LESSON

4
LECTURE
PLUG, BALL AND BUTTERFLY VALVES
SUB-OBJECTIVE
At the end of thi !eon, the t"#inee $i!! %e #%!e to de&ont"#te #n
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,+- INTRODUCTION
Plug, Ball and Butterfly valves are distinguished from other types of valves
by the fact that they are not made with discs that rise and descend from the
valve seating area.
These valves design not to provides the same tight sealing as a globe
valve. The seats are often made of plastic coated, self- lubricating. The
disc on these valves open by rotation. When the valve is actuated the disc
makes a one-quarter turn, to close or open the part. Plug Ball !alves can
be constructed with more than one part for flow through the valve.
,+, PLUG VALVE .COC/0
Plug valves, also called cocks, generally are used for the same full flow
service as gate valves, where quick shut-off is required. They are used for
steam, water, oil, gas, and chemical liquid service.
Plug valves are not generally designed for the regulation of flow.
"evertheless, in some applications, these valves are used for this purpose,
particularly for gas-flow throttling. #or low flow regulation, special plugs are
available.
$any differences in design and detail adapt the valve to various services.
!ariations on the basic concept can borrow from other types of valve, too.
#low resistance is low if the port, usually oblong #ig. %-& is anywhere near
line si'e. The plug valve can throttle on moderately demanding services.
(ts plug has two orifices, which helps in breaking down high pressure drops.
)learances and leakage prevention are the chief considerations in plug
valves. $any plug valves are of all metal construction #ig. %-*. (n these
versions, the narrow gap around the plug can allow leakage. (f the gap is
reduced by sinking the taper plug deeper into the body, actuation torque will
climb rapidly and galling can occur.
+ubrication remedies this. , series of grooves around the port openings, in
plug or body, is supplied with grease prior to actuation, not only to lubricate
the plug motion but also to seal the gap. -rease in.ection into a fitting at
stem top travels down through a check valve in the passage way and then
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past the plug top to the grooves on the plug and down to a well below the
plug.
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(n some older types of taper plug valves without lubricant, mechanisms to
.ack the plug up slightly before turning serve to break corrosion and give
clearance for turning. ,fter actuation, the mechanism is released to set the
plug firmly.
5evelopments in plastics, principally T#/ and nylon, have e6tended the
plug valve7s range. (f the service is under the temperature limit for T#/, a
lining sleeve or shell of T#/ in a plug valve #ig. %-8 can solve the sealing
problem for the metal plug. #riction of T#/ on a metal plug is low enough
to allow easy actuation. The lining method has certain restrictions and calls
for certain design measures not necessary in metal-to-metal sealing.
Fi(+ 4-2+
,+1 LUBRICANT-SEAL VALVES
(n lubricant seal valves, channels for the admission of the lubricant
surround the ports to insure positive sealing against internal or e6ternal
leakage. The lubricant pressure developed by a turn of the lubricant screw
or in.ection of lubricant with a pressure gun e6erts a powerful hydraulic
.acking action on the plug, momentarily lifting it from the seat and making it
easy to turn. 4ince the lubricant pressure is greater than the line pressure,
it is virtually impossible for solids to lodge between the valve body and plug.
The lubricant must be compatible with the temperature and nature of the
fluid of course. The most common fluids controlled by plug valves are
gases and liquid hydrocarbons. 4ome water lines have these valves, too, if
lubricant contamination is not a serious danger. This type can go to *% in.
si'e, with pressure capability psig in si'es to &9 in. 4teel or iron bodies are
available. The plug can be cylindrical or tapered. The functions of
pressure lubrication in plug valves are :
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&. 0ydraulic action, keeping the plug in free working condition
*. $aintenance of positive seal against internal and e6ternal leakage.
8. #ree turning even of the largest si'es and against heavy differential
pressure, and
%. Protection of working surfaces from wear and corrosion. This
principle of pressure lubrication makes it possible to take full
advantage of the inherent simplicity, compactness, and positive
rotary action of the tapered plug valve.
,+2 DESIGN FEATURES
The basic design of plug valves #ig. %-% is similar to the old fashioned
wooden spigot. #ull flow is obtained when the opening in the tapered plug
faces in the direction of flow. When the plug is rotated a quarter of a turn,
flow is stopped.
The body and tapered plug represent the essential features in plug valves.
)areful design of the internal contours of the valve produces ma6imum flow
efficiency.
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The hole, or port, in the tapered plug is generally rectangular. 0owever,
valves are also available with round port design.
$a.or valve patterns or types are identified as regular, venturi, short,
roundport, and multiport.
The regular pattern employs the tapered form of port opening, the area of
which is from ;< to &<< per cent of the internal pipe area. (n some cases,
the face-to-face lengths are greater than those of standard gate valves.
The venturi pattern, available in flanged si'es 9 in. and larger, provides
streamlined flow and thus permits reduction in the port si'e. The port
opening area is appro6imately 8= per cent of the internal pipe area.
The short pattern has face-to-face lengths that conform with &=< and 8<< lb
steel gate valves.
The roundport full-bore pattern has a circular port through the plug and
body efficiency is equal to or greater than that of gate valves of the same
si'e.
2se of multiport valves %-= is advantageous in many installations because
it provides simplification of piping and convenience in operation. 1ne 8-
way or %-way multiport valve may be used in place of two, three, or four
straightway valves.
$a.or types of plug valves involve lubricated and non-lubricated designs.
+ubricant seal plug valves are less sub.ect to sei'ing or wear and may
e6hibit somewhat greater resistance to corrosion in some service
environments.
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"on-lubricated plug valves are used where maintenance must be kept to a
minimum. Both types of valves provides a bubble tight closure and are of
compact si'e.
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These valves generally can be readily repaired or cleaned without
necessitating removal of the body from the piping system. They are
available for pressure service from vacuum to &<,<<< psi and temperatures
from -=< to &=<< #.
,+4 BALL VALVES
(n the past , the use of ball valves %-9 has been rather limited as bubble
tight service was not possible because of problems in the sealing ability of
metal-to-metal seats.
(n recent years, the use of plastics, such as nylon, delrin, synthetic rubbers,
and fluorinated polymers for seating, has substantially increased the use of
ball valves.
With fluorinated polymer seats, ball valves are used for service
temperatures ranging from %=< to =<< (. With graphite seats, temperatures
as high as &<<< # are possible. Ball valves, similar to plug valves, are
quick opening, needing only a quarter turn from full open to full close.
To open the valve, the ball is rotated so that the through port lines up with
the seat openings. When the valve is closed, line pressure forces the ball
against the downstream seat, in an action similar to that of a gate valve.
Ball valves are non-sticking, and they provide tight closure. They also
e6hibit a negligible pressure drop because of their smooth, full-opening
port. These valves are easy to repair, and maintenance costs are low.
$a.or components of the ball valve are the body, spherical plug, and seats.
Ball valves are made in three general patterns venturi port, full port, and
reduced port. The full-port valve has an inside diameter equal to the inside
diameter of the pipe. The reduced port generally involves one pipe si'e
smaller than the line si'e. 4tem sealing is by bolted packing glands and 1-
ring seals.
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Below in #ig. %-; and #ig. %-> we can see a Ball valve in the open and
closed position.
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The seats of these valves are often made for plastic coated or self sealing
materials. ,lthough providing a good seal at low pressures, they are not
usually found in high pressure steam systems. They are very good in
systems carrying dirty materials such as mud or slurry. ,nother advantage
is that fluid can flow through the valve in either direction.
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1+- ;VEE< BALL VALVE
+ike the pinch valve, it has very low pressure drop characteristics and is
designed to maintain the rate of flow through it, it is also highly resistant to
clogging, which makes it adaptable to a wide variety of flow materials.
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The @!//A ball operates .ust like the standard ball valve, but slurries such
as pulp, coal, or ash can also be controlled through @!//A ball valve.
)ontrol is applied by a wedge shearing action. ,s the ball is rotated to
close any material that may clog the passage is seared off.
1+, BUTTERFLY VALVES
Butterfly valves of e6tremely simple design, which are used to control and
regulate flow. They are characteri'ed by fast operation and low differential
pressure drop. They required only a quarter turn from closed to full open
position. Butterfly valves are not intended for pressure-tight service. ,
typical flanged butterfly valve is illustrated in #ig. %-&&.
The disc is attached to the stem, and used primarily for isolation of flow. (n
addition to shut off function, butterfly valves can be used for throttling
application not frequently because poor throttling characteristics. The disc
is always the same diameter as the piping on which the valve is attached.
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When the operating lever is in line with the piping, the valve is open. When
the valve operator is perpendicular to the piping, the valve is closed. $ost
Butterfly valves are constructed with a resilient, natural rubber seat that
provide a firm fit and a tight seal when the disc close on it. The sealing
area must be resilient, but a rigid back up is usually provided, either of non-
metallic type as metal ridges on the body rings or as encapsulated metal
rings in a rubber seat ring.
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Butterfly valves must be removed from a system for all repairs e6cept
packing. 4ince butterfly valves generally hold a single ring of packing,
ad.ustment are rarely made.
1+1 VALVE SEAT DESIGN
5epending upon the type of valve, the valve seat may consist of a bonded
resilient liner, a mechanically fastened resilient liner, an inert-type reinforced
resilient liner a mechanically fastened resilient seal or an integral #ig. %-&*.
Fi(+ 4-,1+
#ig. %-&8. Below shows a butterfly valve in the open position.
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The position of the butterfly valve disc can easily be seen. The operating
lever is in line with the pipe when it is open, and perpendicular or across
the pipe when closed. This is also usually the case with plug and ball
valves. The seats of butterfly valves are often made from a resilient natural
gum rubber to provide a good seal. They are commonly used for
controlling the petrolBair mi6ture in the carburetor of your car. +arger
butterfly valves are servo assisted by electric motors, hydraulics,
diaphragms etc. because they are difficult to move against the flow of the
fluid. The disc is always the same diameter as the piping to which it is
attached. This gives the advantage of a smoother flow and less pressure
drop.
The combination of seating geometry and seal material alloys this type of
eccentric butterfly to close very tightly on liquids and gas at pressures as
high as 8;=< psig. This ability has led the manufactures of the spherical-
seat eccentric butterfly with T#/ seats to call it @high performanceA.
#le6ibility of the ring varies from design to design. (n fig. %-&% , is
comparatively in fle6ible. The B and ) profiles are more fle6ible.. (n any
profile, a ring of T#/ filled with glass fiber or graphite is inherently less
fle6ible than a ring of unfilled T#/. #or ring protection against debris and
e6trusion as the disc nears its seat, rings tend to be recessed in grooves
between retainer and body.
Work continues on metal and graphite seat rings for high temperatures.
4ometimes the rings are assisted by T#/ rings to give superior tightness at
low temperatures, keeping the metal rings for sealing during a high-
temperature e6cursion. The metal seat rings have complicated profiles to
give fle6ibility and ability to survive closure on hard foreign bodies. #luid
pressure assists sealing and often there is a double contact on the disc.
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