Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.

1
SC-GCM-94 CM Issue 1 © Copyright 2005 Spirax-Sarco Limited

Module 12.1
Isolation Valves -
Linear Movement

The Steam and Condensate Loop 12.1.1

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Isolation Valves - Linear Movement

Isolation valves are a key component in any fluid system as they are used to stop the flow of fluid
into a particular area of the system. They are also sometimes used to manually control the flow
of the fluid. The European standard EN 736-1:1995 distinguishes between isolating, regulating
and control valves as follows:
o Isolating valve - A valve intended for use only in the closed or fully open position.
o Regulating valve - A valve intended for use in any position between closed and fully open.
o Control valve - A power-operated device which changes the fluid flowrate in a process control
system.
Isolation valves are used in a wide variety of different applications where on / off type control is
required, these include:
o Diverting process media.
o Flow isolation to:
- Facilitate maintenance
- Allow the removal of equipment
- Allow the shut down of plant
A multitude of different types and designs of isolation valve have been developed in order to
meet this range of applications and the diverse operating conditions in which they are used.
Valves are commonly classified into two groups (see Table 12.1.1), according to the operating
motion of the closure device (or obturator):
o Linear movement valves - The obturator moves in a straight line. Included in this category are
gate valves, globe valves, diaphragm valves and pinch valves. These valves are covered in
greater depth within this module.
o Rotary movement valves - The obturator rotates about an axis at right angles to the direction of
flow. Ball valves and butterfly valves are the two most important rotary valves associated with
steam applications and are covered in greater depth in Module 12.2, Isolation Valves - Rotary
Movement.
Table 12.1.1 Obturator motion in the basic valve types
Valve movement Linear Rotary
Operating motion
of the closing device Straight line Rotating about an axis at
(obturator) right angles to the direction of flow
At right angles to Longitudinal to
Direction of flow Through the Around the
the operating motion the operating motion
in the seating area obturator obturator
of the obturator of the obturator
Basic types Gate valve Globe valve Ball valves Butterfly valve

Schematic
Flow Flow
Flow Flow

12.1.2 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Linear movement valves

Linear movement valves have been developed from the early forms of sluice gates used to control
the flow of water in irrigation channels. Since then, a large number of different designs and types
have been developed for use in almost every type of flow application. Although linear movement
valves are characterised by straight-line obturator movement, the flow of the fluid may be at
right angles to this movement (as in the case of gate valves), or in the same direction, as with
globe valves. The main feature of the linear movement valve is that tight shut-off may be achieved
by tightening down the obturator on a threaded stem.
Gate valves
Gate valves are probably the most common valves in use today due to their widespread use in
domestic water systems, but it should be noted that their popularity in industry has declined in
recent years. However, they are still used where an uninterrupted flow is required, because the
gate fully retracts into the bonnet, creating a minimal pressure drop, when the valve is in an
open position. Gate valves are specifically intended for use in isolation applications.
A gate valve consists of four main components, the body, bonnet (or cover), gate and stem. A
typical gate valve is shown in Figure 12.1.1.

Handwheel

Stem

Gland follower

Gland packing

Bonnet

Body

Wedge shaped gate

Seat ring

Fig. 12.1.1 Typical wedge gate valve

The gate, which slides between the seats, is lifted in a direction at right angles to the flow until
clear of the flow path. The fact that the gate fully retracts into the bonnet ensures that the
pressure drop across the valve is low.
Gate valves are divided into a number of different classes, depending on the design of the gate
and its seating faces.
Solid wedge gate valve
The gate is wedge shaped and it seats on corresponding faces in the valve body. The mechanical
advantage of the activating thread, together with the wedge angle, enables adequate seating
forces to be applied against the fluid pressure without excessive handwheel effort. The seat can
sometimes be coated with PTFE to assist a high integrity shut-off. A typical solid wedge gate valve
is shown in Figure 12.1.1.

The Steam and Condensate Loop 12.1.3

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Flexible wedge gate valve

Although there are several types of flexible wedge gate valves, they all make use of a flexible
two-part disc, which is shaped like two wheels on a very short axle. The flexibility of the disc
ensures tight seating over a wide range of temperatures and pressures.
The most common type of flexible wedge gate valve used in steam applications is the parallel
slide valve. The two plates that constitute the gate are held against the seat by a spring, encased
between them. The fluid pressure moves the upstream disc off its seat, and the force is transferred
onto the downstream disc, thereby ensuring a tight shut-off. The high degree of flexibility in the
gate allows for expansion and contraction when subjected to temperature variations, making it
suitable for use in steam systems.
Globe valves
Globe valves constitute a major class of linear movement valves; they have become more popular
than gate valves as there is a wide variety of configurations available to suit most applications.
The movement of fluid through the valve seat is longitudinal to the operating motion of the
obturator; this means that for a valve in which the inlet and outlet are horizontally opposed, the
fluid must follow a changing course. The main advantage of this arrangement is that a globe
valve opens more rapidly than a gate valve as the disc only needs to move a small distance from
its seat to allow full flow. This is an advantage when there is frequent operation of the valve. The
disadvantage is that the fluid has to change course, increasing the resistance to flow and generating
turbulence. This results in a higher pressure drop across a globe valve than a gate valve.

Stem seal

Bonnet

Body

Valve seat
Valve disc

Fig. 12.1.2 A conventional globe valve

12.1.4 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Globe valves are less likely to leak than gate valves, which means that they can be used for higher
pressure or higher volume applications, for example in steam systems, or where fluid loss can be
hazardous or costly. The increased cost of globe valves over gate valves is therefore offset by the
additional safety they provide, and a reduced chance of fluid loss.
The pressure of the fluid acting over the area of the disc generates an axial load on the stem. This
makes closing the valve difficult, so much so, that it limits the size of a standard globe valve to
DN250. On high differential pressure closed systems, balancing plugs can be used to overcome
this effect, allowing valves with a nominal diameter of up to 500 mm to be used (Figure 12.1.3(a)).
The balancing plug contains a pre-lifting plug that acts as a pilot valve. When the valve is opened,
the pre-lifting plug opens first, allowing the medium to pass through it at a controlled rate
(Figure 12.1.3(b)). This reduces the differential pressure across the valve, enabling the disc to be
easily lifted off its seat (Figure 12.1.3(c)). To assist closing of the valve, isolation valves fitted with
a balancing plug have to be fitted in reverse so that the top of the plug is acted on by the
upstream pressure.

Valve spindle
Upstream
Pre-lifting plug ‘A’
Pilot valve seat
Main valve plug ‘B’

Main valve seat

Downstream
(a) Valve closed

(b) Pilot valve open

reducing pressure drop across the valve

(c) Main valve open

Fig. 12.1.3 Schematic of a typical balancing plug valve

The Steam and Condensate Loop 12.1.5

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Piston valves
One of the main disadvantages of linear movement valves is the fact that their seats are prone to
damage from dirt and wiredrawing, and therefore, depending on the application may require
regular maintenance. Although these seats are replaceable in theory, it usually involves significant
time and cost, and it is often more advantageous to replace the entire valve. To overcome this
problem, piston valves have been developed.
The piston valve is a variant of the conventional globe valve, with the traditional seat and cone
replaced by a piston and lantern bush. The piston is connected to the valve stem and handwheel,
and passes through two sealing rings that are separated by a lantern bush. When assembled, the
two sets of sealing rings are compressed around the piston by the load exerted along the stem.
The upper set of sealing rings acts as conventional gland packing, and the lower set acts as the
seat. Furthermore, the large sealing area between the piston and rings assures a high level of
shut-off tightness.
The piston valve is not designed for throttling duties and must be used in the fully open or closed
positions. When the valve is fully opened, only the bottom face of the piston is exposed to the
fluid as the rest of the body is protected by the upper sealing rings. This means that the sealing
surfaces (the sides of the piston) are protected from erosion by the fluid flow.

Stem

Flow
Upper sealing rings

Piston
Lantern bush
Lower sealing rings

Fig. 12.1.4 A piston valve

If the valve requires maintenance, all the internals can be easily removed by undoing the cover
nuts and withdrawing the piston. The rings and the lantern bush can then be removed using an
extractor tool. This operation is simple and can be undertaken without having to remove the
valve from the pipeline. In general, the piston should never have to be replaced, but the sealing
rings may wear over a long period with frequent operation.

12.1.6 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Diaphragm valves
Diaphragm valves constitute the third major type of linear movement valves. The stem of the
valve is used to push down a flexible diaphragm, which in turn blocks the path of the fluid. There
are two different classifications of diaphragm valve based on the geometry of the valve body:
o Weir type - A weir is cast into the body, and when closed, the diaphragm rests on the weir,
restricting the flow (see Figure 12.1.5 (a)).
o Straight-through type - The bore runs laterally through the body and a wedge shaped diaphragm
is used to make the closure (see Figure 12.1.5 (b)).

Diaphragm Diaphragm

Open Closed
(a) Weir type

Diaphragm Diaphragm

Open Closed
(b) Straight-through type

Fig. 12.1.5 The weir type (a) and straight-through type (b) diaphragm valves

The main advantage of a diaphragm valve is the fact that the diaphragm isolates the moving parts
of the valve from the process fluid. They are therefore suitable for handling aggressive fluids and
for those containing suspended solids. In addition, as the bonnet assembly is not exposed to the
fluid, it can be made from inexpensive materials such as cast iron, thereby reducing the overall
cost. The development of new diaphragm materials enables diaphragms to be used on most
fluids. Their application is however limited by the temperature that the diaphragm can withstand
- typically less than 175°C. Diaphragm valves are generally used on process fluid applications.

The Steam and Condensate Loop 12.1.7

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Linear movement valve stem options

Linear movement valves are available with a number of different stem arrangements:
o Rising / non-rising stems - If the stem is rising, it will move vertically upwards when the
valve is opened, as opposed to only rotating, as with a non-rising stem. The rising stem indicates
the degreee of valve opening, which in turn roughly reflects the amount of flow through the
valve. Valves with rising stems do however require more space above the bonnet to
accommodate the stem in the fully open position. The use of non-rising stems is recommended
on gland packed valves, as they reduce the wear on the packing.

(a) (b)

Fig. 12.1.6 Rising (a) and non-rising (b) stem valves

o Inside / outside stem screws - On a stem with an outside screw, the actuating threads on the
stem are situated outside the valve body and are not exposed to the process fluid. As screw
threads are particularly susceptible to corrosion, outside screws should always be used on
fluids with corrosive or erosive properties. They are also beneficial where the valve is frequently
exposed to large temperature variations, as the expansion and contraction of the stem may
cause binding of the threads inside the body.

Stem thread

Seal

Stem thread

Seal

(a) (b)

Fig. 12.1.7 Outside (a) and inside (b) stem valves

12.1.8 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Stem sealing
In order to prevent leakage of the process media from around the stem of a valve, a barrier must
be placed between the fluid and the environment. Stem sealing is usually achieved by one of
two methods, namely gland packing and bellows sealing. Gland packing consists of a polymeric
material, typically PTFE, packed tightly between the stem and the bonnet of the valve, thereby
preventing any process media escaping.

Secondary gland
packed seal

Bonnet

Metal bellows

Rising spindle

Fig. 12.1.8 Bellows sealed valve

In bellows sealed valves, a flexible metallic bellows is used. It is connected on one end to the
stem and the other end is connected to the bonnet, effectively producing a barrier between the
fluid and the environment. This bellows extends and contracts as the stem moves up and down.
The bellows is so effective, it produces a ‘zero emissions’ seal. Fitted to the bellows is an
anti-torsion device, which prevents the bellows from rotating with the stem. Such a device is
essential, otherwise the repeated twisting of the bellows would lead to the failure of the seal.

Although less costly than the bellows sealed valves, the gland packed valve does not produce
such a tight seal as the bellows. If a gland packed valve is not used for a significant period, the
gland packing can stiffen, and leakage will occur the next time the valve is used. The bellows
sealed valve does not suffer from this problem. Furthermore, gland packed valves require
regular re-packing of the gland, whereas a typical bellows requires no maintenance for over
10 000 cycles.

The Steam and Condensate Loop 12.1.9

Block 12 Pipeline Ancillaries Isolation Valves - Linear Movement Module 12.1

Questions

1. What is the main advantage of a gate valve?

a| They are better than all the other linear movement valves for producing a tight
shut-off on steam systems ¨
b| They can be used in throttling applications as well as for isolation ¨
c| There is a low pressure drop across the valve ¨
d| They are easily automated ¨

2. In which of the following applications should an outside, non-rising stem be used?

a| Where a gland packed valve is used in a corrosive fluid ¨
b| Where a bellows sealed valve is used in a steam system ¨
c| Where there are no temperature variations of the fluid passing through the valve ¨
d| Where a bellows sealed valve is used in a corrosive fluid ¨

3. Why must balancing plugs be used in globe valves that are larger than DN250?
a| The pre-lifting plug enables more precise control of the fluid ¨
b| It reduces the pressure drop across the valve allowing the valve to open easily ¨
c| It allows the valve to be balanced on water circuits ¨
d| A balancing plug has to be used with a bellows seal ¨

4. What is the main reason for choosing a bellows sealed stem over a gland
packed one?
a| A bellows seal will never require maintenance ¨
b| The bellows seal produces a ‘zero emissions’ seal ¨
c| Gland packed seals on valves above DN250 are prone to leakage ¨
d| All of the above ¨

5. Which of the following valves should be used where the valve is to be welded
into a pipeline and rapid seat wear is expected?
a| A globe valve ¨
b| A parallel-side valve ¨
c| A diaphragm valve ¨
d| A piston valve ¨

6. Why is a diaphragm valve not suitable for most steam applications?

a| Condensate collects in the weir, increasing the pressure drop across the valve ¨
b| Diaphragm valves are incapable of producing a tight shut-off above 4.0 bar ¨
c| The diaphragm valve is only suitable for handling fluids containing suspended solids ¨
d| Diaphragm materials are not suitable for temperatures above 175°C ¨

Answers
1: c, 2: a, 3: b, 4: b, 5: d, 6: d

12.1.10 The Steam and Condensate Loop