52689033-valves

7/31/2019 52689033-VALVES

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VALVESVALVES

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VALVE DEFINITIONVALVES ARE MECHANICAL DEVICES

SPECIFICALLY DESIGNED TO:

DIRECT

START

STOP

MIX

REGULATE

FLOW, PRESSURE OR

TEMPERATURE OF A

PROCESS FLUID

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Valves can be designed to handle either

LIQUID or GAS applications.

Industrial Valves : Size 0.5´ Nominal Dia

(DN15) to 48´ (DN1200).

90% of Valves are 4´ (DN100) or smaller in

size.

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SERVICEVacuum to over 13,000 psi (897 bar)

MATERIALS OF CONSTRUCTIONIron, Steel, Plastic, Brass, Bronze (or) a

number of special Alloys

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HISTORY

In 1712, Englishman Thomas Newcomen inventeda simple Iron Plug Valve, to regulate the flow of steam to the piston ± The first known application

of a Throttling valve. Corliss Steam Engine unveiled in 1876 wasdesigned with Self-acting Control Valves.

Invention of Crude oil as an inexpensive and

plentiful form of power in early 19th

centuryspawned the creation of Petroleum Refinery,Petrochemicals, Process Industries, Paper, Food,Beverage Industries creating need for varioustypes of valves.

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VALVE CLASSIFICATION

a) Function classifications:

ON-OFF (Block valves) ± Block or allow

flow

Non-return (Check valves) ± Allow flow totravel in one direction

Throttling (Full open to full close) ±

Regulation of flow (Can be used as ON-OFF

also)

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b) Application Classification:

General Service valves (Manual or Automated) ± -46oC to 343oC, Class 150 to

600, Non-corrosive applications.

Special service ± Custom engineered ± High

pressure, high temperature, corrosive/erosive

medium.

Severe service ± Valves with special features

to handle volatile applications, very high pressure drops, severe cavitation, flashing,

choking, beyond 593oC, liquid Sodium

applications.

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c) According to motion: Linear motion ± sliding stem design.

Rotary motion ± through quarter turn or 45o

range to open or block the flow.

d) According to Port size:

Full port valves Reduced port valves

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Other types of Valves Block & Bleed valves ± To prevent

intermixing of fluids (Fin Fan cooler, wash

water systems)

Butterfly valves ± Water applications

(AWWA standards)

Blow-off valves ± Steam systems

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TERMS AND DEFINITIONS

ANSI rating class ± Numerical pressure designclass defined in ASME B 16.5 and used for reference purposes.

ANSI rating class is designated by the word

µCLASS¶ followed by a number. Ex: Class 150. Bi-directional valve ± Valve designed for blocking

the fluid in both downstream and upstreamdirection.

Bleed ± drain or vent. Block valve ± Gate, Plug or Ball valve that blocks

flow to downstream when in closed position

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Locking device ± Part or an arrangement of partsfor securing a valve in the open and (or) closed position.

NPS ± Nominal pipe size.

PN ± Numerical pressure design class as definedin ISO-7005-1. (PN followed by a number). Ex:PN16.

Pressure containing parts ± Parts such as body,

bonnet, gland, stem, gasket, bolting designed tocontain pipeline fluid.

Process wetted parts ± Parts exposed directly to pipeline fluid.

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ABBREVIATIONSBM Base Metal

CE

Carbon Equivalent =

{%C+(%Mn/6)+(%Cr+%Mo+%V)/5+(%Ni+%Cu)/15}

Limit: 0.43 ± Heat analysis, 0.45 ± Product.

DBB Double Block and Bleed

DN Nominal Size

HAZ Heat Affected Zone

HR Rockwell Hardness

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HV Vickers Hardness

MPD Maximum Pressure Differential

MT Magnetic Particle Testing

NDE Non-Destructive Examination

NPS Nominal Pipe Size

NP Nominal Pressure

WPS Welding Procedure Specification

PQR Procedure Qualification Record

WQR Welder Qualification RecordWM Weld Metal

PT Penetrant Testing

PWHT Post Weld Heat Treatment

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ANSI PRESSURE CLASS

POUNDS OF FORCEPER SQUARE INCH

OF SURFACE AREA

NOMINAL PRESSURE ± ALLOWABLE

PRESSURE IN BAR

150 16

300 40

600 100

900 160

1500 250

2500 400

4500 700

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VALVE SELECTION Valve co-efficient or Flow co-efficient

Cv

= Flow X m sqrt Sp. Gravity at flowing

temperature / pressure drop

Cv = One US gallon (3.78 litres) of 60oF (16oC) water

that flows through an opening (valve) during 1minute with a 1 psi (0.1 bar) pressure drop

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END CONNECTIONS Threaded (1.5´ and smaller sizes) (NPT)

Flanged End (2´ and larger) ± Integral,

separable

Welded End (Class 900 and higher) ±

Socket welded (2´ and smaller), Butt

welded (3´ and higher)

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PRESSURE CLASSES Six standard classes ± 150, 300, 600, 900,

1500 or 2500 ± As per B 16.34 standard

Special classes ± 15, 4500 Etc.

Intermediate classes ± Ex. 3300 (CS valve

for 150oC, 450 bar)

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Casting Quality Factors

ASME Codes / B 16.34

Especially for corrosive, high pressure, high

temperature applications Level ± 1

Level ± 2

Level ± 3 Level indicates severity levels of

imperfections

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Casting imperfections include A ± Gas porosity

B ± Sand, slag inclusions

C ± Shrinkage

D ± Cracks

E ± Hot tears F ± Inserts

G ± Mottling

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Examination of Steel castingsare done as per

ASME Sec:VIII Div:1 Mandatory Appendix:7

ANSI B 16.5

ANSI B 16.34

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Radiographic examination standards

Thickness Standard

Up to 2´ (51 mm)ASTM E 446

(Std Reference Radiographs)

2´ ± 4.5´ (51-114 mm)ASTM E 186


4.5´ ± 12´ (114mm-

305mm)

ASTM E 280


Above 12´ASTM E 280 / UT exam is

done

RT spotsAs per sketch in B 16.34

standards

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VALVE MANUFACTURING Valve design

Pattern development

Establish methoding process with Statistical

Quality Control

Pilot casting

Tests / Acceptance standards Fix quality factors

Machining of castings

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Bought out items (other items like stem,

gasket, packing, fasteners, hand wheel, disc,yoke, seat ring)

Assembly

Testing Marking / Punching

Despatch

VTR / Release note of TPI Spares, valve key Etc.

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MATERIAL Carbon Steel ± up to 425oC

Chrome-Moly Steel ± Corrosive, H2

S

environment

SS - >535oC, high temperature, corrosive

applications

A216 WCB (CS), A217 C5 (AS), A351

CF8M, CF3M (SS)

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TRIM MATERIALAPI 600

Trim No.Service Stem

Body seat

ringWedge

Back seat

bush

8MP / LP

Steam

SS 410

RC22 max

BodyMOC +

HF

BodyMOC +

13% Cr

RC22 max

SS 410

RC22 max

12Corrosive

service SS 316

Body

MOC +HF

Body

MOC + SS

316 RC22

max

SS 316

RC22 max

5 HP Steam Both body seat / wedge is Stellited.

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MATERIAL TESTING Chemical composition ± basic, alloying

elements

Mechanical properties ± UTS, YS, %

elongation, hardness Etc.

Special properties ± Impact, high corrosion

resistant properties Etc.

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Various Heat Treatment processes

conducted in valve manufacturing

Normalizing

Hardening

Annealing

Tempering

Solution Annealing

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EXAMINATIONS Visual

Liquid Penetrant

Magnetic particle examination

Radiography

Ultrasonic examination

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TEST PROCEDURE ± API 600

Gate valve : Shell

Backseat

Air seat

Hydro seat

Globe valve : Shell

Backseat

Air seat

Hydro seat

Check valve : ShellHigh pressure closure test

Low pressure closure test

Low pressure air seat test (optional)

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REPAIR Weld repairs should be approved by TPI /

Client

WPS / PQR / Welder qualifications ± check

NDT

Post weld heat treatment

Tests as above

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Gasket Selection

Purpose : Prevent leakage from joint

Prevent leakage to atmosphereAllow function of internal mechanism

Material / : CAF, Spiral Wound, Ring Joint type

types

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PACKING

Any soft material encased in a bonnet or in a

body used to seal a valve closure elements

stem or shaft is called packing. It is held by

a packing follower or guides.

Ex: Graffoil, Impregnated Graffoil Etc.

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CLOSING ELEMENTS

GATE

GLOBE

BALL

PLUG

BUTTERFLY Etc.

TYPES OF OPERATION

MANUAL

GEAR OPERATED

ACTUATOR OPERATED

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COMMON VALVE PROBLEMS

High pressure drop ± Result in cavitation,flashing, choked flow, high noise levels,

vibrations. Water hammer effects ± Due to sudden

stoppage of flow, shock waves are generated,avoid sudden pressure surges.

Erosion, Corrosion Defects, leaks (Gland leaks)

Operational issues ± closing, opening Etc.

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ACCREDITATIONS API ± Monogram

API ± 6D for Gate, Plug, Ball, Check valves

ISO ± 9001

ISO ± 14000

IBR / EIL, TDC, TPI approvals

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Purchasing Issues Valve data sheet

Drawing

Specifications QAP

Stage / Final inspections

Storage, Installation

Spares

Warranty, Guarantee issues

Vendor surveys for enlistment

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INSTALLATION For best performance, it is recommended that

Gate, Globe valves are installed in vertical

position with the stem operating end at the top,horizontal or at an angle in between.

Swing check valves can be installed in vertical

or horizontal pipelines. However, in vertical

pipelines the flow should always be in theupward direction.

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Swing check valves should never be installed atthe outlet of a Reciprocating pump ± as the

pulsating flow will damage internals of the

valve.

Gate valves have bi-directional capabilities and

can be installed in any direction.

Globe valves to be installed in the direction of

arrow.

Check valves are unidirectional. Flow

direction and arrow direction should coincide.

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OPERATION

GATE VALVES : Should be fully open or fullyclosed. Throttling will cause wire drawing atseating area leading to damage, leak. Clockwise:close, anticlockwise: open.

GLOBE VALVES : Used for throttling. It isadvisable not to use Globe valves for flow controlbelow 10% of full opening. Clockwise: close,anticlockwise: open.

CHECK VALVES : All are swing type whichautomatically open by the velocity pressure of flow and close by the gravitational force whenflow reverses or stops.

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Maintenance Issues Periodical cleaning, flushing, greasing

Check gear box, actuator mechanisms

Installation issues

Online leak arresting (clamps, cold repairs

Etc.)

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PARTS Disc and Seat that directly affect the flow

Stem that moves the Disc

Body and Bonnet that house the Stem /

internal parts

Operator that moves the Stem

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DESIGN / TESTING CODES

VALVE DESIGN TESTING

GATEAPI 600, BS 1414,

DIN 3202 API 598,

ANSI B 16.34,

BS 6755,DIN 3230

GLOBE BS 5352

CHECK BS 5352 (Forged) /

BS 1868 (Cast)

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Other relevant Standards include:

API 6D ± Petroleum & Natural Gas

Industries ± Pipeline Transportation Systems

± Pipeline Valves

ASME B 16.5 ± Pipe flanges and flanged

fittings (1/2´ to 24´)

ASME B 16.10 ± Face to face and end to

end dimensions of valves

ASME B 16.25 ± Butt welded ends

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ASME B 16.34 ± Flanged, threaded andwelding ends.

ASME B 16.47 ± Large Dia steel flanges

(26´ to 60´)

NACE TM 0284 ± HIC testing

NACE MR0175 ± Sulfide Stress Cracking

resistant metallic materials for oil field

equipment

API 6 FD / API 607 ± Fire safe testing of

valves

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PRESERVATION End caps

Water ingress

Check prior to installation

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Special Applications NACE ± MR0175

IBR ± FORM - III C

AWWA Stds. ± Water applications

Custom designed ± PAREX rotary valves

Cryogenic applications ± very low

temperatures : N2, LPG (-180oC)

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TRACEABILITY Manufacturer Name Plate

Heat No. / Lot No. / Sl. No.

Size / Rating

W.O. No.

VTR / Release Note of TPI

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Famous / Approved

Manufacturers

AUDCO

KSB

FOURESS

SANMAR

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COST ASPECTS

Size, Rating

Additional Features (Gear, Actuator)

Special Requirements (NACE, RT Quality)

Location of Supplier vs. User

Mandatory Requirements

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QUESTIONS / VALIDATION:

What is a Valve? What is the purpose of a Valve?

What are types of Valves?

What are the Design/Testing standards?

What NDT are done in manufacturing stage?

What is AWWA Std? Where is it applicable?

What is Cv?

What are Appurtenances for valves? Name any 03. What are different types of ends of valves?

What are NACE application Standards?

What is an IBR valve? What is the Form No.?

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THANK YOUTHANK YOU

52689033-valves

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