Instrument and Control Maintenance Techniques - Process Control Valves

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Level 2: Instrumentation and Control

Maintenance Program
Instrument and Control Maintenance

Techniques: Process Control Valves
Course Description
 This training is designed to provide participants with an understanding the
function, operation and routine maintenance requirements associated with
the Process Control Valves. The training covers types, functions, working
range of control valves functions, working range, application, flow
coefficients, assemblies, instrumentation of pressure safety valves.
1 Copyright ©2009-2020 NExT. All rights reserved
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Course Objectives
 Upon the completion of this module, the trainee will be able to:
– Understand the process control valve basics.
– Describe the function and operating principles of process control valves in the
oil and gas industry
– Describe the function and operating principles of fire and gas system in the
process control valves in Majnoon field
– Outline the normal operating parameters and tolerances for process control
valve
– Describe the working range and application of control valves
– Describe common signs of damage which can occur for process control valves
– Outline typical faults which can occur for process control valves
– Describe the fault finding procedure for control valves
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Course Objectives
 Upon the completion of this module, the trainee will be able to:
– Identify the key sources of technical information and guidelines to inform
maintenance requirements and procedures for process control valves
– Describe the types and role of routine maintenance activities for process
control valves
– Identify relevant maintenance techniques for given maintenance issues for
process control valves
– Describe the procedure for assembling control valves
– Describe the function and operation of the actuators
– Describe the function and operations of pressure safety valves
– Describes the instrumentation of pressure safety valves.
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Maintenance Program
Control Valve Introduction
Valve Function
 Control: pressure / flow rate

regulation.
 Closure at over-speed flow. (i.e.
immediate closure if downstream
pipeline is broken by accident).
 Overpressure protection.
 Back flow prevention ().
 On/Off service.
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Classification of the valve based on function
Copyright ©2009-2020 NExT. All rights reserved
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Classification of the valve based on operation
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Special service
 Gate valves
 Globe valves
 Ball valves
 Plug valves
 Butterfly valves
 Diaphragm valves
 Needle valves
 Pressure relief valves
 Control valves
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Control Valve Function
 Final control elements include control valves, metering pumps,

dampers and louvers, variable pitch fan blades, and electrically
driven control devices.
 The control valve is the most widely used type of final control
element and it must perform satisfactorily with a minimum
amount of maintenance attention, even in severe conditions of
temperature, pressure, corrosion and contamination
 Control valves are such type of valves which are controlled
remotely to maintain flow rate, Level, pressure and
temperature directly or indirectly as per requirement
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 Summary
– The purpose of a control valve is to provide the means of
implementing or actuation of a control strategy for a given
process operation.
– Control valves are normally regarded as valves that provide a
continuously variable flow area for the purpose of regulating
or adjusting the steady state running conditions of a process
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 A power actuated device which modifies the fluid flow rate in a process
control system.
 It consists of a valve connected to an actuator mechanism (including all
related accessories) that can change the position of a closure member in
the valve in response to a signal from the controlling system.
 Control valve is considered the most important final control element in a
process control loops
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 “Control valve” means any power-operated valve, whether used for
throttling or for on-off control.
 Every process control loop contains a final control element, the device that
enables a process variable to be manipulated.
 For most petroleum processes, the final control elements (usually control
valves) adjust the flow rates of materials, and indirectly, the rates of
energy transfer to and from the process
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Basic Control loop

 There are 2 types of control loops
– Open-Loop Control System
– Closed-Loop Control System
Open-Loop Control System Closed-Loop Control System
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Control Valve
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Control valve in flow control
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Control valve in level control
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Control valve in pressure control
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Control valve in temperature control
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 From an operating viewpoint, it is practical to classify the valves according
to the function they perform in the systems.
 A valve can usually provide one of the following services:
– Regulating,
– Isolating,
– Back flow prevention, or Check Valves
– Pressure relief.
 Within a required operating range to ensure the quality of the end product.
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 Valves can be classified by their closing element:
– Gate,
– Ball,
– plug,
– Globe, etc.
 Can be hand-operated or automated with the addition of an actuator.
 Used in mixing applications where a number of fluids are combined for a
predetermined amount of time (exact measurements are not required).
 Used for immediate shut down of a system when an emergency occurs.
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 Valves can be manually operated or can be equipped with an actuator.
 Actuators can be powered by a number of mediums:
– Pneumatic,
– Electrical, or
– Hydraulic.
– Manual
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Principles of Valve throttling Process

 It manipulates a flowing fluid, such as gas, steam, liquid, or chemical compounds,
to compensate for the load disturbance and keep the regulated process variable
as close as possible to the desired set point.
 Used for regulating the flow, temperature, level or pressure of the service.
 Can be moved to any position within the stroke of the valve and hold that
position, including the fully-open or fully-closed positions.
 Also provided with actuation system for greater thrust and positioning capability
(automatic control).
 Example: pressure regulator varies the valve’s position to maintain constant
pressure downstream (close to decrease and open to increase the pressure).
 Control valves are valves that are capable of varying flow conditions to match the
process requirements (always equipped with actuators).
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 A control valve modifies the fluid flow rate in a process pipeline by
providing a means to change the effective cross-sectional area at the
valve.
 This in turn forces the fluid to increase its velocity as passes through the
restriction.
 Even though it slows down again after leaving the valve, some of the
energy in the fluid is dissipated through flow separation effects and
frictional losses, leaving a reduced pressure in the fluid downstream of the
valve.
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Introduction to Control Valve

 Principles Of Valve Throttling Processes
 To display the general behavior of flow through a control valve, the valve is
simplified to an orifice in a pipeline as shown in Figure
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 It is important to understand how the pressure conditions change in the
fluid as it passes through the restriction and the vena contract and then
how the pressure partially recovers as the fluid enters the downstream
pipe area.
 The first point to note is that the velocity of the fluid must increase as the
flow area decreases. this is given by the continuity of flow equation;
 V1.A1=V2.A2
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 Now to consider the pressure conditions we apply Bernoulli's Equation ,which
demonstrates the balance between dynamic, hydrostatic pressure and Static.
Energy must be balanced each side of the flow restriction so that:
 Bernoulli’s equation formula is a relation between pressure, kinetic energy, and
gravitational potential energy of a fluid in a container.
 The formula for Bernoulli’s principle is given as follows:
p+1/2ρv2+ρgh=constant
 Where p is the pressure exerted by the fluid, v is the velocity of the fluid, ρ is the
density of the fluid and h is the height of the container.
 Bernoulli’s equation gives great insight into the balance between pressure,
velocity and elevation.
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 Bernoulli's equation relates the pressure, speed, and height of any two points (1 and 2)
in a steady streamline flowing fluid of density ρ. Bernoulli's equation is usually written
as follows,
 P1+1/2 ρ(v1)2+ρgh1=P2+1/2ρ(v2)2+ρgh2
 The variables P1, V1,h1 refer to the pressure, speed, and height of the fluid at point 1,
whereas the variables P2, V2, h2 refer to the pressure, speed, and height of the fluid at
point 2 as seen in the diagram below. The diagram below shows one particular choice
of two points (1 and 2) in the fluid, but Bernoulli's equation will hold for any two points
in the fluid.
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 Now, we're just going to rearrange the formula using algebra to put all the
terms that refer to the same point in space on the same side of the
equation to get,
P1+1/2 ρ(v1)2+ρgh1=P2+1/2ρ(v2)2+ρgh2
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Maintenance Program
Control Valve Standards
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 Many standards are applicable to control valves.
 International and global standards are becoming increasingly important for
companies that participate in global markets.
 Following is a list of codes and standards that have been or will be
important in the design and application of control valves.
 It covers the following issues
– Face to face dimensions.
– Materials of construction.
– Pressure-temperature ratings.
– Design of some components to ensure adequate strength.
– Testing procedures.
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 Well Known Valve Standards
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 Instrument Society of America (ISA)
– S51.1, Process Instrumentation Terminology
– S75.01, Flow Equations for Sizing Control Valves
– S75.02, Control Valve Capacity Test Procedures
– S75.03, Face-to-Face Dimensions for Flanged Globe-Style Control Valve
Bodies (Classes 125, 150, 250, 300, and 600)
– S75.04, Face-to-Face Dimensions for Flangeless Control Valves (Classes 150,
300, and 600)
– S75.05, Terminology
– S75.07, Laboratory Measurement of Aerodynamic Noise Generated by Control
Valves
– S75.08, Installed Face-to-Face Dimensions for Flanged Clamp or Pinch Valves
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– S75.11, Inherent Flow Characteristic and Rangeability of Control Valves
– S75.12, Face-to-Face Dimensions for Socket Weld-End and Screwed-End
Globe-Style Control Valves (Classes150, 300, 600, 900, 1500, and 2500)
– S75.13, Method of Evaluating the Performance of Positioners with Analog
Input Signals
– S75.14, Face-to-Face Dimensions for Buttweld-End Globe-Style Control
Valves (Class 4500)
– S75.15, Face-to-Face Dimensions for Buttweld-End Globe-Style Control
Valves (Classes 150, 300, 600, 900, 1500, and 2500)
– S75.16, Face-to-Face Dimensions for Flanged Globe-Style Control Valve
Bodies (Classes 900, 1500, and 2500)
– S75.17, Control Valve Aerodynamic Noise Prediction
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– S75.19, Hydrostatic Testing of Control Valves
– S75.20, Face-to-Face Dimensions for Separable Flanged Globe-Style Control
Valves (Classes 150, 300, and 600)
– S75.22, Face-to-Centerline Dimensions for Flanged Globe-Style Angle Control
Valve Bodies (Classes 150, 300, and 600)
– RP75.23, Considerations for Evaluating Control Valve Cavitation
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Valve standards
Standard Application
API SPEC Specification for Pipeline Valves. Petroleum and Natural Gas Industries-Pipeline Transportation
6D Systems-Pipeline Valves. This International Standard specifies requirements and gives
recommendations for the design, manufacturing, testing and documentation of ball, check, gate
and plug valves for application in pipeline systems
API 526 Flanged Steel Pressure Relief Valves. The standard is a purchase specification for flanged steel
pressure relief valves. Basic requirements are given for direct spring-loaded pressure relief valves
and pilot-operated pressure relief valves as follows: orifice designation and area; valve size and
pressure rating, inlet and outlet; materials; pressure-temperature limits; and center-to-face
dimensions, inlet and outlet
API 527 Seat Tightness of Pressure Relief Valves R(2002). Describes methods of determining the seat
tightness of metal- and soft-seated pressure relief valves, including those of conventional, bellows,
and pilot-operated designs
ANSI/API Check Valves: Flanged, Lug, Wafer and Butt-welding. API Standard 594 covers design, material,
STD 594 face-to-face dimensions, pressure-temperature ratings, and examination, inspection, and test
requirements for two types of check valves
API 598 Valve Inspection and Testing. The standard covers inspection, supplementary examination, and
pressure test requirements for both resilient-seated and metal-to-metal seated gate, globe, plug,
ball, check, and butterfly valves. Pertains to inspection by the purchaser and to any supplementary
examinations the purchaser may require at the valve manufacturer's plant
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Valve standards
Standard Application
ANSI/API Metal Plug Valves - Flanged, Threaded and Welding Ends. A purchase specification that covers requirements for
metal plug valves with flanged or butt-welding ends, and ductile iron plug valves with flanged ends, in sizes NPS 1
599 through NPS 24, which correspond to nominal pipe sizes in ASME B36.10M. Valve bodies conforming to ASME
B16.34 may have flanged end and one butt-welding end. It also covers both lubricated and nonlubricated valves that
have two-way coaxial ports, and includes requirements for valves fitted with internal body, plug, or port linings or
applied hard facings on the body, body ports, plug, or plug port.
ANSI/API Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries - Modified National Adoption of ISO
10434:1998
600
API 602 Compact Steel Gate Valves - Flanged, Threaded, Welding, and Extended-Body Ends. The standard covers
threaded-end, socket-welding-end, butt-welding-end, and flanged-end compact carbon steel gate valves in sizes
NPS4 and smaller
ANSI/API Corrosion-Resistant, Bolted Bonnet Gate Valves - Flanged and Butt-Welding Ends. The standard covers corrosion-
resistant bolted bonnet gate valves with flanged or butt-weld ends in sizes NPS 1/2 through 24, corresponding to
603 nominal pipe sizes in ASME B36.10M, and Classes 150, 300, and, 600, as specified in ASME B16.34
ANSI/API Fire Test for Soft-Seated Quarter Turn Valves. The standard covers the requirements for testing and evaluating the
performance of straightway, soft-seated quarter-turn valves when the valves are exposed to certain fire conditions
607 defined in this standard. The procedures described in this standard apply to all classes and sizes of such valves that
are made of materials listed in ASME B16.34
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Maintenance Program
Control Valve Components
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Actuator
I/P Converter
Signal to actuator
Elect Control Signal
Signal from I/P

Pneum.Valve
Positioner
Valve Bonnet
Flanged End
Connections
Valve Body
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Maintenance Program
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Actuator
I/P Converter
Signal to actuator
Elect Control Signal
Signal from I/P

Pneum.Valve
Positioner
Valve Bonnet
Flanged End
Connections
Valve Body
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 Basic Valve Components
– Body
– Bonnet
– Stem
– Trim
– Packing
– Actuator
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 Body
– Is the main part of the valve. All other parts fit onto the body.
– It is usually cast or forged and the shape varies with the type of valve.
– Inlet and outlet pipes fit onto the valve body through Threaded, Bolted (Flanged) or
Welded Joints.
– The fluid passes through the valve body when the valve is open.
– The valve body must be strong enough to take the maximum pressure of the
process fluid.
– It must also be made of a material that is not attacked by the fluid.
 Bonnet
– Is a removable cover fitted to the body. bonnets support the moving parts of the
valve.
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 Trim (Plug and Seat )
– Is the name given to the parts inside
a valve. This normally includes:
– The opening/closing element—
closes the fluid path through the
valve body
– The valve stem—connects the
actuator to the closing element
– The valve seat—makes a seal with
the closing element when the valve
is closed
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 Packing
– It allows the valve stem to pass into the valve body without loss of fluid or fluid
pressure from the valve. It forms a dynamic seal between the valve stem and
the bonnet.
 Actuator
– is the driver that moves the valve stem / plug assembly in the direction either to
open or to close the valve port in response to the control signal
Packing Flange Valve Stem
Packing Lubricator Packing
Cage Trim Bonnet Flange & Bolts

Flow To Rise
Body
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 End Connections
– Must be specified when buying the valve – butt weld end, compression flange,
pipe thread, quick disconnect
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Diaphragm Actuator
Air to Push the Stem Upward

Actuator Assembly
Air Filter / Regulator

A/S Pneum. Positioner with 3 Gages
Actuator Yoke
Pneum. Control Signal
Actuator Stem
Flanged Bonnet
Body Assembly
Valve plug Stem

Flanged End
Connections
Body Bottom Flange
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 End Connections
– Raised Face(RF), FF (Flat Face), Ring Type Joint(RTJ)
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Control Valve Classification
Valve
Linear Rotary
Globe Gate Pinch Diaphragm Disk Butterfly Ball
Single Double
Angle 3 way
Port Port
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 There are two major classifications of motorized/control valves, according the kind of
closure member movement:
– Rotary-Shaft Control Valves.
 (Quarter-turn valve) from the fully-open position to the fully-closed position.
 They are quick opening/closure valves.(include Ball valve, Butterfly valve, Plug
valve, Spherical valve)
– Linear Valves, (Multi-turn valve).
 The closure member has a linear displacement generally by turning its threaded
stem several times.
 This operation is slow, but it gives accuracy and stability to position the closure
member, which is necessary in some control valves.(include Gate valve, Globe
valve, Fixed cone valve, Needle valve and Pinch valve.)
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Linear motion valves and its application
 Sliding-stem valves
– A sliding-stem valve body is one where the moving parts
slide with a linear motion.
Single-ported glove valve Double -ported glove valve
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Gate valve Diaphragm valve
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– Most sliding-stem control valves are direct acting, which means the
valve opens up wider as the stem is drawn out of the body.
– Conversely, a direct-acting valve shuts off (closes) when the stem is
pushed into the body.
– Of course, a reverse-acting valve body would behave just the
opposite opening up as the stem is pushed in and closing off as the
stem is drawn out.
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Three way valves
– The basic body styles are
Globe
Cage
Angle body
Y pattern
Split body Angle body Split body valve
Three way
Single seated
Double seated
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 Single seated valve

– Single seated valves are one form of globe valve
that are very common and quite simple in design.
– These valves have few internal parts.
– They are also smaller than double seated valves
and provide good shut off capability.
– Maintenance is simplified due to easy access with
top entry to the valve components.
– Quite simple
– Good shut-off
– Variety of trims
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– Less vibration
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 Double seated valves
– There are two plugs and two seats that operate
within the valve body.
– These valves are not truly balanced.
– The result of the hydrostatic forces on the
plugs may not be zero due to the geometry
and dynamics.
– They are semi and dynamic forces when sizing
the actuator
– High flow capacity
– Poor shutoff
57 – Heavy and bulky
– More parts to service
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Flow characteristic curves

 Control valves are generally produced with one of three
most widely used characteristic curves for % of rated Cv
(max. Cv) versus percent of rated travel (or lift).
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Principle of operation (Types of valves & application)
 Linear (Sliding Stem Valves )

 Had a sliding-stem design that pushes a closure element into an open or
closed position
 Simple design, easy maintenance, and versatile with various sizes,
pressure class and design options.
 A sliding-stem valve body is one where the moving parts slide with a
Linear Motion. Main types of linear valves :
1. Globe Valves
2. Diaphragm Valves
3. Gate Valves
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Globe Valve - Working Principle

 Named for their spherical body shape with the two
halves of the body being separated by an internal
baffle.
 Globe valves restrict the flow of fluid by altering the
distance between a movable plug and a stationary
seat (in some cases, a pair of plugs and matching
seats).
 It has an opening that forms a seat onto which a
movable plug (also called a disc) can be screwed in to
close the valve
 The globe valve design is one of the most popular
sliding-stem valve designs used in Throttling Service.
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 The disc is connected to a stem which is operated
by screw action in manual valves.
 Automated globe valves have a smooth stem
rather than threaded and are O/C by an actuator
 The bonnet provides a means of sealing against
leakage along the stem by using packing in the
packing box.
 Force is exerted by the stud and nuts in the
packing material to squeeze it against the walls of
the packing box and the valve stem providing an
effective seal.
 The valve stem extends through the bonnet to
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provide a variable restriction to the fluid flow
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Tee pattern globe valves
Angle pattern globe valves
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Globe Valve - Applications

 Globe valves are extensively
used to control flow.
 Conventional globe valves
may be used for isolation
service.
 Globe valves are used for
applications requiring
throttling and frequent
operation.
 Globe valves are the most
frequently encountered
control valves in process
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Globe Valve - Advantages and Disadvantages
Advantages Disadvantages
Full closing feature is good Compared to gate valves, pressure loss is higher.
They require a larger amount of force or an actuator
Throttling feature is good
with a larger torque, to close under high pressure
Compared to gate valves, stroke is
shorter so opening-closing time is
shorter
Body ring seating surface process
is easier
With little change in shaft-disc
connection, they can be used as
stop-s
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 Videos
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 Videos
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 Videos
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Globe valves OPEN / CLOSE STATES
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Globe Valve - Single-Ported Globe
 Requires High Actuator Forces

 Tight shut off
 Used in small diameter applications.
Single Plug
Globe Style Body

Single Seat
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Globe Valve - Double-Ported Globe
 The double seat valve has two valve

plugs on a common spindle, with two Balanced Trim, Double Seat, Two-port Valve
valve seats.
 This means that although the differential
pressure is trying to keep the top valve
plug off its seat (as with a single seat
valve)
 t is also trying to push down and close Bottom Guide for better
plug-seat alignment
the lower valve plug.
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Double-Ported (Double Seated) Globe Valves
• Balanced Trim
• Poor Tight shut-off
• Requires Low Actuator Forces
Trim Moves Down Valve
Opens.
i.e. Reverse Acting
Valve
Two Seats
Bottom Guide
Two Plugs on
Bottom Flange one Stem
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 Advantages:
– Good shutoff capability.
– Moderate to good valve throttling
– Shorter stroke (compared to a gate valve).
– Easy to machine or resurface the seats.
 Disadvantages:
– Higher pressure drop (compared to a gate valve).
– Requires greater force or a larger actuator to seat the valve.
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Globe Valve - Three-Port Valves
 Not all types can be used for both mixing and diverting service.
 Figure shows the incorrect application of a globe valve manufactured as a mixing valve
but used as a diverting valve.
 The flow entering the valve through port AB can leave from either of the two outlet
ports A or B, or a proportion may leave from each.
 With port A open and port B closed, the differential pressure of the system will be
applied to one side of the plug.
 When port A is closed, port B is open, and differential pressure will be applied across
the other side of the plug. At some intermediate plug position, the differential pressure
will reverse.
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Globe Valve - Three-Port Valves
Three – Way Globe Valves
Mixing (Blending) :
Diverting (Splitting):
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Globe Valve – Three-Port Valves
(Mixing)
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(Diverting)
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 To overcome this problem on a plug type valve designed for diverting, a different seat
configuration is used, as shown in Fig. Here, the differential pressure is equally applied
to the same sides of both valve plugs at all times.
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Globe Valve – Angle Valves
 The inlet and outlet ports are at right angle to each other .
Flow In
Flow Out
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Globe Valve – Angle Valves
 Advantages:
– A high flow rate with low-pressure loss is obtained
– Elimination of water hammer and resistance to backflow
– Provides longer service life than ball valves.
 Disadvantages:
– Because it retains the single seat valve structure, the larger the channel, the smaller
the allowable differential pressure.
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Gate Valve - Working Principle

 A gate valve is a linear motion valve used
to start or stop fluid flow; however, more
often used for on/off control than for
throttling
 The name gate is derived from the
appearance of the disk in the flow
stream..
 The disk of a gate valve is completely
removed from the flow stream when the
valve is fully open
 Gate valves work by inserting A Dam
(Gate) into the path of the flow to restrict
it, in a manner similar to the action of A
82 Sliding Door.
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 This characteristic offers virtually no resistance to

flow when the valve is open. Hence, there is little
pressure drop across an open gate valve.
 When the valve is fully closed, a disk-to-seal ring
contact surface exists for 360°, and good sealing is
provided.
 With the proper of a disk to the seal ring, very little
or no leakage occurs across the disk when the gate
valve is closed
 When the valve is fully closed,. With the proper
mating of a disk to the seal ring, very little or no
leakage occurs across the disk when the gate valve
is closed.
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 Rising stems provide a visual indication of valve position. The stem is attached to the gate
such that the gate and stem rise and lower together as the valve is operated.
 Non-rising stem valves may have a pointer threaded onto the upper end of the stem to
indicate valve position, since the gate travels up or down the stem on the threads without
raising or lowering the stem.
 Non-rising stems are used underground or where vertical space is limited.
Rising stem gate valve Non-Rising stem gate valve
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Gate Valve - Applications

 The gate valve is a Subsea hydraulic Hydraulic Wellhead and X-mass
general service valve gate valve gate valve trees with gate valves
used primarily for on--off,
non-throttling service.
 The valve is closed by a
flat face, vertical disc, or
gate that slides down
through the valve to block
the flow.
Cement and standpipe High pressure choke & kill
 General Oilfield Service manifold with gate valves manifolds with gate valve
Oil & Gas
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 Videos
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Gate Valve With Handwheel

 Applications
– Stop valves, (Not throttling, high pressure and temperature not for slurries, viscous
fluids
 Advantages
– Low pressure drop when fully open, tight seal when closed, free of contaminant
build up
 Disadvantages
– Vibration when partially open, slow response and large actuating force
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Gate Valve - Advantages and Disadvantages
Closing feature is very good Cannot be opened and closed quickly
To fully open or close wheel or gearbox actuators, the
Can be used both ways in the
shaft should be rotated as many as the full open
circuit
revolution number
Provide laminar flow, The full open revolution number is equal to the pitch
Assembly, start-up and maintenance require large
Pressure loss is minimum
space
In full closed position, the slow movement of the slide
causes high flow speed. Due to vibration and collision,
abrasion and deformation occurs in the seating
surfaces and the surface gets damaged from friction
At the place of operation, repair and maintenance of
89 seating surfaces are difficult
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Knife Gate Valve
 Knife gate valves, have a simple, one-piece closing element.

 It is a parallel sided plate that may move clear of the flow path to open or may have a
hole that moves into the flow path.
 The advantages of knife gate valves are that they're cheap, easy to actuate, and light.
 One of the most notable disadvantages of knife gate valves is that they're known to
have low-pressure limitations. This makes them less desirable for use in applications
that require cleanliness or sanitary conditions.
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Challenge Questions
Both gate and globe valves are rotary motion valves?
TRUE FALSE
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Knife Gate Valve
 Knife gate valves, have a simple, one-piece closing element.

 It is a parallel sided plate that may move clear of the flow path to open or may have a
hole that moves into the flow path.
 The advantages of knife gate valves are that they're cheap, easy to actuate, and light.
 One of the most notable disadvantages of knife gate valves is that they're known to
have low-pressure limitations. This makes them less desirable for use in applications
that require cleanliness or sanitary conditions.
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Challenge Questions
Both gate and globe valves are rotary motion valves?
TRUE FALSE
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Challenge Questions
 The main job for the regulator is to reduce plant air supply to positioners
and other control equipment's.
TRUE FALSE
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Challenge Questions
 The following figure represents:
– A) Three way valve
– B) Double ported valve
– C) Angle valve
– D) Single ported valve
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Challenge Questions
 The following figure represents:

– A) Three way valve
– B) Double ported valve
– C) Angle valve
– D) Single ported valve
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Challenge Questions
 There are two basic types of control valves: rotary and linear. Which of the
followings is NOT a linear-motion control valve type?
– A) Globe
– B) Butterfly
– C) Angle
– D) 3-way
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Diaphragm Valve- Working Principle

 Diaphragm is a control device that utilizes a
flexible membrane to close or shut, an opening.
 Consists of a valve body with two or more parts,
a diaphragm and a “weir or saddle” or seat
upon which the diaphragm closes the valve.
 Transmits force to open, close or control a
valve.
 Get their name from a flexible disc which comes
into contact with a seat at the top of the valve
body to form a seal.
 Pressure increase or decrease on either side of
the diaphragm cause the valve to move its
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position
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 Diaphragm valves use A Flexible Sheet Pressed

close to the edge of a solid dam to narrow the flow
path for fluid.
 These valves are well suited for flows containing
solid particulate matter such as slurries.
 Precise throttling may be difficult to achieve due to
the elasticity of the diaphragm.
 This diaphragm completely separates the valve trim
from the fluid flowing through the valve.
 This means that the fluid does not contact the trim
and the stem does not need any Gland Packing.
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Diaphragm Valve positions (on-off)
Diaphragm Diaphragm
Open closed
Weir Type
Diaphragm Diaphragm
102 Open Closed
Straight through type
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Diaphragm Valve Positions (Throttling)
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Diaphragm Valve positions (on-off)
Diaphragm Diaphragm
Open closed
Weir Type
Diaphragm Diaphragm
102 Open Closed
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Diaphragm Valve Positions (Throttling)
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Diaphragm Diaphragm
Open closed
Weir Type
Diaphragm Diaphragm
104 Open Closed
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Diaphragm Valve- Applications

 Applications
– Used for regulations of most gases and liquids
 Advantages
– Valve components can be isolated from process fluids
– Valve construction prevent leakage of the fluids without use of a gland seal
(packing)
 Disadvantages
– The diagram becomes worn more easily and regulator maintenance is necessary.
– These types of valves are generally not suited for very high temperature fluids and
are mainly used on liquid systems.
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Diaphragm Valve - Applications

 They are used or opening, closing and
throttling purposes
 To start, regulate, and stop fluid flow
 The diaphragm valve has an extended use
for applications at low pressure and slurry
fluid where most other kinds of valves
corrode or become obstructed.
 Use the diaphragm to separate the flow
from the closer element.
 Excellent for controlling the flow of fluids
containing suspended solids and offer the
flexibility of being installed in any position.
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Diaphragm Valve - Applications
Valve transition has sets, preventing the
Leak proof seal
pipeline from complete discharge
The fluid is isolated from bonnet
Can only be used in moderate temperature (-
group, so there isn’t any shaft
60 to 450ºF)
leakage
The hydrostatic pressure that can be applied
Provide a sealing from bubbles
to the diaphragm is limited.
Reduce leakage to the The body must be made of corrosive
environment resistant material
Easy maintenance Cannot be used in multi-turn operations
107 Repairs can be made without
interrupting pipe line
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Diaphragm Valve - Working Principle

 Videos
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Rotary Valves
 A different strategy for controlling the flow of fluid is to insert a rotary element into the
flow path.
 Instead of sliding a stem into and out of the valve body to actuate a throttling
mechanism, rotary valves rely on the rotation of a shaft to actuate the trim.
 An important advantage of rotary control valves over sliding-stem designs such as the
globe valve and diaphragm valve is a virtually obstruction less path for fluid when the
valve is wide-open.
 Main Types of Rotary Valves
– Ball Valves
– Butterfly Valves
– Disc Valves
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Diaphragm Valve - Working Principle

 Videos
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Rotary Valves
 A different strategy for controlling the flow of fluid is to insert a rotary element into the
flow path.
 Instead of sliding a stem into and out of the valve body to actuate a throttling
mechanism, rotary valves rely on the rotation of a shaft to actuate the trim.
 An important advantage of rotary control valves over sliding-stem designs such as the
globe valve and diaphragm valve is a virtually obstruction less path for fluid when the
valve is wide-open.
 Main Types of Rotary Valves
– Ball Valves
– Butterfly Valves
– Disc Valves
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Ball Valve - Working Principle
 Most ball valves are of the quick-

acting type (requiring only a 90-
degree turn to operate the valve
either completely open or closed),
but many are planetary gear
operated.
 This type of gearing allows the use of
a relatively small hand wheel and
operating force to operate a fairly
large valve.
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 The gearing does, however, increase
the operating time for the valve.
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 Ball valves are quarter-turn, straight-

through valves that have a round closure
element with matching rounded seats
that permit uniform sealing stress.
 The valve gets its name from the ball that
rotates to open and close the valve.
 Ball valves are used in situations where
tight shut-off is required.
 They are wide duty valves, able to
transfer gases, liquids and liquids with
113 suspended solids (slurries).
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 In the ball valve design, a spherical ball with a passageway cut through the
center rotates to allow fluid more or less access to the passageway.
 When the passageway is parallel to the direction of fluid motion, the valve
is wide open; when the passageway is aligned perpendicular to the
direction of fluid motion, the valve is fully shut (closed).
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Stem seals Valve fully Valve half Valve fully

Stem open open closed
Fluid passes
freely through
the orifice
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Screwed end ball valves
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Flanged end ball valves
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Rotary-Shaft Control Valve-Ball
 Problems are usually limited to leaks on packing gland or on the ball seat.
 Ball seal can be adjusted by tightening of gland nut, but not too much.
 When re-installing, tighten bolts evenly and turn valve at the same time to
check for binding.
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Ball Valves Open / Close States
PRC
TRANSMITTER
PROCESS GAS
OUTLET
HAND
PROCESS VALVE
VESSEL
PROCESS GAS
INLET
CORRECTING
ELEMENT
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Rotary-Shaft Control Valve-Ball
 Problems are usually limited to leaks on packing gland or on the ball seat.
 Ball seal can be adjusted by tightening of gland nut, but not too much.
 When re-installing, tighten bolts evenly and turn valve at the same time to
check for binding.
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Ball Valves Open / Close States
PRC
TRANSMITTER
PROCESS GAS
OUTLET
HAND
PROCESS VALVE
VESSEL
PROCESS GAS
INLET
CORRECTING
ELEMENT
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 Videos
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 Videos
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Ball Valve - Applications
Superior ease of operation Poor throttling characteristics
Maintains and regulates high volume, high Difficult to clean, leads to
pressure, and high temp flow contamination
Rugged construction and long
service life
Low purchase and maintenance cost
Able to function without side loads
Permits inspection and repair of seats and
seals without removing the valves' body
from the line
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Does not require lubrication
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Butterfly Valve- Working Principle

 A butterfly valve consists of a circular
disc with its pivot axis at right angles
to the direction material is flowing.
 The valve is made up of a body, seat,
disc, stem, and actuator.
 Each component part is available in a
variety of materials called “trim
features.”
 Properly combining trim features to
address material handled and
environment is important in selecting
the correct model valve for its
127 intended service
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Ball Valve - Applications
Superior ease of operation Poor throttling characteristics
Maintains and regulates high volume, high Difficult to clean, leads to
pressure, and high temp flow contamination
Rugged construction and long
service life
Low purchase and maintenance cost
Able to function without side loads
Permits inspection and repair of seats and
seals without removing the valves' body
from the line
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Does not require lubrication
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 A butterfly valve consists of a circular
disc with its pivot axis at right angles
to the direction material is flowing.
 The valve is made up of a body, seat,
disc, stem, and actuator.
 Each component part is available in a
variety of materials called “trim
features.”
 Properly combining trim features to
address material handled and
environment is important in selecting
the correct model valve for its
127 intended service
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 Butterfly valves are quite simple to understand:

– The “butterfly” element is a disk that rotates perpendicular to the path of fluid flow.
– When parallel to the axis of flow, the disk presents minimal obstruction (open); when
perpendicular to the axis, the disk completely blocks any flow (close).
– Fluid-tight shutoff is difficult to obtain in the classic butterfly design unless the
seating area is lined with a soft (elastic) material.
– The disc turns to open and close the valve.
– The disc or seat may be made of a polymer (plastic) to give a better seal.
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 Butterfly valves are simple and take up little space.

 This makes them especially good for use in large pipelines or where there
is not much space.
 Operating a butterfly valve can take a lot of force as you have to push it
against the fluid pressure.
 Larger valves usually have geared actuators to make operation easier.
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Double Flanged
Wafer Butterfly Valve Lug Butterfly Valve
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Signal
from
Positioner
Rotary Stem Actuator
Valve Disc
I / P Converter
Positioner
Valve Body
Wafer Type
Sliding to Rotary Motion Mechanism
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Signal
from
Positioner
Rotary Stem Actuator
Valve Disc
I / P Converter
Positioner
Valve Body
Wafer Type
Sliding to Rotary Motion Mechanism
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Butterfly Valve- Positions
 Most butterfly discs turn on a stem that passes through the center of the
disc along a diameter.
 When the valve is closed, fluid pressure pushes equally on both sides of
the stem: half the force is pushing in the closing direction and half in the
opening direction
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 Videos
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Butterfly Valve - Applications

 In slurry applications that contain suspended
particles
– A valve disc closing on dry bulk material will
create premature wear to the rubber seat.
– The obstructed orifice created by the disc
may cause bridging of material on the inlet
side of the valve
– A disc opening or closing on a standing
column of dry material may cause the
material to jam / pack.
– Particles of dry material or suspended
particles in slurries may become trapped
140 between the disc and seat, causing
conveying line inefficiencies.
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Butterfly Valve- Applications

 Applications
– Low pressure, large diameter lines where leakage is unimportant
 Advantages
– Low pressure drop, small and light weight
– Low cost and weight relative to globe as size increases
– High flow capacities
– Low stem leakage
 Disadvantages
– High leakage
– High actuation force so limited to low pressure
– Over sizing
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 In slurry applications that contain suspended
particles
– A valve disc closing on dry bulk material will
create premature wear to the rubber seat.
– The obstructed orifice created by the disc
may cause bridging of material on the inlet
side of the valve
– A disc opening or closing on a standing
column of dry material may cause the
material to jam / pack.
– Particles of dry material or suspended
particles in slurries may become trapped
140 between the disc and seat, causing
conveying line inefficiencies.
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Butterfly Valve- Applications

 Applications
– Low pressure, large diameter lines where leakage is unimportant
 Advantages
– Low pressure drop, small and light weight
– Low cost and weight relative to globe as size increases
– High flow capacities
– Low stem leakage
 Disadvantages
– High leakage
– High actuation force so limited to low pressure
– Over sizing
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 Used to stop, regulate, and start fluid flow.
 Are generally specified for most air, gas,
steam, and liquid applications.
 Positive shut-off valve for handling fluids
that are easily displaced by the valve disc
as it closes.
 When handling this type of material,
butterfly valves provide a reliable, bubble-
tight, bi-directional shut off
 Well-suited for the handling of large flows
of liquids or gases at relatively low
pressures and for the handling of slurries
142 or liquids with large amounts of suspended
solids.
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Available in large sizes Difficult to clean
Savings in weight, space, and cost Throttling limited to low differential pressure
Unguided disc movement is affected by flow

Maintenance costs are usually low
turbulence
Moving parts and there are no
Potential for cavitation and choke
pockets to trap fluids.
Portion of the disc is always presented to the
High coefficient of flow
flow, even when fully opened
Low pressure drop and high- Always results in a pressure switch across
143 pressure recovery the valve, regardless of the setting
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Disk Valve- Applications
 Disk valves (often referred to As Eccentric Disk Valves, or as high-

performance butterfly valves) are a variation on the butterfly design
intended to Improve Seat Shut-off.
 The disk’s center is offset from the shaft centerline, causing it to approach
the seat with a “cam” action that results in high seating pressure. Thus,
tight shut-off of flow is possible even when using metal seats and disks.
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Plug Valve- Working Principle

 Plug valve also called cocks, are generally
used for the same full flow service as a gate
valve where quick shutoff is required
 They are quarter tune valves and are operated
by turning the plug a quarter turn in the
clockwise for (closing) or anticlockwise
direction for (opening)
 The rotation of the plug and hence the port,
can be used to control the opening to allow the
fluid flow.
 Plug valves are either cylindrical or conically
tapered.
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 The lubricated plug valve is of the "block" or
complete shut-off type .
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 The simple design of the plug valve makes it well suited for general use.
 A parallel or tapered plug rotates in relation to the inlet and outlet ports of the body.
 The plug valve can be adapted for multiport operation, thereby simplifying pipe layouts.
 Normally used for open and shut operation, coarse throttling is possible on some low
flow applications.
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Plug Valve - Working Principle

3 way-port valve 3 way -3 port valve
$ way-4 port valve
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Plug Valve - Working Principle

 Videos
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Plug Valve - Applications

 Used in a wide array of equipment.
 Usually found in natural gas lines as a
device to control gas flow within the pipes
 also used in vacuum devices, as part of the
controls in removing pressure from a given
amount of space.
 Gas and liquid fuel
 Water.
 Extreme temperature flow
 Boiler feed water.
 Low Pressure Steam .
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 Corrosive Liquids and Gases
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Because of high friction, first movement
Simple design with few parts. (opening-closing) requires a large amount
of force
Open and close easily (except Larger valves require a gearbox or an
large dimensions). actuator
Maintenance and repair can be Valve transitions are narrowing flows due
done at the place of operation to conic plug
Generally, their costs are much larger than
They have low flow resistance
ball valves
They provide reliable leak-
153 proofness
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 Used in a wide array of equipment.
 Usually found in natural gas lines as a
device to control gas flow within the pipes
 also used in vacuum devices, as part of the
controls in removing pressure from a given
amount of space.
 Gas and liquid fuel
 Water.
 Extreme temperature flow
 Boiler feed water.
 Low Pressure Steam .
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 Corrosive Liquids and Gases
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Because of high friction, first movement
Simple design with few parts. (opening-closing) requires a large amount
of force
Open and close easily (except Larger valves require a gearbox or an
large dimensions). actuator
Maintenance and repair can be Valve transitions are narrowing flows due
done at the place of operation to conic plug
Generally, their costs are much larger than
They have low flow resistance
ball valves
They provide reliable leak-
153 proofness
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Maintenance Program
Pressure Relief Valve
154
Pressure Relief Valve- Working Principle

 Releases excess pressure to
protect system.
 Prevent equipment damage by
relieving accidental over-
pressurization of fluid systems.
 Use with gases & vapors & liquid.
 Open full at once at set pressure.
 Outlet port larger than inlet port.
 Never adjust whilst in service.
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Relief Valve
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Pressure Relief Valve- Applications

 Safety valve :
– Used with compressible gases .steam and air services
– Rapidly pops fully open as soon as the pressure setting is reached
– will stay fully open until the pressure drops below a reset pressure.
 Relief valve :
– Used in liquid systems. as pressure overspill devices
– Gradually opens as the inlet pressure increases above the setpoint
– Opens only as necessary to relieve the over-pressure condition
 The main difference between a relief valve and a safety valve is the
extent of opening at the setpoint pressure.
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Relief Valve
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Pressure Relief Valve- Applications

 Safety valve :
– Used with compressible gases .steam and air services
– Rapidly pops fully open as soon as the pressure setting is reached
– will stay fully open until the pressure drops below a reset pressure.
 Relief valve :
– Used in liquid systems. as pressure overspill devices
– Gradually opens as the inlet pressure increases above the setpoint
– Opens only as necessary to relieve the over-pressure condition
 The main difference between a relief valve and a safety valve is the
extent of opening at the setpoint pressure.
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Basic Function of a Spring Loaded Safety Valve

 Valve closed Safety Valve
 In a direct spring loaded safety valve the
closing force or spring force is applied by a
helical spring which is compressed by an
adjusting screw.
 The spring force is transferred via the spindle
onto the disc.
 The disc seals against the nozzle as long
as the spring force is larger than the
force created by the pressure at the inlet of
the valve:
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 Valve closed (P < Pset) Valve closed

– Fp < Fs
– Fs= Spring force
– FP = P*As= Force by pressure
– As = Seat area affected by
pressure P
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 Valve Opening (P ~ Pset)
Valve at set pressure
– In an upset situation a safety valve will open
at a predetermined set pressure.
– The spring force Fs is acting in closing
direction and Fp, the force created by the
pressure at the inlet of the safety valve, is
acting in opening direction.
– At set pressure the forces Fsand Fp are
balanced. Fp = Fs
– There is no resulting force to keep the disc
down on the seat or to provide seat tightness.
– The safety valve will visibly or hearably start
162
to leak (initial audible discharge)
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 Valve flowing (P > Pset)
Valve Flowing
– Overpressure is the pressure increase
above the set pressure necessary for the
safety valve to achieve full lift and
capacity
– The overpressure is usually expressed as
a percentage of the set pressure
– Codes and standards provide limits for the
maximum overpressure.
– A typical value is 10%,
– ranging between 3% and 21% depending on
the code and application
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Functional diagram of a safety valve

Typical operation diagram of a safety valve
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Loading principle of safety valve
Safety Valve
Reclosing Non reclosing
Direct loaded Controlled Buckling pin valve
Spring loaded Weight loaded
Pilot operated Controlled

(POSV) (CSPRS)
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Loading principle of safety valve

 Direct spring loaded safety valve: a safety valve in which the disc is held
closed by a spring
 Direct weight loaded safety valve: a safety valve in which the disc is held
closed by a weight, or by a lever and a weight
 Pilot operated safety valve (POSV): a safety valve in which the disc is held
closed by system pressure and the holding pressure is controlled by a
pilot valve actuated by system pressure. The pilot valve itself is a spring
loaded safety valve.
 Controlled safety pressure relief system (CSPRS): a system consisting
of a main valve in combination with control units. The closing force is
applied by a control device which will typically control an actuator on a direct
acting safety valve
166  Rupture / Buckling pin safety valve: a safety valve in which the disc is held
closed by a buckling pin.

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Codes and Standards

 ASME PTC 25 : Pressure Relief Devices Performance Test Codes
 API 520 Part I : Sizing, Selection, and Installation of Pressure-Relieving
Devices in Refineries
 API 526: Flanged Steel Pressure Relief Valves
 ISO 4126 - Part 1 : Safety devices for protection against excessive
pressure, Part 1: Safety Valves
 ISO 4126 - Part 4: Safety devices for protection against excessive
pressure, Part 4: Pilot operated safety valves
 ISO 4126 - Part 9: Safety devices for protection against excessive
pressure, Part 9: Application and installation of safety devices excluding
standalone bursting disc safety devices
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 Videos
 ..\..\Valve video\Pressure relief valve\Pressure Relief Valve-2.mp4
 ..\..\Valve video\Safety Valve video\Pressure Safety Valves,
Operation and Testing - sample.mp4
 ..\..\Valve video\Pressure relief valve\Safety Relief Valves, Pressure
Relief Valves, Steam Safety Relief Valves.mp4
 ..\..\Valve video\Pressure relief valve\PRV- Pressure Relief
Valve.mp4
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Pressure Relief Valve - Applications
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Pressure Relief Valve - Applications

 Prevent equipment damage by relieving accidental over-
pressurization of fluid systems
 Relief valves are typically used for incompressible fluids such
as water or oil
 Safety valves are typically used for compressible fluids such
as steam or other gases
 Used to provide automatic overpressurization protection for a
system.
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Maintenance Program
Control Valve Packing
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 Bonnet Style & Packing are selected based on the service temp. and the degree of
hazard of the process fluid.
 STD, extended (plain surface or finned surface) bonnets are used for normal, low or
high service temp., respectively.
 Single, duplex or bellows seal packing are used depending on the service P&T as well
as degree of hazard of the service fluid.
 Packing material is selected in view of the temp. limits of the different seal materials ,
(For example pure PTFE cannot be used for continuous duty when temperature is
higher than 200 °C as well as pure graphite is mandatory when temperature exceeds
250 °C.
 The selection of stem (or shaft) packing for a control valve must be done taking into
account very important factors such as:
– Temperature of process fluid
– Characteristics of fluid
– Working pressure
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 Its function is to minimize the process fluid leakage through the clearance around the valve stem.
 All stem-actuated control valves require some form of seal allowing motion of the stem from some
external device (an actuator ) while sealing process fluid, so no leaks occur between the moving stem
and the body of the valve.
 The general term for this sealing mechanism is Packing.
 Types:
– ingle V-ring packing for normal services
– Double for extreme hazard services, e.g., nuclear plants
– Bellows Seal for extreme hazard services with limited pressure.
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 All stem-actuated control valves require some form of seal allowing motion
of the stem from some external device (an actuator ) while sealing Process
Fluid so No Leaks occur between the moving Stem and the body of the
valve.
 The general term for this sealing mechanism is Packing.
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 Packing in a sliding-stem valve fits in a section of the valve body called the
bonnet, shown in this simplified diagram (1) of a single-ported, stem-
guided globe valve
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 A closer look at the bonnet shows a multitude of components working
together to form a low friction, pressure-tight seal for the moving valve
stem.
 An alternative to “stationary” loading is to insert a metal spring into the
packing assembly, so that the elasticity of the spring helps to maintain an
appropriate amount of packing stress as the packing material wears and
ages. This is called live loading.
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Adjusting Packing Assemble
 Photographs taken of an actual valve packing assembly removed from the

bonnet (left) and reassembled on the valve stem (right) reveal the structure
of the packing and associated components.
 There is no lantern ring in this packing assembly, but there is a coil spring.
This makes it a live-loaded packing as opposed to a jam packing.
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Packing
Follower
Packing Rings
Packing Rings
Compression
Spring
Packing Box Ring

Lantern Rings
Packing Box Ring
Anti Extrusion Washers
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Packing Material Selection

 The two most common packing materials in use today are Teflon (PTFE) and graphite.
 Teflon is the better of the two with regard to fluid sealing, stem friction, and stem wear.
 Teflon is also quite resistant to attack from a wide variety of chemical substances.
Unfortunately, it has a limited temperature range and cannot withstand intense nuclear
radiation.
 Graphite is another self-lubricating packing material, and it has a far greater
temperature range than Teflon as well as the ability to withstand harsh nuclear
radiation but creates much more stem friction than Teflon.
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Valve Trim
 This comprises the closing (sealing) members, such as gate, disk and seat
ring(s), including the stem or spindle, which are normally replaceable as
they are subject to wear or degradation.
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Maintenance Program
Actuators
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Actuators
 An actuator is an assembly fitted to Electric Actuator Electrohydraulic
Actuator
the control valve to provide a muscle
power for the moving elements.
 Three main types of this prime
mover namely Pneumatic, Hydraulic
and Electrical are highlighted
 Sizing of actuators requires
Pneumatic Actuator
consideration of static and dynamic
forces acting on the valve trim as
well the loading required from a
spring closure action
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Control Valve Actuators
 These are The Main Types of Actuator:

– Manual
– Pneumatic
– Electric motor
– Hydraulic
– Self-actuated
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Pneumatic actuators
 For most typical chemical process
plant operations
 The most widely used method
 Best able to provide fail-safe
responses on loss of drive power
 They are broadly classified into two
types.
– Linear diaphragm actuators
– Rotary diaphragm actuators
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Pneumatic Actuators
 They are basically of two types

– Diaphragm actuator
– Piston actuator
 These actuators are designed so that with a specific change of air
pressure, the spindle will move sufficiently to move the valve through its
complete stroke from fully-closed to fully-open.
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Pneumatic Actuators
Loading Pressure Diaphragm
Diaphragm Case
Diaphragm Plate
Actuator Spring
Yoke
Actuator Stem
Spring Force Adjustor
Spring Seat
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Diaphragm Actuators
 They have compressed air applied to a flexible membrane called the diaphragm.
 They are single acting i.e. Air is supplied from single side of the diaphragm.
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Pneumatic actuators
 video
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 Direct-Acting Actuator Nomenclature
 Air to close- failure to open - FO
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 Reverse-Acting Actuator Nomenclature
 Air to open- failure to close - FC
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Hydraulic Actuators
 Use a pressurized fluid to control valve movement.
 The hydraulic fluid used is either water or oil and is fed to either one or both sides
of a piston to cause movement.
 The Advantages of Hydraulic Actuators Include:
1. More powerful than a pneumatic actuator of the same size
2. Precise control of valve position
3. Capable of converting a small input pressure into a large output pressure
4. Incompressibility of the fluid, which means very little energy is lost during
operation
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Hydraulic actuators
 Hydraulic actuators use liquid pressure
rather than gas pressure to move the valve
mechanism
 Nearly all hydraulic actuator designs use a
piston rather
 than a diaphragm to convert fluid pressure
into mechanical force
 The high pressure rating of piston
actuators lends itself well to typical
hydraulic system pressures
 Some hydraulic actuators contain their
own electrically controlled pumps to
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Hydraulic Actuators
 The Disadvantages of Hydraulic Actuators Include:

– External hydraulic pump required
– Efficiency can be influenced by changes in temperature
– More expensive and complex than pneumatic actuators
– Can leak, causing a potential fire hazard
– For application, Hydraulic actuators are often used to operate the main stop and
control valves for high-pressure steam turbine piping.
– The actuator’s ability to operate the valve against the high-pressure steam, as well
as the ability to quickly shut the valve on the loss of control oil, makes hydraulic
actuators well suited for this task.
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Hydraulic actuators
 Hydraulic actuators use liquid pressure
rather than gas pressure to move the valve
mechanism
 Nearly all hydraulic actuator designs use a
piston rather
 than a diaphragm to convert fluid pressure
into mechanical force
 The high pressure rating of piston
actuators lends itself well to typical
hydraulic system pressures
 Some hydraulic actuators contain their
own electrically controlled pumps to
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Hydraulic Actuators
 The Disadvantages of Hydraulic Actuators Include:

– External hydraulic pump required
– Efficiency can be influenced by changes in temperature
– More expensive and complex than pneumatic actuators
– Can leak, causing a potential fire hazard
– For application, Hydraulic actuators are often used to operate the main stop and
control valves for high-pressure steam turbine piping.
– The actuator’s ability to operate the valve against the high-pressure steam, as well
as the ability to quickly shut the valve on the loss of control oil, makes hydraulic
actuators well suited for this task.
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Hydraulic Actuators
 Examples
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Electric actuators
 Electric actuator designs use an electric
motor solenoid-actuated valves and a gear
reduction drive to move the valve in linear
or rotational travel
 Electric motors can be used to open,
close, and position a valve manually,
automatically.
 Initially designed for on-off applications for
large isolating valves
 The electrical actuator has been adapted
to provide continuous positioning control
by providing position feedback to a
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reversible drive action
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Electric actuators
 Video
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Actuated Valve Assembly
 Video
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Electric actuators
 Advantages of electric actuators include:

– No source of pressurized air or fluid required
– Useful where low temperatures could cause freezing of condensation in air supply
lines
– Capable of producing very large amounts of torque
– Capable of producing consistent and adjustable operating speeds
– Electric cables are easier than piping to route to an actuator
 Disadvantages of electric actuators include:
– More expensive and complex than other types of actuators
– Slower comparative operation speeds
– Susceptible to a loss of power
– Potential fire hazard
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Hand Actuators
 The most common manual actuators are:

– Hand wheel—for linear motion valves: Gate valves, Globe valves.
– Lever—for rotational motion valves: Ball valves, Butterfly valves.
– It can be operated normally with all type of valves
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Hand Actuators
Rotary Movement Hand

Wheel (Female Threads)
Sliding Movement Only (Male

Threads)
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Self Actuated Valves

 Although not a type of actuator itself, a form of actuation worthy of mention is
where the process fluid pressure itself Actuates A Valve Mechanism.
 This self-operating principle may be used in Throttling Applications or On/Off
Applications, in gas or liquid services alike.
 The process fluid may be directly tubed to the actuating element (diaphragm or
piston), or passed through a small mechanism called A Pilot to modulate that
pressure before reaching the valve actuator.
 This latter design allows the main valve’s motion to be controlled by an adjustable
device (the pilot).
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 Self-operated, Spring-loaded Gas Pressure Regulating Valve
 A spring tries to force the plug off the seat, while “feedback” gas pressure from the
downstream side of the valve acts against a flexible diaphragm to move the plug
toward the seat.
 The less downstream pressure, the more the trim opens up; the more downstream
pressure, the more the trim shuts off.
 This spring establishes the pressure-regulating “setpoint” value for the regulator.
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 Pilot-loaded or Externally-loaded Pressure Regulator
 Externally supplied loading pressure does that. Since this loading pressure is easily
adjusted by turning the knob on the manual-set pressure regulator, the main regulator
now becomes adjustable as well.
 The pilot mechanism controls the main gas throttling mechanism, hence the name
pilot.
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Actuator Types Symbols
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Maintenance Program
Valve Problems
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Phenomena Associated to the Control Valve & How to avoid

 Cavitation
– Cavitation may occur when Control Valve
the local static pressure in a
fluid reaches a level below
the vapor pressure of the
liquid at the actual
temperature
Upstream Trim Downstream

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Cavitation
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How to avoid cavitation

 Tortuous path (use low recovery valves)
 Pressure drop staging
 Expanding flow area
 Isolation (separate flow from critical items)
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Flashing
 It is a system problem occurs
when the required Control Valve
downstream pressure is lower
than the vapor pressure at the
certain process condition
 Damage by flashing is
smother than damage by
cavitations
Upstream Trim Downstream
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Flashing
 When a fluid passes through the constrictive passageways of a control

valve, Its Average Velocity Increases.
 This is predicted by the Law of Continuity, which states that the product of
fluid density (ρ), cross-sectional area of flow (A), and velocity (v) must
remain constant for any flow stream:
 As fluid velocity increases through the constrictive passages of a control

valve, the fluid molecules’ kinetic energy increases.
 in accordance with the law of energy conservation, potential energy in the
form of fluid pressure must decrease correspondingly.
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Flashing
 Flashing is almost universally undesirable in control valves.

 The effect of boiling liquid at the point of maximum constriction is that flow through the
valve becomes “Choked” by the rapid expansion of liquid to vapor as it boils, severely
inhibiting the total flow rate allowed through the valve.
 Flashing is also Destructive To The Valve Trim, as boiling action propels small Droplets
of Liquid at extremely high velocities past the plug and seat faces, Eroding The Metal
Over Time.
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How to avoid flashing

 An angel valve with standard trim in the flow down
direction with down stream liner is the best to prevent
flashing damage
 Rotary plug style valve with the plug on the down stream
side of the valve
 Material of construction
 Position the valve where flashing damage could be as
minimum as possible
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Noise
 It is a natural side effect of turbulence and energy absorption of
control valves
 Sources of Valve Noise
– Mechanical noise
Result from valve plug vibration due to random pressure
fluctuation within the valve body
Resonant vibration when a valve component resonates at it is
natural frequency
– Hydrodynamic noise
Resulting from liquid flow. Cavitations is the most and major
source for this type of noise
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What are parameters affect Valve Noise ?
 Pressure drop across the valve

 Valve flow coefficient
 Valve flow geometry (noise is
proportional to the square of the port
area)
 Pipe size and schedule
 Downstream pressure
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How to attenuate Valve Noise ?

Valve Trim Design for Reducing Aerodynamic Noise
 Path Treatment
– Use of high schedules pipes
– Use acoustical or thermal
insulation
 Source treatment Valve and inline diffuser combination
– Use cage with many narrow

parallel slots designed to
minimize turbulence
– Use inline diffuser
– Use cages with many holes to
separate the flow stream
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Balanced versus unbalanced valves
 Cage-guided globe valves are available with both balanced and

unbalanced plugs.
 A balanced plug has one or more ports drilled from top to bottom, allowing
fluid pressure to equalize on both sides of the plug.
 This helps minimize the forces acting on the plug which must be overcome
by the actuator:
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Balanced versus unbalanced valves

 Unbalanced plugs generate a force equal to the product of the differential pressure
across the plug and the plug’s area (F = PA), which may be quite substantial in some
applications.
 Balanced plugs do not generate this same force because they equalize the pressure
on both sides of the plug, however, they exhibit the disadvantage of one more leak
path when the valve is in the fully closed position (through the balancing ports, past the
piston ring, and out the cage ports):
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Cage-guided Globe Valve

 Pressure recovery factor
 This factor compares The Valve’s Total Pressure Drop from inlet to outlet versus the
pressure drop from inlet to the point of minimum pressure within the valve.
 Where,
 FL = Pressure recovery factor (unitless)
 P1 = Absolute fluid pressure upstream of the valve
 P2 = Absolute fluid pressure downstream of the valve
 Pvc = Absolute fluid pressure at the vena contracta (point of minimum fluid pressure
within the valve)
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Special Trim Design
 This way, the same final permanent pressure drop (P1 −P2) may be
achieved without the lowest pressure ever falling below the liquid’s vapor
pressure limit.
 Valve trim may be specially deigned for Cavitation Abatement by providing
multiple stages of pressure drop for the fluid as it passes through the trim.
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Stiction
 How stiction affect valve movement
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Stiction
 Solutions
– Avoid Over Tighten Packing assembly to help in Stopping Leakage .
– Smart Positioners can adjust force supplied to actuator stem to help in Improving
Stiction Problem
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Ball Valve Special Trim
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Chocked Flow
 Both gas and liquid control valves may experience what is generally known
as choked flow.
 Simply put, “choked flow” is a condition where the rate of flow through a
valve does not change basically as downstream pressure is reduced.
 In a gas control valve, choking occurs when the velocity of the gas reaches
the speed of sound for that gas.
 This is often referred to as Critical or Sonic Flow.
 In a liquid control valve, choking occurs with the onset of flashing.
 The reason sonic velocity is relevant to flow capacity for a control valve
has to do with the propagation of pressure changes in fluids
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Ball Valve Special Trim
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Chocked Flow
 Both gas and liquid control valves may experience what is generally known
as choked flow.
 Simply put, “choked flow” is a condition where the rate of flow through a
valve does not change basically as downstream pressure is reduced.
 In a gas control valve, choking occurs when the velocity of the gas reaches
the speed of sound for that gas.
 This is often referred to as Critical or Sonic Flow.
 In a liquid control valve, choking occurs with the onset of flashing.
 The reason sonic velocity is relevant to flow capacity for a control valve
has to do with the propagation of pressure changes in fluids
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Pressure drop staging

 The first method of source control of aerodynamic noise is
called "pressure drop staging”.
 Pressure drop staging means that instead of taking The
Entire Pressure Drop In One Step, the pressure drop is
divided up into two or more steps.
 When the pressure drop is taken in more than one step,
the individual velocity peaks are smaller than the velocity
peak that would result from a single stage pressure drop.
 Because of the strong relationship between noise and
velocity, small reductions in velocity can have a large effect
on reducing the noise.
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Pressure Drop Staging

 Special valve trim A common cage-guided globe valve trim
design for noise reduction uses a special cage designed
with numerous, small holes for process gas to flow through.
 These small holes do not in themselves reduce
aerodynamic noise, but they do shift the frequency of that
noise up.
 This increase in frequency places the sound outside the
range where the human ear is most sensitive to noise, and
it also helps to reduce noise coupling to the piping,
confining most of the noise “power” to the internal volume of
the process fluid rather than radiating outward into the air.
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Flow Division
 The second method of source control of aerodynamic noise is called "flow division"
 Flow division means that instead of having the flow pass through a single opening, the
flow is divided up so that it passes through several openings in parallel.
 Every time you double the number of openings, you reduce the noise by 3 dBA.
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Flow Division
 Example Of How The Principle of Flow Division Can Be Applied To Globe Control
Valves.
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Erosion
 Another cause of erosion in control valves is Wet Steam, where steam

contains Droplets of Liquid Water propelled at high velocity by the steam
flow.
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Bonnet damage
 Bonnet damage
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Erosion
 Another cause of erosion in control valves is Wet Steam, where steam

contains Droplets of Liquid Water propelled at high velocity by the steam
flow.
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Bonnet damage
 Bonnet damage
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Shutoff Classes
 Seat Leakage Class is selected to meet the specific process requirements

and shut-off P.
 Note that some designs are not suitable for tight shut-off requirements
(e.g., double port unbalanced trim design).
 The quantity of test fluid passing through an assembled valve in the closed
position
 if upstream valve pressure= 60 psi and downstream valve pressure = 58
psi, so P = 2
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Valve Seat Leakage

 In some process applications, it is important that the control valve be able to
completely stop fluid flow when placed in the “closed” position.
 Many control valves spend most of their operating lives in a partially-open state, rarely
opening or closing fully. Additionally, some control valve designs are notorious for the
inability to completely shut off (e.g. double-ported globe valves).
 Given the common installation of manual “block” valves upstream and downstream of a
control valve, there is usually a way to secure zero flow through a pipe even if a control
valve is incapable of tight shut-off. For some applications, however, tight control valve
shut-off is a mandatory requirement.
 A control valve's ability to shut off has to do with many factors as the type of valves for
instance.
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Types of Leakage
 There are two types of leakage from a valve
– fugitive emissions from the valve to atmosphere
Can be detrimental to the environment and a potential safety
hazard.
Valves are considered to be the major contributors to fugitive
emission losses
– leakage through the valve but contained within the piping
system.
Valve can also be a safety hazard
Can be detrimental to the process
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Reasons that Valves leak

 Common causes of leakage through the valve include
– Valve is not fully closed. This can be due to various reasons,
including
Valve seat is prevented from closing fully due to dirt, rust, or
line debris
Insufficient actuator travel
The seat is damaged, e.g. scored
– The seal is damaged
 Common causes of leakage to atmosphere:
– Gasket between valve-body and valve-bonnet is damaged
– Stem Packing is worn, loose or damaged
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Valve Leakage Classifications
 Class I - Valve Leakage Classifications Identical to Class II, III, and IV in construction
and design intent, but no actual shop test is made.
– Class I is also known as dust tight and can refer to metal or resilient seated valves.
basic class , no test required.
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 Class II
– Intended for double port or balanced single port valves with a metal piston ring seal
and metal to metal seats.
– 0.5% leakage of full open valve capacity (0.005 * 10 LPM= 0.05 LPM = maximum
seat leakage)
– Service P or 50 psi (3.4 bar differential), whichever is lower at 50-to-125-degree F
– Test medium air at 45 to 60 psig (test pressure (drop))is the test fluid (or water)
– Typical constructions:
 Balanced, single port, single graphite piston ring, metal seat, low seat load
 Balanced, double port, metal seats, high seat load
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 Class I - Valve Leakage Classifications Identical to Class II, III, and IV in construction
and design intent, but no actual shop test is made.
– Class I is also known as dust tight and can refer to metal or resilient seated valves.
basic class , no test required.
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 Class II
– Intended for double port or balanced single port valves with a metal piston ring seal
and metal to metal seats.
– 0.5% leakage of full open valve capacity (0.005 * 10 LPM= 0.05 LPM = maximum
seat leakage)
– Service P or 50 psi (3.4 bar differential), whichever is lower at 50-to-125-degree F
– Test medium air at 45 to 60 psig (test pressure (drop))is the test fluid (or water)
 Balanced, single port, single graphite piston ring, metal seat, low seat load
 Balanced, double port, metal seats, high seat load
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 Class III
– intended for the same types of valves as in Class II.
– 0.1% leakage of full open valve capacity (maximum seat leakage)
– Service P or 50 psi (3.4 bar differential), whichever is lower at 50 to 125 degree F
– Test medium air at 45 to 60 psig is the test fluid (test pressure (drop))is the test fluid
(or water)
 Balanced, double port, soft seats, low seat load
 Balanced, single port, single graphite piston ring, lapped metal seats, medium seat
load
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 Class IV
– Intended for single port and balanced single port valves with extra tight piston seals
and metal to-metal seats.
– 0.01% leakage of full open valve capacity (maximum seat leakage)
– Service P or 50 psi (3.4 bar differential), whichever is lower at 50 to 125 degree F
– Test medium air at 45 to 60 psig is the test fluid (test pressure (drop))is the test fluid
(or water)
 Balanced, single port, Polytetrafluoroethylene (PTFE) piston ring, medium seat load
 Balanced, single port, multiple graphite piston rings
 Unbalanced, single port, lapped metal seats, medium seat load
 Class IV is also known as metal to metal
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 Class V
– Intended for the same types of valves as Class IV
– The test fluid is water at 100 psig or operating pressure
– Maximum seat leakage is 0.0005 ml/min of water per inch of seat diameter per psi
differential (e.g if 4 inch seat and 50 psig, 0.0005 *4*50=0.1 ml/min)
– Service  P at 50 to 125 degree F
– Test pressure (drop) = maximum operating
 Unbalanced, single port, high seat load
 Balanced, single port, Poly Tetra Fluoro Ethylene (PTFE) piston rings, soft seats
 Unbalanced, single port, soft metal seats, high seat load
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 Class Vl
– Is known as a soft seat classification. Soft Seat Valves are those where the seat or
shut-off disc or both are made from some kind of resilient material such as Poly tetra
fluoro ethylene (PTFE).
– Intended for resilient seating valves.
– Maximum seat leakage, The test fluid is air or nitrogen (bubble test)
– Pressure is the lesser of 50 psig or operating pressure
– The leakage limit depends on valve size and ranges from 0.15 to 6.75 ml per minute
for valve sizes 1 through 8 inches
– Test pressure (drop), 50 psig (or) max, rated differential pressure across the valve
plug whichever is lower
 Unbalanced, single port, soft seats
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Maintenance Program
Actuator Response
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Actuator Response Problem

 A limitation inherent to pneumatic valve actuators is the amount of air flow
required to or from the actuator to cause rapid valve motion.
 This is an especially acute problem in all-pneumatic control systems,
where the distance separating a control valve from the controller may be
large.
 This was serious problem in pneumatic control systems .
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Valve Leakage Classification Summary
Class Application
Class I Identical to Class II, III, and IV in construction and design intent, but no actual shop test is
made.
Class II. Intended for double-port or balanced singe-port valves with a metal piston ring seal and
metal-to-metal seats. Air or water at 45 to 60 psig is the test fluid. Allowable leakage is
0.5% of the rated full open capacity
Class III. Intended for the same types of valves as in Class II. Allowable leakage is limited to 0.1%
of rated valve capacity.
Class IV. Intended for single-port and balanced single-port valves with extra-tight piston seals and
metal-to-metal seats. Leakage rate is limited to 0.01% of rated valve capacity. (known as
metal to metal)
Class V Intended for the same types of valves as Class IV. The test fluid is water at 100 psig or
operating pressure. Leakage allowed is limited to 5 X 10 ml per minute per inch of orifice
diameter per psi differential
Class VI Intended for resilient-seating valves. The test fluid is air or nitrogen. Pressure is the lesser
of 50 psig or operating pressure. The leakage limit depends on valve size and ranges
from 0.15 to 6.75 ml per minute for valve sizes 1 through 8 inches. (known as soft seat
classification)
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 2nd Using Volume booster
– One way to improve valve response in either type of system is to use a device known as a
volume booster to source and vent compressed air for the valve actuator.
– A “volume booster” is a pneumatic device designed to reproduce a pneumatic pressure signal
(1:1 ratio), but with far greater output flow capacity.
– A 3 to 15 PSI pneumatic pressure signal applied to the input of a volume booster will result in
an identical output signal but with greatly enhanced flow capacity.
– A pneumatic control system equipped with a volume booster would look something like this:
– the only variable capable of reducing time lag is increased air flow rate, and a volume booster
directly addresses that deficiency.
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Actuator Response
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Actuator Response
 1st Using I/P Transducer
– If the pneumatic valve actuator is driven by an I/P transducer instead of directly
by a pneumatic controller,
– The problem is lessened by the ability to locate the I/P close to the actuator,
thus greatly minimizing tube friction and thus minimizing the “time constant” ( τ)
of the control valve’s response if the pneumatic actuator is particularly large in
volume, an I/P transducer may experience trouble supplying the necessary air
flow rate to rapidly actuate the control valve.
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 I/P transducer
– A “current to pressure” transducer (I/P) converts an analog signal (4 to 20 mA)
to a proportional linear pneumatic output (3 to 15 psig).
– Its purpose is to translate the analog output from a control system into a
precise, repeatable pressure value to control pneumatic actuators.
– The I/P converter uses an electromagnetic force balance principle to change
electrical signals into pneumatic signals.
– Typically, a 4 – 20mA input is converted into a 3 – 15 pisg output.
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 2nd Using Volume booster
– One way to improve valve response in either type of system is to use a device known as a
volume booster to source and vent compressed air for the valve actuator.
– A “volume booster” is a pneumatic device designed to reproduce a pneumatic pressure signal
(1:1 ratio), but with far greater output flow capacity.
– A 3 to 15 PSI pneumatic pressure signal applied to the input of a volume booster will result in
an identical output signal but with greatly enhanced flow capacity.
– A pneumatic control system equipped with a volume booster would look something like this:
– the only variable capable of reducing time lag is increased air flow rate, and a volume booster
directly addresses that deficiency.
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Actuator Response
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Maintenance Program
Control Valve Characterization
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 Control valve characteristic

 Control valve characteristic is the relation between CV and valve travel
 Why we need Control valve characteristic? , in order to provide loop stability in process
 A. Quick opening inherent flow characteristic
 From the pervious graph, at 60% valve travel = 90 % of valve coefficient CV
 SO, from 60 % to 100% valve travel = 10% rated CV
 From the above statement, high valve gain with low valve travel
 Application, On/Off services and Emergency Relief Services
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 Inherent versus installed characteristics
 The flow characteristic of a control valve is the relationship between the
flow rate through the valve travel as the travel is varied from 0 to 100%.
 Inherent flow characteristic refers to the characteristic observed with a
constant pressure drop across the valve.
 Installed flow characteristic means the one obtained in service where the pressure
drop varies with flow and other changes in the system.
 To establish The Flow Characteristic Needed to match a given system
requires a dynamic analysis of the control loop.
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 Inherent versus installed characteristics

 When control valves are tested in a laboratory setting, they are connected to a piping
system providing a nearly constant pressure difference between upstream and
downstream (P1 −P2).
 With a fluid of constant density and A Constant Pressure Drop across the valve, flow
rate becomes a direct function of flow coefficient (Cv).
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 Installed characteristics
– When valves are installed with pumps, piping and fittings, and other process
equipment, the pressure drop across the valve will vary as the plug moves through
its travel.
– When the actual flow in a system is plotted against valve opening, the curve is
called the installed flow characteristic.
– In most applications, when the valve opens, and the resistance due to fluids flow
decreases the pressure drop across the valve.
– This moves the inherent characteristic:
 Linear characteristic curve
 Quick opening characteristic curve
 Equal percentage characteristic curve
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 Installed characteristics
– Furthermore, let us assume the control valve has a “linear” inherent characteristic
and a maximum flow capacity (C_v rating) of 18.
– This means the valve’s C_v will be 18 at 100% open, 13.5 at 75% open, 9 at 50%
open, 4.5 at 25% open, and 0 at fully closed (0% open).
– We may plot the behavior of this control valve at these Four Stem Positions by
graphing the amount of flow through the valve for varying degrees of pressure drop
across the valve.
– The result is a set of characteristic curves for our control valve:
– Q = C_v * sqrt {Delta P}
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 Ideal Characteristic Curves
– Linear - flow capacity increases linearly with valve travel.
– Equal percentage
 Flow capacity increases Exponentially with valve trim travel.
 Equal increments of valve travel produce equal percentage changes in the existing
Cv.
 Quick opening
– Provides Large Changes In Flow for Very Small Changes In Lift.
– It usually has Too High A Valve Gain for use in modulating control.
– So, it is limited to on-off service, such as sequential operation in either batch or semi
continuous processes.
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Ideal Characteristic Curves
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 linear inherent flow characteristic
 From the pervious graph, valve gain is constant over valve travel
 Application, Pressure drop remain constant, over the entire operating range of the
system
 Equal percentage flow characteristic
 Equal incremental of valve travel provides equal % changes in CV
 0 to 50 % valve travel = 15 % rated CV only, i.e very small range, beyond 50% valve
travel provides very large range
 So, low valve gain with low valve travel
 and high valve gain with high valve travel
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Characterized Cages for Globe-Style Valve Bodies
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 Ideal Characteristic Curves
– Linear - flow capacity increases linearly with valve travel.
– Equal percentage
 Flow capacity increases Exponentially with valve trim travel.
 Equal increments of valve travel produce equal percentage changes in the existing
Cv.
 Quick opening
– Provides Large Changes In Flow for Very Small Changes In Lift.
– It usually has Too High A Valve Gain for use in modulating control.
– So, it is limited to on-off service, such as sequential operation in either batch or semi
continuous processes.
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Ideal Characteristic Curves
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 linear inherent flow characteristic
 From the pervious graph, valve gain is constant over valve travel
 Application, Pressure drop remain constant, over the entire operating range of the
system
 Equal percentage flow characteristic
 Equal incremental of valve travel provides equal % changes in CV
 0 to 50 % valve travel = 15 % rated CV only, i.e very small range, beyond 50% valve
travel provides very large range
 So, low valve gain with low valve travel
 and high valve gain with high valve travel
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Characterized Cages for Globe-Style Valve Bodies
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Valve Trim Assignments
 Different Valve Characterizations are be achieved by Different Valve Trim

Shapes.
 For instance, Plug profiles of A Single-ported, Stem-guided Globe Valve
may be modified to achieve the common quick-opening, linear, and equal-
percentage characteristics
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Cage Guided
 Cage-guided globe valve trim characteristic is a function of port shape.

 As the plug rises up, the amount of port area uncovered determines the
shape of the characteristic graph:
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Maintenance Program
Valve Testing
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Valve Testing
 API 598 “Valve Inspection & Testing”
– Specification covers inspection, examination, and pressure test
requirements for resilient seated, non-metallic, and metal-to-metal seated
Gate, Globe, Plug, Ball, Check and Butterfly valves.
– The following tests and examinations are specified in this standard:
Shell test,
Backseat test,
Low-pressure closure test,
High-pressure closure test,
Double block and bleed high-pressure closure test,
Visual examination of castings by the manufacturer,
High-pressure pneumatic shell test.
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Check Valve Testing

 Videos
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Check Valve Testing

 Videos: Field Testing Backflow Preventers
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Check Valve Testing

 Videos
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Check Valve Testing

 Videos: Field Testing Backflow Preventers
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Check Valve Testing

 Videos: How to Test a Double Check Valve Backflow
Preventer
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Diaphragm Valve Testing
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Maintenance Program
Valve Failure Modes
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Valve Failure Modes

 What is the meaning Failure ?!
 By failure we mean the loss of the source of the actuating power supplied
to the valve body .
 For electrically actuated valves, this is typically the last position the valve
was in before loss of electric power.
 For pneumatic and hydraulic actuated valves, the option exists of having a
large spring provide a known “fail-safe” position (either open or closed) in
the event of fluid pressure (pneumatic air pressure or hydraulic oil
pressure) loss.
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Valve Failure Modes

 Direct/Reverse actions
– The fail-safe mode of a pneumatic/spring valve is a function of both the
actuator’s action and the valve body’s action.
 1st Actuator :
– A direct-acting actuator pushes down on the stem with increasing pressure
while a reverse-acting actuator pulls up on the stem with increasing pressure.
– 2nd Valve Body
– Sliding-stem valve bodies are classified as direct-acting if they open up when
the stem is lifted and classified as reverse-acting if they shut off (close) when
the stem is lifted.
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Valve Failure Modes
Direct Acting Actuator : Air Pushes down the Stem
Loading Pressure
Sliding Stem
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Valve Failure Modes

Reverse Acting Actuator : Air Pushes up the Stem
Loading Pressure
Sliding Stem
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Valve Failure Modes
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Valve Failure Modes
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Failure modes Symbols

 Valve fail mode may be shown in instrument diagrams by either an arrow
pointing in the direction of failure (assuming a direct-acting valve body
where stem motion toward the body closes and stem motion away from
the body opens the valve trim) and/or the abbreviations “FC” (fail closed)
and “FO” (fail open).
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Bench-Set Adjust
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Bench-Set Adjust
 There are really only Two Mechanical Adjustments that need to be made when
coupling a pneumatic diaphragm actuator to a sliding-stem valve:
1. The stem connector
2. and the spring adjuster.
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Bench Set: How to select failure mode for a control valve

 Valve actuators provide force to move control valve trim.
 For precise positioning of a control valve, there must be a calibrated relationship
between applied force and valve position.
 Most pneumatic actuators exploit Hooke’s Law to translate applied air pressure to
valve stem position.
 Where,
 F = Force applied to spring in newton's (metric) or pounds (British)
 k = Constant of elasticity, or “spring constant” in newton's per meter (metric) or
pounds per foot (British)
 x = Displacement of spring in meters (metric) or feet (British)
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Bench Set: How to select failure mode for a control valve

 Hooke’s Law is a linear function, which means that spring motion will be linearly
related to applied force from the actuator element (piston or diaphragm).
 Since the working area of a piston or diaphragm is constant, the relationship
between actuating fluid pressure and force will be a simple proportion (F = PA).
 By algebraic substitution, we may alter Hooke’s Law to include pressure and
area:
 Solving for spring compression as a function of pressure, area, and spring

constant:
 X= PA/K
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Bench-Set Adjust
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Bench-Set Adjust
 There are really only Two Mechanical Adjustments that need to be made when
coupling a pneumatic diaphragm actuator to a sliding-stem valve:
1. The stem connector
2. and the spring adjuster.
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Bench-Set Adjust
 Case 1
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Bench-Set Adjust
 Case 2
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Bench set Summary

 Bench set is initial compression placed on The Actuator Spring with a Spring
Adjuster.
 For air-to-open valves, the lower bench set determines the amount of seat load
force available and the pressure required to begin valve-opening travel.
 For air-to-close valves, the lower bench set determines the pressure required to
begin valve-closing travel.
 Seating force is determined by pressure applied minus bench set minus spring
compression due to travel. Because of spring tolerances, there might be some
variation in the spring angle.
 The bench set, when the valve is seated, requires the greatest accuracy .
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 Summary
 Once the stem length has been properly set by adjusting the stem connector, the
spring adjuster must be set for the proper bench set pressure.
 This is the pneumatic signal pressure required to lift the plug off the seat.
 For an air-to-open control valve with a 3 to 15 PSI signal range, the “bench set”
pressure would be 3 PSI.
 Bench set is a very important parameter for a control valve because it establishes
the seating force (seat load) of the plug against the seat when the valve is fully
closed.
 Proper seating pressure is critical for tight shut-off, which carries safety
implications in some process services.
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 Summary
 Consult the manufacturer’s instructions when adjusting the bench set pressure for
any sliding-stem control valve.
 These instructions will typically guide you through both the stem connector and
the spring adjuster procedures, to ensure both parameters are correctly set.
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Maintenance Program
Maintenance & Troubleshooting Techniques
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 Proper installation is as much important as selecting the right control valve

for any process control. Because having properly selected a given control
valve does not automatically ensure that it will do the right job.
 In addition to the right selection, also depend greatly on the experience of
the person who designed the piping layout.
 It means a piping designer has to consider valve physical parameters such
as height, mounting practices, accessibility, and the proper location for
mounting the valve.
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 Optimizing valve efficiency depends on:
– Correct valve selection for the application,
– Proper storage and protection,
– Proper installation techniques, and
– An effective maintenance program. (preventive maintenance), Ensure safe and
efficient operation of your relief valves (as example) with the following three simple
steps.
 Check each valve to see if it relives at the correct PSI.
 If required, make adjustments to the valves.
 Replace any damaged seals or parts during the time of inspection and calibration.
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Proper Storage and Protection
 Typically, manufacturers have packaging standards that are dependent

upon the destination and intended length of storage before installation.
 The valve must be stored in a clean, dry place away from any traffic or
other activity that could damage the valve.
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Proper Installation Techniques

 Control Valve Accessibility
– The control valves should be installed in such a way that they are readily accessible for maintenance
purposes.
– If a control valve is mounted at a certain height, a permanent platform or walkway with ample
clearance for maintenance operations is required.
– The control valve can be installed in any orientation, but the preferred installation is in a horizontal
pipeline with an actuator in a vertical position.
– It is recommended to install pressure gauges before and after the control valve to check the line
pressure status as shown in the previous figure.
– Tips, Also, check the following points below:
 Sufficient workspace to remove the actuator when a repair is necessary.
 Sufficient clearances should be provided above and below the control valve so that the bottom
flange and plug or the top works and the plug, may be removed with the valve body in place.
 Can the flange bolts or the tie rods be removed?
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 Can the positioner gauges or valve travel indicator be seen?
 Can the positioner be adjusted?
 If a handwheel is provided, it in a position so that it can be rotated?
 Can the pipe leading to the valve be de-pressurized or drained for purpose of valve removal?
 suitable for manual operation?
 Be Sure the Pipeline Is Clean
 Foreign material in the pipeline could damage the seating surface of the valve or even obstruct the
movement of the valve plug, ball, or disk so that the valve does not shut off properly.
 To help reduce the possibility of a dangerous situation from occurring, clean all pipelines before installing.
 Make sure pipe scale, metal chips, welding slag, and other foreign materials are removed.
 Inspect pipe flanges to ensure a smooth gasket surface.
 For screwed end valves, apply a good grade of pipe sealant compound to the male pipeline threads.
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Valve Manual Operation

 In many critical applications, it is necessary to consider a manually operated throttling
valve in a bypass around the valve.
 With appropriate block and drain valves on either side of the control valve that allows
for the repair or replacement without shutting down the process.
 A by-pass should be installed if continuous operation is required during maintenance
and inspection.
 Valve Location
– The location of the valve chosen must be sufficient to permit repair.
– Correct location to help prevent cavitation.
– In the case of high-pressure gas or steam pressure-reducing applications, try to
have only straight pipes downstream of the valve or use the long sweeping elbow to
avoid additional pipe noise. Allow for drainage through the valve. This is particularly
important for sanitary valves and for valves handling dangerous fluids.
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 Study the possibility of corrosion caused by leaky flange gaskets or valve stem
packing on the equipment located below the valve.
 Control valve should not be located near a source of extreme heat. Control valves
that handle combustible fluids should be kept away from the hot pumps, lines, or
equipment.
 Check and consider the ambient temperature rating of the actuator or positioner or
heat trace the valve or airlines. In order to prevent premature failure of diaphragms
and electric or electronic components.
 Electrical accessories must meet safety standards as applicable for installation in
hazardous and other locations.
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Inspection and Maintenance of Control Valves
 Inspection before starting operation

– Before starting operating of the control valve, check & confirm the following to
ensure all conditions are correct and secure:
– Confirm that the flow direction marked on the control valve conforms with the
process fluid flow direction.
– Confirm that the bolts and nuts of the diaphragm are securely tightened.
– Confirm that bonnet clamp bolts are securely tightened.
– Confirm that the yoke clamp bolt is securely tightened.
– Confirm that the clamp bolts of any accessory devices (positioner, regulator valve,
etc.) are securely tightened.
– Confirm that the air connection to the actuator is securely tightened and there is no
air leak.
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Inspection and Maintenance of Control Valves
 Inspection before starting operation

– Confirm that the bolts of the stem connector that connect the actuator stem to the
valve stem are securely tightened.
– Confirm that the actuator stem and valve stem are not warped or show any other
sign of defect.
– Confirm that the control valve smoothly operates within its full lift scale range.
– Confirm that the actuator spring is correctly compressed.
– Confirm that gland packing bolts are sufficiently tightened.
– If the control valve employs asbestos packing, it is recommended to lubricate it with
the lubricator.
– If the control valve has a manual handwheel, check that the pointer of the operation
nut is at AUTO position and the handwheel is locked.
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Periodical Inspection and Maintenance
 Periodically inspect and perform maintenance service to the control valve

for the following:
– Check that there is no air leak from between the diaphragm case and diaphragm.
– Check that there is no process fluid leak from the bonnet and flanges.
– Check that the yoke clamp bolt is not loose.
– Check that there is no air leak from the air piping of the actuator.
– Check that there are no loose bolts on the stem connector which connects the
actuator stem to the valve stem.
– Check that the actuator stem and valve stem are not warped and show no sign of
damage.
– Check that valve operation is smooth and valve lift is correct
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Control valve preventive maintenance

 It is the primary and quick inspection, check for external leakage, corrosion etc.,
Inspection of the packing area, with adjustment of the packing only if necessary, is
a type of visual inspection. Items that can be detected by external visual inspection
are listed below:
– Structural integrity
– Subcomponent damage
– Loose, broken, missing fasteners, especially in high vibration areas
– Damaged or loose electrical connections
– Air leakage from pneumatic components
– Process leakage inspection (for example, soap bubble check) to include packing
area, body to bonnet area, flange joints, leak off lines, and pressure boundary
– Actuator shaft condition
– Condition of the valve stem and stem nut connector
– Pneumatic pressure readings within expected ranges
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Approaches to Control Valve Maintenance
 Preventive:
– This is the most advisable form of maintenance procedure.
– Here, a routine maintenance practice is conducted to detect any defect that may
hinder the working of the valve in the near future.
– Thus, preventive maintenance helps avoid an expensive breakdown or accident in
the future.
– Conducting preventive maintenance, not only keeps your valves working efficiently
but also minimizes costly repairs.
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 Control valve preventive maintenance
– There is no doubt that preventive maintenance can improve the performance
and safety of control valve function.
– The control valve maintenance includes inspection of all valve parts, check the
condition of auxiliary pipe fittings connected to the valve and pneumatic inlet
pressure check if the valve is pneumatically actuated.
 Closer Test:
– The closer test is required for gate valve and all valves.
– The test is done periodically to verify the valve is working properly and check the
requirement for maintenance.
– The closer test is done under full flow condition with one end closed, then mainly
check for the leakages in valve packing and to ensure the valve will work in
severe conditions.
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 Seals and Seal seats:
– Annually:
 Annually check the seat leakage at high pressure, scheduled maintenance of
seats are required.
 Check the rubber seals for cracking or other sign of deterioration and bronze
seal for wear, cavitation, erosion.
– Unscheduled:
 Check for seal retainers and bolts.
 Check water actuated seal are free to move and that water lines and port are
clear.
 Check seal seats, wallplates, gate sills and adjacent concrete for wear and
damage.
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 Valve body:
– Annually:
 Exterior of valve should be checked for corrosion, leakage and cracks.
 Interior of the valve body should be checked for cavitation erosion, corrosion,
scale buildup that may interface with valve movement or sealing and for other
damages.
 Check for lubrication to bearing and oil level of gear box.
– Not schedule:
 Check bearings and bronze seal rings for wear or other damages and replace
if necessary.
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 Valve Assembly:
– Stem and trim condition (for example, seating) can be inferred by diagnostics to
detect leakage, although an inspection is needed to assess the amount of leak
by and the extent of damage to the seat.
 Check and replace:
– Replace soft goods, for example, gaskets, packing, diaphragms, seals, etc
– Bearing surfaces
– Bolting or stud holes
– Stuffing box
– Valve Stem
– Electrical connections
– Fasteners that might be loose, especially in high vibration areas
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 Auxiliary piping system:
– Visually inspect all threaded, welded and flanged fitting check for any leaks and
corrosion.
– Remove external and internal corrosion.
– There are nondestructive methods for detecting internal corrosion
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Trim Maintenance
 Disassembly
– Remove the seat ring and seat ring gasket (keys
9 and 13).
– Inspect parts for wear or damage which would
prevent proper operation of the valve. Replace or
repair trim parts according to the following
lapping metal seats or valve plug maintenance
as appropriate.
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Actuator Maintenance
 Actuator parts are subject to normal wear and must be
inspected and replaced when necessary. The frequency
of inspection and replacement depends on the severity
of service conditions.
 This procedure describes how the actuator can be
completely disassembled and assembled. When
inspection or repairs are required, disassemble only
those parts necessary to accomplish the job; then, start
the assembly at the appropriate step. And refer to
manufacture manual instruction
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 Valve Assembly:
– Stem and trim condition (for example, seating) can be inferred by diagnostics to
detect leakage, although an inspection is needed to assess the amount of leak
by and the extent of damage to the seat.
 Check and replace:
– Replace soft goods, for example, gaskets, packing, diaphragms, seals, etc
– Bearing surfaces
– Bolting or stud holes
– Stuffing box
– Valve Stem
– Electrical connections
– Fasteners that might be loose, especially in high vibration areas
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 Auxiliary piping system:
– Visually inspect all threaded, welded and flanged fitting check for any leaks and
corrosion.
– Remove external and internal corrosion.
– There are nondestructive methods for detecting internal corrosion
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 Valve Body Maintenance
– Avoid personal injury or damage to property from sudden release of pressure or
uncontrolled process fluid. Before starting disassembly:
– Shut off operating lines to the actuator,
– Isolate the valve from the process,
– Release process pressure, and
– Vent the actuator loading pressure.
– Valve parts are subject to normal wear and must be inspected and replaced as
necessary.
– Inspection and maintenance frequency depends on the severity of service conditions.
– Whenever a gasket seal is disturbed, by removing or shifting gasket parts, a new
gasket should be installed upon re-assembly.
– This is necessary to ensure a good gasket seal since the used gasket may not seal
properly.
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Trim Maintenance
 Disassembly
– Remove the actuator and the bonnet according
to steps 1 through 5 of the replacing packing
portion of this Doc.
– Packing parts can be removed if desired.
Replace these parts as described in the
replacing packing procedure.
– Lift the valve plug and stem assembly, seat ring
retainer and gaskets out of the valve body and
set them on a protective surface. With the
assembly out of the body, slide the seat ring
retainer and bushing (keys 3 and 26) up over the
valve plug and stem. if the valve plug is to be
reused, protect the valve plug seating surface to
prevent scratches.
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Trim Maintenance
 Disassembly
– Remove the seat ring and seat ring gasket (keys
9 and 13).
– Inspect parts for wear or damage which would
prevent proper operation of the valve. Replace or
repair trim parts according to the following
lapping metal seats or valve plug maintenance
as appropriate.
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Actuator Maintenance
 Actuator parts are subject to normal wear and must be
inspected and replaced when necessary. The frequency
of inspection and replacement depends on the severity
of service conditions.
 This procedure describes how the actuator can be
completely disassembled and assembled. When
inspection or repairs are required, disassemble only
those parts necessary to accomplish the job; then, start
the assembly at the appropriate step. And refer to
manufacture manual instruction
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Packing Maintenance
 This procedure covers only PTFE V-ring and PTFE/composition packing.
 For spring-loaded single PTFE V-ring packing, the spring (key 8, figure I-6.6A)
maintains a seating force on the packing.
 If leakage is noted around the packing follower (key 13, figure), check to be sure the
shoulder on the packing follower is touching the bonnet.
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 Packing Maintenance
 If the shoulder is not touching the bonnet,
tighten the packing flange nuts, until the
shoulder is against the bonnet.
 If leakage cannot be stopped in this manner,
proceed to the replacing packing procedure.
 If there is undesirable packing leakage with
other than spring-loaded packing, first try to
limit the leakage and establish a stem seal by
tightening the packing flange nuts
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 Troubleshooting Techniques :
 Stroke check
 Make travel adjustments when the motion observed during actuator travel is
different from the travel stamped on the actuator nameplate. If the actuator
mounting procedure was followed correctly, this adjustment should not be
necessary.
 When adjusting travel of a direct-acting (push-down-to-close) valve, apply a low
supply pressure to the actuator diaphragm casing. This move the valve plugs off of
the seat, reducing the chance of damaging the valve plug or seat during
adjustments.
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 Stroke check
 Back the stem lock nuts and indicator disk away from the stem connector, and
slightly loosen the stem connector cap screws. (Do not use wrenches or other
tools directly on the valve stem. Damage to the stem surface and subsequent
damage to the valve packing might result).
 Tighten the lock nuts together, use a wrench on these lock nuts, and screw the
valve stem either into the stem connector to lengthen travel or out of the stem
connector to shorten travel.
 Cycle the actuator to check the travel. If travel is not equal to the specified travel,
adjust and check travel until correct. Tighten the stem connector cap screws when
correct travel is obtained.
 Raise the travel indicator disk by threading the stem lock nuts against the stem
connector.
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 Friction (stiction)
 A force that tends to oppose the relative motion between two surfaces that are in
contact with each other.
 The friction force is a function of the normal force holding these two surfaces
together and the characteristic nature of the two surfaces.
 Friction has two components: static friction and dynamic friction.
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Troubleshooting Techniques
– Static friction is the force that must be overcome before there is any relative
motion between the two surfaces. Once relative movement has begun, dynamic
friction is the force that must be overcome to maintain the relative motion.
– Running or sliding friction are colloquial terms that are sometimes used to
describe dynamic friction. Stick/slip or “stiction” are colloquial terms that are
sometimes used to describe static friction.
– Static friction is one of the major causes of dead band in a valve assembly.
– Stiction: the force required to cause one body in contact with another to begin to
move.
– All valve assemblies have friction, and static friction will always be slightly
higher than dynamic levels.
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– This results in a tendency for valve assemblies to move in a stick-slip mode for
small corrections, and there is minimum size to this jump that defines the
positioning resolution.
– The size of this jump seems to vary with friction, the ratio of static-to-dynamic
friction, and the dynamic characteristics of the actuator and positioner.
– If the minimum jump is 5 percent of the span, for example, it follows that the
best you could do is to get within about 2.5 percent of the correct position.
– The overshoot would result in a correction back the other way, and a limit cycle
would be set up whereby the valve and the loop would bounce back and forth
over the correct setpoint.
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 Travel time
– The movement of the closure member from the closed position to an
intermediate or rated full open position.
– Travel Indicator: A pointer and scale used to externally show the position of the
closure member typically with units of opening percent of travel or degrees of
rotation.
– Flow Characteristic: Relationship between flow through the valve and percent
rated travel as the latter is varied from 0 to 100 percent. This term should
always be designated as either inherent flow characteristic or installed flow
characteristic.
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 Travel Deviation and Relay Adjustment
– The travel deviation diagnostic is used to monitor actuator pressure and travel
deviation from setpoint.
– This diagnostic is useful in identifying a stuck control valve, active interlocks,
low supply pressure or shifts in travel calibration.
– The relay adjustment diagnostic is used to monitor crossover pressure on
double-acting actuators. If the crossover pressure is too low, the actuator loses
stiffness, making the valve plug position susceptible to buffeting by fluid forces.
If the crossover pressure is set too high, both chambers will be near supply, the
pneumatic forces will be roughly equal, the spring force will be dominant and
the actuator will move to its spring-fail position.
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 Limit switches
– Limit switches operate discrete inputs to a distributed control system, signal
lights, small solenoid valves, electric relays, or alarms. The cam-operated type
(figure) is typically used with two to four individual switches operated by
movement of the valve stem.
– An assembly that mounts on the side of the actuator houses the switches.
– Each switch adjusts individually and can be supplied for either alternating
current or direct current systems. Other styles of valve-mounted limit switches
are also available.
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 Predictive:
– Here, maintenance of the control valves is rendered on the basis of the evaluation
results of monitoring and testing equipment.
– Using several diagnostic equipment-like non-intrusive diagnostics, smart positioners,
distributive control systems, and programmable logic controllers (PLCs), the
performance of the valve, actuator, and controller is monitored.
– Immediate maintenance or repairing action is taken in case of any discrepancies.
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Maintenance Program
Valve Maintenance
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Valve Maintenance Procedures

 Consider the scope and duties of a typical maintenance
team with regard to valves.
 The key subjects that are identified by most suppliers
and guide manuals are:
– Installation practices
Ensuring that each valve is properly mounted
without risk of being compromised by poor
mounting arrangements, pipeline stresses and
foreign bodies
– Documentation and identification of the valve
This includes making sure you have the correct
specification sheets for the valves and seeing that
each valve is properly identified by a tag number
that matches the specification sheet
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Valve Maintenance Procedures

– Filing and record keeping:
It is essential to maintain a life history of
each valve under supervision.
– Its maintenance record and its settings
along with any failure events or faulty
performance will enable to understand
what level of care and attention each
valve requires and will assist with trouble
shooting.
– Cost of maintenance
Costs are high this will support the case
for upgrading the control valve to obtain
a return on investment
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Valve Maintenance Procedures (DOT)

 Planning
– Review equipment file to establish history.
– Write maintenance plan based on past
experience and valve manufacturer’s
recommended maintenance procedures.
– Obtain tools, materials, and safety
equipment
– Obtain a Work Permit through operations
– Gain approval for partial valve closure if
necessary
– Give a copy of your plan to your
supervisor
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 Site Preparation
– Determine that work site is safe.
– Clear work site of vegetation and soil
accumulation.
– Check “DANGER” and “WARNING” signs
for proper location and replace if
necessary.
– Verify valve wheels, handles, or wrenches
are in place or available.
– Insure protective devices to prevent
unauthorized use are adequate and install
correctly.
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 Clean and Lubricate
– Perform maintenance in accordance with
manufacturer’s recommendations. As
mini-mum requirements perform the
following:
Clean dirt and corrosion from the valve.
Lubricate as specified by the
manufacturer.
Check the open-close indicators for
integrity.
Touch up paint as required
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 Function Test
– Operate the valve, fully or partially, to
insure functionality.
– Determine reason(s) for any malfunction
and repair if possible.
– Schedule additional maintenance or repair
as required.
– Return the valve to its original position.
– Return valve wheels, handles and/or
wrenches to secured position to prevent
unauthorized operation.
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 Fugitive Emissions Test
– Use a CGI or soap bubble test to check
for fugitive emissions on all fittings and
connections.
– Tighten leaking fittings, flanges, or valve
packing, if necessary and possible.
– Reschedule maintenance and indicate the
special requirements for correcting the
defect if immediate repair is not possible.
–.
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 Documentation
– Maintenance report shall be placed in the
equipment file.
– Send a copy of the report to DOT
coordinator.
– Send a copy of the report to the Senior
Inspector.
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 Documentation
– Maintenance report shall be placed in the
equipment file.
– Send a copy of the report to DOT
coordinator.
– Send a copy of the report to the Senior
Inspector.
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Maintenance Program
Gate Valve Maintenance
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 Simpler gate valves require stem seal Typical Forged Steel Gate Valve
maintenance only
 Some of the more elaborate and larger
diameter gate valves in high-pressure and /
or sour service have provisions for seat
sealant injection.
 Periodic maintenance consists of inspecting
the stem for leakage and tightening the
gland nut as required
 Cycle the valve (if possible) to keep the
valve from seizing in one position
 Keep paint away from the stem threads, as
it can build-up and increase torque and may
keep the valve from seating properly
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Wellhead Gate Valve Maintenance

 For API gate valves, add more plastic stem
API Gate Valves
packing putty sticks as stem leaks develop
 Be careful while removing the bolt or stinger of
the packing injector
 Occasionally the ball check in the body of the
packing injector will not seat properly and gas
or liquid can escape under high pressure
 Remove the bolt slowly, it should unscrew by
hand after one or two turns if there is no
pressure behind it.
 There is a small vent hole near the top of the
packing injector body which should vent
leakage as the bolt is unscrewed if the ball
check has failed
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Wellhead Gate Valve Maintenance

 The fine threads on the bolt portion of the
API Gate Valves
packing injector can generate up to 30,000 PSI
without much effort with a short wrench.
 Turn the screw in slowly until the leakage stops
 The body cavity is often filled with body filler
grease to lubricate the gate and seats, prevent
internal corrosion and keep hydrates from
collecting in the valve body
 Always consult the proper manufacturer manual
for advice on body filling instructions before
starting
 DO NOT exceed the maximum working pressure
of the valve being serviced when filling the body
cavity
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Pipeline Gate Valves Maintenance

 Pipeline gate valves are designed so that the
Typical Through Conduit Pipeline
gate is in a fixed position and the seats are Gate Valve
spring loaded and allowed to float

 Because of the long travel of the valve stem,
pipeline gate valves are prone to stem leakage
 In the case of O-ring seals, the O-rings will roll as
the stem rises which can lead to pinching and
tearing of the O-ring.
 Care should be taken when injecting sealants
into a valve stem
 Continued high pressure injection may extrude
the O-ring stem seals out of their recess and
make the leakage worse
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 Valve cleaner should never be injected into a Gate Valve Stem Packing
button head fitting on a valve stem with O-ring
type seals because there is no way to displace
the cleaner
 In the case of plastic putty type packing, the long
travel of the stem shaft has a tendency to pull
some of the packing out as well
 Periodic Inspections
– stem packing should be inspected at least monthly
– f the stem packing shows signs of leakage, simply
tighten the adjusting nuts to compress the packing
– It is not recommended that additional packing rings be
added to the stuffing box as this may cause damage to
the stem sealing system
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 Periodic Inspections Gate Valve Stem Packing
– The lubrication of the yoke nut should be
inspected at least monthly
– A high pressure grease gun should be used for
valves supplied with ball type grease fitting
– Bonnet bolt tension should be checked
periodically when valves are used in high
temperature applications where creep may
occur
– Although leaks through ring joints are rare,
erosion or corrosion could cause rings to fail.
In these cases, a new ring gasket is required
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Gate Valve Inspection
Part Inspect for Remarks

Evidence of wear or mechanical damage which could Minor damage can be corrected by lapping the seats
prevent tight sealing with the body in the line. Major damage or wear will
Body Seats
necessitate removal of the body from the line or
replacement or remachining
Evidence of wear or mechanical damage to seating surface Minor damage, such as out-of-flatness, can be
corrected by lapping the seating surfaces. Major
Disc or
damage or wear will require remachining of the seating
Wedge
surfaces and many require replacement of the disc or
wedge to ensure fit.
Evidence of wear or mechanical damage on stem area which Remove minor damage by polishing; major damage
Stem
passes through packing rings. will require stem replacement
Assembly
Evidence of wear on stem threads Replace stem assembly if wear is excessive
Evidence of wear or roughness in bushing bore and adjacent Remove minor damage by polishing and major
Yoke Ends machined areas damage will require machining or replacement of yoke
Evidence of wear on underside surface Remove minor wear by polishing or remachining.

Handwheel which runs against yoke end Replace handwheel if extensive wear is evident
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 Videos Gate Valve Stem Packing
– Replacing the packing
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 Videos Gate Valve Stem Packing
– Lubrication
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Gate Valve Repair

 Disassemble completely
 Clean all component parts
 Inspect all component parts for wear and defects
 Non Destructive Examination-PT (Penetrant
Testing) all seating surfaces i.e. seat ring faces,
disc faces, bonnet and stem backseat areas
 Grind/polish disc and seat surfaces. Seat contact
proved by360 degree blue in
 Verify body/guide disc guide clearances
 Verify stem straightness for TIR(true indicator
reading) run out
 Polish stem to necessary RMS finish
 Clean all gasket surfaces
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Gate Valve Repair

 Pressure seal valve
– Hone bore to proper surface finish and record
dimension for new pressure seal gasket
(required when a valve is disassembled).
Recondition pressure seal angle on valve
bonnet
– Re-assemble using premium quality packing
and gasket materials
– Hydrostatically test seat/s and shell at 1.5 times
rated pressure
– Paint, tag and ship
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Gate Valve Repair

 Pressure seal valve
– Hone bore to proper surface finish and record
dimension for new pressure seal gasket
(required when a valve is disassembled).
Recondition pressure seal angle on valve
bonnet
– Re-assemble using premium quality packing
and gasket materials
– Hydrostatically test seat/s and shell at 1.5 times
rated pressure
– Paint, tag and ship
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Globe Valve Maintenance

 Repairs
– it is usually less expensive to replace the
complete valve than to have maintenance
personnel effect repairs
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Globe Valves Maintenance

 Videos
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 Stem thread lubrication
– Globe valves requires proper lubrication
to stem threads and or to bonnet.
– If the valve is closed
Apply grease below the yoke nut onto
stem threads
Open valve to the full open position
Apply grease to the stem thread
protruding above the yoke nut
Close valve to the full close position
cycle 1 additional time full open to full
close to evenly apply grease inside
yoke nut
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 Stem thread lubrication
– If valve is open:
Apply grease above the yoke nut onto
stem threads
Close valve to the full close position
Apply grease to the stem thread below
the yoke nut
Open valve to the full open position
Cycle 1 additional time full open to full
close to evenly apply grease inside
yoke nut
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 Repairs
– it is usually less expensive to replace the
complete valve than to have maintenance
personnel effect repairs
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Globe Valves Maintenance

 Videos
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Problem Solution
If the equipment is loaded with scales, dirt,
In instances where the obstructing material cannot be blown
or heavy grease, this can already prevent
through, it is best to open the valve and clean it thoroughly
the disk from being properly positioned
Examine if the damage is minimal and if it is, the valve can still
Erosion can potentially cause scraping of be restored and it can go back to its proper working order.
the valve seat or disk. Nevertheless, if the damage is substantially massive, the valve
should be repaired and re-seated so that it can function again
Fitting the guides way too tight and bending
the spindle guide and valve stem can result
If the conditions mentioned above become present in your
in disk distortion. If you are making use of a
equipment, it is time to replace the valve
valve disk that is too weak, it can
potentially cause damage
The remedy for this can be done by tightening the gland or by
means of repacking it. If repacking the gland would be
necessary, it is just essential to know if it is the string type or the
Occurrence of packing gland leakage; this
ring type; the string packing is commonly used for small valves
problem can persist if the valve stem is
with low pressure systems and ring packing is utilized mainly for
scored o bent.
huge valves for high pressure systems. Remember to get the
Copyright ©2009-2020 NExT. All rights reserved right tools for the replacement to ensure that it will fit the
pressure and temperature that it will be exposed
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Globe Valve Inspection

Evidence of wear or mechanical damage Minor damage can be corrected by lapping the seats
which could prevent tight sealing with the body in the line. Major damage or wear will
Body Seats
necessitate removal of the body from the line or
replacement or remachining
Evidence of wear or mechanical damage which could prevent Minor damage, such can be corrected by lapping the
tight sealing seating surface. Major damage or wear will require
remachining of the seating surface and may require
replacement of the disc
Disc Evidence of galling on the stem side of the disc, particularly If galling is evident, remachine or replace the disc
where the bottom of the stem bears against the disc
Damaged thread on the disc which mate with disc swivel nut Repair threads with thread chaser, or tap or
threads and may cause assembly difficulties replace the disc
Evidence of galling on bottom surface which bears against the Minor damage can be polished or repaired by
disc machining taking a very light cut. Major damage
requires replacement of the stem.
Stem Evidence of wear on stem area which passes through packing Minor damage can be polished out. Major damage
rings, particularly indications of a spiral being requires replacement of the stem
worn into the stem by rotation of the stem through the packing
rings
Evidence of wear on underside surface If thread wear or damage is evident replace the yoke
Yoke Bushing which runs against yoke end bushing, yoke bushing nut, and yoke nut pins
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Maintenance Program
Ball Valve Maintenance
372
Welded Body Ball Valve Maintenance

 Routine maintenance procedure
– Apply a small quantity of fresh lubricant / sealant
and cycling the valve periodically can add years
to the effective service life of the valve
– Top-up the sealant system with a small quantity of
fresh lubricant / sealant.
– Use proper cleaning techniques
 The best results are achieved by cycling the
valve to the closed position
– Adding Fresh Lubricant / Sealant
– Seat Sealing Procedures
– Maintaining a Seal
– Stem Lubrication
– Gearbox Maintenance
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 Follow this maintenance guide, and avoid frequent
repairs, save money, save time and have
smoother flow control operations
 The manual will be your reference guide in case
there are some parts you are finding difficulty with
unlocking, turning, twisting
 Protect the valve’s spare parts by sealing them
 During disassembly, gradually unscrew the bolts in
uniform and symmetrical motion.
 Apply the appropriate cleaning agents on the
different parts of the valve
 Clean the parts of the valve that cannot be
dismantled from the valve itself
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 Take the spare parts out of the cleaning
agents once they are cleaned.
 Apply lubricants on the valve and its spare
parts when putting them back together
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Ball Valves Maintenance

 Videos
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Ball Valves Maintenance

 Videos
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Plug Valves Maintenance

 Videos
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Maintenance Program
Diaphragm Valve Maintenance
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 Need minimal lubrication using knobs
according to the type of liquid substance
being changed at the setup of intervals
 In cases of replacement needs, these
valves are insulated and exhausted before
opening the valve
 External parts should be periodically
inspected and all parts that show damage,
excessive wear or corrosion should be
replaced
 Any fluid seepage from under the hand
wheel indicates diaphragm failure and
requires immediate diaphragm
replacement.
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 Any fluid leakage from the body/diaphragm
joint indicates that the bonnet bolts need to
be re-tightened
 To re-tighten the bonnet bolts
– Depressurize the system
– Open the valve slightly
– Tighten the bolts to the require torque
– If leakage continues, diaphragm replacement is
required
– Diaphragms should be inspected periodically for
wear and should be replaced at least once per
year
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 Diaphragm replacement
– Isolate and de-pressurize that part of the system where
the valve is installed. Rotate the hand wheel counter
clockwise until the valve is fully open.
– Remove the bonnet bolts
– Lift off the bonnet/diaphragm assembly and rotate
hand wheel clockwise a few turns to un-mate the
diaphragm from the bottom of the bonnet flange.
– Replacement diaphragms should be the same size
and grade as original diaphragm being replaced
– Rotate the hand wheel counter clockwise until the
diaphragm mates with the bottom of bonnet flange.
Fully open position.
– Place bonnet/diaphragm assembly onto the valve body,
making sure that the body weir is aligned properly with
the diaphragm center bead
– Replace bolts and nuts and hand tighten
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 Bonnet lubrication
– Bonnets are lubricated at the factory and
do not have grease fittings.
– When used under normal operation,
additional lubrication is not necessary
– When valves are exposed to weather
conditions or corrosive atmospheres,
external contacting areas of bonnet
assemblies should be lubricated.
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Diaphragm Valves Maintenance

 Videos
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 Videos
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 Need minimal lubrication using knobs
according to the type of liquid substance
being changed at the setup of intervals
 In cases of replacement needs, these
valves are insulated and exhausted before
opening the valve
 External parts should be periodically
inspected and all parts that show damage,
excessive wear or corrosion should be
replaced
 Any fluid seepage from under the hand
wheel indicates diaphragm failure and
requires immediate diaphragm
replacement.
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 Any fluid leakage from the body/diaphragm
joint indicates that the bonnet bolts need to
be re-tightened
 To re-tighten the bonnet bolts
– Depressurize the system
– Open the valve slightly
– Tighten the bolts to the require torque
– If leakage continues, diaphragm replacement is
required
– Diaphragms should be inspected periodically for
wear and should be replaced at least once per
year
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 Diaphragm replacement
– Isolate and de-pressurize that part of the system where
the valve is installed. Rotate the hand wheel counter
clockwise until the valve is fully open.
– Remove the bonnet bolts
– Lift off the bonnet/diaphragm assembly and rotate
hand wheel clockwise a few turns to un-mate the
diaphragm from the bottom of the bonnet flange.
– Replacement diaphragms should be the same size
and grade as original diaphragm being replaced
– Rotate the hand wheel counter clockwise until the
diaphragm mates with the bottom of bonnet flange.
Fully open position.
– Place bonnet/diaphragm assembly onto the valve body,
making sure that the body weir is aligned properly with
the diaphragm center bead
– Replace bolts and nuts and hand tighten
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 Bonnet lubrication
– Bonnets are lubricated at the factory and
do not have grease fittings.
– When used under normal operation,
additional lubrication is not necessary
– When valves are exposed to weather
conditions or corrosive atmospheres,
external contacting areas of bonnet
assemblies should be lubricated.
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 Videos
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 Videos
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 Videos
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 Videos
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Maintenance Program
Check Valve Maintenance
394
Swing Check Valve Maintenance

 Routine Maintenance
– One basic advantage of a swing
check is its simplistic design
– Inspect the valve for noisy or
erratic operations. If this condition
exist correct flow through the pipe
– If the system permits, depressurize
the piping until the valve closes.
Then pressurize the piping to
assure if the valve opens
– Check all the cover stud bolt nuts
for proper torque values and
tighten the nuts as necessary to
meet requirements
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Swing Check Valve Maintenance

 Disassembly
– After disassembly of the swing check
valve, all parts should be inspected for
evidence of wear or distortion or
mechanical damage. Perform the
inspection to assure satisfactory operation
of the affected parts
– Inspect the housing and the checking
device for evidence of corrosion. Replace
the valve if there is corrosion or excessive
roughness
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Swing Check Valve Inspection

Evidence of wear resulting in out-of roundness, galling or Minor wear can be polished out.
Hinge Pin roughness Major wear will necessitate hinge pin replacement
Evidence of wear on hinge pin end resulting in out-of- Minor wear can be polished out.
roundness or roughness in hinge pin bore Major wear will necessitate hinge replacement
Hinge
Evidence of wear resulting from movement of the disc in the Minor wear can be polished out.
hinge Major wear will necessitate replacement.
Evidence of wear resulting in out-of roundness or roughness Minor wear can be polished out.
Cover in the hinge pin holes on the underside of the cover. Major wear will necessitate cover replacement
Evidence of wear or damage on seating surface which could Lap, grind or remachine disc seating surface to assure
prevent tight seating adequate seating or replace disc.
Disc
Minor damage can be polished out. Major damage
Evidence of wear on surfaces which mate with hinge requires replacement of the disc
Evidence of wear or damage on body seat from hammering, Correct minor seating surface damage by lapping seat
sliding, etc. which could prevent tight seating to obtain a flat surface with the body in line. If damage
Body or wear is extensive, remove the body from the line for
remachining of the seat or replacement of the body
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Instrument and Control Maintenance Techniques - Process Control Valves

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Instrument and Control Maintenance Techniques - Process Control Valves

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11/20/2022

Level 2: Instrumentation and Control

Instrument and Control Maintenance

1 Copyright ©2009-2020 NExT. All rights reserved

2 Copyright ©2009-2020 NExT. All rights reserved

3 Copyright ©2009-2020 NExT. All rights reserved

Level 2: Instrumentation and Control

Control Valve Introduction

 Control: pressure / flow rate

5 Copyright ©2009-2020 NExT. All rights reserved

Classification of the valve based on function

Copyright ©2009-2020 NExT. All rights reserved

Classification of the valve based on operation

Copyright ©2009-2020 NExT. All rights reserved

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Function

 Final control elements include control valves, metering pumps,

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Function

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Introduction

11 Copyright ©2009-2020 NExT. All rights reserved

Control Valve Introduction

12 Copyright ©2009-2020 NExT. All rights reserved

Basic Control loop

Open-Loop Control System Closed-Loop Control System

13 Copyright ©2009-2020 NExT. All rights reserved

14 Copyright ©2009-2020 NExT. All rights reserved

Control Valve Function

Control valve in flow control

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Function

Control valve in level control

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Function

Control valve in pressure control

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Function

Control valve in temperature control

Copyright ©2009-2020 NExT. All rights reserved

Control Valve Introduction

19 Copyright ©2009-2020 NExT. All rights reserved

Control Valve Introduction

20 Copyright ©2009-2020 NExT. All rights reserved

Control Valve Introduction

21 Copyright ©2009-2020 NExT. All rights reserved

Principles of Valve throttling Process

22 Copyright ©2009-2020 NExT. All rights reserved

Principles of Valve throttling Process

23 Copyright ©2009-2020 NExT. All rights reserved

Introduction to Control Valve

24 Copyright ©2009-2020 NExT. All rights reserved

Principles of Valve throttling Process

25 Copyright ©2009-2020 NExT. All rights reserved

Principles of Valve throttling Process

Principles of Valve throttling Process

27 Copyright ©2009-2020 NExT. All rights reserved

Principles of Valve throttling Process

28 Copyright ©2009-2020 NExT. All rights reserved

Principles of Valve throttling Process

29 Copyright ©2009-2020 NExT. All rights reserved

Level 2: Instrumentation and Control

Control Valve Standards