VALVES

FUNCTIONS
• To stop or allow the flow of fluids.

• To act as safety device.

• To Prevent excess pressure generation in the system.

• To prevent the back flow of the fluid into upstream.

• The regulate the quantity or pressure of the flowing fluid.

• Quantity regulating valve for spray system.

• Pressure reducing valve in PRDS. .
CLASSIFICATION OF VALVES

A. BASED ON THE RELATIVE MOTION OF THE

CLOSING ELEMENT WITH THE DIRECTION OF
THE FLUID FLOW OR PRESSURE –

– The closing element in the same axis in which the fluid

flows. ( Globe Valves, Safety Valves, NRV)
– The closing element moves in the perpendicular
direction in which the fluid flows. (Gate valves, cocks,
ball valves etc.)
B. BASED ON FUNCTION OF VALVES.
– Stop / shut - off valve.
– Control / Regulating valve.
– Non-Return valve.
– Safety valve.
– Blow down valve.
C. BASED ON CONSTRUCTION OF
DISC / PLUG
– Gate valve - Solid Wedge.
– - Flex Wedge.
– Globe valve / Plug valve.
– Check valve (Piston type).
– Swing Check Valve (Flap Type)
– Needle Valve.
– Ball Valve.
– Butterfly valve.
– Diaphragm valve
D. BASED ON END CONSTRUCTION
– Flange joint.
– Screwed.
– Socket welding.
– Butt welding.
E. BASED ON OPERATION OF VALVES
– Manual.
– Electric Motor.
– Pneumatic.
– Hydraulic.
F. BASED ON BODY CONSTRUCTION

– Welded Bonnet.
– Bolted Bonnet.
– Pressure Seal
WEDGE GATE VALVE
 PRESSURE SEALING METHOD
• For large size and operates under high temperature and pressure
valve, the bonnet flange type and gasket seal method have
become irrational technically and economically.
• The rational sealing method which satisfies these requirements is
pressure sealing method. This method has been adopted for valves,
class 1500 and above for 65 mm size and higher.

PRINCIPLE OF PRESSURE SEAL

This method is also known as self-sealing method. In this method,
required pressing force is applied to the sealing gasket by the pressure
in the valve bonnet through the bonnet without external aid.
GLOBE VALVE
 COMPRESSION BETWEEN GLOBE & GATE VALVE
GLOBE VALVE GATE VALVE

Full flow area around the periphery is Full flow is obtained by completely travel
obtained by lift of d/4 (d= nominal bore). of gate across the bore of valve hence lift
must be >d
Head room and time required to operate is Head room and time required to operate is
less more
Only one pair of seals to be matched and Manufacture and maintenance of a gate
body seal is easily accessible for lapping. valve is difficult due to the tapper seats in
wedge and perfect matching with body
seat.
Disc has to function against the full Gate valve cuts across the medium and
medium pressure and hence the stem load is hence only partial load is transmitted to the
quite high. steam.
Due to the flow direction changes and Flow is straight and with least turbulence.
possible turbulence in a globe valve the
flow loss is more.
Check valve (Piston type).
Swing Check Valve (Flap Type)
BUTTERFLY VALVE
Masoneilan's 21000 Series control
valve is a heavy top guided globe
valve design featuring noise
attenuation and anti-cavitation
trim options. It is the most
versatile single ported control
valve on the market today, well
suited to handle a wide variety of
process control applications.
Masoneilan's 700 Series control valve
is a split body design with PTFE
internal lining for use in highly
corrosive services. This valve includes
a standard PTFE bellows seal design
and optional trim configurations.
Masoneilan's 41005 Series
control valve is a cage-guided
globe valve design with
balanced trim configurations.
This product line is engineered
to efficiently handle demanding
process conditions, including
applications with high pressure
drops and large temperature
variations.
 FACTORS DETERMINING SELECTION OF VALVES

• High temperature.
• High Pressure.
• High Pressure Drop.
• Combined High Temperature, Pressure & Pressure
Drop.
• Continuous Throttling.
• Tight shut off capabilities.
• Aerodynamic noise.
• High rangeability.
• Cavitation and flashing.
 CAUTIONS AT THE TIME OF INSTALLATION

Actuators / Motors are fitted to suit the working conditions as per the particular tag no. do
not inter change actuators / Motors
1. Installation shall be done as per tag no. indicated on the name plate and
corresponding drawing no.
2. Ensure foreign matters do not exist in the piping.
3. Remove Silica gels by all means after removing the protectors for the edge
preparations.
4. Ensure the anti-rust paint is removed (if provided) with the help of an alcoholic
cleaner before welding to pipe.
5. At the time of welding (pre-heating-welding-post heating), hand wheel should be
rotated by one or two revolution to keep the valve open slightly.
6. The area for preheating and post heating shall be approximately 2.5 times of the
width of weld area. Care should be taken to avoid temperature rise at other parts of
valve.
7. After completing welding (when temperature drops to normal), close the valve.
8. Ensure the threaded sections of clamping bolts and nuts are applied with anti-seizure
component.
 PRESSURE TEMPERATURE RATING
The service conditions for valves has a wide range. To cover these
whole range of the service conditions with a fixed wall thickness of
valve body is highly irrational. In order to solve the irrationality,
‘Normal Pressure’ is established. The ratings of these valves are as per
be called the representative pressure of valve. The ratings of these
valves are as per ANSI B16:34 for information.
1. 150 Class rating & Nomenclature.
2. 300 Class for low temperature & low pressure (Aux. steam upto 16 Kgf/Cm2)
3. 800 Class valve upto 40 Kgf/Cm2 and 300°C (Soot Blower drain
valves etc.).
4. 1500 Class valve (High Pressure 170 to 250 Kgf/Cm2
low temperature 350°C FOR drum & feed line.)
5. 2500 Class valves for super heat i.e. High Pressure and High
temperature (main steam lines etc.).
VALVE CODIFICATION
PRESSURE TEMPERATURE RATING OF CAST STEAL VALVE
 INSTALLATION AND MAINTENANCE OF VALVE

INSTALLATION / LAYOUT RECOMMENDATIONS

1. Ensure sufficient head room shall be available for easy accessibility during
maintenance.
2. Sufficient support shall be provided for heavier valves as well as for bypass
arrangement whenever it is provided.
3. Ensure grease / lubricant filling points are in upward direction and easily
accessible.
4. Ensure all valves shall be installed in horizontal lines with stem / spindle in
vertical position for easy disassembly / assembly and lapping.
5. Straight pipe at inlet/outlet of the needle / Regulating valves shall be as follows:
Inlet of Valve :12 to 20 times of Pipe OD.
Outlet of Valve :06 to 10 times of pipe OD.
IMPORTANT POINTS FOR BETTER MAINTENANCE OF VALVE-

1. Avoid the control of flow under the partial opening except flow control (needle
valves) valves.
2. Use the valve in the full open or close position. When valves are required to
operate in partial open condition, suitable bore size to be selected according to
operating conditions. Hence for such operation it is suggested to discuss the
same with the supplier.
3. Two globe valves are some times used in series (on the drain lines etc.) while
operating the valve, outlet valve is opened only after the inlet valve is opened.
For closing the inlet valve is closed only after the outlet valve is closed. As such,
it is desirable to close or open the inlet side valve without flow condition.
4. When leak is detected after closing valve, close it again and abrupt open, this
will remove foreign matters between disc and valve seat, and the leaking will
stop. In spite of this, leaking does not stop, a complete overhaul is required.
5. Wedge gate valve shall not be over-tightened. This may cause locking of the disc
in between two valve body seats.
6. Check valves (Flap valves) shall be installed in horizontal lines as far as possible.
7. Tighten the gland packing nuts evenly so that uniform loading is applied
throughout the packing area.
8. Check and apply sufficient lubricant on the stem nut threads.
9. Check and apply anti-seizure compound on threaded areas.
10. Check and confirm that there is no abnormal sound during operation of non-
return valves. Fluttering or chattering may occur due to incorrect size of valve
used in lines.
11. Ensure there is no damage on guiding surfaces.
12. Ensure all globe valves are closed with required torque.
13. Ensure all wedge gate motor operated valves 100 mm and above are closed with
position seating. For further details please check test certificates.
14. It is preferable to replace the sealing gaskets whenever valve is dismantled and
assembled.
15. Ensure no scratch marks formed on self sealing during dismantling and
assembling.
INTERNAL INSPECTION
After dismantling for any damage / score marks on:
a) Seat ring / seating faces.
b) Welded flap seating faces.
c) Yoke back seat.
d) Steam.
e) Threaded parts, gland, stem etc.

PROBLEMS

a) Leakage through valve seats i.e. passing on closure.

b) Leakage through gasket (Bonnet).
c) Leakage through gland.
d) Operational difficulty.
e) Damage to any parts.
 LAPPING
1. Not used for deep imperfection.
2. Lapped surface is to be cleaned properly.
3. Lapping plate should be first lapped by lapping plate.
4. Lapping plates / surface should be kept perfectly flat.
5. Lapping compound should be used sparingly:
a) Coarse compound: removes scores.
b) Fine compound polishes.
c) Paraffin oil gives final shin & finish.
6. Apply CW & CCW rotation alternately to the lapping plate or to be lapped surface.
7. Surface is to be cleaned by cotton cloth after lapping.
8. Excessive pr. should not be applied while lapping.
9. 80-90% blue matching means surface matching is OK.
10. Big scores can be filled up by material ground and then lapping can be done.
LAPING BLOCK
ON LINE LEAK SEALING

This is done in running i.e. on-line.

Accessories / Consumables.
A. Silicate compound.
B. Asbestos Yarne.
C. Iron chips / balls as per requirement of problem.
D. 3 mm to 6 mm drill.
E. Plug / Nipple.
F. Valve & pump for pumping the compound.
G. Copper wire for flange keakage.
Hole is drilled through at the fault / leakage and nipple filled in the
hole after tapping thread in the hole and then material is pumped
gradually till leakage is arrested. Valve is used for controlled feeding
of material.
 GATES & DAMPERS
• DUCTS ARE PROVIDED WITH GATES AND DAMPERS.

• TO STOP OR ALLOW THE FLOW OF FLUIDS.

• TO ACT AS SAFETY DEVICE.
• TO PREVENT EXCESS PRESSURE GENERATION IN
THE SYSTEM.
• TO PREVENT THE BACK FLOW OF THE FLUID INTO
UPSTREAM.
• THE REGULATE THE QUANTITY OR PRESSURE OF THE
FLOWING FLUID.
 GATES
• USED FOR FULL ISOLATION.

GATES PARTS
• BLADE OR SS PLATE.
• DRIVE & IDLER SHAFT (HOLLOW).
• CHAIN.
• SPROCKET.
• IDLER BEARING.
• SPRING SEAL ASSEMBLY. ( PORT, BONNET, SIDES, BOTTOM)
• GATES ARE NORMALLY MOTOR OPERATED.
TORQUE SWITCH / LIMIT SWITCH
• HAG IS PNEUMATIC OPERATED.
 DAMPER
• USED FOR ISOLATION AS WELL AS REGULATION IN GAS / AIR
PATH.

• CAN BE MOTOR OR PNEUMATIC OR HAND OPERATED.

DAMPER PARTS

• BLADE / FLAP / LOUVERS ASSEMBLY/ BIPLANE.

• BLADE SEAT.

• DRIVE & SLEEVE SHAFT.

• GRAPHOIL BUSH BEARING & GLAND.

• LINKAGES (ADJUSTING LINK & OPERATING LEVERS)

• JAMB SEAL ASSEMBLY.

LOUVER DAMPER
LOUVER DAMPER
BIPLANE DAMPER
BIPLANE DAMPER