Valves, Piping and Pipelines Handbook 3rd Edition T. Christopher Dickenson F.LMgt. ELSEVIER ADVANCED TECHNOLOGYUK USA JAPAN Elsevier Science Ltd, ‘The Boulevard, Langford Lane, Kidlington, Oxford OXS 1GB, UK Elsevier Science Inc., 665 Avenue of the Americas, New York, NY 10010, USA Elsevier Science Japan, Tsunashima Building Annex, 3-20-12 Yushima, Bunkyo-ku, Tokyo 113, Japan Copyright ©1999 Elsevier Science Ltd. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocopying, recording or otherwise, without permission in writing from the publishers. Third edition 1999 Library of Congress Cataloging-in-Publication Data Dickenson, T. Christopher. Valves, piping, and pipelines handbook /T. Christopher Dickenson. ~ 3rd ed. p.cm ISBN 1-85617-252-X (he) 1. Valves Handbooks, manuals, etc. 2. Piping Handbooks, manuals, ete. 3. Pipelines Handbooks, manuals, ete. I. Title. 1S277.D53 1999 99-26575 621.8'4-de2] cre British Library Cataloguing in Publication Data A catalogue record for this title is available from the British Library. ISBN 1 85617 252X No responsibility is assumed by the Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Published by Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OXS5 1GB, UK Tel.: +44(0) 1865 843000 Fax: +44(0) 1865 843971 Printed and bound in Great Britain by Cambridge University PressPreface “A Vital Contribution to Modern Industry” Over recent years, a number of significant developments in the application of valves have taken place: the increasing use of actuator devices, the introduction of more valve designs capable of reliable operation in difficult fluid handling situations; low noise technology and most importantly, the increasing attention being paid to product safety and reliability, Digital technology is making an impact on this market with manufacturers developing intelligent (smart) control valves incorporating control functions and interfaces. Computer Integrated Processing is now a fact of life. New metallic materials and coatings available make it possible to improve application ranges and reliability. New and improved polymers, plastic composite materials and ceramics are all playing their part. Fibre-reinforced plastic pipe systems, glass-reinforced epoxy pipe systems and the traditional low-cost polyester pipe systems have all undergone sophisticated design and manufacturing technology changes. The potential for growth and expansion of the industry is huge. The 3rd Edition of the Valves, Piping and Pipelines Handbook salutes these developments and provides the engineer with a timely first source of reference for the selection and application of valves and pipes Tt would not have been possible to provide so much information and data in this Handbook without the co-operation given by the individuals and companies listed overleaf, as well as the manufacturers who supplied information and data. Their contribution is gratefully acknowledged. This is the decade of the customer, and the Valves, Piping and Pipelines Handbook 3rd Edition is intended to provide essential, practical product information and reference data where and when they are needed most. T. Christopher Dickenson F.{. Met. September 1999CONTENTS Section 1. Section 2. Section 3. Fundamentals Classification of Valves Basic Valve Nomenclature Valve Selection Guides Pipes and Pipelines—Definitions and Explanations Valve Types Design and Construction Plug Valves (Cocks) Ball Valves Ball Float Valves Butterfly Valves Rotary Disc/Rotor Valves Globe Valves Gate Valves Needle Valves Pinch Valves Diaphragm Valves Slide Valves Screw-down Valves Spool Valves Solenoid Valves Swing Check (Flap) Valves Penstocks Miscellaneous Valves Pressure Valves and Services Check Valves Safety and Relief Valves Self-Acting Reducing Valves Ait Relief Valves Foot Valves 41 63 67 85 91 98 107 110 118 127 133 138 146 164 168 172Section 4. Section 5. Section 6. Section 7. Section 8. Control and Automation Valve Actuators Control Valves Float Control Valves ‘Temperature Control Valves Regulators Pipes Icon and Steel Pipes Fibre-Reinforced Plastic (FRP) Pipe ‘Thermoplastic Pipe Pipe Joints and Couplings Expansion and Contraction Joints Corrosion and Cathodic Protection Corrosion of Stainless Steel Valve Corrosion Protective Coatings and Linings Pipelines/Pipework Pipeline Cleaning Pipe Cutting and Bending Pipeline Inspection and Evaluation Jacketing and Dual Containment Performance and Calculations Flow of Liquids through Pipes Flow of Mixtures through Pipes Compressible Flow in Pipes Losses in Bends and Fittings Strength of Pipes (Calculations) Buried Pipes Collapsing Pressure for Pipes and Tubes Boiler-Feed Calculations Steam Flow Calculations Cavitation Noise Control Balancing of Hydronic Systems Duties and Services Water Services Hygienic Services Steam Services Fire-Safe Valves Fire Hydrant Valves 249 280 301 306 314 325 339 356 396 427 443 457 462 465 479 497 sll 522 533 556 572 584 601 610 628 637 645, 658 667 682 693 718 728 743 754Section 9. Section 10. Section 11. Marine Servi Vacuum Services Cryogenic Valves Nuclear Services High Pressure Services Engineering Data Glossary Standards and Designations Author's Acknowledgements Buyers’ Guide to Valves and Pipes Classified Index by Product Category Alphabetical List of Manufacturers ‘Trade Names Index Editorial Index Advertisers Index 759 763 768 775 784 793 800 855 863 865 867 872Acknowledgements— Illustrations and Tables Page Number 3 Stop Sbottom 28 29 B2top 45 46 Figure 6(aandb) 47 48 Figure | 49 top 49 bottom 50 top 50 Figure 2 52top 52 bottom 53 Figures 55 Figure 55 Figure 6 S6F: 60 Figure 11 63 64 64 Figure U 67 68 69 Figure 1 70t0p 70 Figure 2 71 Figure 3 PL Rigure + 73 Figure Company Neles-Jamesbury Neles-Jamesbury Neles-Jamesbury BF Goodrich Biwator Industries Secck Audco Valves Johnson Valves Serck Audco Valves International Hwashen Corporation Fortune Manufacturing Co Worcester Controls Worcester Controls Neles-Jamesbury Orbit Harwin Valves Flow Safe. Inc ‘Tyco Valve Argus Argus Neles-Jamesbury Neles-Jamesbury Neles-Jamesbury Argus Worcester Controls Argus Neles-Jamesbury Argus Guest and Guest and Chrimes Guest and Chrimes KSB Armaturen GmbH KSB Armatucen GmbH Neles-famesbury KSB Armaturen GmbH Neles-jamesbury Netes-Jamesbury Baronshire Engineer KSB Armaturen GmbH Wouter Witzel GmbH 1d Controls Page Number Figure 6 75 76 Figure 7 77 Figure 8 77 Figured 79 Figure 10 81 top 81 bottom 82 Figure 12 87 Figures 88 Figure 6 8910p bo Figure 7 93 bottom left 93 bottom right 94 Figure 3 95 top 95 Figure 4 95 Figures 98 99 bottom 102 top 102 bottom 103 bottom 104 Figure 5 104 Figure 6 104 Figure 7 10s 108 bottom 1 Figure 2 112 Pigure + 115 Figure 10 116 Figure 11 116 Figure 12 122 Figure 3 124 Figure 6 125 Figure 7 129 Figure 3 130 igure 5 Company Neles-Jamesbury Guest and Chrimes Tyco Valves and Controls Posi-Flate Posi-Flate Neles-Jamesbury Tyco Valves and Controls Tyeo Valves and Controls Charles Winn (Valves) Lid Quality Controls inc Quality Controis Ine Quality Controls ine Nu-Con Equipment OMB SpA, ASAHI/America Hitachi Valve OMBSpA KSB Armaturen Gmb8 KSB Armaturen GrabIt Brooksbank Valves Ltd KSB Armaturen Gmbi, KSB Armaturen GmbH Johnson Valves Guest and Chrimes OMB SpA OMBSpA, OMBSpA, OMBSpA, Johnson Valves, Red Valve Company ine Red Valve Company Ine Crane Resistofiex Crane Resistoflex Crane! Resistoflex Humphrey Products Komutee Powder Technology Kemutec Powder Technology Hopkinsons Ltd Hopkinsons Lidxii Page Number 131 Figare 6 134 135 136 437 146 147 Bigure 1 148 Figure 2 149 Figure 3 150 Figures 151 Figure 5 152 Figure 6{a and b) 152 top 153 Figure 7(a and b) 153 Figure 8 (a and) 154 Figure 9 154 Figure 10 155 156 Figure 31 156 Figure 12 158 top let 158 topright 164 Figure J 165 bottom 166 Figure 3 167 Figure 4 170 Figure 3 171 Figure + 171 Figure 5 172 Figure 1 174 Figore 2 175 Figure 3 176 Figure 17 Figure 6 178 Figure 8 178 Figure 9 179 Figure 10 179 Figure 11 179 Figure 12 180 Figure 12 180 Figure 13 185. 186 top 186 Figure 1 188 Figure 3 188 bottom let 188 bottom right 189 Figure 5 190 Figure 6 190 Figure 7 191 Figure 8 191 Figure 9 ‘Company Bush-Wilton Grasso Spirax Sarco Spirax Sarco Johnson Valves Asco Joucomatic Ltd Asco Joucomatie Led Asco Joucomatie Ltd sco Joucomatic Ltd ‘Asco Joucomatie Ltd Asco Joucomatic Ltd Automatic Switch Co Asco Joucomatic Lid Automatic Switch Co Automatic Switch Co Asco Joucomatic Ltd ‘Asco Joucomatic Lid ‘Asco Joucomatic Ltd Asco Joucomatie Lud Asco Joucomatic Ltd Asco Joucomatic Ltd Asco Joucomatie Led ‘SOCLA Danfoss Water Valves ‘Simon Hartley Lid Abacus Valves Manufactaring Ltd K. Controls Lid Simon Hartley Ltd Simon Hartley Lid Simon Hartley Ltd Crosby Valve Ine ItalvalvoleyZella Apporeechi e Machine Idrauliche Special, Apporeechie Machine Idrauliche Special Deaurik, a division of SPX Banjo Corp, Banjo Corp, Worcester Controls ‘SchuF Armaturen & ‘Apparatebau GmbH ‘SchuF Armaturen & ‘Apparatebau Geib# SchuP Armaturen & Apparatebau GmbH SchuP Armaturen & Apparatebau GmbH K.Controls Lid Johnson Valves Delta Pacific Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves Johnson Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves Durabla Fluid Technology Ine Page Number 192 193 194 Figure 10 195 Figure 11 195 top 196 Figure 12 197 198 Figure 13 198 Figure 14 201 Figure 1 202 Figure 2 202 Figure 3 202 Figured 204-206 Table L 207 Figure S 208 Figure 6 209 Figure 7 210 Figures 211 Figure 9 212 Figure 10 212 Figure 11 213 Figure 12 213 Figure 13 214 Figure 14 214 Figure 15 215 Figure 16 216 igure 17 217 top 217 bottom 218 Figure 18 218 Figure 19 218 Figure 20 219 Figure 21 226 Figure] 227 Figure 2 227 Figure3 233 PigureS 233 Figure 6 235 Figure 8 238 toplett 238 topright 240 243 Figure 3 244 op 244 Figure 2 245 Figure 3 245 Figures 243 Figure 5 246 Figure 6 249, 252 253 254 255 236 257 Company Durabla Fluid Technology Ine Durabla Fluid Technology Ine Durabla Fluid Technology Ine Abacus Valves Manufacturing Lid Baronshire Engineering Ltd Spirax Sarco Durabla Fluid Technology ine Kepner Products Company Kepner Products Company Spirax Sarco IMI Bailey Birkett Ltd Realen IMI Bailey Birkett Lic Crosby Valve tne IMI Bailey Birkett Lid Ceosby Valve Ine Crosby Valve tne Crosby Valve Ine IMI Bailey Birkett Cid [Mi Bailey Birkett Lid Ini Bailey Bickete Led Plast-O-Matic Valves Ine Port Valve Ine. Circle Seat Controls tne Circle Seal Controls ine Crosby Valve Ine Crosby Valve Ine Flow Safe Ine. Spirax Sarco ‘Anderson. Greenwond-Co Crosby Valvetne Spirax Sarco IMI Bailey Birkett Ltd Spirax Sarco Spirax Sarvo Spirax Sarco Spirax Sarco Spirax Sarco Spirax Sarco Guest and Chrimes Guest and Chrimes, Guest and Chrimes SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves SOCLA Danfoss Water Valves SOGLA Danfoss Water Valves SOCLA Danfoss Water Valves Saunders Valve Co Neles-Jamesburry Neles-Jamesbury KSB Armaturen Gunbtl KSB Armaturen GmbH. Neles-Jamesbuiry Rotork Contols LtdPage Number 258 260 Figure 1 260 Figure 2 261 Figure 3 262 Figure. 4 263 Figure 5 264 Figure 6 265 267 Figure 7 268 Figure 8 268 Figure 9 269 Figure 10 270 igure 11 EPigure 12 273 Figure 13 274 Figore 1 275 Figure 14 276 277 Figare 16 277 top 278 Figure 17 280 Figure 1 281 top 281 bottom 282 bottom right 282 top left 282 wp right 284 Tigure 2 284 Figures 285 Figure 286 Figuee 5 287 Figure 6 287 Bigure 7 288 Figure 8 288 Figure 9 288 Figure 10 289 Figure 11 290 Figure 12 291 Pigure 13 292 Figure 14 293 Figure 15 294 top 294 Figure 16 295 296, 297 Figure 17 297 Figure 18 298 Figure 19 298 Figure 20 299 Figure 21 299 Figure 22 304 Figure 6 305 Figure 7 307 Figure 2 308 Figure 3 310 Figure § 310 Figure 6 Company Shafer Valve Co KSB Armaturen Gmbkt KSB Armaturen Gmbll NelesJamesbuty Shaler Valve Co Shafer Valve Co Bel Valves KSB Armaturen GmbHt Rotork Conteos Lid Hitachi Valve Rotork Controls Lid Rotork Controls Ltd Rotork Controls Lid Rotork Conteols Lud Rotork Controls Lid Dreamo tlecteo-Mechanik GmbH Dreamg Blecteo-Mechanik Gmott Rotark Conteols tid EL-0-Matic International ‘Tyco Valves and Conteols Bxeeco Ltd Spirax Sarco Spicax Sarco Denurik.a division of SPX Plast-O-Matie Valves inc Severn Glocon Guestand Chrimes Spirax Sarco Spirax Sarco Deauik, a division of SPX Spirax Sarco Spirax Sacco Spirax Sarco Spirax Sarco Spirax Sarco Spirax APV/lnvensys APV/lnvensys APV/Invensys K. Controls Lid Reaim, Osmonies Gems Valves Lid ‘SOCLA Dantoss Water Valves SOCLA Danioss Water Valves Emile Egger-Co. AG Eanile Eyger-Co. AG sco Joucomatie Ld AAsco Joucomatic Lid ‘sco oucomatie Lid Curtis Wright Control Flow Corporation Spirax Sarco Spirax Sarco SpiraxSarco Spirax Sarco Spicax Sareo| Spirax Sarco Page Number 315 topleft 315 topright 316 Figure 3 316 Figure 3 317 Figure 4 317 bottom 318 Figure 6 319 Figure 7 325 326 327 328 329 Table 1 330 Figure L 330 Figure 2 330 Table 2 331 Table 3 331 Table 5 333 Figure 3 334, 335 Table 7 336 337 338 Figure 4 339 Figure | 340 Figure 2 341 356 Table 1 357 358 Figure1 3590p 360 361 368, 369) 370109 370 bottom 371 372 374 Piguee 4 378 379 380 384 Table 6 391 top 393 Table 7 395, 396 400-4001 Figure L 402 4003 Figure 2 403 Figure 3 404 Figures 405 Figure 5 405 bottom 406 Figure 6 407 408 Figure 8 xiii Company Dycon Dynamic Controls Dycon Dynamic Controls ‘Apeo Controls Eisher Rosemount Fisher Rosemount Fisher Rosemount Circle Seat Controls Ine Ciecle Seal Controls Inc Griffin Pipe Products Co. Hitachi Valve Biwater Industries Griffia Pipe Products Co. Biwater Industetes BiwaterIndustries Biwaler Industries Biwater Industries Biwater Industries Biwater Industeies Srffin Pipe Products Co. Rath Manufacturing Company Inc Special Metals Corporation Dow Chemical Co Dow Chemical Co Crane George Fischer George Fischer George Fischer George Fischer George Fischer George Fischer Harvel Plasties George Fischer Upnor Led ‘Agru Company George Fischer George Fischer ASAHI/America ASABI/America ASABI/America Wiik and Hoeglund George Fischer George Fischer George Fischer George Fischer George Fischer George Fischer Harvel Blasties Griffin Pipe Products Co. Griffin Pipe Products Co. Griffin Pipe Products Co. Biwater Industries Vietwalic, Vietwalic Victualic Vietualte Harvel Plastics Griffin Pipe Products Co. Biwater Industriesxiv Page Number 410 top an 412 igure 13 413 Figure 14 414 top 422 Figure 15 422 bottom 423 425 op 441 Figure 13 445 top 449 Figures 450 top 450 Figure 5 454 Figure 7, 454 Figures 467 468 top 468 bottom 472 Table 2 474 475 wp 475 bottom 483 Table 3 484 op 484 Figure 2 486-487 Figure 3 488-489 Figure 4 492 Table 5 497 498 499 top 499 bottom 501 top 307 508 top 508 bottom. 509 510 sia 515 Figure] 516 Figure 2 SL? Figure 3 519 520 522 Figure 1 523 Figure 2 523 Figure 3 525 Table 1 526 Figure 4 528 Figure S 529 Figure 6 638, 640 641 Company Biwater Industries Biwater Industries APV/Invensys 3X Engineering France 3X Engineering France George Fischer George Fischer George Fischer International Hwashen Corporation| George Fischer Vietualic Metal Samples Metal Samples Metal Samples Pi Conversion Engineering Ld Pi Conversion Engineering Ld Plascoat International Dow Chemical Co Dow Chemical Co Biwater Industries Dow Chemical Co Dow Chemical Co Dow Chemical Co T.D. Williamson, Ine.” 18-7. Molehtechnik GmbH 7.D. Wilhamson, Ine.” TD. Williamson, Ine. .D. Williamson, Inc. TD. Williamson, Ine.” EH. WachsCo E.H.WachsCo EH. WachsCo ‘Tubelar Engineering. EH. Wacks Co TD. Williamson. Ine." T.D. Williamson, Inc. T.D. Williamson, Ine. T.D. Williamson. Ine.” ‘V.D Williamson. Ine." Radiodetection Dyno-Rod Dyno-Rod Cabletime Systems Lid Radiodetection Shaler Valve Co Controls Soutbeast ac Controls SoutheastIne Controls Southeast Ine Controls Southeast Ine Controls Southeast Ine International Plastic Systems Lad Enfield Industrial Corporation Spirax Sarco Weir Pumps: Weir Pumps Page Number 656 "Table 2 661 Figure S 665 668 670 Figure} 670 Figure? 671 Pigure3 672 Figured 672 Fipure Ss 673 Figure 6 673 Figure? 674 Figures 674 Figured 675 Figure 10 677 Table1 679 Figure 12 679 Figure 13 680 Figure 14 680 Figure 15 634 694 695 Table 1 697 Figure 3 698 Figures 699 Figure 5 699 right 700 Figure 6 701 Figure 7 702 703 bottom 703 top 704 207 708 top 708 bottom 716 Figures 716 Figure 9 719, 720 721 Figure 1 72) Figure 2 722 Figure 723 Pipure 5 725 figures 726 729 Figure 1 730 Figure 2 731 Figure 3 733 bottom 733 top 734 bottom 735 Figure 739 Figures 739 Figure 6 246 Table 1 748 Figure 3 749 bottom 749 Figure + 750 Table 3 733 Company Spirax Sazco Kent Process Control Dresser Valve Division Neles-Jamesbury Neles-Jamesbury Fisher Rosemount Fisher Rosemount Fisher Rosemount Fisher Rosemount Fisher Rosemount Fisher Rosemount Neles-jamesbury Nelesamesbury Nelesamesbury Ceosby Valve inc Engineering Applications Lid Engineering Applications Lid Engineering Applications bid Engineering Applications bed Tour + Andersson AB SOCLA Danfoss Water Valves Spicax Sarco ABV/lnvensys Dezurik, 2 division of SPX KSB Acmuaturon GmbH Guest and Cheimes Wouter Witzel GmbH Dezuei a division of SPX Guest and Choimes ‘Adams Brooksbank Valves Ltd Johnson Valves SOCLA Danfoss Water Valves Lancashire Fittings Lid Delta Capillary Products Lid IM Bailey Birkett Ltd Int Batley Birkett Led Realm Realm Bray Valves + Goatrols (UK) Quality Controisine GSR Veatiltechaik GmbH Dressee Valve Division Schott Industrial Glass Harvel Plasties Spirax Sarco Spicax Sarco Spirax Sarco 1.6. Black Polymers Ltd Crosby Valve tne Crosby Valve Ine Spirax Sarco BIG. Spirax Sarco Solvent + Pratt Hindle Cockburns Ltd OMBSpA Solvent + Pratt Solvent + Pratt ‘oMBspAPage Number 754 755 Figure] 755 cop 756 Table 1 757 Figure 2 759 761 bottom Jol top 764 bottom 764 Figure 2 765 Figure 3 766 Figure 4 768 769 770 Figure 1 Note: Company Brooksbank Valves Ltd Guest and Cheimes Brooksbank Valves Ltd Guestand Chrimes IMI Bailey Birkett Lid Brooksbank Valves Ltd KSB Armaturen GmbH Blakeborough Valves Neles-Jamesbury Neles-Jamesbury Neles-Jamesbury Circle Seal Controls ine Reiss Engineering Co. Ltd Solvent + Bratt ‘Tyco Valves and Controls Figures from’T. D. Williamson, Ine.": Reproduced with the permission of TD. Williamson, Inc.® Registered Trademarks of T.D. Williamson. tne. in the United States and in foreign counties. Page Number 71 Figure 2 772 Figure 3 773 top 773 Figure 775 776 77 Figure 2 778 ¥igure 3 782 784 786 788 Figure 6 788 middle 789, wv Company ‘Tyco Valves and Controls Neles-Jamesbury IMI Bailey Birkett Lid Circle Seal Controls Ine Worcester Controls Vanatome Crane® Resistotlex EDP. Mannesmannrohren-Werke AG Neles-Jamesbury GSR Ventiltechaik GmbH, Adams Kepner Products Company ‘Adamst - ee ait) 5 As the inventor of the solenoid valve, ASCO JOUCOMATIC-has been guiding new/developmén Pe mE MCL Vata ie esc ueeR ege ea cceeen Urs) 8, and Pr Se Rumi eee con mae eutectic COR Ruri Mem Roel Reels ea eee aol a Sie Ri aL Ct with your specifications, we provide even more. i eats er ernment n Mr eee eo Neon eee eee a ea Laced elias ate ee Poesia tne eum arise ariel lists Meet iench (rel iat pce CE ee LN eC ue cee acc e eM ea ene a niet Fi fe ASCO JOUCOMATIG (Asoo Gontrols BY) Sree Mere ee ante een eek ec eee iE Ea mee eaSECTION 1 Fundamentals Classification of Valves Basic Valve Nomenclature Valve Selection Guides Pipes and Pipelines—Definitions and ExplanationsClassification of Valves Valves may be classified in a number of ways, e.g. by category (general type), specific type, purpose or name; or by flow characteristics (e.g. straight-through, full-flow or throttled-flow). Descriptions can also differ slightly in different countries although the main type names are established internationally (with some exceptions). Classification of valves by category is given in Table 1. This follows British Standards and general practice adopted by British manufacturers, but is also generally applicable to American practice. One major difference in this respect is that the important class of ball valves is considered as a type of plug valve in the tabular summary, whereas American practice would favour regarding it as a separate category. The ball valve is, in fact, a major type in its own right. ‘Moduiar bat! valve based on standardised components.4 Fundamentals Table 1. Classification of valves Category Cock Setew- down stop valve Gate valve (wedge gate valve} Gate valve (slide valve) Check valve Butterily valve Diaphragm valve Ball oat valve) Patterns. 1 3 4 1 2, 1 . Outside serew 3. Plug Gland Packed cock Compound gland Plain Lubricated Inside screw - Outside serew Inside screw Lever (a) Sliding stem (b) Rotary stem, Horizontal Vertical Angle - Double flanged Water (a)Singledange (0) Flangetess Single beat Double beat ‘Types of construction ‘Tapered plug Plug retained by gland or packing Packing between plug face and body seat Stuffing box in cover, 1 2. 3 ‘Taper plug - Parallel plug Ball plug, Globe valve Angle Oblique Others Wedge (gate) Sluice (valve) Double dise Swing (check) ate (a) Dise (b) Piston (o) Ball Foot (valve) Each flange is individually bolted. Primarily designed for insertion between pipe flanges Flexible diaphragm mounted over a weir. 1 2, 3. 4, . Direct (lever}- operated Pressure-operated Droptight Non-droptight Remarks Also parallel plug. Passage through port in rotatable, plug supported or mounted to reduce friction. Spherical body. Spherical body with ends at right angles, Spherical body, stem axis oblique, Usually described by type (e.g. needle valve) or geometry of body e.g. tee valve) Closure effected by wedge action {a) Solid wedge or {b) Split wedge. Solid wedge gate valve. Gate composed of parallel sliding discs or slides. Hinged flap check mechanism. Dise check mechanism. Disc plus piston check mechanism, Ball check. Check valve fitted to bottom ofa suction pipe. Based on rotatable dise valve. Single beat—flow through single seating ring, Double beat—flow through two seating rings.Table 4 (continued) Category Safety Relief valve Pressure control valve Air celief valve Purbine valve Free discharge valve Valves are classified and de: Patterns 1 2 3. 6 ‘Types of construction, Direct spring-loaded Direct weight-loaded Lever and spring-loaded Lever and weight-loaded Tension spring-loaded Torsion bar Direct spring-loaded Direct weight-loaded Self-contained 1. Pressure-reducing Spring-loaded 2. Pressure-retaining Weight-loaded 3. Indirect Pressure-louded Externally-piped Tight-closing Non-tight-closing, Relay-operated Single-orifice LP ingle-oritice HP Single-oritice with integral isolating, valve Double-orifice with, integral isolating valve Regulating Quick-closing Guarding Needle-type Hollow jel-lype Sleeve-type Classification of Valves 5 Remarks Also designated by 1 Hligh-lit valve 2. Pulllit valve. 3. Pilot-operated valve Blectrically-assisted valve Also designated by: 1. High-Uft (relief) valve. 2. Pilot-operated (relief) valve. bed by specific type in Section 2, which also include a number of individual designs best categorised as miscellaneous. Some other valve types are given in Table 2. Descriptions of various valve types may also differ and Table 3 lists some other descriptions, standard terminology in this case being based on that adopted for Table 1. This is by no means complete, but is offered as a general guide.6 Fundamentals Table 2. Some other valve types Category Flow-regulating valve Temperature-regulating valve Automatic process-control valve Anti-vacuum valve Blow-down valve Bulkhead valve Free-ball valve Fusible-ink or fire valve Hydraulic valve Jet-dispersal valve Penstock Plate valve Radiator valve Rotary-slide valve Rotary valve Solenoid valve Spectacle-eye valve Thermostatic mixing valve Throttle valve Description For controlling rate of flow in a system. For controlling fluid temperature level in a systern. For controlling rate of flow relative to value of a command system, An automatic type of air valve for the prevention of the formation of vacuum or the release of vacuum in large bore pipelines. A valve which is used for cleaning stndge and other foreign matter from a boiler. A gate valve. Avalve in which a ball, free to rotatein any direction. is, moved at 90° to the flow stream from a position removed rom the flow stream until finally rolling into a circular orifice for shut off, A fire prevention valve which has a weighted lever held open by a wire and fusible link which melts at an increase in room temperature. Accontro! valve for either water, oil, or hydraulic systems. A valve incorporating an element by virtue of which the energy within the emitting jetis dissipated A single-faced type of valve consisting of an open irame and door, and used in terminal positions only: usually located in tanks or channelsas a means of controlling flow into a pipe A gate valve incorporating a sluicing effect. A valve for conteolling the flow of water through a radiator, A valve in which rotation ofinternal parts regulates flow by opening or closing a series of segmental ports. A spherical-plug valve in which the plug, which rotates through 90°. is provided with a circular waterway to match the body and ports. A valve operated by an electrical solenoid ‘A type of parallel slide valve in which the ‘spectacle gate’ has one ‘lens’ of circular waterway and the other of solid section. Avvalve which combines temperature selection and flow control in the same body Anon-tight-closing butterfly valve with a centrally-hinged flap which can be locked in any desired position. Classification of valves by function yields the following general list where any individual type of valve may be capable of performing one or more of these functions. Excluded [rom this list are specific functions or specialised services for which special designs of valves are normally employed. (i) On-offservice. (it) Throttling or flow control. (iti) Preven g of reverse flow.Classification of Valves 7 Table 3. ‘Terminology 1 General or ‘popular’ description |_ Standard terminology Back-pressuce valve Check valve Block and bleed valve Gate valve Clack valve Check valve Conduit valve Gate valve with full-bore aperture Controllable check valve | Screw-down stop and check valve Controllablenon-return valve Screw-down stop and check valve Dashpot valve Check valve (piston-check disc-type) Excesslow valve Plow-regulating valve Excess-orminimum-pressure valve | Flow-regulating valve Flap valve Check vaive (swing-type) Follower-ring valve Gate valve Pullway valve Gate valve Governor valve Pressure-control valve Non-return self-closing valve Check valve Parallel-gate valve | Safety valve (ditect spring-loaded) Proportional-flow valve Flow-regulating valve Reflux valve Check valve Retention valve Check vaive Screw-down non-return and flood valve Screw-down stop and check valve Wheel valve Screw-down stop valve ¥-type valve Oblique valve (iv) Pressure control (v) Directional flow control, (vi) Sampling. (vii) Flow limiting. Valves classified by duty or the service they are intended to perform are described in Section 3. Necessarily these embrace types already described under specific types and the relevant chapters can be studied together where appropriate. A further source of reference and information in this respect is the chapter on Valve Selection Guides. Industrial valves operate under many different situations and temperatures which range from the cryogenic to high-temperature applications and with different materials including grit, sludge, corrosive chemicals, gases and liquids. In general, valve technology is mature. There are two main divisions in the industry: control valves giving precise control of flow and on/off valves which may be further subdivided into linear (multi-turn) and rotary (quarter-turn). Actuators which control the movement ofa valve can be manual or automatic and area major ancillary item for valves Valves can be purchased as standard products (commodity valves) or as engineered units, purpose-built for a specific application. The emphasis today is on providing solutions to problems and automation wherever possible.8 Fundamentals High-performance butterfly valve with sectioned spring-diaphragm actuator for modulating control. Rotary segment-control vaive with noise-control trimClassification of Valves 9 Processes are required to be more economical and run uninterrupted for longer periods. ‘The intervals between production shut-downs for plant maintenance are growing longer and environmental protection legislation is becoming more stringent. Intelligent valves, based on digital control technology and incorporating control functions and communication interfaces are already making an impact and computer integrated processing (CIP) isa reality. The most striking changes in valve technology appear to be in the field of materials of constructions with new metals, ceramics and composites being explored. Valve connections Valves are normally designed to take either threaded pipe ends, or with flanges for flanged connection. Threaded connections are simpler and cheaper to produce and more easily installed. However, it can prove difficult to remove valves so mounted without dismantling a considerable portion of the piping unless a number of extra fittings, such as unions, are incorporated, Lok Wm SY fe Plain Jace Raised face Ch cdo AI Somat Large imaile avd female tongue arnd groove yn np Ste Large mate and female Sra Ring joint longue and groove Figure 1. Blanged ends.10. Fundamentals Flanged ends make a stronger, tighter and more leak-proof connection. Where heavy viscous media are to be controlled, as in refineries, process and chemical plants, etc., flanged-end valves are normally used. The initial cost is higher, not only because of the extra metal but because the flanges must be carefully and accurately machined. Also the installation cost is greater because companion flanges, to which the valve-end flanges are bolted, as well as gaskets, bolts and nuts must be provided, All flat faces are commonly termed plain faces. Bronze and iron flat faces can have a machined finish. Cast iron raised faces may be smooth finished or have a serrated finish (preferably with no fewer than 16 serrations per inch) which may be spiral or concentric. Steel flat faces and raised faces should have a serrated finish of approximately 32 serrations per inch, The serrations may be either spiral or concentric. Steel male and female and tongue-and-grooved [aces should have a smooth finish. Steel ring-joint faces should have smooth finished grooves. If spiral- wound gaskets are used on flange faces, the flanges should have a smooth finish. Examples of flanged ends are shown in Figure 1 Socket or butt-welded ends are used on all-welded pipeline systems. For specific services valves are also to permit connection to pipes by soldering or brazing. In the latter case the valve may be supplied with integral preformed brazing-material inserts.Basic Valve Nomenclature Most valves consist of a body containing a flow control element (discs, plug. gate, etc.) attached to and operated by rotation ofa stem. (There are exceptions: e.g. swing check and pinch valves have no stem.) The stem, together with any stem seals, is enclosed within a bonnet. The top of the stem is fitted with a handwheel (or lever) for rotation of the stem (although some stems may have a sliding operation for quick action). With threaded stems (giving a screw-down, screw-up motion) the threaded portion may be fully enclosed by the bonnet, known as inside screw: or exposed beyond the bonnet, known as outside screw. The former obviously provides maximum protection for the screw thread. Outside screws have the advantage of being easier to lubricate. With rising-stem valves the handwheel and stem move together. giving a visual indication of the degree of valve opening. With a non-rising stem the handwheel does not rise (or lal) with the turning movement. The advantage of this type is that it can be installed in situations providing only minimum headroom above the handwheel. Various types of bonnet may be used, e.g. screw-in, screw-on, union-style and bolted or flanged bonnet. Screw-in or screw-on bonnets are the simplest and cheapest, but largely limited to smaller valves used on low-pressure services. Union bonnets generally provide tighter sealing and are particularly suitable for valves which are dismantled frequently for servicing. Plain (flat) flange and male-and female-flanged bonnets are generally preferred for high-temperature or high-pressure valves, and also larger sizes of valves. An alternative type for high-pressure and/or high-temperature services is the breech-lock bonnet. Valve trim Trim is the term used to describe the parts of a valve which are replaceable, i.e. normally those parts likely to be subject to wear or degradation. The following parts are considered as trim: Gate valves—stem, seat ring, wedge. back-seat bushing Globeand angle valves—stem. seat ring, disc, disc nut, back-seat bushing12 Fundamentals Screwed bonnet. Union bonnet Bolted flanged bonnet Disc valve—disc, disc nut, back-seat bushing. Swing-check valves—disc, disc holder, disc nut, side plug, carrier pin, disc-holder pin, disc-nut pin, seat rings. Lift-check valves—disc, dise guide, seat rings. Stem seals and other internal seals (where fitted) are arguably included under the definition of trim, but are not normally used in describing trim materials. Standard abbreviations The following abbreviations are used to describe or designate valve parts features, etc.: Alliron. all parts of iron construction, All bronze all parts of bronze construction. BB bolted (flanged) bonnet. cWp cold working pressure. DD double disc. DW double wedge. FE flanged end (connection). FE flat flange. IBBM iron body bronze-mounted IPS iron pipe size. ISNRS inside screw non-rising stem. ISRS inside screw rising-stem. NRS non-rising stem. RE raised flange. RS rising stem SIB screwed bonnet.Basic Valve Nomenclature 13 sw solid wedge. SintorintS _internalseat. Srenorren$ renewable seat. OS&Y outside screw and yoke. woG water, oil, gas pressure rating, Nomenclature covering the individual parts of various different types of valvesis included in Section 2.Valve Selection Guides The main parameters concerned in selecting a valve or valves for a typical general service ar (i) Fluid to be handled—this will affect both type of valve and material choice for valve construction. (ii) Functional requirements—mainly affecting choice of type of valve. (iti) Operating conditions—affecting both choice of valve type and constructional materials. (iv) Flow characteristics and frictional loss—where not already covered by (ii), or setting additional specific or desirable requirements (v) Size of valve—this again can affect choice of type of valve (e.g. very large sizes are only available ina limited range of types); and availability (matching sizes may not be available as standard production in a particular type) (vi) Any special requirements ~e.g. quick-opening, free-draining, etc In the case of specific services, choice of valve type may be somewhat simplified, e.g. by following established practice or selecting from valves specifically produced for that particular service. On a broad basis, Table 1 summarises the applications of the main types of general purpose valves. It has only limited use as a selection guide, i.e. can be regarded as a starting point. Table 2 carries general selection a stage further in listing valve types normally used for specific services. Table 3 isa particularly useful expansion of the same theme relating the suitability of different valve types to specific functional requirements. Normally, for general services (and for many specific services), several valve types may appear as possible choices. These may then need evaluating individually, and comparing on the basis of the flow characteristics they offer. Even more important, calculations may be necessary to establish a suitable size of valve to meet a specific performance requirement, e.g. a maximum, acceptance pressure drop or head loss through the valveTable 1. Valve types—typical applications Vabvec Serew-dnwa sop valve Cock Gate valve Paralel-side valve Battery valve Prapbragm valve all valve Pioch valve “Atomatie process: control valve Aiceraiel valve “Tarbine valve Genera application(s) Actuation ShutoTor regulation ofdow afliguids!) Handwheet |ond gaseste seni) Low-pressureserviceon clean cold lds fe. water oils. ee Nosmally used ether flly open or fully closed for ono regulation fom wate, cil. gas steam and other Aid services Regulation offlow. particularly min services in processindusties andsteam powerplant Shut-off and regulation in large pilings in waterworks, process industries. petrochemical industri. Inydroeletri power stations and thermal power stations, Widerange of applications nat services for ow regulation, Widevange of applications foc all sles. inching very laegesiaesi6 cl ppatines ev Portioularly suitable foe haneling corrosive veda saldsin suspension Designedto meet particular servieeconsiions ‘sedi water works ce. torelene ped ae and prevent formation of vactam pockets Designed to meet requirements o “seam and water tucbines in industrial, marine snd power (jf) Blctee motor {for nyacouticsystems actuate dv Hydenutic actuator (1 Aiemotor Usually mangal ) Handwheet (hy Boetrie motor (iy ydroutie systems act le) Hydraulic actuator (8) Airmotor {)) Handwheet | i). Hlectric motor {hi hyena systems actuator «dy Hydraulic actuotor | W) Airmotor {Pp Haodwsbeet | i) ecreie motor L, (fh) hydraulic systems actuns tty) Hydraulic actuator () Aicmotor UW) Bandeheet (Pt Blectlemotor (Qi) bydeauli systems aetuatne (0) Hyérautie actuator )) Mechasicat ly Blecrricmotor kay nydrautiesystems actuador jv) Hydraulic actuator 5) Fuld pressure “modied design) Fomect particular sevice coultions jutomatiemresponding tpchangesin flow. | fomect particular service conlitions @ i Valve Selection Guides 15 inited application for low peessure/lowvolame systems hecause of relatively high cost “Limited suitability for handling viscous contaminated Nui LUmited application for tear services. a 6) & wr 1 @ wo ry “ a ib wo) @ ‘Not recommended for use as throttling vave Solid wedge gates fee fom chatter‘ and jamming, brfersunresteetedhore a fll ‘opening Can incorporate veeturi bore to ceduce operating rorque. Relatively simple constcuction. Readily producedin very largestaes (ex, upto 18itormore). Can handle all eypes of alts, facluding shurvis.shudges, ete ‘and contaminated Mids LUenited fr stesn services by lemperatureand pressuce rating ofdiaphcagrm ‘Unrestricted bore at full opening Can hanile all ypes of duis {ow opereting torque. Not normally used asa throtling valve UUnrestrlted bore at Fllopening. (Cap handle all ypes of ud Simple servicing. Limited maximum pressurerating. Most commonly afsingle or double beat-globe valve configuration Provides guaranteed control over maximum and animes tarbine spcesand pawerin asociotion16 indamentals Table 2. Valve types for specilic services Service Gi Liquids, clear up to sludges and sewage Slucries and liquids heavily contaminated with solids Steam Main Butterfly valves | Check valves Diaphragm valves Lubricated plug valves Screw-down stop valves Butterfly valves Screw-down stop valves Gate valves Lubricated plug valves Diaphragm valves Pinch valves Butterfly valves Pinch valves Gate valves Sctew-down stop valves Lubricated plug valves Butterfly valves Gate valves Screw-down stop valves Turbine valves Secondary Pressure-control valves Pressure-reliel valves Pressure-reducing valves Safety valves Relief valves Check valves Pressure-control valves Pre-superheated valves Safety and reliet valves Valve coefficients and flow values ‘The valve coefficient is a convenient method of relating flow rates to pressure drop through valves and, in fact. is sometimes called a flow value. This coefficient can only be determined empirically for a specific type of valve as it will be influenced by detail design and construction. It will also vary with the physical size of the valve and the degree of opening in the valve. Valve coefficient values are normally quoted for L00% opening (full open), with individual valves foreach size. Some confusion can aise from the fact that the coefficient quoted for a valve can have three different values depending on the basic units on which it was computed. Normally these are apparent from the designation of the valve coefficient, viz: cy in units of US gal/min, 1bf/in? Kyork, in units of l/min, bar t in Imperial units of Imp gal/min. 1bf/in? The following conversions apply: : Cy f Ky - 14.28 17.09 GQ 007 — 1.1966 f 0.0589 0.8357 -Valve Selection Guides 17 Table 3. Typical valve suitability chart Valve type Service orfunetion (sgt cle. Bis €2 5 2 2 2 8 35 Boel fo gs 2) 2 2) 2 we § = 4,3 £2 & a EE Ball soM os ~~ ~~ 8 ~|s is Butterfly ss is os ls (ss ‘Diaphragm simi-|—|-|_/-]u om o— |s Gate soo --)s sos - Globe wo) ow 2 PSS Plug M so--M oss is ‘Oblique (Y) MM =| lo tw | fo - TS [- Pinch PSTIITITTS TTIT Ts Is Slide Mo - = M = Ms ss Swing-check s —-|—- —|)—|-ls — Tilting-dise i a ee ee a Lift-check —-j}-ji-is/}/-j-j-)-|j-|- - Piston-check — Butterfly-check —|- | - Pressure-reliet sj-—- - - - s -|-(- = Pressurereducing — | — — — S$ oe Sampling ee ee | ya Needle - — | -|- - = May be suitable in modified form LS~ Limited suitability18 Fundamentals Typical flow coefficient equations can be shown as follows: For liquids where Q = flow, gallons per minute Cy = flow coefficient AP = pressure drop, psi s.g. = specific gravity (water=1) For gases (non-critical flow) Q= 16.07, 2(Pj = P3) \ tx (sg) where = flow, SCFM = flow coefficient upstream pressure, psia = downstream pressure, psia compressibility factor absolute temperature (°F +460) 8.g. = specific gravity (air=1) For gases (critical flow): P/P) =R, and Z Q= 16. OF OPS a (sg) where R and J are functions of the specific heat ratio 'r' as follows: r R J r R 1.20 0.825 1.36 0.535 122) 0.828 138 0.532 124) 0.831 1.40 0.528, 1.26 0.833 142 0524 1.28 0.836 144 0.521 1.30 0.838 1.46 0.528 132 0.840 148 0.515 134 sas 1.50 0.512 1 0.845 0.847 0.849 0.851 0.853 0.855, 0.857 0.859Valve Selection Guides 19 Combining flow coefficients v=CyytCy2+Cy3t. (2) Flowinseries: (2) = (2 4 2.) +(2)+ (2) Flowinseries: (+) = (4) +(4) +(4) +. Flow characteristics of valves (1) Flow in parallel: Where the flow characteristics through the valve are of significance, the following notes can be useful. Plug valves (Figure 1) offer a straightway passage through the ports with a minimum of turbulence. Flow can be in either direction and a quarter-turn will fully open or fully close the valve. Similar comment applies to ball valves. Gate valves (Figure 2) present a substantially straightway flow through the ports in the full-open position since the wedge or ‘gate’ is lifted clear of the flow passage. Turbulence and pressure drop are low. Again flow can be in either direction. Globe valves (Figure 3) are normally installed so that pressure is under the disc, assisting operation and eliminating a certain amount of erosive action. Turbulence and pressure drop ate higher than with straightway valves. Angle valves (Figure 4) have similar characteristics to globe valves, with flow directed through 90°. Again flow is normally directed under the disc. Reverse flow may be used in the case of high-temperature steam. Ball, globe and angle valves are suitable for throttling. <| d yp | = Figure 1. Phug valve. Figure 2. Gate valve.22 Fundamentals 8 - Eo a7 a 8 % Sat 180 8 n | 7 ea 1 | or & ROR ae mol ms § 1 | wo BS x | eee m | a Fa De | 1700 3 a ~é fod Gate Lubricated plug ‘Se | ‘190 oe 8 {or 2 a 22 a 8 % 2 mf mw | on ““ a8 » es » rg | 380 % om B 1 700 ‘a | awe Og ne | 1800 2 | 0 = Mm | 600 2 | 1700 2 | 2100 «| 2700 3 | 6500 4 {000 Balt Diaphragm ‘Nominal a 5 ® Flow fet 85% of Knoo Butterfly Figure 8. Examples offlow values Ky. The K, table for angle-seat valves gives a Ky19y factor of 327 for size 1 in, 484 for size 1/4 in and 725 for size 1/2 in. In this example the correct size to use is 11/4 in (See also Table 5). Example 2 (Figures 9 and 10) (i) What is the K, factor for a 11/4 in water pipeline with a flow of 300 l/min, an inlet pressure of 0.5 bar and an outlet pressure of O bar? (ii) Ifa valve has to be fitted and the minimum acceptable flow rate in the pipeline is 250 l/min, which type of valve should be used?Valve Selection Guides 23 Table 4. Typical'K’ values and pressure drops for various 150 mm (6 in) bore valves Service Kvalue bar Ibi/in? Globe Def 5.0 059 | 85 ‘Swing-check Sr ss 0.40 5.9 Y-pattern pe 29 0.34 49 Angle (globe) D 22 0.25 | 3.7 Venturi parallel-stide (with eyepiece) DH 013 | 19 Butterfly pt 20 oa 47 Parallel-slide without eyepiece DHF 015 oo 03 Parallel-slide with eyepiece 0.05 0.007 | oa Ball (full bore} Dac 00s 0.007 | O1 tcaight pipe (the length of an average —— 0.085 0.005 0.075 6 in bore valve) *Flow 40 mjs {140 [t/s) at 24 bar (350 Ibi/in?) saturated steam. Solution to (i) (Figure 9) Calculate the K, for the pipeline (K.p) Co L Figure 9 Given: Q 300 I/min Y Lkg/dm? AP P\—P2=0.5-0=0.5 bar24 Fundamentals Then: 300. 424 Table 5. Typical sizes and operating ranges of valves Valve Ball Butterfly Butterfly-check Gate Globe Plug, lubricated Plug, non-lubricated ‘Swing-check Swing-check .Y-type Lift-check ‘Tilting-dise Diaphragm Y¥ (oblique) Slide Pinch Needle Key: A= Atmospheric Size Min. Max. mm (in) 6 1220 Wh) (48) 501830 2) 72 25° 1830 ay (72) 3 1220 (4s) (48) 3 760 Cys) BO) 6 760 Ch) (30) 6 406 Ch) (16) 6 610 Ci (24) 6 150 lor 6 6 250 Ws) 0) 50760 2 Gol 3 610 hs) 24) 3 760 i) GO 501900 Q) (75) 25° 305 ay (2) 3 25 'Ois) (1) Pressure range Min. Max. bar (Ibyin?) A 525 (7500) v 8a (1200) A 84 1200) v 700 (20.000) v 700 20.000) A 350 (5000) A 210 (3000) A 175 (2500) A 175 (2500) A 175 (2500) A 84 (1200) v 21 (300) v 175 (2500) A 28 (400) v 21 (300) v 700 (10.000) ‘Temperature range Min. Max. “CCR 55 300 {-65) (575) =30 538 (-20) (1000) 18 260 (0) (500) 277 675 (1250) 540 1000) 315 {-40) (600) -75 220 (100) 425) -18 540 (0) (1200) 18, 540 (0) (2200) 18 340 {0} (1200) —260 590 {-450) (1100) 50 230 {-60) (450) -272 540 (455) (1000) —18 650 wo (1200) 260 (-100) G00) -78 260 {-100) {500}Valve Selection Guides 25 Solution to (ii (Figure 10) First it is necessary to calculate the K, factor for the total system (Ky_). Figure 10 Given: Q@ = 2501/min y = 1ke/dm? AP =P, -P)=0.5—0=0.5 bar Then 1 Ke = yf “ OV ae (1 = 250,/— VS Ky = 354 ‘The K, factor for the valve (K,y) can now be established by subtracting the K, factor for the pipeline (Kp) Irom the ky factor for the total system (K,,). For this purpose, the formula for calculating the flow factors in series should be used, which is thus:26 Fundamentals 1 _ 1 1 Ki, 3542 4242 = 7.98 x 10-6 — 5.56 x 10-6 = 2.42% 107° K, |. 1 SV 242 x 10-6 = 643 ‘The calculation shows that the valve used must be one with a minimum Ky100 factor of 640. From the Ky tables it can be seen that a 17/4 in ball valve has a Ky .99 factor of 1000 anda 1!/, in diaphragm valve has a Ky1o9 factor of 332. ‘Therefore only the 1/4 in ball valve can be usedPipes and Pipelines—Definitions and Explanations According to the Oxford Dictionary, a pipe is a tube whereas a tube is a long, hollow cylinder. Neither is of any help in establishing true definitions, for there are recognised differences between pipes and tubes—but not those the dictionary gives. The more obvious distinction is that ‘a pipe is a big tube, and atubeisa small pipe’—which is not far from the truth in application. But we are also concerned with differences in usage of terms in different industries—and in different counties. Taking the big tube/small pipe premise as substantially correct, we can further comment that pipes which may run up to several metres or feet in diameter are cast, spun, welded up ot otherwise fabricated, depending on the materials and sizes involved. Nobody could logically visualise producing very small sizes of pipes—e.g. under 25 mm (1 in) diameter—by such time consuming methods. It is much quicker and cheaper to produce them by extrusion. Hence tubes are basically (but not exclusively) extruded products, involving reduction in size during manufacture in the case of metal tubes, and a moulding process in the case of plastic tubes. Just to confuse the issue, some tubes are produced by rolling to shape and seam welding or seam jointing: and large-size plastic tubes, which then become pipes, are produced by the same methods as small plastic tubes. But ignore that for the moment. A main difference does emerge from the two different methods of manufacture. Inherently, tubes have a smooth bore as manufactured. Pipes will have a varying degree of bore roughness, depending both on the material involved and the actual fabrication method. Once you extend tube- manufacturing process to pipe production, then these pipes also have a smooth bore (e.g. plastic pipes). Pipes produced by pipe-manufacturing methods normally require specific after-treatment to render them smooth bore. With this difference (and there are exceptions to the rule), we can further differentiate between the two by size ranges and terminology adopted by different industries. One of the main users of smooth-bore small-diameter tubes is the hydraulic industry where line sizes may range from 3 mm (1/8 in) bore up to 32 mm (13 in) bore, or larger in low-pressure hydraulic systems—and28 Fundamentals CPVC pipes and tubesPipes card Pipelines—Definitions and Explanations 29 we have called them lines, not pipes or tubes. The industry itself may call them hydraulic pipes. hydraulic tubes or hydraulic lines; and larger hydraulic tubes (pipe sizes!) ace produced for cylinder tubes. Industries and applications concerned with the conveyance of fluid products almost invariably refer to their tubular products as pipes or piping. ‘Again, sizes may range down into tube sizes (and even be drawn or extruded products or true tubes}—e.g. gas pipes and small-bore water service pipes. But they are still pipes or piping. And the system they provide is a pipeline. Hopefully this has established a satisfactory definition and explanation of why the title of this handbook is specifically concerned with pipes and pipelines, for these are the areas mainly covered. And those who work in these areas call Ductile iron pipe for drinking water applications.30 Fundamentals Summary of pipe materials—metallic Manulactering Material process Siserange Typical aplications Remarks Aluminum Drawing orcolling Cryopentcandchemical Low weight and good (seamless tube) pipelines-hightweight hydraulic corrosion resistance Pipes. copper Deawingorcolling | Maimlysmallbore Marine epplicatons. Resistant to conrasion (enmless tubing) | tubes ot water services [domestic but costly Ductlewon —_Spaning | Upto600mm — | Gasandwaterdisteibution Stronger than cast ron. | eaim systems, Greycastiron Casting Vpt0 120mm Gas, waterund drainage settle materi (480) systems Mulleableiroo _ Heat-reated casting Mainly usd for small tings Less rite thaa easton, Steet Various Upto4000mm Gavan pipelines, Available aide ange (26010) of tensile strength Stainlessrtesl Various Cryogenic andchemical pipelines. Corrosion-esstant. but Staiolesssteet tubing fordomestic high cost water supplies, plumbing and heating Tangsten Exteusion Meinl small Marine applications CCorrosion-resisant, bore tubes Specialised hydeuullesystmms. | aon-sparkiogmatela their tubular products pipes, but tubes are mentioned and described where appropriate. There remains one distinction between British and American practice to clarify. In the UK the handling and installation of pipes, performance calculations, etc., embracing the complete system are commonly referred to as pipework, e.g. pipework installations, pipework calculations, etc. In the USA the word ‘pipework’ does not appear to be accepted and is seldom, if ever. used. In the interest of rationalisation, this handbook uses the single description pipeline. It means the same as pipework. It is to be regretted that similar rationalisation is not possible between British and American and metric units and standards. This leads to diflerences in values of ‘flow loss’ coefficients for pipe bends, valves, etc., the British/ American coefficient being based on m?/h at 1 bar pressure loss. Equally, pipe sizes are standard in both millimetre and inch sizes, together with match fittings and valves. There are no exact equivalents. You work in standard manufactured sizes, either in millimetres or inches. To give equivalent sizes in tabular data for either would be meaningless. With rare exceptions, the exact equivalent size is just not obtainable. That is a problem, too, which complicates the presentation of working formulae. We have attempted, within reason, to cover most possibilities in the case of the main formulae for flow-performance calculation in other forms embracing all the units most likely to be used, both in metric and Imperial units. Here, in fact. Imperial units are often less rational than their metric equivalents, with volumes expressed in cubic inches, US gallons, Impetial‘Summary of pipe materials—non-metallic teria! ‘abestos Cay concrete Spun conerete Pre-streseal Prcbytibre laste pipes ABS ane Polyvinyl chloride ueve Polyvinyl chloride cPve Polypropylene wer Polypropylene Polypropylene ever Polytuylene (eB Polythene PE) wel Palyhene (eN | Potythene (ree, Polythene asw-PeHy Pex Fluorocarhon (oP. PrA. rin Site range 5010 1050m warn 150%0 19500 (610 76101 Upto 3000 (20:0) 50c0225 mma Quins 1210 150mm Ehtosiny UUpto4800mm (19010) Upto 050mm (210) {Upto 360mm ie pro J000mun dom [Uk saes upto isin} {pt0 300 mm (22in) {up 600 au 2419) {Upt0 200 mm (on {ipto 300. ony Upto 1800 mm oun upto 1200 m0 Sing Comasion Very good in mest soil. Very good, Very goed in most soll Good resistance to sulphate attack and sewer gas. Very good in mest seis Very good in most sails ‘Corrosion: tree but Tower chemical resistance than PVC. Corrosion tee. Coveosinn-fre. Corrosion tee. Similar to PE. but superiorfor detergents, igh ebemical: resistance inchiding: service temperatures than posible ‘elds. uals aod hydrocarbons store. Corrosion-tree Corresin-tree Coerosion tee. outstanding. Pipes and Pipelines—Definitions and Explanations 31 Typical applications Dred water pipelines ond drainage systems | Drainage ppcines wad duets | Drainage pipelines | Sewerage. drainage. ete Large watorand drainage pipelines ‘Small drainage pipeloes Alternative to PVC wherebetter | inechanical pipelines required Large water and drainage pipelines General purpose pipeines stable fora wie variety ofexterior nd Interior applications Cold and hot water services domestic plumbing. te Applications requiring good combined temperature/pressuce Pipelines cg. eluent. pulp mills, Specialised applications: higher with other thermoplastic pipes Hot-watec applications suitable Ir temperatsres op to 110°C (230°, Agriculture and ireigation ascistrbution. General purpose pipelines forexterioe and Interior applications Water distbution. sewage, industrial eBuent, ee | Gas dirrbtion, Hot water applications | Used asliners bonded 19 GRP ‘ormetali pipes for complete ‘eorrosion resistance Limited avaitabiity ia tobe oem (PUP and FEA} Remarks Fete mate | Battle material Normally salt-plozed, Produced in wnreinforced | and reintorced forms. | Smooth, concentric bore, Smooth external Bais | Mighsdensiy, tele | retaforced | Suitable or very large | diameters. Suitable for solvent Dointing, [thecmoset material. Also avallabiein other =oinforeod-plastic mattis RPM) consteuctions Disadvantage high cost. Ugplasicised PVC. Suitable or solvent welding | widely avaitabie Rigid PVC. Subjecttoembeitlement | atlow temperatures, Copolymer of PP with Detter resistance Fusion ented, ‘Cheaper than PE, beter Abrasion resistance than | PEE (partiatuey at clevated temperatures) Cannot be solvent-welded owrdensity polythene pressures 106 bar. | Medium density polythene: fusion jointed | ormechanice! joints. High tensity polythene fusion-jinted (socket. bbutor saddle}: also ‘echanveal forms. High molecular weight | PEN limited avait D npipeformsand expensive | Crosslinked PE,