VALVES

DEFINITION:

(I) Valves are mechanical devices that control the flow of fluid.
(II) Valves are devices with a moveable feature that opens and closes a
passageway in order to allow, prevent or control the flow of fluids.

CONSTRUCTION:

Generally all valves are constructed with the following parts;

(a) The operating hand wheel or lever; this is the part that is operated upon
in order to operate the valving or control element.
(b) Stem or spindle; this is the part that connects the lever or hand wheel to
the control element and effect the movement.
(c) Valving or control element; the part that actually controls the fluid. The
movable part that opens and closes in order to allow, prevent or redirect the
fluid.
(d) Valve seat; this is the area that comes into contact with the valving element
in order to close and seal off the opening.
(e) Valve body; the housing that accommodates the operating parts of the valve
(f) unit.
(g) Stuffing box; this provides a sealing arrangement around the stem or
spindle. This part is optional, some valves do not have stuffing boxes.

(h) Bonnet; A bonnet acts as a cover on the valve body. It is commonly semi-
permanently screwed into the valve body or bolted onto it. During
manufacture of the valve, the internal parts are put into the body and then
the bonnet is attached to hold everything together inside. To access internal
parts of a valve, a user would take off the bonnet, usually for maintenance.
Many valves do not have bonnets; for example, plug and butterfly valves
usually do not have bonnets

CLSSIFICATIONS OF VALVES (TYPES):

There are two main types of valves: normally open and normally closed. The
normally open valves remain open under normal operating conditions and are only
closed when the operations are stopped. The normally closed also operate in the
closed position unless there is a problem then the valve is opened.

Take note that there are various methods of classifying valves. With-in these two
main groups we have other types of valves. Here are some of the common methods:

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 1. By the function of valve
(a) Direction control valve; this valve guides the fluid into which direction it
should go, e.g. check valve
(b) Pressure control valve; this limits the range of pressure to that which is
required for the system normal operation. e.g. relief valve
(c) Flow control valve; control the amount of flow or volume of fluid that must
flow into the system.
(d) Safety valve

2. By area of application
(a) Steam valves – used on steam plant
(b) Hydraulic valves – used on hydraulic systems
(c) Pneumatic valves – used on air systems

3. By their normal condition / activity

(a) Normally open e.g. main valve in a house system
(b) Normally closed e.g. valve on a tyre

4. By number of paths of fluid flow

(a) Two way valve
(b) Three way valve
(c) Four way valve e.t.c

5. By features of construction
(a) Globe valve
(b) Gate valve
(c) Diaphragm valve e.tc.

WORKING PRINCIPLE OF VALVES:

The principle of operation depends so much on the particular type of valve.

However, a valve operates when pressure is exerted on the device causing the
opening or flow path to reduce, increase or close completely. An essential factor in
valve design is that it should give minimum resistance to flow when open.

SIZE OF VALVE:

The size of a valve is specified by:

(1) the size of pipe where it will be fitted or by

(2) the amount of pressure it will control.

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TYPES OF VALVES

1. Ball Valves

Ball valves offer very good shut-off capabilities. A simple quarter-turn (90°)
completely opens or closes the valve. This characteristic minimizes valve operation
time and decreases the likelihood of leakage due to wear from the gland seal. . The
closure member is a spherical plug with a through hole. When the valve is in open
state, the through hole is in-line with the fluid flow and hence, the fluid passes
through it. The valve is closed by rotating the globe by 90 Deg. such that the hole
now becomes perpendicular to the flow and hence, stops the flow. The seat can be
made either out of plastic or metals. The handle lies flat in alignment with the flow
when open, and is perpendicular to it when closed, making for easy visual
confirmation of the valve's status.

Ball valves can be divided into two categories: reduced bore and full bore. In
reduced bore valves, the valve opening is smaller than the diameter of the piping; in
full bore valves, the valve opening is the same size as the diameter of the piping.
Full bore ball valves are often valued because they minimize the pressure drop
across the valve.

Balls valves are usually only recommended for use in the fully open or fully closed
position. They are not suited to regulate flow by being kept partially open because
ball valves make use of a ring-shaped soft valve seat. When used in the partially
open position, pressure is applied to only a portion of the valve seat, which can
cause it to deform. If the valve seat deforms, its sealing properties are impaired and
it will leak as a result. Also ball valves are not recommended to be used in a
partially open condition, due to misalignment between the flow direction and
opening of the plug, large pressure drop takes place in partially open condition.

Due to above specified challenges, ball valves are mostly used in shutoff
applications. Ball valves are commonly used in steam, water, oil, gas, air and
corrosive fluids. They can handle slurries and dusty dry fluids. Ball valves are not
used with abrasive and fibrous materials as it poses risk of damage to the seat and
plug surface.

ball valve (Duplex make)

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 2. Butterfly Valves

In butterfly valves, the flow is regulated through a disc-type element held in place in
the centre of the valve by a rod. Similar to ball valves, valve operation time is short
because the valving element is simply rotated a quarter turn (90°) to open or close
the passageway.

Butterfly valves are most simple yet versatile valves. They are quarter turn operated
valves which are commonly used for varied applications. Quarter turn operation
ensures quick operating of the valve. In the open condition there is minimum
obstruction to the fluid flow through the valve. This results in very less pressure drop
through the valve.
Due to its unique mode of operation, the valve can be actuated easily without
requiring high torques and wear and tear. Due to lack of friction, use of bulky
actuators can be avoided. Another advantage offered by butterfly valve is their
compact size. The valve is quite compact, resembling a metal disc. This makes their
installation very easy. They can be used to handle slurries and fluids with suspended
solids as there are no cavities for deposition of solid particles inside the valve body.

Butterfly valves are characterized by their simple construction, lightness in weight,

and compact design. Their face-to-face dimension is often extremely small, making
the pressure drop across a butterfly valve much smaller than globe valves.

Materials used for the valving element and sealing can limit their applications at
higher temperatures or with certain types of fluids. Butterfly valves are often used
on applications for water and air, and in applications with large pipe diameters. A
common example of butterfly valve is the one found on the carburettors.

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 small butterfly valve

3. Globe Valves

A globe valve is a linear motion valve used to stop, start, and regulate the fluid flow.
The globe valve disk can be removed entirely from the flow path, or it can
completely close the flow path. During opening and closing of globe valve, the disc
moves perpendicularly to the seat.

This movement creates the annular space between the disk and seat ring that
gradually close as the valve is being closed. This characteristic provides the globe
valve good throttling ability required for regulating the flow.

Leakage from globe valve seat is less as compared to the gate valve, mainly due to
right angle contact between the disk and valve-seat, which allows tighter sealing
between seat and the disk.

The image also shows flow direction. Globe valves can be arranged in such a way
that the disk closes against the flow or in the same direction of flow of fluid.

When the disk closes in the direction of flow, the kinetic energy of the fluid helps
closing but obstructs opening. This characteristic is preferable when a quick-acting
stop is required.

When the disk closes against the direction of flow, the kinetic energy of the fluid
obstructs closing but helps to open the valve. This characteristic is preferable when
quick-acting start is required.

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In this type of valve, flow rate control is determined not by the size of the opening in
the valve seat, but rather by the lift of the valve plug (the distance the valve plug is
from the valve seat). One feature of globe valves is that even if used in the partially
open position, there is less risk of damage to the valve seat or valve plug by the fluid
than with other types of manual valves. Among the various configurations available,
needle type globe valves are particularly well suited for flow rate control.

Another point to consider about globe valves is that the pressure drop across the
valve is greater than that of many other types of valves because the passageway is
S-shaped. Valve operation time is also longer because the valve stem must be
turned several times in order to open and close the valve, and this may eventually
cause leakage of the gland seal (packing). Furthermore, care must be taken not to
turn the valve shaft too far because there is a possibility it could damage the seating
surface.

Care should also be taken to ensure that the stuffing box seal are adequately
adjusted to avoid leakages.

Globe Valve parts

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ADVANTAGES OF GLOBE VALVE

(1) Better shut off compared to gate valve

(2) Good for frequent operation due to minimum wear on valve seat and disc
(3) Easy to repair due to good access to seat disc from valve top
(4) Fast operation compared to gate valve

DISAVANTAGES OF GLOBE VALVE

(1) High head loss due to right angle turns of flowing liquid within valve body
(2) Costly compared to gate valve
(3) Heavier than other valve types of same rating
(4) Large valves require a lot of power to operate
(5) It is noisy in operation

4. Gate Valves

The construction of a gate valve is similar to that of a floodgate: flow is controlled by

raising or lowering the valving element, which is a simple blade or disc (gate). Gate
valves are used as full-on flow or full-off position.

Gate valves are characterised as having either a rising or a non-rising stem. Rising
stems provide a visual indication of valve position because 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

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 Non-rising stem gate valve

Like ball valves, gate valves are not usually used to regulate flow. One of the
reasons for this is because the valving element can be damaged when in the
partially open position and creates the problem of turbulence around the gate.
Similarly, they also limit the pressure drop across the valve when fully open.
However, setting the valve to the fully open or closed position requires the handle to
be turned many times, which generally makes these valves have the longest
operating times among those valve types mentioned here.

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ADVANTAGES OF GATE VALVE

(1) Siutable for high pressures and temperatures

(2) Pressure drop across the valve during opration is minimal
(3) Can be used as bi-directional
(4) Require less maintenance
(5) Slow operation prevents water hammering

DISADVANTAGES OF GATE VALVES

(1) Not able to control flow (throttling)

(2) Slow in operation and take time to open or close
(3) Creates vibrations and noise in partially open positions
(4) Repair such as lapping and grinding of seats are more difficult due to limited
access

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 5. Diaphragm Valves

Diaphragm valves use a 'pinching' method to stop the valve flow using a flexible
diaphragm e.g. rubber. This is a shut off and flow control valve. Diaphragm valves
are available in two types: weir and straight-way. The most commonly seen of the
two is the weir-type. This is because the straight-way type requires additional
stretching of the diaphragm, which can shorten the diaphragm's life-span. The flow
resistance when fully open is small.

One of the major advantages of using diaphragm valves is that the valve
components can be isolated from the process fluid. Similarly, this construction helps
prevent leakage of the fluid without the use of a gland seal (packing) as seen in
other types of valves. On the other hand, the diaphragm becomes worn more easily
and regular maintenance is necessary if the valve is used on a regular basis. These
types of valves are generally not suited for very high temperature fluids and are
mainly used on liquid systems.

6. PLUG VALVE

Similar to ball valves, plug valves are also a quarter turn type of valves. This valve
consists of a plug which can be either cylindrical or conical in shape. The plug has a
through slit which remains in-line with the flow in the open condition. When the plug
is turned by 90 Deg., this slit becomes perpendicular to flow and the valve gets
closed.
Plug valves are well suited to handle fluids with suspended solids, slurries etc. Plug
valves are primarily used for on-off applications. When used for throttling purpose,
the pressure drop through the valve is higher because of misalignment between flow
direction and the direction of the opening (slit).

Plug valves are capable of providing bubble tight shut off. They can be used in
vacuum to high pressure and high temperature applications.

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Plug valve applications can be on:

- Air, gaseous, and vapour services

- Natural gas piping systems
- Oil piping systems
- Vacuum to high-pressure applications

Advantages:

(a) Quick quarter turn on-off operation

(b) Minimal resistance to flow
(c) Smaller in size than most other valves
(d) Does not clog

Disadvantages:

(a) Requires a large force to actuate, due to high friction.

(b) large valves requires the use of an actuator.
(c) Reduced port, due to tapered plug.

7. CHECK VALVE

Check valves prevent back flow of liquid in piping system. The pressure of the fluid
passing through a pipe line opens the valve while any reversal of flow will close the
vale e.g. foot valve on pump system.

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 8. RELIEF VALVE

Pressure Relief valve or safety valve is used to protect equipment or piping system
during an overpressure event or in the event of vacuum or under pressure
situations. This valve releases the excess pressure or vacuum down to pre-defined
set pressure.

Schematic diagram assembly picture cut away view, parts.

9. NEEDLE VALVE;

Needle valves are similar to the globe valve in design. The difference is the sharp
needle like disc that regulate flow. Needle valves are designed to give very accurate
control of flow in small diameter piping systems. The sharp pointed conical disc and
matching seat give the name to the valve.

10. SOLONOID VALVE;

Solenoid valves are electromagnetically controlled industrial valves. They are

automatic acting basic components used to control fluids. They are self actuators
and are not limited to hydraulic and pneumatic. They are used to adjust flow,
speed, and direction of flow and other parameters of the media in industrial control
systems. Solenoid valves can be combined with different circuits to achieve the
desired control, and the control accuracy and flexibility can be guaranteed. There

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are many kinds of solenoid valves. The most commonly used ones are one-way
valves, safety valves, directional control valves, speed control valves, etc.

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Globe valve components and functions

Cross-sectional diagram of an open globe valve.

1. body 2. ports 3. seat 4. stem 5. disc when valve is open

6. handle or handwheel when valve is open 7. bonnet 8. packing
9. gland nut 10. fluid flow when valve is open 11. position of disc if valve
were shut 12. position of handle or handwheel if valve were shut

The main parts of the most usual type of valve are the body and the bonnet.
These two parts form the casing that holds the fluid going through the valve.

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Body

The valve's body is the outer casing of most or all of the valve that contains the
internal parts or trim. The bonnet is the part of the encasing through which the stem
passes and that forms a guide and seal for the stem. The bonnet typically screws
into or is bolted to the valve body.

Valve bodies are usually metallic or plastic. Brass, bronze, gunmetal, cast iron, steel,
alloy steels and stainless steels are very common. Seawater applications, like
desalination plants, often use duplex valves, as well as super duplex valves, due to
their corrosion resistant properties, particularly against warm seawater. Alloy 20
valves are typically used in sulphuric acid plants, whilst monel valves are used in
hydrofluoric acid (HF Acid) plants. Hastelloy valves are often used in high
temperature applications, such as nuclear plants, whilst inconel valves are often
used in hydrogen applications. Plastic bodies are used for relatively low pressures
and temperatures. PVC, PP, PVDF and glass-reinforced nylon are common plastics
used for valve bodies.

Bonnet

A bonnet acts as a cover on the valve body. It is commonly semi-permanently

screwed into the valve body or bolted onto it. During manufacture of the valve, the
internal parts are put into the body and then the bonnet is attached to hold
everything together inside. To access internal parts of a valve, a user would take off
the bonnet, usually for maintenance. Many valves do not have bonnets; for example,
plug valves usually do not have bonnets. Many ball valves do not have bonnets since
the valve body is put together in a different style, such as being screwed together at
the middle of the valve body.

Ports

Ports are passages that allow fluid to pass through the valve. Ports are obstructed
by the valve member or disc to control flow. Valves most commonly have 2 ports,
but may have as many as 20. The valve is almost always connected at its ports to
pipes or other components. Connection methods include threading, compression
fittings, glue, cement, flanges, or welding.

Handle or actuator

A handle is used to manually control a valve from outside the valve body.
Automatically controlled valves often do not have handles, but some may have a
handle (or something similar) anyway to manually override automatic control, such
as a stop-check valve.

An actuator is a mechanism or device to automatically or remotely control a valve

from outside the body. Some valves have neither handle nor actuator because they

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automatically control themselves from inside; for example, check valves and relief
valves may have neither.

Disc

Valve disc

A disc or valve member is a movable obstruction inside the stationary body that
adjustably restricts flow through the valve. Although traditionally disc-shaped, discs
come in various shapes. Depending on the type of valve, a disc can move linearly
inside a valve, or rotate on the stem (as in a butterfly valve), or rotate on a hinge or
trunnion (as in a check valve). A ball is a round valve member with one or more
paths between ports passing through it. By rotating the ball, flow can be directed
between different ports. Ball valves use spherical rotors with a cylindrical hole drilled
as a fluid passage. Plug valves use cylindrical or conically tapered rotors called
plugs. Other round shapes for rotors are possible as well in rotor valves, as long
as the rotor can be turned inside the valve body. However, not all round or spherical
discs are rotors; for example, a ball check valve uses the ball to block reverse flow,
but is not a rotor because operating the valve does not involve rotation of the ball.

Seat

The seat is the interior surface of the body which contacts the disc to form a leak-
tight seal. In discs that move linearly or swing on a hinge or trunnion, the disc
comes into contact with the seat only when the valve is shut. In disks that rotate,
the seat is always in contact with the disk, but the area of contact changes as the
disc is turned. The seat always remains stationary relative to the body.

Seats are classified by whether they are cut directly into the body, or if they are
made of a different material:

• Hard seats are integral to the valve body. Nearly all hard seated metal
valves have a small amount of leakage.
• Soft seats are fitted to the valve body and made of softer materials such as
PTFE or various elastomers such as NBR, EPDM, or FKM depending on the
maximum operating temperature.

A closed soft seated valve is much less liable to leak when shut while hard seated
valves are more durable. Gate, globe, and check valves are usually hard seated
while butterfly, ball, plug, and diaphragm valves are usually soft seated.

Stem

The stem transmits motion from the handle or controlling device to the disc. The
stem typically passes through the bonnet when present. In some cases, the stem
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and the disc can be combined in one piece, or the stem and the handle are
combined in one piece.

The motion transmitted by the stem may be a linear force, a rotational torque, or
some combination of these. The valve and stem can be threaded such that the stem
can be screwed into or out of the valve by turning it in one direction or the other,
thus moving the disc back or forth inside the body. Packing is often used between
the stem and the bonnet to maintain a seal. Some valves have no external control
and do not need a stem as in most check valves.

Valves whose disc is between the seat and the stem and where the stem moves in a
direction into the valve to shut it are normally-seated or front seated. Valves
whose seat is between the disc and the stem and where the stem moves in a
direction out of the valve to shut it are reverse-seated or back seated. These
terms don't apply to valves with no stem or valves using rotors.

spring

Gaskets

Gaskets are the mechanical seals, or packings, used to prevent the leakage of a gas
or fluids from valves.

Valve balls

A valve ball is also used for severe duty, high-pressure, high-tolerance applications.
They are typically made of stainless steel, titanium, Stellite, Hastelloy, brass, or
nickel. They can also be made of different types of plastic, such as ABS, PVC, PP or
PVDF.

Spring

Many valves have a spring for spring-loading, to normally shift the disc into some
position by default but allow control to reposition the disc. Relief valves commonly
use a spring to keep the valve shut, but allow excessive pressure to force the valve
open against the spring-loading. Coil springs are normally used. Typical spring
materials include zinc plated steel, stainless steel, and for high temperature
applications Inconel X750.

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