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TTS MODULE # 39

VALVES

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Table of Contents

Module

Introduction……………………………………………………….03

Lesson 1: About

Valves……………………………………………………04

Lesson 2: Major Components of

Valves………………………………….09

Lesson 3: How Valves

Work……………………………………………….13

Lesson 4: Operating

Valves……………………………………………….23

Lesson 5: Maintaining

Valves……………………………………………..28

Module

Conclusion…………………………………………………………33

Glossary……………………………………………………………………..3

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Module Introduction

For a system to perform effectively, fluid movement through the system must

be controlled and equipment must be protected from overpressure. The

purpose of a valve is to start, stop, or regulate a flow of liquid or gas. In

addition, a valve can be used as a safety relief device for process equipment.

Valves are chosen based on specific process requirements. The choice is based

on the type of service and the temperature, pressure, and flow rates of the

liquid or gas flowing through the valve.

In this module, you will learn the basic functions of valves, major types of

valves, and their components. You will also learn how valves operate and the

basic maintenance requirements for valves.

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Lesson 1
About Valves

LESSON INTRODUCTION
Valves are broadly classified by the shape of their disc, which is the part of the valve that controls
the flow of a liquid or gas through the valve; or by their function in the system. Some valves are
manually operated, and some are remotely controlled. Other valves operate without any active
control as a safety feature of the system. In order for you to work safely and efficiently in a facility,
you must know the common types of valves.

In this lesson, you will learn the main functions of valves, seven major types of valves, and four
common types of automatic valves.

The main purpose of a valve is to perform one or more of four functions: starting or stopping a flow,
regulating a flow, preventing a backflow, and relieving pressure. Valves can be grouped by the
function they perform.

STARTING OR STOPPING FLOW

All processes require periodic starting and stopping of flow streams throughout their operating
units. This may be necessary due to maintenance requirements, production limitations and
scheduling, or emergency conditions. Valves in the process piping network provide the ability to
completely stop flow or permit full flow, depending on the process conditions and demands. The
most important requirements of these valves are that they:

 Have minimum flow restrictions and pressure drop when open.

 Have no leakage through the valve when closed.

A valve that can start or stop a flow exclusively is called a block valve.

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REGULATING FLOW
Many plant processes require that a flow be regulated (throttled) somewhere between fully open
and fully closed. Some valves can be used to regulate a flow at any point between fully open and
fully closed as dictated by process conditions. While these valves can also start or stop a flow that is
not their main function.

WARNING

Valves that regulate flow should not be relied upon to isolate systems or equipment. This could
result in personal injury and equipment damage.

A valve that is used to throttle a flow is called a control valve.

PREVENTING BACKFLOW
In some processes, it is critical to prevent a fluid from flowing backward to avoid product
contamination or a potentially dangerous surge of pressure. Certain valves are designed to allow
flow in only one direction. Valves used for this purpose are kept in the open position by the fluid’s
forward flow. These valves can close either by gravity, or by a decrease or reversal of the fluid’s
forward flow.

A valve that allows flow in only one direction is called a check valve. A common use of check valves is
for a pump discharge line. Without the check valve, the backflow would uncontrollably spin the
pump backwards when the pump was shut down.

RELIEVING PRESSURE
Excessive pressure may sometimes develop in piping or other process equipment. Some valves can
be used as safety or relief devices. To protect the equipment from rupturing, these kinds of valves
are often installed. They are designed to open when the line, equipment, or system pressure
exceeds a preset limit.

These types of valves are known as safety/relief valves.

There are seven common types of valves used in the process industry: gate, globe, needle,
diaphragm, plug, ball, and butterfly. There are many other types of valves used in more specialized
services.

GATE VALVE
Gate valves are block valves. They are used to start or stop a flow.
Gate valves are normally placed where a straight, free flow is
required; or where an immediate shutoff may be necessary.

CAUTION

Gate valves should never be used to throttle the

flow in a system. This will cause damage to the

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valve.

Figure 1-1
Gate Valve

GLOBE VALVE
Globe valves are control valves that can throttle a flow as well as
provide a possible shutoff. This type of valve is generally used in liquid
service.

Figure 1-2
Globe Valve

NEEDLE VALVE
A needle valve is a specialized form of globe valve. It is a control valve that
provides precise throttling control for metering a very small flow.

Figure 1-3
Needle Valve

DIAPHRAGM VALVE
Diaphragm valves are control valves that are used to shut off or
throttle a flow of abrasive or corrosive materials such as slurries,
acids, or caustic substances.

Figure 1-4 illustrates open and closed conditions of a diaphragm

valve.

Figure 1-4
Diaphragm Valve

PLUG VALVE
Plug valves are used to start, stop, or in some cases, throttle a flow. Plug valves are
used both as block valves and as control valves. This type of valve can be
used in systems that handle clean fluids or slurries.

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Plug valves are sometimes referred to as “quarter-turn valves” because it

takes a quarter of a turn to rotate the valve from fully open to fully close.

Figure 1-5 illustrates open and closed conditions of a plug valve.

Figure 1-5
Plug Valve

BALL VALVE
A ball valve is a special type of plug valve. It too can be used as a block valve or a control
valve. Ball valves are commonly used when the original pipe diameter
must be maintained with the valve in a fully open position. Ball valves
cannot be used in high temperature service because of the plastic seal
gaskets used for the ball.

Figure 1-6 illustrates open and closed conditions of a ball valve.

Figure 1-6
Ball Valve

BUTTERFLY VALVE
Butterfly valves are another type of quarter-turn valve. They are most
frequently used as block valves in low-pressure services. Because of
their poor throttling characteristics, butterfly valves are seldom used
as control valves.

Figure 1-7 illustrates open and closed conditions of a butterfly valve.

Figure 1-7
Butterfly Valve

Four common types of automatic valves are: control, check, relief, and safety. Each of these types is
used to accomplish one or more of the basic functions of a valve.

CONTROL VALVE
Control valves can be remotely or locally controlled to start, stop, or
throttle a flow. The operation of the control valve is governed by
sensors that detect level, pressure, temperature, etc. These valves
can be actuated electrically, pneumatically, hydraulically, or
manually.

Figure 1-8 illustrates open and closed conditions of a

pneumatic control valve.

Figure 1-8
Pneumatic Control Valve

CHECK VALVE

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Check valves are automatic valves that are used to prevent a

backflow in a piping system. These valves are generally kept
open by the flow of a fluid, and close either by gravity or by reversal
of the fluid’s forward flow.

Figure 1-9 illustrates open and closed conditions of a check valve.

Figure 1-9
Check Valve

RELIEF VALVE
Relief valves are automatic valves that are designed to relieve
excess pressure in a system before piping or equipment gets
damaged. Once the pressure is relieved, the relief valve closes
automatically.

Figure 1-10
Relief Valve

SAFETY VALVE
Safety valves are automatic valves. Their function is basically the same as that of a
relief valve. Unlike relief valves, however, safety valves are designed to “pop” nearly
wide open immediately to relieve excess pressure. They also have an external
lifting lever that allows the valve to be tested.

Figure 1-11 illustrates a safety valve.

Figure 1-11
Safety Valve

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Lesson 2
Major Components of Valves

LESSON INTRODUCTION
Many types of valves exist. In the previous lesson, you learned about some of the most common
types. Each type of valve may look different from the others, but they are all composed of many
parts that have functions common to all valves. You must know these common parts in order to
communicate effectively with other personnel at your site.

You also learned about control valves. There are four major types of automatic control valves, each
with parts that have functions common to all automatic control valve systems.

In this lesson, you will learn about the parts that are common to most valves and about the parts
that are common to most automatic control valve systems. In addition, you will identify valves and
their parts in the field.

COMMON VALVE PARTS

Ten parts are common to most valves.

Valve Body

The valve body connects to the piping or directly to the equipment. The body is the casting that
provides the supporting structure for the valve. Valve bodies are commonly made of cast iron,
bronze, or cast steel. Depending on the service, parts of the body, such as the seat, may be made
of Teflon ®, brass, bronze, stellite, etc.

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The valve body may also be designed to change the direction of the fluid’s flow. A valve such as this
is commonly referred to as an angle valve.

Port

The ports are simply the fluid inlet and outlet sections of the valve body.

Bonnet

The bonnet is the upper part of the valve. The bonnet guides the stem, contains the stem packing
assembly, and provides a housing for the disc as it rises from the seat. The bonnet may be a separate
part that is bolted, welded, or threaded to the valve body.

Actuator

The actuator (often called the operator) is the mechanism that is used to open, position, or close the
valve. The actuator can be operated manually, electrically, pneumatically, or hydraulically.

Stem

The stem is the rod, shaft, or spindle that connects the actuator to the disc. The stem acts as a
driver, transferring the motion from the actuator to the disc.

Packing

Packing (also called stuffing) consists of rings of compressible material, such as rubber or plastic, that
wrap around the stem to contain pressure and to prevent fluid from leaking out of the valve while
permitting movement of the stem.

Packing Gland

The packing gland is a ring-shaped piece that fits around the stem. It is used to compress the packing
in the stuffing box in order to prevent fluid from leaking by the stem. The packing gland is held in
place on the top of the bonnet by either a packing nut or a bolted packing follower.

Stuffing Box

The stuffing box is a recessed area on the top of the bonnet, where the stem comes through. The
stuffing box contains the packing material.

Disc

The disc (sometimes referred to as the element) is the part of the valve that fits against the seat to
start, stop, or throttle the fluid’s flow through the valve. It is the shape of the disc that often gives
the valve its name.

The disc may either rise from and descend to the valve seat (gate, globe, and needle valves) or
rotate on the seat (plug, ball, and butterfly valves).

Seat

The seat is located inside the valve body. This is what the disc fits against to start,
stop, or regulate the fluid’s flow through the valve. The seat and disc must be
smooth and fit snugly together in order to provide a positive shutoff.

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The seat can be threaded, press fitted, or welded to the valve body. Like other parts
of the valve body, the seat can be made of various materials, depending on
the service.

Figure 2-1
Common Valve Parts

Control valves can be operated pneumatically, hydraulically, or electrically. The actuator on each
type is designed differently. All control valves generally have a manual backup.

PNEUMATICALLY OPERATED CONTROL VALVE

The actuator of a pneumatically operated control valve consists of a pneumatic supply line,
diaphragm, and spring.

Pneumatic Supply Line

The pneumatic supply line (also called an airline) conveys compressed air to provide the pressure for
moving the stem of the control valve.

Diaphragm

The diaphragm provides a broad surface on which the air pressure can act. The diaphragm presses
against the top of the valve stem, and moves the stem in response to the air pressure.

Spring

The spring provides a force that the air pressure must overcome in
order to move the valve. The actuator design dictates whether the
spring holds the valve open or closed.

Figure 2-2 illustrates a pneumatic control system.

Figure 2-2
Pneumatic Control System

HYDRAULICALLY OPERATED CONTROL VALVE

The actuator assembly of a hydraulically operated control valve consists of an actuator valve,
hydraulic lines, and piston.

Actuator Valve

A small actuator valve (not shown) directs the hydraulic fluid to one side or the other of the piston.
Depending on the actuator valve’s position, the hydraulic fluid drives the control valve toward either
the fully open or fully closed position.

Hydraulic Lines

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Hydraulic lines are used to carry the hydraulic fluid to one side of the piston while allowing the
hydraulic fluid to drain from the other side.

Piston

The hydraulic fluid acts against the piston to position the control valve.

Figure 2-3 illustrates a hydraulic control system.

Figure 2-3
Hydraulic control system

ELECTRICALLY-OPERATED, REMOTELY-CONTROLLED VALVE

There are two types of electrically-operated, remotely-controlled valves: motor-driven and solenoid-
actuated.

MOTOR-DRIVEN VALVE
Motor-driven valves generally consist of an electric motor and a reduction gearbox.

Electric Motor

A reversible electric motor is used to move the valve’s disc to any desired position.

Reduction Gearbox

The reduction gearbox reduces the output speed of the electric motor shaft.

Figure 2-4 is an example of a motor- driven valve.

Figure 2-4
Motor-driven Valve

SOLENOID-ACTUATED CONTROL VALVE

The solenoid -actuated control valve consists of a wire coil, iron core, and spring.

Wire Coil

The wire coil carries an electric current that generates a magnetic field. The iron core is moved
through the wire coil by the magnetic field.

Iron Core

The iron core is attached to the valve stem. When the iron core is moved through
the wire coil, the valve opens or closes, depending on the design.

Spring

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The spring opposes the motion of the iron core and when the electric current is
removed, returns the valve to the closed position.

Figure 2-5 illustrates a solenoid-actuated control valve.

Figure 2-5
Solenoid-actuated Control Valve.

Lesson 3
How Valves Work

LESSON INTRODUCTION
You have learned the four functions performed by valves, the names of seven major types of valves,
and the parts common to most valves. It is now time to learn how the various types of valves
perform the functions for which they were designed.

As you have seen, all valves are not the same. Different types of valves are used for different
purposes. You need to have a basic understanding of which type of valve is best suited for which
service.

In this lesson, you will learn how major types of valves work, and how automatic valves work. In
addition, you will learn how automatic control valve systems work.

All valves perform one or more of the following functions: starting or stopping a flow, throttling flow,
preventing a backflow, and relieving pressure.

GATE VALVE
Gate valves are used primarily as block valves for isolating systems and equipment. Gate valves are
normally placed where a straight-through flow is desired.

GATE DESIGN

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Two basic gate designs are used in gate valves:

 Wedge-shaped

 Double disk

Wedge-shaped Gate

This gate is wedge-shaped and designed to wedge against the seat. In

high-pressure systems or systems subject to temperature variations, this disc can
become jammed against the seat.

Double Disk Gate

To counteract jamming, a double disc gate is often used. This type of gate
design is made of two separate discs with a spring between them. In
high-pressure service, the up-stream disc is pushed off its seat,
compressing the spring. The spring forces the downstream disc against its seat,
thus forming a tight seal. The double disc gate will not jam with variations in
temperature.

Figure 3-1
Gate Valve Designs

STEM DESIGN
Two common stem designs are used for gate valves:

 Rising

 Non-rising

Rising Stem

As the actuator is turned, the stem rises out of the bonnet as the disc
is pulled off the seat. The stem becomes a visual indicator of the
valve’s position (open or closed).

Figure 3-2 illustrates the rising stem design.

Figure 3-2
Rising Stem Design

Non-rising Stem

With this design, the disc is threaded to the stem. When the
actuator is turned, the disc rises on the stem and is pulled off
the seat. With a non-rising stem design, a valve position
indicator is usually attached to the valve.

Figure 3-3 illustrates the non-rising stem design.

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Figure 3-3
Non-rising Stem Design

NOTE

Recognizing a valve’s position by looking at the stem is discussed further in Lesson 4.

HOW IT WORKS
With a gate valve, the flow is stopped by operating the actuator to place the disc in the path of the
flow. The flow is started by removing the disc from the path of the flow. Valves with discs that pull
away from the seat are sometimes referred to as “up-and-down” valves.

Open Valve

When the valve is open, the gate should be fully retracted into the bonnet. If any of the gate
protrudes into the fluid stream, unwanted throttling will occur. Because a partially exposed gate will
wear unevenly, gate valves are not generally used for throttling. Uneven wear will prevent the gate
from sealing tightly.

Closed Valve

When the valve is closed, the gate should fit tightly against the seat. The gate should never be forced
to seat with excessive stem tightening. Such force will spread the seat and cause the valve to leak.

GLOBE VALVE
Globe valves are used to stop, start, or throttle a flow.

Globe valve discs have three basic designs:

 Plug

 Ball

 Composite

Plug Disc

The plug disc is cone-shaped and fits into a cone-shaped seat. The plug disc is the most widely used
shape for a globe valve disc. This type of disc has a large seating area that allows small, gradual
changes in the flow rate. The plug disc has excellent throttling characteristics.

Ball Disc

The ball (globe) disc has a small seating area. Because of this, a globe valve with a ball disc is
generally used for stopping or starting a flow, or for moderate throttling in low-pressure service.

Composite Disc

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The seating surface of a composite disc is generally made of a rubbery material. Different
compositions are available, making the composite disc useful in both high- and low-pressure services
that use fluids such as water, air, and steam. A composite disc has poor throttling characteristics.

STEM DESIGN
Globe valves are usually constructed with rising stems.

HOW IT WORKS
Flow begins when the disc is lifted off the seat. The flow can be throttled by varying the disc’s
position between fully open and fully closed. The valve body can be cast to allow a straight-through
flow or to change the direction of the flow (angle globe valve).

Open Valve

Globe valves are installed so that when they are open, fluid flows through the seat and across the
seat face. This ensures even wearing of the seat and disc, thus allowing a tight seal even in a worn
valve.

Closed Valve

When closed, a globe valve provides a positive fluid shutoff. Flow under the seat will prevent the
valve from slamming shut and causing water hammer (pressure rise in a pipeline, caused by a
sudden change in the rate of flow or stoppage of the flow in the pipe).

NEEDLE VALVE
A needle valve is a specialized form of globe valve with a plug disc.

DISC DESIGN
The plug disc and seat have large surface areas, which allow very accurate throttling.

STEM DESIGN
The stem is finely threaded to allow extremely accurate control over the position of the disc.

HOW IT WORKS
A needle valve works in much the same way as the globe valve described above.

DIAPHRAGM VALVE
The diaphragm valve is used to start, stop, or throttle a flow. It is used primarily in systems that
handle dirty, abrasive, or corrosive fluids.

DISC DESIGN
The diaphragm valve does not have a disc in the conventional sense. Instead, it uses a flexible
diaphragm to control the flow. The diaphragm is attached to a plunger that moves up and down with
the stem.

STEM DESIGN
Diaphragm valves usually have non-rising stems.

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HOW IT WORKS
When the valve is open, the diaphragm is pulled away from a weir (seat), allowing the fluid to flow
freely. Since the weir and diaphragm are not subject to wear, the diaphragm valve can be used for
throttling. This type of valve has good throttling characteristics.

The weir can be cast at different heights in the valve body. The weir can be quite high, leaving a
small opening for the fluid when the valve is fully open. It can also be low, allowing the fluid to flow
nearly straight through the valve body.

Open Valve

The diaphragm acts as a seal, keeping the fluid from contacting the operating parts of the valve.
Because of this, no packing is needed.

Closed Valve

When the valve is closed, the diaphragm is pressed against the weir, thus preventing flow.

CAUTION

Never use excessive force when closing the valve. This may jam the diaphragm into the weir,
damaging the valve.

PLUG VALVE
Plug valves are used for starting or stopping a flow. The main feature that differentiates a plug valve
from other types of valves is that the disc rotates in place instead of rising from the valve seat. This
allows the plug valve to be opened quickly. The plug valve is also called a quarter-turn valve.

DISC DESIGN
The disc can be wedge-shaped or spherical (for a ball valve). The port of a wedge-shaped disc is
generally 60% to 70% of the line opening.

A plug generally has a single port, although multiport valves can be used to change flow’s direction,
or to change the source of a feed stream without interrupting the flow.

STEM DESIGN
The stem of a plug valve requires only a one-quarter turn to fully open or close the valve. A handle
(actuator) or a position indicator attached to the stem will be parallel to the flow when the valve is
open and perpendicular to the flow when the valve is closed.

HOW IT WORKS
Plug valves are effective for systems that handle slurries. When the valve is closed, material can be
deposited on the disc. As the disc is rotated open, any deposit is scraped off and carried away by the
fluid. Because of this, plug valves are often referred to as self-cleaning valves.

Open Valve

When fully open, the plug valve offers little resistance to the fluid’s flow. If left partially open, the
disc and seat are subject to uneven wear. In addition, a partially exposed port causes a turbulent

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flow, which often leads to cavitation and noise. A special plug shape (eccentric disc) is
available that makes throttling possible without causing uneven wear or excessive turbulent
flow.

Closed Valve

With a wedge-shaped disc, the valve does not form a tight seal when
the valve is closed. Consequently, a plug valve is generally used in
low-pressure service. With a spherical disc, the line pressure forces
the disc against the outlet port seat, forming a tight seal.

If a plug valve is closed too quickly in a liquid service, excessive water

hammer may result.

Figure 3-4
Plug valve stem design

BUTTERFLY VALVE
Butterfly valves are generally used in low-pressure service. They are also quarter-turn valves that can
be opened quickly.

DISC DESIGN
The butterfly valve’s disc is circular in shape, and has the same diameter as the pipe to which the
valve is attached.

STEM DESIGN
The stem of a butterfly valve requires only a one-quarter turn to fully open or close the valve. A
handle (actuator) or position indicator attached to the stem will be parallel to the flow when the
valve is closed.

HOW IT WORKS
Because of their disc’s shape, butterfly valves are widely used in large-diameter pipes. However,
these valves are not a good choice for systems that carry sludge or sticky fluids because solid
substances can build up at the base of the disc, impeding flow. Large build-ups can require excessive
force to close the valve, which could damage the actuator and internal bearings.

Open Valve

When the valve is fully open, the disc is said to be streamlined with the flow. Unfortunately, even a
streamlined disc can cause turbulence in the flow. Like a plug valve, the butterfly valve has poor
throttling characteristics.

Closed Valve

The disc closes against a soft seal. Because of the design of the disc and seat, the butterfly valve does
not provide a tight seal in high-pressure service. If the valve is closed too quickly in a liquid service,
excessive water hammer may result.

CHECK VALVES

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Check valves, relief valves, and safety valves are passive valves that work automatically, without
action from an operator or input from a sensor.

Check valves include the following types:

 Swing

 Lift

 Ball

 Stop

SWING CHECK VALVE

With this type of valve, the disc is attached to the body by an arm that pivots at the
body. A flow in the forward direction holds the disc off the seat. When the flow
stops, the disc falls across the seat and prevents the flow from reversing
direction.

Figure 3-5 illustrates an open swing check valve.

Figure 3-5
Swing Check Valve (Open)

LIFT CHECK VALVE

In a lift check valve, the disc is not attached directly to the
valve body. If the pressure is high enough, the disc is lifted
off the seat, allowing the fluid to flow. If the flow decreases
to a point where the pressure will not hold the disc off the
seat, the disc drops onto the seat and prevents further flow.
Flow through a lift check valve is similar to that of a globe valve.

Figure 3-6
Lift Check Valve

BALL CHECK VALVE

A ball check valve operates similarly to a lift check valve. Fluid flowing in the desired
direction pushes the ball out of the way. The ball rotates in the fluid, thus wearing
evenly. This makes the ball check valve particularly useful in systems that
process liquids containing large amounts of scale or sediment that can cause
wear.

Figure 3-7
Ball Check Valve (Open)

STOP CHECK VALVE

A stop check valve looks like a globe valve. However, the disc is free to slide
a short distance on the stem. When the stem is completely down, the disc is

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pressed against the seat, thus stopping flow. When the stem is retracted,
the disc is free to rise off the seat if the pressure is sufficient to overcome
the weight of the disc.

Figure 3-8 illustrates a stop check valve in the open and closed
positions.

Figure 3-8
Stop Check Valve

RELIEF VALVE
A relief valve is another type of passive, automatic valve. It is designed to relieve excess system
pressure, and to close when the pressure drops back to a predetermined set point. Relief valves are
used for controlling upstream pressures.

A relief valve has a disc that is held against the valve seat by a spring. The spring’s force can be
adjusted by turning a screw. This allows the valve to be set for relieving at a specific pressure.

As the system pressure rises above the valve’s relief set point, the disc is pushed off the seat by the
force of the pressure. As long as the pressure remains above the set point, the relief valve remains
open. The relieved liquid goes to a drain or a collection vessel.

When the system pressure drops back to the set point, the
disc reseats to stop the liquid from being relieved.

Relief valves must be very reliable because they are usually

the last line of defence to protect a system from damage.

Figure 3-9 illustrates a relief valve in the open and closed

positions.

Figure 3-9
Relief Valve

SAFETY VALVE
A safety valve, like a relief valve, is used to protect piping and equipment from damage due to
excessive system pressure.

A safety valve also has a disc that is held against the valve seat by a spring. The spring’s tension is
adjustable so that the valve will open at a predetermined set point. Only part of the disc is exposed
to the gas. As the pressure reaches and exceeds the set point (popping pressure), the disc is pushed
off the seat. This exposes more of the disc to the pressure exerted by the gas. Because the gas now
has a larger disc area to work against, the gas can exert a greater pressure against the disc. This
additional force causes the disc to pop to nearly a fully open position.

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Because the popping action of a safety valve provides a large opening for gas to escape,
the speed of the escaping gas is low. This is an additional safety feature because a
stream of high-speed gas can be dangerous.

Unlike a relief valve, the pressure in a safety valve must drop below the popping
pressure for the disc to reseat. This will prevent the valve from continually popping.
The difference between the popping pressure and the pressure at which
the valve reseats is called the blowback or blowdown of the valve.

Safety valves are built with an external handle. This handle allows the
valve’s disc to be lifted manually off the seat in order to test for proper
operation of the valve.

Figure 3-10 illustrates a safety valve.

Figure 3-10
Safety Valve

HOW AUTOMATIC CONTROL VALVES WORK

Control valves can be operated pneumatically, hydraulically, or electrically. The function of each of
these automatic systems is basically the same, to operate the valves in response to a remote sensor
or a controller in the control room.

PNEUMATIC SYSTEM
A pneumatic operated control valve relies on air pressure to control the valve’s position. A remote
sensor measures flow, level, pressure, temperature, etc., and compares the reading to a desired set
point. If the measurement is too high or too low, a command is sent to allow more or less air
pressure to the valve’s actuator.

NOTE

Whether more air pressure is used to increase or decrease the flow through the valve depends
on the valve’s design. Valves may be designed as “air-to-open” or “air-to-close.”

In an air-to-close design, the air pressure forces the diaphragm against

the stem. Increasing the air pressure overcomes the spring’s tension
and allows the valve to close.

Additional air pressure is used to precisely control the position

of the disc, which accurately throttles the flow. Decreasing the air
pressure allows the valve to move toward the open position.

Figure 3-11 illustrates a pneumatic control system.

Figure 3-11
Pneumatic Control System

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HYDRAULIC SYSTEM
A hydraulically operated control valve relies on hydraulic pressure to position the valve. As with the
pneumatic control valve, a remote sensor is used to control the valve’s position.

Depending on the control input signal, an actuator valve is positioned

to direct the flow of hydraulic fluid to one side or the other of a piston.
The hydraulic pressure moves the control valve’s stem to position the
disc to the desired location.

Because there is no spring on the valve stem, hydraulic pressure is

required to both open and close the valve.

Hydraulic control is generally used on large valves.

Figure 3-12 illustrates a hydraulic system.

Figure 3-12
Hydraulic System

ELECTRIC SYSTEM
A control valve can be operated electrically in two ways, by a solenoid or by an electric motor.

Solenoid Operators

A control valve operated by a solenoid relies on an electric current to position the valve. The flow of
current is controlled by a controller in the control room.

This type of control is capable of only opening or closing a valve, not throttling the
flow. When an electric current passes through the wire coil, it creates a magnetic
field. The iron core is pulled rapidly up through the coil by the magnetic field. This
moves the valve stem to either open or close the valve. (Like the pneumatic system,
these valves can require power to either open or close the valve.) After the electric current is
removed, the spring returns the valve to its previous position.

Solenoid actuators are most often used on small valves where valve response must be
nearly instantaneous.

Figure 3-13 illustrates solenoid operation.

Figure 3-13
Solenoid Operation

Electric Motor Operators

An electric motor operator can be used to position a gate valve to an open, closed, or throttling
position. In response to a remote sensor or control-room controller, the motor drives the valve to
the desired position.

Because the speed of the motor’s output shaft is too high, a reduction gearbox is
used to slow the speed. This allows greater control of the valve’s position.

A motor-controlled valve requires that the motor be used to open and close
the valve. However, if the motor fails, a hand wheel can be used to manually
position the valve.

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Figure 3-14 illustrates an electric motor operated valve.

Figure 3-14
Electric Motor Operated Valve

Lesson 4
Operating Valves

LESSON INTRODUCTION
It can be very important to your health and safety to know how to properly operate a valve. In
addition, proper operation can reduce maintenance costs.

In this lesson, you will learn that there are three major steps to follow when operating a valve.
Within the first step are two very important activities to perform prior to operating a valve.

At the end of this lesson, you will have the opportunity to go into the field and operate various
valves.

Prior to operating any valve, you must perform two important activities: identify the correct valve
and identify the valve’s current position.

IDENTIFYING THE CORRECT VALVE

A critical task before valve operation is to identify which valve to operate. Although this may sound
too obvious to mention, opening or closing the wrong valve could result in line contamination,
product waste, and shutdown of operations, equipment damage, or a safety hazard for personnel.

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You need to have the knowledge and skills necessary to recognize valves, and know their functions
within the piping systems on which you are working. You must understand what happens to the
process and equipment when a valve is opened, throttled, or closed.

It is critically important for you to positively identify a valve before operating it in any way.

IDENTIFYING THE VALVE'S POSITION

There are two basic methods to determine a valve’s position:
mechanical and sensible.

MECHANICAL
There are two basic mechanical indicators of a valve’s position:

 Stem Position

 Position indicator

Stem Position

For up-and-down valves with rising stems, the valve position can be
identified by physically observing the actuator’s or stem’s position.

Figure 4-1 illustrates rising stem designs.

Figure 4-1
Rising Stem Designs

Virtually all quarter-turn valves are designed so that the actuator is

parallel with the flow when the valve is open. Conversely, the actuator
is positioned perpendicular to the flow when the valve is closed.

Figure 4-2 illustrates quarter-turn valve designs.

Figure 4-2
Quarter-turn Valve Designs

Position Indicator

When a valve’s position is not readily apparent from its stem’s position, there will be some type of
position indicator.

Figure 4-3 is an illustration of a position indicator.

There are two senses that the operator can use to identify the valve's position:

 Hearing

 Touch

Hearing

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Generally, you can hear a fluid flowing through a valve. The sound comes from turbulence in the
fluid, caused by the valve. A sound or its absence only indicates whether the valve is open, or if the
flow is below a detectable hearing level. You can develop this sense with experience.

Touch

The same turbulence that causes a fluid to make a noise also causes a vibration which you can feel.
Again this is only an indication of whether the valve is open, or if the flow is below a detectable level.
This sense can also be developed with experience.

WARNING

Always use the proper PPE (personal protective equipment) to minimize safety and health
hazards when working near a valve.

Figure 4-3
Position Indicator

Three major steps must be performed when operating valves: preparing to operate the valve,
operating the valve, and following up. These steps are general in nature, but can be applied to any
valve.

1.0 Prepare to Operate the Valve

1.1 Wear the required PPE.

1.2 Confirm (double check) that you are about to operate the correct valve.

1.3 Identify the current position of the valve.

NOTE

This prevents accidental opening/closing of a valve that is already in the correct position.

1.4 Position yourself to allow adequate hand and arm clearance around the actuator.

1.5 Ensure that you have secure footing.

1.6 Apply hand pressure to the actuator (wheel, lever, hand wheel, chain wheel, etc.).

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CAUTION

Use of a valve wrench is not recommended, especially when closing a valve. Excessive force can
harm internal parts, primarily the seat. Use of a valve wrench should usually be the last resort.

Three major steps must be performed when operating valves: preparing to operate the valve,
operating the valve, and following up. These steps are general in nature, but can be applied to any
valve.

2.0 Operate the Valve

NOTE

Nearly all valves follow the convention of opening counter clockwise and closing clockwise, but it
is always necessary to check that the valve you are operating follows this convention. The
operating guidelines below are based on this convention.

2.1 Operate a gate valve

To open:

 Turn the hand wheel counter clockwise all the way.

 Turn the valve one-quarter turn clockwise to prevent the valve from “freezing” open.

To close:

 Turn the hand wheel clockwise all the way.

CAUTION

Turn the handwheel slowly to prevent water hammer, so as to avoid damaging pipes and
equipment.

2.2 Operate a globe/diaphragm valve

To open:

 Turn the handwheel counterclockwise.

To throttle:

 Open the valve slightly past the desired position, then throttle back to the desired position.

To close:

 Turn the handwheel clockwise.

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2.3 Operate a needle valve (Operate a needle valve similarly to a globe valve.)

NOTE

When throttling, the fine threads of the needle valve’s stem allow greater accuracy of flow
control.

2.4 Operate a plug valve

NOTE

The handles of most plug valves follow the open-parallel/closed-perpendicular convention.

Ensure that this applies to the valve you are about to operate.

To open:

 Turn the handle one-quarter turn to the parallel-with-flow position.

To throttle:

 Slowly open the valve to the desired position.

To close:

 Turn the handle to the perpendicular-with-flow position.

2.5 Operate a ball valve (Operate a ball valve similarly to a plug valve.)

NOTE

When closing, ensure that a full quarter turn is made. This allows the line pressure to press the
disc against the outlet seat.

2.6 Operate a butterfly valve

If the valve has a handle, follow the procedures for operating a plug valve. If the valve has a
handwheel, follow the procedures for operating a globe valve.

3.0 Follow-Up

3.1 Observe the valve for leaks. Listen for leakage through the valve when closing a valve.

3.2 Ensure that the flow and pressure are within prescribed limits.

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Lesson 5
Maintaining Valves

LESSON INTRODUCTION
Valves require maintenance because of wear that is caused by their type of service. Parts deteriorate
and valves are sometimes operated incorrectly. Every time you operate a valve, you can and should
perform a brief inspection of the valve.

Leaks are an indication that maintenance is required immediately. However, many valves require
preventive maintenance to ensure that they continue to work correctly. There are some important
considerations when performing preventive maintenance.

Valves are rated for a specific type of service. It is important that the correct valve be used. When
working near valves, you should always be alert to the condition of the valve. It only takes a few
minutes to perform a routine inspection. You can take some simple corrective actions to remedy
problems you may find.

OBSERVE THE FEEL OF THE VALVE'S OPERATION

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The valve should open and close smoothly. There should be no catching or sticking when moving the
actuator.

Catching or Sticking

Catching or sticking occurs when a valve needs to be lubricated, or when the valve stem or stem
threads have been damaged.

Corrective Actions

Corrective actions include:

 Lubricate the valve according to the manufacturer’s recommendations and maintenance

procedures.

 Check the valve’s stem. Look for a scored or bent stem. Have the stem repaired or replaced.

 Check any visible threads on the valve stem for damage, and have the valve repaired or
replaced if it is damaged.

LOOK FOR LEAKS

Valves leak at five common locations:

 Line

 Stem

 Bonnet

 Flange

 Fracture

Line Leakage

Line leaks are leaks past the valve seat and through the valve. They occur when the valve’s disc does
not fit properly against the valve seat. This leak can often be detected by the sensible methods
(hearing or touch) previously discussed. However, you may only have an indication of this type of
leak from a pressure or flow gauge.

Corrective Actions

Corrective actions include:

 Open the valve one or more turns and reclose it. This may dislodge any sediment, etc.
Repeat this action several times, if necessary.

CAUTION

Never use a valve wrench or bar to force the valve closed. This can damage the valve seat.

 With approval, purge the line or reverse the flow to remove or dislodge sediment.

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 Have the valve repaired or replaced, if necessary.

Stem Leakage

Stem leaks are leaks from where the stem enters the bonnet. They occur because the stem is
damaged, or because the packing is not providing an adequate seal between the stem and the
bonnet.

Corrective Actions

Corrective actions include:

 Clean the stem of dirt and grime to allow a better seal. Lubricate the stem to reduce friction
and wear.

 Check the valve stem. Look for a bent stem or for scoring. Have the stem repaired or
replaced, if necessary.

 Tighten the packing nut or the packing gland flange to further compress the packing and
form a tighter seal.

 Have the packing replaced.

Bonnet Leakage

Bonnet leaks are leaks from the mating surfaces of the bonnet and the valve body. They occur when
there is not a tight seal between the bonnet and the body.

Corrective Actions

Corrective actions include:

 Cross-tighten the bolts that attach the bonnet to the body. This will prevent warping of the
mating surface and provide a better seal.

CAUTION

Do not overtighten the bolts. This can damage the gasket and the bolts.

 Have the gasket between the bonnet and body replaced, if necessary.

Flange Leakage

Flange leaks occur along the flanges that mate the valve with piping or equipment. They occur when
there is not a tight, even seal.

Corrective Actions

Corrective actions include:

 Cross-tighten the flange bolts. This will prevent warping of the mating surface, and provide a
better seal.

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CAUTION

Do not overtighten the bolts. This can damage the gasket and the bolts.

 Have the gasket between the flange and the mating surface replaced, if necessary.

FRACTURE LEAKAGE
Fracture leaks are from the valve body itself. If a crack is found or suspected, have the valve
replaced.

OBSERVE THE OPERATION OF AUTOMATIC VALVES

You should pay attention to the operation of automatic valves as you work in a process. If you
suspect that an automatic valve is not operating properly, you may need to have the control room
operator, maintenance personnel, or an instrument person check the valve. Never tighten the
packing on an automatic control valve. It should be removed from service and repacked.

Some valves have specific maintenance considerations. Whether you perform the routine
maintenance yourself or not, you should be aware of the following considerations.

GATE VALVE
If the disc must be replaced, first check the upstream side for wear. Many times, the disc can be
reversed for continued use before it is replaced.

GLOBE VALVE
Do not reverse an entire globe valve if significant disc wear is found. To do so could cause the
direction of flow to come from above the disc instead of from below it. This arrangement would be
poorly suited for this type of valve’s intended use.

CHECK VALVE
It is not unusual for some minor line leakage to occur in a swing or ball check valve when the
backflow pressure is very low. This is usually acceptable.

CONTROL, SAFETY, AND RELIEF VALVES

Occasional inspection, adjustment, or even replacement of the spring may be necessary to maintain
the proper tension on the disc.

PLUG VALVE
Plug valves must be greased for ease of turning. In addition to reducing friction between the disc,
body, and seat, the grease seals against leaks. Proper lubrication prevents galling (friction wear)
and seizing (metal-on-metal binding).

NOTE

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Some valves are self-lubricating.

The service rating of a valve is its design pressure limit for different types of service. The service
rating of a valve must be equal to or higher than the service rating of the piping or equipment to
which it is connected.

SERVICE MARKINGS
Service markings are a series of raised numbers and letters imprinted on a valve to indicate its
service rating. These markings should not be confused with any manufacturer’s brand markings or
valve size markings.

NOTE

Many valves also have additional markings known as “bridge wall markings.” These markings
indicate the arrangement of the internal parts and the direction of fluid flow within the valve.
They should not be confused with the service markings.

In figure 5-1, an example of typical service markings is shown for a brass valve.

150 S

In this example, “150 S” indicates that the service rating of the valve is 150psi (pounds per square
inch) of saturated steam.

300 W.O.G.

The marking “300 W.O.G.” indicates that the valve has an additional service rating of 300 psi in
water, oil, or gas service.

For the meaning of other specific service markings, refer to the manufacturer’s service manual.

NOTE

For additional markings, refer to the valve manufacturer’s manual.

Figure 5-1
Service Markings

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Module Conclusion

In this module, you learned basic information about valves. You learned the

major types of valves, their major parts, how valves work, how to operate

valves, and basic maintenance requirements for valves.

You will likely be working with valves a great deal during your career. To

operate valves in the safest and most efficient manner possible, you must

thoroughly understand them.

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Glossary

BACKFLOW
Flow in a direction opposite from the intended direction of flow.

BLOWBACK
The difference between the popping pressure of a safety valve and the pressure at which the valve
reseats.

BLOWDOWN
See blowback.

BRIDGEWALL MARKINGS
Markings on the side of a valve that indicate the internal arrangement of parts and the direction of
fluid flow through the valve.

CROSS-TIGHTEN
A method of tightening flange bolts where each successive tightening is as far away as possible from
the previous bolt tightened.

ECCENTRIC DISC
A disc shape that improves the throttling characteristics of a plug valve.

FLUID
A pure stream or mixture of gases, liquids, slurries, etc.

GALLING
Damage to metal surfaces, resulting from friction.

GASKET
A packing made of deformable material used to make a pressure-tight joint between two immovable
surfaces.

PACKING
Compressible material used to form a pressure tight seal in a joint between two metal pieces. In a
valve, it is used as a seal between the stem and the bonnet. Also known as stuffing.

POPPING PRESSURE
The pressure at which a safety valve opens.

PPE
Personal protective equipment.

PSI
Pounds per square inch; a measure of pressure.

REDUCTION GEARBOX
A gear or series of gears used to lower the output speed of the shaft on a motor.

SCORING
Scratching the surface of a metal.

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SEIZING
Excessive binding, to the point where motion is stopped, of adjacent surfaces that are normally in
motion with respect to each other. Seizing is usually caused by excessive pressure, temperature, or
friction.

SERVICE MARKINGS
Raised letters and numbers on the side of the valve body that indicate the valve’s service rating.

SLURRY
A pumpable suspension of fine solid material in a liquid.

SENSIBLE
Perceptible to the senses.

SOLENOID
An electrically energized coil of wire that creates a magnetic field and pulls an iron core through its
center.

STELLITE
A group of hard, wear- and corrosion-resistant alloys that are resistant to softening at high
temperatures.

STUFFING
See packing.

TEFLON ®
A synthetic coating that prevents sticking.

THROUGH-LEAK
A condition in which fluid leaks past the disc of a valve and exits through the outlet port.

THROTTLING
Regulating the fluid flow through a valve. The valve’s disc is somewhere between fully open and fully
closed.

VALVE WRENCH
A wrench that is designed to gain additional leverage for moving a valve’s actuator.

WATER HAMMER
A sudden pressure rise in a pipe, caused by rapidly closing a valve.

WEIR
A dam over which a fluid passes.

X………………………………….............……X……………..
……………………………………X

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