all

stress

analysis

ii J

C.. Areas to be eorrected/incorporated on the drn;wmg me mmed. in red.

J!equirements are met or not.

The new print after ,correction is "bac.k: checked" fol' iincorporation.

Points to be checked 00 tbe p~piug dra:wmg includes:

Pi:ping; Drawings

14