Valves & Valve Maintenance PDF

Kingdom of Saudi Arabia
Saline Water Conversion Corporation

General Directorate Of Training Programs
Training Center JUBAIL
MAINTENANCE DEPARTMENT
MAINTENANCE ENGINEERS SPECIFIC COURSE
MECHANICAL MAINTENANCE COURSE
VALVES & VALVE MAINTENANCE
"
Course Code: VALVE & VALVE MAINTENANCE

Version 1.0
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Date:
Valve & valve maintenance VALVES
LESSON
1 VALVES
LECTURE
Objectives
At the end of this lesson, the trainee will be able to demonstrate an
understanding of Valves.
1 INTRODUCTION
Valves are extensively used in piping systems and on equipment to

which piping is connected. Some valves are used continuously, others
intermittently, and some, like safety values, are utilized only in rare
instances.
1.1 FUNCTION OF VALVES
Function of Valves is to start, stop or regulate a flow of liquid or gas

through a plant system. This is accomplished by maintaining the valve in
a partially open position or an open or closed liquid or gases flow from
areas of higher pressure to areas of lower pressure because there
control of flow is of high importance. Mechanical devices that are used in
industrial piping for flow control are called valves. The term Valves
includes all equipment that acts on the movement of fluid by one of the
following two functions:
1. Opening or closing a circuit.

2. Controlling of flow.
The fluid may be liquid, gas or a loose solid such as powder, sand of
slurry.
When a valve allows some flow, but not maximum flow it is said to be in
the THROTTLING position to Throttle with a valve is to regulate the
(Rate or direction) flow.
Lesson 1 Page 1
1.2 VALVE CLASSIFICATION AND TYPES
Valves can be classified by function, by disc arrangement, by

operating condition such as temperature and pressure, or by the way
they are incorporated into plant systems.
The most common way to classify a valve is by the arrangement or

shape of the disc, which is part of the valve that controls the flow of fluid
through the valve.
Gate, plug, ball, or butterfly valves are most widely used for the
interruption or start of flow. Diaphragm valves may be preferred in
corrosive applications or in service where contamination of the fluid is not
permissible, such as in the drug and beverage industry.
REGULATION OF FLOW. Many applications require that the flow of the

fluid or gas be regulated (or throttled) in various steps between closed
and open limits. This is generally done by introducing resistance to flow
either by a change in direction, or by causing a restriction, or by
combinations of these. Commonly used valves designs are of the globe,
angle, needle, and butterfly types.
Fig. 1-1. Families of Valves.
A common method of classification is the method by which they actually

control flow Fig. 1-1 illustrates these methods together with some
examples of valves in each family.
Lesson 1 Page 2
1.3 CONSTRUCTION
a. Fig. 1-2 shows the basic construction of a common valve type,

namely a stop valve, and shows the principle of operation.
b. Fluid flows into the valve through Inlet Port through the passages
in
the valve body past the element that controls the flow, and then
flows out via the Out let or Discharge port
Fig. 1-2. How a valve operates.
c. If the closing element (named a disc) in the close position the

passage way is blocked and no fluid can flow until it is opened
again. This is done, as in the case of Fig. 1-2.
1.4 MATERIALS
Valves are subjected to the effects of heat, pressure and corrosion, so it is

important that they are made from appropriate materials. That can be made
from :
Bronze
Cast iron
Steel
Stainless steel
Monel
Brass and other metals as well as from plastic and glass. Valves are
usually made to the some standards and specifications of the pipe work I
the system. They also come in a large variety of sizes.
Manufacturing method relates closely to body design. Casting is well

suited to complicated shapes and can give well formed fluid paths.
Forging requires heavy tooling costs or considerable boring and
machining to create internal passages. Welding allows buildup of the
body from simple tubular and plate forms, reinforced as necessary.
Lesson 1 Page 3
Casting is simple and cheap in many metals, such as irons and bronzes.
Steel and steel alloys are more difficult. Flaws in castings may require
heavy rework in demanding nuclear services.
Forging, for steel and alloys, gives a body with uniformity through the
metal and with good surface. Machining may create stress problems, of
course.
Fabrication by welding may begin with plates, rings, forging, or even

castings. Stiffeners may be added as needed. Interior surface is usually
smooth, but the flow passages may not be as streamlined as they are in
cast bodies. Welded joints need attention to assure quality and corrosion
resistance.
In some designs the body itself is split into two sections that bolt
together. This is common in ball and butterfly valves, and also in some
control valves requiring periodic disassembly for inspection and cleaning.
The bonnet complicates manufacturer, increases valve size, and

introduces another potential leakage path to the outside.
Fluid-control elements inside the valve include the seat, the disc, plug, or
ball the stem or spindle, and any sleeves needed to guide the stem and
disc. These elements are also called the trim. The disc/seat interface
and the relation of disc position to seat determine valve performance to a
large extent.
Two basic motions are possible. Either the disc (ball or plug) can side
closely past the seat to produce a change in flow opening, or else the
disc can lift perpendicularly away from the seat, so that an annular orifice
appears. Sliding past the seat characterizes ball, plug, and gate valves.
Perpendicular movement away from the seat occurs in globe valves,
check valves, and safety valves.
Combination of the two basic motions is possible, too. A symmetric

butterfly valves disc slides past the seat ring, but the opening quickly
extends nearly all the way around the seat opening.
Disc and seat interaction is a vital factor in valve tightness and actuation
force. Wear from erosion or Cavitations may destroy disc and seat
surfaces in a single opening of a valve on high pressure-drop or slurry
service. Sliding of disc past seat under high fluid pressure or heavy
interference fit can injure the sealing surfaces enough to develop leaks.
Particles embedded or caught between the surfaces also scar the sealing
area.
On the other hand, in designs where the disc lifts off the seat, the very
narrow annular orifice when the disc is close to the seat allows high-
speed fluid flow with danger of erosion and Cavitation. The taper-plug
Lesson 1 Page 4
type disc is one remedy for this, and many control valves reflect the
results of especial attention to the problem.
There are many aspects of valve technology and application that call for
in-depth study by the manufacturer and the user. Fire safety for valves
with soft Elastomer seats is an example of this. Need for many valves to
fail safe, meaning that a loss of actuating force will bring into play a
system for valve opening, closing, or holding in last position, is another
important area.
Demanding special services have involved into almost separate

branches of the valve field. Nuclear valves, with radiation exposure and
low-leakage requirements, are an example. Maintainability in this service
is especially important if worker exposure to radiation is to be within
bounds.
High pressure drops through valves and noise originating in such drops
are added examples of problems calling for research and experiment. At
far lower pressures, but with liquids carrying heavy particle loads, there is
the slurry valve problem crucial to flue-gas desulfurization, coal firing,
and ash and waste disposal.
In valve design work, considerable advances have been made with the
help of finite-element analysis. Made possible for practical applications
by the computer and pioneered in nuclear-valve design this analysis
procedure has often superseded trial and error and enlightened hunches
in determining stresses and deflections of irregular shapes of valve
bodies and trim elements. The disc of butterfly valves and the
components of pressure seals are two examples of success in reducing
unnecessary metal but assuring adequate margins for strength and,
above, all, stiffness for leak prevention.
Service conditions and material choice are closely interconnected.

Temperature is perhaps the most influential condition in power plants
valve work. Pressure effects are easier to handle, requiring only
moderate changes in a wall thicknesses that usually exceed by far the
values needed for pressure retention alone.
The way in which flow rate through the valve changes as the disc
approaches the seat is another principal element of valve section. A
control system can depend on the valve flow characteristic, as the curve
is called. A glance at the instrument valve characteristic immediately
tells the systems designer that the valve flow decreases quickly during
closing from a partly open setting, which could be an important
consideration in case of an emergency with an instrument or a control
line.
Bi-directionality of a valve is a large consideration with several types and

specific models of valve. This concept involves flow characteristics,
actuator sizing, trim life, and even safety. Obviously, it is to the
Lesson 1 Page 5
advantage of cost and maintenance effort if a valve has exactly the

same behavior, whichever the direction of flow.
Reparability and maintainability are factors in valve section. The cost of

removal of a large weld-end valve, either to be replaced or repaired in the
shop, is so high that in-line repair is attractive. Leakage through the seat
may call for grinding or lapping of the seat and disc or for replacement of
seat ring and disc. In both cases, special tools may be needed, and the
repair may demand the services of outside specialists.
Fig. 1-3. Valve Components.

1.5 VALVE COMPONENTS :
1. Valve body : is the largest structural part of the valve. It provides
the means for attaching the valve to the system components or
piping.
System flow passes through the body of the valve. The

design of the valve body can allow for (1) Straight-through
Lesson 1 Page 6
Fig. 1-4. Straight - Through Flow. Fig. 1-5. Angled Globe Valve.
2. Seating Area: is located inside of the valve body. This is the area
where the disc closes on the valve body seat. The disc and seat
must be smooth, and must fit together perfectly.
The seat can be :
1. threaded
2. Press-fit
3. Welded into the body
4. Cost as part of the valve body. See Fig. 1-6.
In high temperature, high pressure system, a combination of threading

and welding is used to prevent leakage between the valve body and the
seat.
Materials used for seat construction:
* For low-pressure low temperature system valve seat may be made

of bronze or Teflon type material.
Lesson 1 Page 7
Fig. 1-6. Threaded and Welded Seat Attachment
For high pressure & temperature the seat area must be very strong same
as stellite.
3. Disc is the part of the valve that close against the seat to stop flow
the could be-disc arrangement is designed for special proposals.
Its used to equalize the pressure difference across the disc.
4. Stem is connects the disc to the hand wheel. The stem transmits
the motion of the hand wheel to the internal disc open & close the
valve ways
disc attached to the stem:
* In slip-type joint
* Threading is another method
* Stem & Disc manufactured as one piece
5. Bonnet: is attached to the valve body by bolting, threading, or

welding. The shape of the bonnet is determined by the type and
shape of the disc, since it provides housing for the disc when its
raised up from the valve seat.
6. Stuffing box: is filled with a packing to prevent leakage.
7. A packing gland: Is to hold and compressed the packing in place to

prevent leakage by the stem and through the bonnet.
8. Hand wheel or Operator: is control the movement of the disc inside

the valve. A hand wheel is generally turned manually, while an
operator is controlled by an electric, pneumatic, or hydraulic motor.
9. Bridge wall markings: is provide useful information indicates how

the internal parts of the valve are arranged, will show the direction
of flow.
10. Service markings: indicates the maximum allowable pressure

service the letters W, O, or G on the valve body indicate the
type of service the valve is designed for.
* The smaller the valve, the finer the control.

* Reparability and Maintainability are factors in valve
selection.
* The component that make up all valves are essentially the
same.
Lesson 1 Page 8
1.6 VALVES APPLICATIONS :
Lesson 1 Page 9
Lesson 1 Page 10
Lesson 1 Page 11
Valves & Valve Maintenance Gate Valves
LESSON
2 GATE VALVES
LECTURE
Objectives
At the end of this lesson, the trainee will be able to demonstrate
an understanding of Gate Valves.
1 INTRODUCTION
Gate valve the disc arrangement is not designed to control the rate of
flow. Its used for isolation or for on or off unable to throttle.
Normally, gate valves are placed where straight free flow is desired
and where an immediate shut off of flow may be necessary.
Often described simply as a GATE, this type of valve has a gate that
goes up and down in the body, integral with a stem ending in screw
thread on which the hand wheel is screwed. The hand wheel rotates
freely at fixed height, so that its rotation causes vertical movement of
the stem or the gate depend on the stem type. The gate valve is used
exclusively on lines for liquid.
In a gate valve, the disc is wedge-shaped with mating surfaces on two

sides. These mating surfaces close against the seats to stop the flow of
fluid.
Bodies of gate valves, whether small or large, can take the form of two
intersecting cylinders, with one for the fluid flow and the other to house
the raised disc. Fig. 2-1. Illustrates this. Bonnet closures can be simple,
for small low pressure valves, or they can be as advanced as the
pressure-seal type.
Lesson 2 Page 1
Fig. 2-1. Gate Valve
2 GATE VALVE CONSTRUCTION
The exterior construction of most gate valves is similar. The body

houses the fluid, and the bonnet acts as a lid for the body. The
operator (a hand wheel, for example) opens and closes the valve.
The interior construction of gate valves varies, depending on the type

of valve and the manufacturing design. Fig. 2-1 shows a typical
example of a gate valve.
STEM BUSHING Many valves are equipped with a neck bushing, or stem
bushing, to act as guide for the stem and to form the bottom
of the stuffing box. The threaded end of the stem, screws
through the stem, bushing, the hand wheel and the stem
bushing are solidly connected, thus raising or lowering the
stem when the hand wheel is turned.
BODY Main part of the valve directly attached to the pipe.
FLANGED ENDS Part of the body with bolt holes to allow the connection with
the flanges set on the pipes.
GASKET Inserted between pipe and valve to have a tight, leak proof
connection.
BONNET Part of the valve mounted on the top of the body to form a
tight enclosure.
YOKE Part of the valve to support the hand wheel and bushing.
STEM Solidly connected to the gate, the rotation of the stem raise
or lowers the gate.
HAND WHEEL The operator is used to control the stem, which moves the
disc up and down to control the flow of fluid through the
valve.
GATE Is the part of the valve that controls the opening.
SEAT RINGS When the gate is lowered, the seat rings fit with the gate to
Lesson 2 Page 2
stop all flow.
STUFFING BOX Every valve with a stem has (STUFFING BOX) to ensure the
sealing between the fluid and the atmosphere.
PACKING Special material (made of asbestos, grease, neoprene each

manufacturer specifies a given type and size of packing for
each stuffing box) used to fill the stuffing box.
GLAND After the packing is installed the gland compresses the

packing, the gland also serves as the stuffing box covers.
Packing is installed in the stuffing box to control the flow of
fluid along the stem. The packing is held in place and
compressed by the gland follower.
BACKSEAT In order to permit re-packing under pressure, some valves

are equipped with a back seat. The back seat is a tapered
restriction which mates with a widened section on the stem
to stop the flow of fluid along the stem.
BONNET The bonnet gasket is provided to eliminate leakage between

GASKET the bonnet and body. The yoke acts as a support for the
stem, and has a stem nut that raises and lowers the stem.
3 NON RISING-and RISING STEM
The stem on a gate valve is either rising stem (RS) or non rising stem
(NRS) as per Fig.2-2. Rising stem (RS)kind of gate valve is an indicator
attached to shows the position of the disc and whether the valve is
open or closed .The Yoke in this type has no threads, so the stem is
kept from rising when hand wheel is rotated. A limit switch often
connected to a valve to control the movement of the open & close of
the valve like remote control device. It indicate the position of the valve
on panels so that operator dont have to inspect the valve to tell
whether it is open or close. Stem does not rise through the hand wheel.
* Hard to tell if valve is opened or closed.

* Threads are exposed to the fluid
* Very little overhead room needed
Lesson 2 Page 3
Fig. 2-2 Rising Stem
Fig. 2-3. Non-rising stem gate valve
3.1 NON RISING-STEM
In the non-rising stem valve, the lower end of the stem is threaded and
screws into the disk, vertical motion of the stem being restrained by a
thrust collar. Fig. 2-3.
The non-rising stem (NRS) configuration places the stem threads

inside, out of contact with the environment, and also assures that the
stem merely rotates in the packing, without much danger of carrying
dirt into the packing from outside or inside.
Lesson 2 Page 4
3.2 RISING-STEM
In the rising stem type of valve, the upper part of the stem is threaded
and a nut is fastened solidly to the hand wheel and held in the yoke by
thrust collars. As the hand wheel is turned, the stem moves up or
down. The rising stem valve requires a greater amount of space when
opened. It is generally to be preferred because the position of the stem
indicates at once whether the valve is open or closed. as per Fig.2-4.
In the open position there valves can be recognized by the fact that the
threaded stem rises above the hand wheel. Stem rises through the
hand wheel easy to tell if valve is opened or closed threads are not in
contact with fluid needs over head space.
Fig. 2-4. Rising stem gate valve with circular bonnet
Up to a steam working pressure of 250 psig, gate valves are usually

made with an oval bonnet flange to reduce the face-to-face dimension.
In the valves designed for higher pressures, a bonnet flange or circular
shape is preferred to provide a recessed gasket joint.
4 GATE DESIGNS
Gate valve shave two vertical seating surfaces. Their discs are
generally constructed in a wedge shape as Fig. 2-5 or a double disc.
The seats on a gate valve are either cast as part of the valve body or
are installed, which make them replaceable. Large valve generally
replaceable:
Lesson 2 Page 5
There are several types of gates:
a. Solid wedge gate As per Fig. 2-5.
Such a gate is made of one part. The complete shut off with a
solid gate is accomplished through a close fit between the gates
and the seat rings. A solid wedge gate is lowered into closed
position.
SOLID FOR HIGH FLOW RATES
The flow exerts pressure on one of the gate liquids or gases

flowing under high pressure tend to erode material that opposes
their flow.
Fig. 2-5. Solid Wedge Gate 2-6. Solid Split Gate
b. Solid split Gate as per Fig. 2-6.
SPLIT NORMALLY FOR POSSIBLE MISALIGNMENT
c. Parallel discs and wedge gate Fig. 2-7.
When closing, the parallel discs descend between two matching

seats. When the lower wedge, or spreader, reaches the top, it
cannot descend further as the upper.
Spreader is forced on to the lower spreader, the discs are

pushed outward against the seat rings.
Lesson 2 Page 6
Fig. 2-7. Parallel Discs
d. DOUBLE DISK:
Disk touches the seat as soon as closing beings and used in

high temperatures sealed by spring pressure sealed by fluid
pressure sealed by wedging action of the stem as per fig. 2-8.
Fig. 2-8. Double Disk with Spring. The flow exerts pressure on one
side of the disk or gate
Lesson 2 Page 7
In the double-disk parallel-seat gate valves, the disks are forced

against the valve seats by a wedging mechanism as the stem is
tightened.
Some double-disk parallel-seat valves employ a design which depends

for its tightness mainly upon the fluid pressure exerted against one side
or the other of the disk. The major advantage of this type is that the
disk cannot be jammed into the body, which otherwise might make it
difficult to open the valve subsequently. This is particularly important
where motors are used for opening and closing. However, the tightness
of the solid wedge gate valve may also result to a significant degree
from the action of fluid pressure against one side or the other. Thus,
the two types are essentially similar in this respect.
Each disk in the parallel-seat types slides against its seat while the
valve is being opened or closed. Consequently, these components
must be made of metals which do not tend to gall or tear when in
sliding contact with each other. By means of guides, the wedge gate
does not come into contact with the seat until the closing point is
almost reached. The double-disk parallel seat gate valve is often
favored for high-temperature steam service because it is less likely to
stick in the closed position as a result of change in temperature. Gate
valves are used where a straight through flow is desired with a
minimum amount of pressure loss.
4.1 LUBRICANT VALVES :
Some gate valves are furnished with lubricant seal systems to fill
damaged valve seats which have become scored or pitted. In these
valves, a sealing material, which is insoluble in the liquid or gas flowing
through the valve, is pressed through a small port in the valve body into
a groove under the seat ring From the groove, the sealing material
passes through small holes in the seat ring into an annular groove in
the face of the ring. The holes in the seat ring are made small in order
to prevent the sealant from being washed out. The lubricant also
reduces sliding friction between the seat and wedge. Lubricant-seal
systems are available in cast-iron and cast steel bodies.
Fig. 2-9 Gate valve with lubricant sale system
Lesson 2 Page 8
5 DIFFERENT TYPES OF GATE VALVES :
(A) Rising stem, double wedge disk (B) Solid wedge disk, rising stem
Non-rising stem single wedge disk (D) Outside screw and yoke union
bonnet, single wedge disk. (E) Non-rising stem, single wedge disk,
renewable seat rings.
Fig 2-10 Gate valves
5.1 IN-SERVICE INSPECTION:
Valves are inspected while in service to determine if the components

function properly under routine operating conditions. When inspecting a
valve, it may be necessary to perform minor adjustments, such as
adjusting the packing or the operator, to keep the valve in good
operating condition.
Lesson 2 Page 9
Particular attention should be given to the stuffing box and flanges to

check for leaks in the packing or gaskets. When defects are found that
cannot be corrected immediately, they must be reported so that
necessary action can be taken.
5.2 REASONS FOR MAINTENANCE :
Depending on facility procedures, repair of a valve may be required

because of failure or loss of efficiency.
Efficiency can be lost due to stem leaks, stem binding, improper

operator adjustment , leaking while the disc is closed against the seat,
leaks in flange mating surfaces, or other defects.
Valves are not usually disassembled for periodic maintenance. In most

instances, valves are not taken out of service until a loss of operating
efficiency is noted. Of course, failure of a valve may require a complete
overhaul.
When performing maintenance, the manufacturers instructions should

be reviewed before proceeding with any disassembly work.
The maintenance of the valve follows commonsense lines. The stem

threads should be kept lubricated and free from dirt. When the valve is
wide open for a long period of time, the exposed stem threads should
be protected by a light sheet-iron tube placed over them.
To repack the valve, move the swing gland bolts out of the way. The
gland is raised and rests on the ledges provided for that purpose. The
stuffing box is then accessible for renewal of the packing. Each ring of
new packing should be compressed by the gland before another ring is
added. Splits in split ring packing should be staggered. The valve can
be repacked under pressured.
Should the downstream seats become scored, the upstream seats will
frequently be found to be in good condition. Reverse the valve 180,
and the valve will be as good as new.
Should it become necessary to replace the seat rings, remove the

valve from the line and prepare a correct size pipe with square notches
to fit the lugs in the seat rings. As the pipe with lugs is twisted (by
means of a bar), tap the body smartly with a hammer to help loosen the
ring. Clean all threads and seating surfaces with a wire brush before
installing new rings. Graphite or pipe dope can be used. A new disk
should be installed with new rings. It may have to be lapped in.
Retighten body bonnet bolts uniformly using a crisscross pattern and at
least three passes.
Normally valve attached to low pressure & temperature system are

made of bronze or brass. Cast iron valves will be found on low-
Lesson 2 Page 10
pressure steam or lubricated system valves used in high pressure &

temperature systems are made of special alloy metals. Stainless steel
is commonly used where there is possibility of corrosion to the valve.
In large gate valve on steam service, closure of the valve in fully

heated state can lead to jamming when the valve cools later. This is
because the heated body expands along the pipe axis, increasing axial
distance between seats. Cooling when the valve has been closed with
enough thrust to make it leak proof may result in enough contraction
between seats to prevent re-operating without heating the body. The
parallel disc is intended to prevent this difficulty. Both low pressure iron
valves and high-pressure steel types have this disc. Principle of
operation is that wedge surfaces between the parallel faced disc halves
are caused to press together under stem thrust and spread apart the
discs to seal against the seats. The tapered wedges may be part of the
disc halves or may be separate elements. The lower wedge must
bottom out on a rib at the valve bottom so that the stem can develop
seating force. In one version, the wedge contact surfaces are curved to
keep the point of contact closed to the optimum.
Lesson 2 Page 11
Valves & Valve Maintenance Globe Valves
LESSON
3 GLOBE VALVES
LECTURE
Objectives
and understanding of Globe Valves.
1 GLOBE VALVES
The Globe valve can be used as a regulating valve, or as a stop valve

for isolating systems. If it is used for regulation it is often called a
control valve.
The control valve is distinguished from a regular globe valve by the

shape and arrangement of the disc and seating area.
By its design, the globe valve generally provides for a tight seal and
has good throttling characteristics.
Globe valves are similar to gate valves in that the bonnet, body, and
operator are common to both. Also, the various bonnet connections
and end connections used in gate valves are found in globe valves,
along with rising and non-rising stems.
The differences in construction between gate valves and globe valves

are due to their different applications. Gate valves are used for on-off
service. Globe valves can be used for this purpose, but they are
primarily used in throttling applications, as showing in Fig. 3-1.
Fig. 3-1
In some of these valves the direction of flow is important, in which case

an arrow will be shown on the VALVE BODY to illustrate the direction
in which it should be installed. This valve is used extensively on high
pressure systems and particularly on steam line. As a result, globe
valves must have a disc that can be moved gradually away from the
Lesson 3 Page 1
seat to increase the flow of fluid. This is done by using one circular disc
which mates with a single seat. In order to insure that the disc will mate
with its seat in valves operating under high pressures, a guide stem is
attached to the bottom. This guide stem mates with a guide in the
center of the seat.
As showing in Fig. 3-2, in the next page.
Fig. 3-2. Components of Globe Valve
The offset flow pattern is also related to the operation of the disc. After
entering the valve inlet, the fluid stops against the disc but exerts an
upward force. This force is sometimes used to help reduce the amount
of work required to open the globe valve. Of course, the opposite is
also true. If fluid flowed in the outlet side, the fluid pressure would tend
to hold the disc closed. For this reason, it is important that the direction
of flow by considered when installing globe valves. Many manufactures
place flow direction arrows on their valve bodies to help in positioning
the valve.
The change in direction of the fluid as it flows through the valve results
in increased resistance to the flow. Complete drainage of the piping
system is also not readily accomplished with globe valves. Fig. 3-3.
Lesson 3 Page 2
Fig. 3-3. Variation of basic valves as to design (A)Angle. (B) Globe
The statement that a valve is used to completely stop of regulate flow

deserves consideration, as it indicates when a globe valve or when a
gate valve is to be used. A globe valve is used to regulate flow, and a
gate valve should be used where the service requires the valve to be in
full open or closed position. The flow through a throttled globe valve is
distributed uniformly around the entire periphery of the disk, giving
even and less rapid wear. The flow through a throttled gate valve is
concentrated at the bottom of the wedge giving uneven and more rapid
wear. This is illustrated in Fig. 3-1.
Also owing to the construction of the valve, a globe valve is

recommended when the valve is to be operated frequently. The disk in
a globe valve touches the seat only at the instant of closing. In a gate
valve, the wedge travels over the full face of the seat and consequently
sliding wear will develop.
When a globe valve in these services finally wears, the globe valve is
easier to repair than a gate valve.
Frequently, engineering specifications will state Globe valves shall be

used on throttling service or where the valve is to be opened and
closed frequently. Gate valves shall be used for full-flow conditions or
where the valve is normally in an open or closed condition.
When an ordinary globe valve is used in severe throttling service, rapid

wear of the seat and the disk can result. For tight closing it is
Lesson 3 Page 3
sometimes better to use two valves on the line, one for throttling and
one that is either full open or closed.
2 DESIGN FEATURES
Globe valves are constructed in several ways. The seat surface, the
body type, and the disc arrangement differ according to the design and
function of the valve. Globe valve discs come in different designs. The
most widely used one is the plug disc. The plug disc is cone shaped.
Basic types of disc and seat arrangement for globe valve are:
2.1 BALL - SHAPED DISC :
This disc fits on a tapered, flat surfaced seat and is usually used on
relatively low pressure, low temperature system Fig. 3-4. Its generally
used in a fully open or shut position, but may be for moderate throttling.
Fig. 3-4. Ball Shaped Disc. A. Ball Type disc
2.2 THE COMPOSITION DISC :
This disc is renewable and can be adapted to varying types of flow.

The seating surface is often formed by a rubber O ring or washer. Fig.
3-5.
Lesson 3 Page 4
Fig. 3-5. Composition Disc
2.3 THE PLUG-TYPE DISC:
This disc is also renewable, along with its seat rings and is very useful
for heavy duty throttling. Disc is cone shape and it fits into a cone
shaped seat. Fig. 3-6.
Fig. 3-6. Plug-Type Disc
Lesson 3 Page 5
2.4 THE NEEDLE DISC:
This disc which is very narrow and, therefore, best suited for close
regulation of flow. The diameter of flow. The diameter of the seat
opening is very narrow, and the disc descends well below it and into
orifice formed by the seat. Fig. 3-7.
Fig. 3-7. Needle Point Disc
Many globe valves used for steam service, are built with a back seat. A
back seat is a seating arrangement that provides a seal between the
stem and the bonnet. When the valve is fully open, the back seat on
the stem seats with the bonnet seat. Fig. 3-8.
Fig. 3-8. Back Seat Design
The back seat design prevents system pressure from building against
the valve packing. In its fully open position, the back seat of the disc
prevents leakage into the upper part of the valve.
Globe valves are usually constructed with a rising stem, similar to that
found on many gate valves. The stem is threaded into the bonnet or
yoke bushing.
Lesson 3 Page 6
Valves & Valve Maintenance Plug, Ball & Butterfly Valves
LESSON
4 PLUG, BALL & BUTTERFLY VALVES
LECTURE
Objectives
an understanding of Plug, Ball and Butterfly Valves.
1 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
Valves can be constructed with more than one part for flow through the
valve.
1.1 PLUG VALVE (COCK)
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.
Nevertheless, in some applications, these valves are used for this
purpose, particularly for gas-flow throttling. For low flow regulation,
special plugs are available.
Many differences in design and detail adapt the valve to various

services. Variations on the basic concept can borrow from other types
of valve, too.
Flow resistance is low if the port, usually oblong Fig. 4-1 is anywhere
near line size. The plug valve can throttle on moderately demanding
services. Its plug has two orifices, which helps in breaking down high
pressure drops.
Lesson 4 Page 1
Fig. 4-1. Plug Valve
Clearances and leakage prevention are the chief considerations in plug

valves. Many plug valves are of all metal construction Fig. 4-2. In these
versions, the narrow gap around the plug can allow leakage. If the gap
is reduced by sinking the taper plug deeper into the body, actuation
torque will climb rapidly and galling can occur.
Lubrication remedies this. A 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. Grease
injection into a fitting at stem top travels down through a check valve in
the passage way and then past the plug top to the grooves on the plug
and down to a well below the plug.
Lesson 4 Page 2
Fig. 4-2. Plug Valve
In some older types of taper plug valves without lubricant, mechanisms

to jack the plug up slightly before turning serve to break corrosion and
give clearance for turning. After actuation, the mechanism is released
to set the plug firmly.
Developments in plastics, principally TFE and nylon, have extended

the plug valves range. If the service is under the temperature limit for
TFE, a lining sleeve or shell of TFE in a plug valve can solve the
sealing problem for the metal plug. Friction of TFE 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.
Lesson 4 Page 3
1.2 LUBRICANT-SEAL VALVES
In lubricant seal valves, channels for the admission of the lubricant

surround the ports to insure positive sealing against internal or external
leakage. The lubricant pressure developed by a turn of the lubricant
screw or injection of lubricant with a pressure gun exerts a powerful
hydraulic jacking action on the plug, momentarily lifting it from the seat
and making it easy to turn. Since 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. Some water lines have these
valves, too, if lubricant contamination is not a serious danger. This type
can go to 24 in. size, with pressure capability psig in sizes to 16 in.
Steel or iron bodies are available. The plug can be cylindrical or
tapered. The functions of pressure lubrication in plug valves are :
1. Hydraulic action, keeping the plug in free working condition
2. Maintenance of positive seal against internal and external

leakage.
3. Free turning even of the largest sizes and against heavy

differential pressure, and
4. 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.
1.3 DESIGN FEATURES
The basic design of plug valves Fig. 4-4 is similar to the old fashioned
wooden spigot. Full 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. Careful design of the internal contours of the valve produces
maximum flow efficiency.
Lesson 4 Page 4
Fig. 4-4. Plug valve with lubricant system, as specified in API

Standard 600.
The hole, or port, in the tapered plug is generally rectangular. However,

valves are also available with round port design.
Major valve patterns or types are identified as regular, venturi, short,

round port, and multi port.
The regular pattern employs the tapered form of port opening, the area
of which is from 70 to 100 per cent of the internal pipe area. In some
cases, the face-to-face lengths are greater than those of standard gate
valves.
The venturi pattern, available in flanged sizes 6 in. and larger, provides
streamlined flow and thus permits reduction in the port size. The port
opening area is approximately 35 per cent of the internal pipe area.
The short pattern has face-to-face lengths that conform with 150 and
300 lb steel gate valves.
The round port 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 size.
Use of multi port valves 4-5 is advantageous in many installations

because it provides simplification of piping and convenience in
operation. One 3-way or 4-way multi port valve may be used in place of
two, three, or four straightway valves.
Major types of plug valves involve lubricated and non-lubricated

designs. Lubricant seal plug valves are less subject to seizing or wear
Lesson 4 Page 5
and may exhibit somewhat greater resistance to corrosion in some

service environments.
Non-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 size.
Fig. 4-5. Multi port valves
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 10,000 psi and
temperatures from -50 to 1500 F.
1.4 BALL VALVES
In the past , the use of ball valves 4-6 has been rather limited as
bubble tight service was not possible because of problems in the
sealing ability of metal-to-metal seats.
In 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 450 to 500 I. With graphite seats,
temperatures as high as 1000 F 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
exhibit a negligible pressure drop because of their smooth, full-opening
port. These valves are easy to repair, and maintenance costs are low.
Major components of the ball valve are the body, spherical plug, and
seats. Ball valves are made in three general patterns venturi port, full
Lesson 4 Page 6
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 size smaller than the line size. Stem sealing is by bolted
packing glands and O-ring seals.
Fig. 4-6. Ball Valve Components
Lesson 4 Page 7
Below in Fig. 4-7 and Fig. 4-8 we can see a Ball valve in the open and
closed position.
Fig. 4-7. Ball valve in closed position
Fig. 4-8. Ball valve in open position
The seats of these valves are often made for plastic coated or self
sealing materials. Although 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.
Another advantage is that fluid can flow through the valve in either
direction.
Lesson 4 Page 8
Fig. 4-9. Variations of Ball valves design
1.5 BUTTERFLY VALVES
Butterfly valves of extremely simple design, which are used to control

and regulate flow. They are characterized 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. A typical flanged butterfly valve is illustrated in
Fig. 4-11.
The disc is attached to the stem, and used primarily for isolation of
flow. In 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.
Lesson 4 Page 9
Fig. 4-11. Typical butterfly valve
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. Most 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.
Butterfly valves must be removed from a system for all repairs except
packing. Since butterfly valves generally hold a single ring of packing,
adjustment are rarely made.
Lesson 4 Page 10
1.6 VALVE SEAT DESIGN
Depending 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 Fig. 4-12.
Fig. 4-12
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 petrol/air mixture in the carburetor of your car. Larger
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 3750 psig. This ability has led the manufactures
of the spherical-seat eccentric butterfly with TFE seats to call it high
performance.
Flexibility of the ring varies from design to design. In fig. 4-13 A is

comparatively in flexible. The B and C profiles are more flexible.. In any
profile, a ring of TFE filled with glass fiber or graphite is inherently less
flexible than a ring of unfilled TFE. For ring protection against debris
and extrusion as the disc nears its seat, rings tend to be recessed in
grooves between retainer and body.
Lesson 4 Page 11
Work continues on metal and graphite seat rings for high temperatures.
Sometimes the rings are assisted by TFE rings to give superior
tightness at low temperatures, keeping the metal rings for sealing
during a high-temperature excursion. The metal seat rings have
complicated profiles to give flexibility and ability to survive closure on
hard foreign bodies. Fluid pressure assists sealing and often there is a
double contact on the disc.
Fig. 4-13. Below shows a butterfly valve in the open position.
Fig. 4-13
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
Lesson 4 Page 12
Valves & Valve Maintenance Diaphragm Valves, Pinch Valves
LESSON
5 DIAPHRAGM VALVES, PINCH VALVES
LECTURE
Objectives
an understanding of Diaphragm valves, Pinch valves and
Instrument valves.
1 DIAPHRAGM VALVES
Most valves depend on a controlled geometry and rigid materials for

closure. The diaphragm valve operates on an entirely different basis: A
highly flexible and extensible Elastomer sheet forced down into a rigid
edge, the seat, causes closure. If the valve body, including the
seating area, is rigid plastic or a metal with corrosion-resistant
Elastomer lining, then the diaphragm valve has an important potential
advantage - high resistance to corrosive liquids. This is its chief
application, naturally, in water-treatment work and for liquids that might
be contaminated by metal contact.
The cushioning effect of the Elastomer diaphragm also tends to protect

it as it seals tightly on large and small foreign solids in the stream.
Slurries and waste water are therefore other applications.
The body configuration of Fig. 5-1 causes friction loss and disturbs flow
paths more than the straight-through type of Fig. 5-2. This can be a
factor in slurry and suspended-solids service. On the other hand, the
straight-through type is not recommended for vacuum lines.
Fig. 5-1a Fig. 5-2a
Lesson 5 Page 1
Fig. 5-1b. Fig. 5-2b
2 VALVE DESIGN
Two basic body designs are used for diaphragm valves:
1. The straight - through has no obstructions where the diaphragm

seats. Fig. 5-1.
2. The weir has a raised surface where the diaphragm seats on the
valve body Fig. 5-2.
The weakness of the diaphragm valve is in its Elastomer diaphragm,

which can crack from repeated flexing or be torn by sharp-edged
foreign bodies in the fluid. Special design attention goes to the
diaphragm itself and to the actuator head that forces the diaphragm
into closure.
The contact between head and diaphragm must be uniform to prevent

localized damage to the diaphragm. This head, also called compressor,
may have radial flanges that pass through cutouts between supporting
prongs in a finger plate.
Breakage of the diaphragm, whether from flexing, cutting or impact of

the fluid and particle load as the liquid makes the sharp turn over the
center weir, will admit fluid to the bonnet space, corroding the actuating
elements. A vent plug in the bonnet allows check for the presence of
leakage. Replacement of a defective diaphragm is not difficult, but
Lesson 5 Page 2
often corrosion in the bonnet will require more extensive repairs. Stem
sealing by packing or O-rings is also advisable to prevent escape of
corrosive agents to the outside.
One drawback of the weir-type diaphragm valve is inability to drain a

horizontal line through it directly. Turning the valve until the stem is
about 20 deg. Above the horizontal greatly improves draining ability.
The straight-through-flow design Fig. 5-1, however, can drain even
when the stem is straight up.
The wide choice of metals and Elastomer for bodies and of Elastomer
for diaphragms allows the diaphragm valve to meet all power plants
chemical needs. Temperature limits range from about 180 F for natural
rubber and Buna N to as high as 350 F for weir-type TFE diaphragms
with Elastomer backing and 400 F for all TFE diaphragms.
For abrasive service, the diaphragm can be gum rubber or ethylene

propylene. The body lining need not be as flexible as the diaphragm.
Materials like ethylene tetra fluro ethylene (ETFE), polypropylene,
polyvinyl chloride, and poly vinyl iodine chloride are choices.
Although most diaphragm valve designs are not intended for precision
throttling, they can maintain good throttling qualities, and some types
have relatively low pressure-deep features.
3 VARIATIONS OF THE DIAPHRAGM VALVE
Two specialized variations of the diaphragm valve are good for

throttling characteristic.
1. The Pinch Valve is equipped with a flexible tube that goes

through the valve body and forms flange gaskets between the
valve and the connecting pipe Fig. 5-3. Due to the smooth
straight flow path through a pinch valve, there is minimum
pressure drop across the valve. Closure occur through
squeezing together of Elastomer walls over a wide area, rather
than against a narrow metal ridge. The ability of the pinch valve
to handle abrasive and slurries has given it wide application in
such power plants services as such disposal, flue-gas
desulfurization, waste water, water treatment and, in future, fuel-
slurry handling.
Lesson 5 Page 3
Fig. 5-3. Pinch Valve Cutaway. 5-4. Boot Valve
The heat of the simplest form of pinch valve is a flanged Elastomer

tube Fig. 5-6 mounted in a split flanged casting connected to a
compressed-air line. The tube is reinforced by fabric plies which are
carried outward over the flanges.
In the open state, the valve, bolted between pipe flanges, transmits
fluids just as if it were part of the piping. Admission of compressed air
to the valve body pinches the tube into an oval shape at the center and
finally shuts off flow at the center and finally shuts off flow completely.
All pinch valves close over a long contact area, so that the seating
surfaces can envelop even large objects without leaking or being cut.
2. The Boot Valve Its similar to the Pinch Valve Fig. 5-4, but there
are two compressors that flex the boot to open and close, and
also provide throttling action. The double compressor is used
with each side of the boot flexing to close the valve, wear on
each side reduced-thus giving added life to the valve.
Lesson 5 Page 4
Valves & Valve Maintenance Check Valves
LESSON
6 CHECK VALVES
LECTURE
Objectives
an understanding of Check valves.
1 CHECK VALVES
Up to here, all valves described have been actuated from outside the
pressure envelope. Not only can they be opened and closed by direct
force at any desired time, but in addition, the human supervisor can
verify the position by sight or by test of the actuation means.
The elementary check valve lacks these characteristics. Its functioning

is entirely within the pressure envelope, its opening and closing are
governed by flow direction, with the human supervisor powerless to
intervene; and also unable to sense the position of the disc.
In addition, check-valve reliability must be high. Failure to close and

prevent backflow even once in a valves life could cause vast damage.
For a check valve, reliability is broader than for other valve types. Not
only must the valve close, it also must close according to the desired
position/time relationship. A check valve that closes suddenly and late
can destroy itself, along with considerable piping and supports.
The pressure drop through an open check valve is a source of energy

loss. Cost evaluation of the valve should include this effect, although
energy loss will not be as significant in the overall a picture as reliability
and shockless closure.
A satisfactory check valve should therefore: open easily and

completely to pass flow with little pressure drop or disturbance to flow
patterns; resist damage to seat disc and disc hanging or guiding means
in all flow conditions during valve life; close quickly, without valve injury
or water hammer, at the instant or flow stoppage. This adds up to a
demanding design effort, and success has been sporadic.
How tightly a check valve should be required to seat depends on the

service. Often, some leakage is permissible. Discharge lines of pumps
are an example. As long as flow is not enough to rotate the impeller or
rapidly empty an overhead tank, the valve will be satisfactory. On the
other hand, if the check valve is supposed to isolate a machine for
maintenance, a leak can prevent work from being done and in the long
Lesson 6 Page 1
run make a separate isolation valve necessary. The repair work called
for in keeping check valves tight is part of the life costs.
The continuing difficulties with check valves have forced many changes
in and ingenious additions to the basic elements. Examples of
additions are internal and external dashpots, exercise mechanisms,
aspirator tubes, spring or power-assisted closure, and position
detection.
Two basic disc motions for conventional check valves are

perpendicular lift from the seat (lift) and pivoted lift (swing) which is
nearly perpendicular when the disc is near the seat. Another motion is
rotation of an eccentrically mounted butterfly disc seating in a slated
seat (tilting disc).
2 CHECK VALVES DESIGN AND TYPE
1. Swing Check
2. Lift Check
3. Ball Check used to prevent back flow.
2.1 SWING CHECK VALVE
The only moving part is a disc assembly that is attached to the body by
a pivot pin. The disc is raised when system pressure is greater than the
weight of the disc. Fig. 6-1 used mainly in horizontal piping. The pivot-
pin mounting leaves the disc assembly free to swing toward and away
from the valve seat. Swing checks commonly are in horizontal lines
with pivot above the seat.
When there is no flow through the valve the disc is positioned so that
the valve is closed. Liquid or gas flows only when there is a difference
pressure between two points. If the pressure is higher at A than B the
direction of the flow is from A to B.
Lesson 6 Page 2
In the swing check valve, the hinge pin may be located internally or
externally. ON low pressure systems the hinge will be connected
externally; on high pressure systems, the hinge pin will usually be
internally connected. The opening or closing of a swing check valve is
automatic.
Fig. 6-1. Swing Check Valve
A swing disc must largely clear out of the fluid path when open but
must still have a readily accessible space above it to convert backflow
to pressure and closing torque in case torsion springs or disc weight
cannot close the disc. Swing-check valves have failed because of this.
The leverage of fluid forces on the cantilevered disc, too, tends to wear
the pivot and hinge.
Spinning of the disc by asymmetric turbulence of fluid can harm lift

checks, especially in non-lubricating fluids, although the danger is not
as serious as it is for swing checks. Disc and stem wear can break off
stems or cause hang-up, so stops to limit rotation may be necessary.
Spinning of the disc by fluid forces has injured many swing-check

valves. Some times the disc stem has worn completely through,
allowing the disc to float down stream. Anti-rotation pins can prevent
this.
An important modification of the swing disc check is the dual-disc

which two D-shaped pieces pivot about a vertical pin and seat on flat
D-shaped seats, which can be Elastomer for moderate temperatures.
These dual disc valves, with flaps pressured on by a torsion spring, can
close with low chock, because the flaps are directly in the pipe center
and are fully exposed to fluid backflow force to assist closure if the
spring action is too slow.
Lesson 6 Page 3
Fig. 6-2 & 6-3 Swing-Type Check Valve
2.2 LIFT CHECK VALVES
Lift check valves used in horizontal and vertical piping good for high
pressure and velocity. The line of flow through a lift check valve is
similar to the line of flow through globe valve. The direction of the flow
is always from under the disc. Fig. 6-5. The lift check valve allows flows
in only one direction. When flow occurs from A to B, it raises the disc.
As flow stops, gravity pulls the disc into the seating, and the back flow
assist also.
Seat surfaces in lift checks can be flat or conical. Lift is low and must
never be so high that back flowing water cannot reach the disc top to
create closing pressure in case the disc stocks open. A light helical
spring may assist closing.
Lesson 6 Page 4
Fig. 6-4 & 6-5 Lift- type check Valve
The lift type must have disc guiding of one sort or another. For larger
discs for low to moderate pressure Fig. 6-5 sleeve on the disc top
envelops a pin protruding from the bonnet, and a pin on the disc under
surface slides in a guide bushing supported by arms integral with the
seat ring.
The lift check valve works CORRECTLY when installed in the

HORIZONTAL position. An other design allows to use a lift check valve
is a vertical position.
The Stop check valve resembles a modified globe valve, but when the
stem is raised, the disc operates like that of lift type check valve.
Lesson 6 Page 5
Fig. 6-6 & 6-7 Stop Check Valve
In large check valves, the danger of water hammer damage from

sudden closure after back flow has started has given impetus to
internal dashpots Fig. 6-7. Closure-speed choice bases on water-
hammer calculations, often done from computer programs.
2.3 BALL CHECK VALVES
The ball valve is also a check valve used mainly for heavy liquids.
The line of flow through such a valve is in a straight line.
The part of the valve that controls the opening is a ball.
When flow occurs, the ball is raised by the pressure of the flow.
The Fig. 6-8. Check is for vertical up flow, but the principle adapts to
horizontal flow, too, resulting in a globe-like body with flow upward
through the seat and out through the holes in a ball-guide cage.
Fig. 6-8. Ball Valve
Lesson 6 Page 6
Valves & Valve Maintenance Piston Valves
LESSON
7 PISTON VALVES
LECTURE
Objectives
an understanding of Piston valves.
1 PISTON VALVES
Interior partitioning of the valve is the same as in the preceding types.

The cut-off member is a hollow cylindrical piston sliding between two
sealing rings screwed into the body. The piston is provided with
openings which go up and down in front of the outlet hole, thus
permitting variation of flaw section Fig. 7-1 show valve components.
Fig. 7-1. List of Piston Valve components
The piston is of chrome steel and perfectly machined; the sealing rings
are often of self lubricating Teflon. So that lubrication is unnecessary.
At the beginning of opening a displacement uncovers a small flow
section, permitting precise control of low rates of flow. For each profile
the manufacturer supplies the curve of the variation of flow as a
function of the height of lift of the disc. Most automatic valves are of the
double disc type.
Lesson 7 Page 1
The double disc design can be used to equalize the pressure across
the disc and it can be varied to change flow characteristics through the
valve or to change the operation of the valve, such as by decreasing
the response time of the valves action. Often, double disc valves used
for flow control will be designed for special flow characteristics.
Fig. 7-2. Piston Balance Valve showing double disc arrangement
When a single disc valve is put into operation, all pressure drop across
the valve is exerted on the area of the valve seat. This force of
pressure must be over come by the valve actuator see Fig. 7-2. To
overcome this problem, certain valves are designed with a double disc
arrangement. This design is especially serviceable where system
pressure is very high or where constant adjustment must be made to
control a flow through the valve.
A piston balance valve allows the force exerted across the seating area
to be as equal as possible, while being directed in opposite direction.
The double disc arrangement has the flow coming from the left. In the
closed position, the fluid pressure would press against the bottom of
Lesson 7 Page 2
the top disc and against the top of the bottom disc equalizing flow
pressure. Even when the valve is open, there is an equalizing force
which gives the valve a smooth operation.
When the standard valve is fully closed, there is of course, zero flow.
As the valve is opened, flow begins to increase rapidly through it.
When the valve is open, there is almost no additional increase as the
valve is opened all the way.
When fine flow control required, such as during controlled chemical

additions or for boiler feed flow, a precise control of flow through the
valve as it open is required. This control can be achieved by a valve
designed to have linear flow characteristics. An example of this type of
valve is one designed with a double disc arrangement and used for the
control of water going to a boiler.
Lesson 7 Page 3
Valves & Valve Maintenance Valve Maintenance
LESSON
8 VALVE MAINTENANCE
LECTURE
Objectives
an understanding of Valve Maintenance and Valve Packing.
1 VALVE DISASSEMBLY
1.1 PREPARATION FOR DISASSEMBLY
After checking that the valve is isolated and tagged out, the first step in
disassembly is a thorough cleaning of the outside of the valve. This
cleaning task is important; it minimizes the amount of foreign matter
that gets into the valve and piping system.
Later, before reassembly all foreign matter will have to be removed

from the inside of the valve. It is much easier to remove dirt from the
outside of the valve now than to clean it from the inside before
reassembly.
Cleaning methods vary with the valve and operating conditions. Wire
brushing is usually sufficient, but it may be necessary to wipe away any
loose material with a clean rag. In some cases, the outside of the valve
may have to be washed. The most important areas to clean are the
flange mating surfaces and the area around the gland follower.
In this section, the valve to be disassembled is a regular globe valve,

which is common to industrial plant use. Fig. 8-1 illustrates the parts of
the Gate valve to be described during disassembly.
Fig. 8-1. Gate Valve
Lesson 8 Page 1
1.2 REMOVAL
The first step is to loosen the put on the handwheel (Fig. 8-2). Then the
gland nuts (Fig. 8-3). On both sides and the bonnet nuts (Fig. 8-2) are
loosened. It is easier to loosen these nuts now than when the bonnet is
separated from the valve body. Next, the gland nuts are unscrewed
and removed to relieve pressure on the packing (Fig. 8-3). Then the
bonnet nuts are taken off 8-3. This will allow for the removal of the
handwheel and bonnet assembly.
Fig. 8-2. Loosening the Nuts Fig. 8-3. Removing the Nuts
After the gasket is removed, the handwheel is rotated in the closed

direction as far as possible. Now the nut and handwheel are taken off
of the valve.
The valve stem is rotated until it is out of the bonnet. This can be done
manually or with the aid of a wrench. If a wrench is used, care must be
taken not to damage the stem. A soft-faced wrench is good to use, or a
piece of soft material held between the wrench and the stem will
protect the stem. The stretch is applied between the disc and the back
seat of the valve. Accidental scratching of the stem with the wrench is
not good, but it will not cause leakage when the valve is reinstalled,
since this part of the stem does not come in contact with the packing.
However, if the wrench is applied above the back seat or on a threaded

portion of the stem, significant damage could result. A leak could
develop or the stem could become difficult to rotate, making the valve
inoperable.
The packing gland will come off as the stem is rotated out of the
bonnet. When the stem is out, the packing can be removed. It is taken
out with a packing removal tool, or if the valve is small, the packing
may easily come out by turning the bonnet over and pushing it out of
the stuffing box. Fig. 8-4 illustrates the use of a packing removal tool.
Lesson 8 Page 2
Fig. 8-4. Packing Removal
After the packing is removed, the bonnet and the stuffing box can be
cleaned and inspected. The body and bonnet are checked for steam
cuts and pits. If any are found, they should be repaired through lapping
if the damage is minor. Deep cuts or pits may have to be machined on
a lathe before lapping can be done.
2 LAPPING, SPOTTING-N, AND GRINDING-IN
The processes of lapping, spotting-in, and grinding-in are part of

routine valve maintenance. Most minor cuts and pits can be removed
through lapping and grinding-in; the spotting-in test should always be
performed to check the mating of the valve seating area.
2.1 LAPPING
To lap the seating surface of the bonnet, small amount of lapping

compound is first applied on the lapping block . Usually, the process is
begun with a coarse grade of compound, changing gradually to a fine
grade to achieve a smooth, polished surface at the seating area.
After applying compound to the lapping block, the bonnet is rotated in a

figure-eight motion, as illustrated in Fig. 8-4, with care taken not to
exert excessive pressure on the bonnet. In lapping, the weight of the
part usually provides adequate pressure to smooth the surface.
Frequently, the bonnet seating surface is checked by wiping the
compound from it and inspecting it. The process is repeated until the
seating surface is smooth.
Lesson 8 Page 3
Fig. 8-4. Lapping Motion
For example, if too much metal is taken from the seating surface of the
bonnet or body of a valve, the gasket that fits between them will not be
compressed sufficiently. Leakage will result when the valve is put back
into service.
Deep cuts or pits that cannot be removed by lapping may be filled in by

welding and then machined on a lathe. However, maintenance
personnel must usually decide if such action is worth the time that must
be invested. In some cases, it may be cheaper to replace the valve.
After refurbishing the seating surfaces of the bonnet and body, the
valve disc and seat are inspected for proper seating. On inspection, if
the disc and seat are seating properly, there will be a clearly defined
area to indicate this. If not, it is quite likely that the disc has not been
seating properly, if at all, and that the valve has been leaking.
2.2 SPOTTING-IN
A more accurate way to inspect the disc and seat for positive seating is
through the method of spotting-in.
Many discs rotate freely on the stem. This gives the disc a self-seating
feature and provides a good seal when the valve is closed. However,
during spotting-in, the disc must not be allowed to rotate. To prevent
rotation, a piece of shim stock can be used to hold the disc in place
and prevent its movement. The shim stock should be positioned
between the stem and the disc. Another way to prevent the disc from
rotating is to take the disc out of the stem, put a piece of shim stock
between the disc and the bottom of the stem, and then reassemble the
disc.
To spot-in a valve seat, a thin coating of Prussian blue is applied

evenly to the surface of the disc. It is important to use a type of blueing
that is non-drying. Before applying the blueing, the seat and disc must
Lesson 8 Page 4
be cleaned. A light grinding-in or lapping can be used to accomplish

this cleaning.
2.3 GRINDING-IN
Imperfections to the disc or seat will require that the part either be
repaired or replaced. Some valves are equipped with replaceable
parts. In this case, it may be more economical to replace the disc and
seat then to repair them. However, if minor imperfections are found, it
is best to make repairs. One method for repairing minor damage to the
seating area of a disc or seat is called grinding-in.
Grinding-in is accomplished by applying a small amount of lapping

compound to the disc. The disc is placed on the seat and rotated back
and fourth, using a light downward pressure. The disc is moved
forward one-quarter turn occasionally to ensure even grinding-in.
Lapping compound should be changed frequently, and finer grades
should be used as lapping progresses.
A flat-surfaced disc, like the one on the gate valve illustrated in Fig. 8-
5, is repaired in a different fashion. A lapping block can be used to
remove minor imperfections. Lapping compound is applied to the block,
and the disc is then placed on the block. The disc is rotated in a figure-
eight motion, using the same light downward pressure as before.
Fig. 8-5. Gate Valve Disc
The disc should be checked frequently during the grinding-in process.

The compound is removed, and then the disc is inspected. After the
lapping compound is wiped from the block and disc, the disc is rotated
on the bare metal block in a figure-eight as before. Dark areas on the
surface indicate areas where the disc is not seating properly. When
lapping or grinding-in has been completed, the seat and the disc
should be spotted-in. Then the shim stock (if used) should be removed
from between the disc and the stem.
Lesson 8 Page 5
Briefly, then, the lapping and grinding-in processes are as follows:

When the original disc is rotated against the original valve seat, the
process is called grinding-in. When the disc is rotated against another
surface, such as the block, or a lapping tool is rotated against the disc,
it is called lapping. However, both processes use lapping compound to
smooth out minor imperfections to the seating surfaces.
The following important points should be kept in mind when lapping or

grinding in a valve:
a. Never bear heavily on the lap or valve disc.

b. Never bear sideways.
c. Always use clean lapping compound.
d. Spread the compound evenly and lightly.
e. Never lap or grind-in more than necessary.
f. Rotate to change the relationship of the disc or lap with the seat
frequently.
g. Always grind-in the disc to the seat after lapping or cutting on a
lathe.
h. Always spot-in the seat and disc after grinding-in.
3 VALVE PART MAINTENANCE
In addition to the processes used to inspect and repair the seating

areas of valve parts, other types of maintenance should be performed
on a disassembled valve.
The stem bushing should be inspected for wear and damage.

Normally, on a rising stem valve, the threads of the stem rotate on the
threads of the bushing to open and close the valve. For this reason, the
stem bushing receives a great amount of wear as the valve is
operated. If the bushing threads are allowed to wear out on a rising
stem valve, the valve will no longer close. System pressure will force it
open, and the valve operator will not be able to close the valve.
Thus, the bushing threads should be carefully checked for wear. If they
are found to be worn, it is best to replace the bushing. to do this, a file,
grinder, or hacksaw may be required, since the bushing is usually tack-
welded in place. After the tack-weld is removed, the bushing can be
turned with a wrench and taken out. The bushing threads are different
from the stem threads, but, on a disassembled valve, the bushing can
be replaced by using this method.
If the valve is in place while the bonnet bushing is being replaced, the
stem would be rotated at the same time the bushing is removed and
threaded into the bonnet. Otherwise, the stem and bushing threads
would bind; this would damage the threads and prevent the installation
of a new bushing.
Lesson 8 Page 6
The valve stem is inspected next. It must be straight. A bent stem can
cause excessive and rapid wear to the valve packing. Just a slight
bend in the stem can render a valve inoperable, and can prevent the
packing from sealing properly, which would result in leakage.
The stem is placed on a lathe or V-block, as illustrated in Fig. 8-6,

where the total run-out is checked with a dial indicator. The dial
indicator is arranged to so that it is in contact with the stem. As the
stem is rotated, the run-out is indicated on the dial. If the dial remains
constant on zero, the stem is straight. If it is not straight, the dial will
indicate the degree of deviation. If the stem is bent, it must be
straightened or replaced.
Dial Indicator
V-Block
Stem
Fig. 8-6. Stem Inspection
While the valve is fully disassembled, all threaded surfaces should be

cleaned thoroughly with a wire brush. The bolts and studs threads
should be chased with a thread chaser.
Finally, the flanges should be carefully inspected. The flanges of both

the valve and the pipe should be cleaned with a wire brush before
inspection. A putty knife may be needed to scrape material that is hard
to remove. Care must be taken, however, to avoid making nicks or
gauges on the flange surfaces with the scraper, as that could result in
leakage when the valve is placed back in service.
While the valve is out of the system, maintenance can be performed to

the exterior surfaces. Sandblasting and then painting external surfaces
will help to preserve the valve.
Lesson 8 Page 7
4 VALVE REASSEMBLY
When cleaning and inspection have been completed, the valve is ready
to be reassembled. An important part of reassembly, after all repairs
have been made, is proper lubrication. All moving and threaded parts
should be well lubricated during valve reassembly. Many lubricants,
both wet and dry, are available, and the proper type must be used for
each surface . The manufacturer's instructions should be checked to
determine which lubricant is correct for a particular valve.
The first stem in reassembly is to put the stem through the bonnet, and
then slide the packing gland over the stem (Fig. 8-7). Then the stem is
carefully threaded through the yoke bushing until the valve is in the
fully open position.
Fig. 8-7. Reassembly, of the Stem and Packing Gland
A gasket is set on the body seating surface. Then the stem, bonnet,
and packing gland assembly is placed on the valve body. It is important
that a new gasket be used each time a valve is reassembled following
maintenance. Previously compressed gaskets will not provide a proper
seal once they are removed from the valve.
The body-to-bonnet bolts are set in and tightened evenly to compress

the new gasket uniformly. A cross-torque pattern is used to tighten the
body-to-bonnet bolts. In this type of pattern, one bolt is tightened, and
then the bolt opposite to that bolt is tightened. Then, a bolt next to the
first bolt is tightened, and then the bolt opposite it. The pattern is
continued until all bolts are torque to their proper valves. The valve
manufacturer's manual will indicate the proper torque valve.
Lesson 8 Page 8
In reassembling a valve, it is important that the disc be kept in the fully

open position. This prevents the disc from being driven into the seat,
which could cause damage to the seating surfaces or bend the valve
stem. In addition, the bonnet must seat squarely on the body of the
valve as the bonnet bolts are torque.
After the bonnet is installed, the valve is repacked. Finally, if the stem
bushing is equipped with a grease fitting, the valve stem should be
greased.
The valve is now fully reassembled.
When a valve is damaged severely enough to warrant replacement,

several points must be considered in choosing a new one. The
replacement valve must be the same type as the damaged valve and
must be rated for the same kind of service. The flanges on a new valve
must be the same size and type as those of the damaged valve in
order to fit with the piping of the system. The flanges must also have
the same face-to-face clearance and hole alignment.
5 PARTICULAR MAINTENANCE PROCEDURES
The maintenance procedures discussed thus far concerning valve

disassembly, re-packing, repairing, and reassembly are basically the
same for all types of valves. There are certain procedures, however,
that the performed only on a certain type of valve.
6 VALVE PACKING
6.1 INTRODUCTION TO PACKING
Packing is a tough rope-like material which is commonly impregnated

with a lubricant. It is used to prevent leaks of liquids and gases around
a valve stem and bonnet.
Usually, packing is contained in an assembly called a packing gland.

Fig. 8-8 shows a typical valve packing gland assembly.
Lesson 8 Page 9
Fig. 8-8. A typical valve packing gland assembly
To produce a seal around moving parts, packing is cut into rings.

These rings are wrapped around a valve stem. They are then fitted into
a cavity in the packing gland called a stuffing box. Fig. 8-9 shows
packing rings fitted into a valve stuffing box.
Lesson 8 Page 10
Fig.8-9. Packing Rings Fitted into a Valve Stuffing Box
Once the packing rings have been fitted and seated in a stuffing box,
they are compressed by a gland follower. The gland follower causes
the packing to put pressure on a valve stem. This produces a seal. Fig.
8-10 shows packing being compressed by a gland follower.
Fig. 8-10. Packing Being Compressed by a Gland Follower.
Lesson 8 Page 11
For packing to work correctly, it must be checked regularly. The

packing will need regular adjustment to take up wear caused by shaft
or the opening and closing of a valve.
7 PACKING MATERIALS
Valves are just one item in which packing is used. Nearly all machines
that have shafts or stems passing through their casings or housings
use packing. Because there are many uses for packing, it is
manufactured in a wide range of materials and sizes shown in Fig. 8-
11.
Fig. 8-11. Range of Typical Valve Packing Materials
Packing is manufactured from fibrous materials such as flax, cotton,

and asbestos. Packing is also made from metals such as lead,
aluminum, babbitt, and plastics like Teflon, nylon and kevlar.
These materials are usually constructed to from a continuous square or

round-shaped strand. The packing is sometimes impregnated with a
lubricant like graphite or mineral oil.
7.1 FIBER PACKING
Fiber packing is manufactured in many different forms as shown.

Interlocking braid and braid over braid is very strong. It is suitable for
use where there is high pressure.
Square braid and twisted packing is very flexible and is usually used on
reciprocating shafts.
Lesson 8 Page 12
Fig. 8-12. Examples of Fiber Packing
Fiber packing is also woven into cloth which may be wrapped or

laminated between layers or rubber, plastic, and graphite
Fig. 8-13. Fiber Packing woven into Cloth
7.2 METAL PACKING
Metal packing is made in crimped or spiral wound form. It may have a

hollow core. Because of their low melting points, lead and babbitt
packing are used for temperatures below 450 C. Aluminum foil is used
for temperatures above 450 C.
Lesson 8 Page 13
Fig. 8-14. Crimped and Spiral Wound Metal Packing
7.3 PLASTIC PACKING
Plastic and other synthetic packing materials are usually manufactured

in performed "Vs" called chevrons and also in solid rings.
Fig. 8-15. Examples of Plastic Packing
As previously stated, there are many types of packing materials and

many uses for them. The packing material reference table, shown
below, will assist in the correct selection of packing materials for
various applications.
8 IN-SERVICE INSPECTION
Valves are inspected while in service to determine if the components

function properly under routine operating conditions. When inspecting a
valve, it may be necessary to perform minor adjustments, such as
adjusting the packing or the operator, to keep the valve in good
operating condition.
Lesson 8 Page 14
Particular attention should be given to the stuffing box and flanges to

check for leaks in the packing or gaskets. When defects are found that
cannot be corrected immediately, they must be reported so that
necessary action can be taken.
9 REASONS FOR MAINTENANCE
Depending on facility procedures, repair of a valve may be required

because of failure or loss of efficiency.
Efficiency can be lost due to stem leaks, stem binding, improper

operator adjustment, leaking while the disc is closed against the seat,
leaks in flange mating surfaces, or other defects.
Valves are not usually disassembled for periodic maintenance. In most

instances, valves are not taken out of service until a loss of operating
efficiency is noted. Of course, failure of a valve may require a complete
overhaul.
When performing maintenance, the manufacturer's instructions should

be reviewed before proceeding with any disassembly work.
10 PACKING REMOVAL
The first step in removing worn or damaged packing from a valve is to

lockout and isolate the valve from all process flow. The next step is to
slacken and remove the gland follower nuts as shown in Fig. 8-16
Depending on the type of valve, the gland follower nuts may be
threaded onto dogs, in which case they may be swung aside.
Fig. 8-16. Gland Follower Nuts being Removed
After the gland follower nuts have been removed, the gland follower
can be positioned and wired next to the yoke. If the gland follower is of
a split type, it can be removed completely.
Lesson 8 Page 15
The next step is to remove the packing gland as shown in Fig. 8-17.
The packing gland is also positioned and wired next to the gland
follower and/or yoke. In many applications, the packing gland is part of
the gland follower.
Fig. 8-17. Wiring a Packing Gland Next to Gland Follower
To remove the packing from the valve stuffing box, a flexible packing
extractor is used as shown in Fig. 8-18.
Fig. 8-18. Flexible Packing Extractor
The spiral end of the extractor is inserted and screwed into a packing
ring. When the extractor has been firmly screwed into a packing ring it
is then removed as shown in Fig. 8-19. All remaining packing rings are
removed in the same way.
Lesson 8 Page 16
Fig. 8-19. Packing Ring Being Removed from a valve Stuffing box
11 PACKING INSTALLATION
11.1 MANUFACTURE OF VALVE PACKING RINGS
The first step is manufacturing packing rings is to determine the size

and number of packing rings needed to repack a stuffing box and the
type of packing material to be used.
The type of packing material to be used will depend on the type of

liquid or gas flowing through the piping system.
The size and number of packing rings can be determined by referring

to the manufacturer's specifications (information sheet supplied with
the valve). These are usually kept in the plant maintenance office
records. If the information sheets are not available, it will be necessary
to measure the valve stuffing box to determine the size and number of
packing rings.
The packing ring size is determined by measuring the gap between the
stuffing box wall and the stem outside diameter using a rule, as shown
in Fig. 8-20 or inside calipers. The measurement should be recorded
so that it is not forgotten.
Lesson 8 Page 17
Fig. 8-20. Measuring a Valve Stuffing Box to Determine Packing

size
The next step is to determine the number of packing rings needed. This
is done by measuring the depth of the stuffing box using a flexible rule.
If there is limited space and a rule cannot be used, the measurement
can be taken by inserting a piece of wire into the stuffing box. Use your
thumb to mark the depth as shown in Fig. 8-21. When the wire has
been removed, the distance from your thumb to the end of the wire can
be measured with a rule. This measurement should also be recorded
so that it is not forgotten.
Fig. 8-21. Measuring the Depth of a Valve Stuffing Box
Lesson 8 Page 18
EXAMPLE OF RECORDED MEASUREMENTS
Size of packing, width 1/4"
Depth of stuffing box 1-5/16"
Determine the size and number of packing rings as follows:
Size, width of packing ring = 1/4"
Depth of Stuffing Box

Number of Packing Rings =
Size of Packing
1- 5 / 16"
Number of Packing Rings =
"
Number of Packing Rings = 5
To repack the stuffing box, 5 packing rings need to be cut from 1/4"
thick packing.
11.2 MANUFACTURE BUTT JOINT PACKING RINGS
After the size and number of packing rings required to repack a valve
has been determined, select the correct packing material. This will be
determined by the type of liquid or gas flowing through the piping
system.
When the correct packing material has been selected, the next step is
to manufacture the packing rings.
Packing rings are cut on a mandrel. This is a piece of round bar which
is the same diameter as the valve stem. The packing material is
wrapped around the mandrel the correct number of times, i.e.: 5 times
if 5 packing rings are required.
The packing material is held in position on the mandrel. A sharp knife is

then used to cut the packing material lengthwise as shown in Fig. 8-22.
The packing material must be cut in a straight line along the mandrel.
Lesson 8 Page 19
Fig. 8-22. Cutting Butt Joint Packing Rings on a Mandrel
11.3 MANUFACTURE SKIVE (45 ANGLE) JOINT PACKING

RINGS
After the size and number of packing rings required to repack a pump
has been determined, select the correct packing material. This will be
determined by the type of liquid or gas flowing through the piping
system.
When the correct packing material has been selected, the next step is
to manufacture the packing rings.
Packing rings are cut on a mandrel. This is a piece of round bar which
is the same diameter as the valve stem. The packing material is
wrapped around the mandrel the correct number of timeis 5 times if 5
packing rings are required.
The packing material is held in position on the mandrel. A sharp knife is

then used to cut the packing material lengthwise at an angle of 45 as
shown in Fig. 8-23.
Lesson 8 Page 20
Fig. 8-23. Cutting A Skive (45 Angle) Joint Packing Rings on a

Mandrel
11.4 INSTALL PACKING
Before packing can be installed in a valve packing gland assembly, the

stuffing box, stem and packing gland should be cleaned using a
solvent.
If dirt or sand is allowed to get into the stuffing box, it will cause
damage to the stem and packing. After cleaning, the stem and packing
gland should be inspected for damage and wear.
To install the packing, a packing ring is placed around the stem as
shown in Fig. 8-24.
Fig. 8-24. A Packing Ring being placed around a Valve Stem
The packing ring is then pushed down and seated in the bottom of the
stuffing box using the packing gland.
Lesson 8 Page 21
On larger valves, a split bushing can be used to install and seat the
packing rings. Fig. 8-25 shows a packing gland being used to install
and seat a packing ring.
8-25. A Packing gland Being used to install and seat a Packing

Ring
When the first packing ring has been seated correctly, the packing
gland is removed from the stuffing box.
The remaining packing glands can be installed and seated using the
same steps. But before doing so, they must be placed so that their
butted ends face a different direction (staggered) from that of the
previous packing ring.
If the butted ends of all the packing rings were placed in a straight line,
the liquid or gas flowing through the valve would leak through the gap./
Fig. 8-26. Angle Method of Staggering Packing Rings.(Butted

Ends are Staggered at 90)
Lesson 8 Page 22
Fig. 8-27. Alternative Method of Staggering Packing Rings
When the last packing ring has been installed and seated, the packing
gland, gland follower dogs, and gland follower are replaced.
The gland follower nuts are then nipped down equally, while the valve
hand wheel is turned. This is done so that the packing is not over
compressed so as to cause the stem a seize.
Lesson 8 Page 23
12 Valve Troubleshooting Table
Possible
Possible Causes Corrective Action
Problem
Leakage Gaskets Replace

Packing Adjust or replace
Loosen Bolts ( Bonnet, Flange Packing) Retighten
Groove in Flange Repair by welding or replace
Passing Seat Repair or replace
Disc Repair or replace
Hard to Packing over tight loosen
operate Thread Rethread and clean
Dirt & Scale Clean
Incorrect flow direction Correct flow direction
Stem damaged by improper maintenance Replace
procedures
Piping and valve flanges are misaligned Reinstall valve
Gasket degradation due to exposure to Replace with compatible materials
high temperature
Bent or damaged shafts/stems resulting Disassembly and repair
in sticking or binding
Plug and cage galling from overheating Disassembly and repair. Replace with
or selection of incompatible materials compatible trim.
Stem and guide bushing galling Disassembly and repair
Grit, debris, or welding slag preventing Disassemble, clean, and repair
proper plug movement
Buildup of viscous, sticky, or coking Select compatible valve style
fluids impeding plug movement
Undersized actuator Replace
I/P calibration underranged Calibrate
Incorrect flow direction Correct flow direction
Undersized actuator Install stiffer spring or larger actuator
Bent, galled, or missing components Disassembly and repair
interfering with proper operation
Plug frozen by debris between plug and Disassembly and repair
cage, stem and bushing, or plug and seat
Excessive actuator force has welded Disassembly and repair
plug into seat
Plug slamming (from dynamic Check flow direction, valve type, valve
instability) has welded plug into seat ratings
Galling caused by high temperature Replace sticking components with
compatible components
Welding slag introduced during Disassemble, clean, and repair
installation or during subsequent
upstream retrofit or maintenance has
bound components
Mechanical obstruction to plug Disassemble, clean, and repair
movement, e.g.: welding slag, pipeline
debris
Lesson 8 Page 24
Valves & Valve Maintenance Safety Valve
LESSON
9 SAFETY VALVE
LECTURE
Objectives
an understanding of Safety Valves.
1 PRESSURE
Is a force per unit area. (1pound per sq.in.) (PSI) = .143 or kilo Pascal.
7 k Pascal = 1 PSI.
2 RUPTURE DISC
Is a piece of metal on other material that is designed to rupture at a

predetermined pressure: As per (Figure 9 1 and 9 2).
FIG: 9 1 FIG: 9-2
2.1 Rebuckling or Reverse buckling
another type of rupture disc is two piece component; one piece is the
disc and the other is a frame that holds a sharp knife point. As per
(Figure 9-3).
Lesson 9 Page 1
FIG: 9-3 Rebuckling Disc
Notice:
1. A rupture in a system will occur at the weakest point in that

system.
2. A rupture disc can protect a system from pressure damage

because the rupture disc is the weakest point in a system, so it
will rupture before any other part of the system is damage by
excess pressure.
3. Rupture disc may be connected to discharge piping to ensure

the safe removal of pressurized fluid in the event of a rupture.
4. When a rupture disc is replaced, the new disc must have the
same pressure rating as the original disc.
2.2 Advantages of rupture disc
a) Simple.
b) Light weight.
c) Fast opening.
d) Relatively inexpensive.
e) No maintenance.
2.3 Disadvantages of rupture disc
1. The major disadvantage of rupture discs is that they must be

replaced when they rupture and this required shut down the
system.
2. When a rupture disc is used in a vacuum system, a support

device is needed to hold the disc in place and prevent
atmospheric press. A support device can be used to keep the
rupture disc bulging out word. The rupture disc and the support
Lesson 9 Page 2
device fit into a holder that can be bolted in place between two
flanges. As per (Figure 9-4).
FIG: 9 4 Rupture Disc Built- In Support
FIG: 9 5 Parts of a Typical Relief Valve
Lesson 9 Page 3
3 Relief Valve
To relieve excess pressure in a system. As per (Figure 9 5).
Advantages of relief valve over rupture disc are:
1. They close when system pressure returns to normal levels.
2. They can be adjusted as necessary to maintain a very accurate

set point.
Notice:
Relief valves are used primarily on systems that handle pressurized

liquids.
The spring washer forms a flat surface on the top of the spring. The
flat surface ensure even contact between the spring and the
adjusting screw.
The position of the adjusting screw is changed to adjust the tension

of the spring.
As the pressure increase over the set pressure, the valve disc will
continue to lift, until it has risen as far as it can go. That point is
called the fully open position of the valve.
3.1 Accumulation of the valve
Is the difference between the pressure at which the disc begins to lift
and the pressure at which the valve is fully open position. (Start open
at 20 psi, full open at 25 psi, accumulation of the valve 5 psi).
Lift or Travel: is the distance that the disc moves from the closed
position to the fully open position. A relief valve remains in fully open
position until the excess pressure in the system has been relieved.
Difference between liquids and Gases:
1. Volume.
2. Compressibility. Gas take up much more space (volume) then

liquid do, and the molecule of a gaseous substance can be
squeezed closer together (compressed), while the molecules of
a liquid can not.
Example: If one cubic inch of water (liquid) is boiled, the amount of

steam (gas) that is produced will fill a space of over 1500 cubic inches,
if press does not increase.
Lesson 9 Page 4
FIG: 9 6 valve seat
It is important that the mating surface of the disc and nozzle seat fit
together perfectly. This will prevent the valve from leaking under
pressure. It is also important that the seat is wide enough to carry
the bearing load from the spring and narrow enough to eliminate
simmer. For most safety relief valves of this type, the seat width is
between .030 and .037.
Set at width can be accurately measured using a measuring

magnifier. The measuring magnifier is placed against the nozzle
seat as shown in the (Figure 9 6) shows what you will see when
you look through the eye piece of the magnifier.
4 Huddling Chamber Safety Valves
As per (Figure 9-7) safety valves can be classified according to the

way that they open and the number of adjusting rings that they contain.
Figure 9 7 is cut way drawing of Huddling Chamber Safety Valve.
The spindle is threaded past the disc threads so that it sits on the
disc and acts like a ball joint. When the spindle is fully threaded into
the disc the thread of the spindle are disengaged from the thread of
the disc. In the position, normal vibrations of the valve can not
separate the spindle from the disc or the disc from the seat.
The disc of the huddling chamber safety valve is shaped quite

differently from the disc of a relief valve. The safety valve disc has a
lip that is not exposed to system pressure when the valve is closed.
The disc in a huddling chamber safety valve is also called a feather.
Lesson 9 Page 5
FIG: 9 7
4.1 Operation of Huddling Chamber Safety Valve
The center portion of the disc in a huddling chamber safety

valve is called pressure-sensing area.
If the valve is set to open at 20 psi, the disc will begin to left
off the seat when that pressure is reached. When this
happens, the lip of the disc which was not previously
exposed to system pressure, suddenly is exposed to system
pressure. This larger area of the disc exposed to the same a
mount of system pressure (20 psi) so there is more total
force exerted on the bottom of the disc.
Force = pressure X Area there for, an increase in area

results in a increase in force, while pressure remains the
same. The increased force causes the disc to pop open to a
bout a 60% open position.
Lesson 9 Page 6
At this point two force hold the disc at 60% open position:
1. System pressure.
2. The velocity of the escaping steam striking the disc.
In terms of relieving excess pressure, if one cubic foot water must be

released to relieve one psi of pressure in water system, then 1500
cubic feet of steam would have to released from a steam system of the
same size and pressure to relieve same a mount of pressure one psi.
There are two major reasons for not using relief valve on gas
steam systems:
1. A relief valve open gradually. It does not open juicily enough to

let out the large volume of gas or steam that is needed to relieve
excess pressure in the system.
2. The possibility of damage to the valve seat and disc. When a

relief valve first begins to open the space between the valve disc
and its seat is extremely small. The velocity of the steam or gas
escaping through that small space could actually cut the metal.
This damage called steam cut Wire drawn in contrast, the
initial popping action of the safety valve instantly provides a
relatively wide escape route for excess gas or steam. Because
the escape route is wide, the velocity of the escaping fluid is
relatively low. By reducing the velocity of the gas or steam in this
way, the popping action of the safety valve minimizes the steam
cutting that would occurs if the disc were exposed to a high
velocity flow of steam.
If the system pressure continues to increase the velocity of

the escaping steam will also increase and the two forces will
lift the disc even higher. After the initial popping to the 60%
open position, the valve open more gradually (if system
press. continues to increase) until it reached the fully open
position.
The valve does not close until the system press drops a
predetermined a mount below the set point (20 psi). then the
valve snaps shut quickly due to the shape of the disc, to cut
off the flow of steam and thus minimize steam cutting. This
occurs at about the 20% open position, as the force of the
escaping steam is lost. A small cushion of steam trapped in
the huddling chamber of the valve keeps the disc and the
seat from slamming together hard enough to be damaged.
Lesson 9 Page 7
4.2 The basic concepts of safety valve operation:
Popping pressure: Is the pressure at which the valve will pop open.
Can be adjusted by adjusting screw.
Simmering: When the press. in a system reaches the popping press.

of a safety valve, the disc begins to rise off its seat. The valve does not
pop open immediately, because the press. has no time to act on the lip
of the disc. The condition in which the disc has lifted only slightly is
called simmering. In most cases, simmering lasts for only a fraction of
a second, until system press. acts on the lip of the disc and the valve
pop open.
Positive seating: When system press. drops below the popping press,
the spring is able to snap the valve shut. When the disc is firmly in
place against its seat, the valve is said to have positive seating.
Positive seating is important, because it means that the valve will not
leak.
Blowdown or blowback: The difference between the popping press.

of a valve and its positive seating press. is called Blowdown or
Blowback. Can be adjusted by adjusting ring.
Chattering: If the valve has a popping press. of 20 psi and also a

positive seating press. of 20 psi. In this example, the blowdown is 0.
After the excess press. is relieved, system press. start to drop. When it
reaches 20 psi, the valve does not know whether it should remain
closed or pop open again. The disc is likely jump up and down its seat
until press. either increase enough to pop the valve open or decrease
enough to keep it closed. This condition is known as chattering,
because of the sound made by the disc as it moves up and down.
Chattering can damage the disc and the seat, so it must be prevented.
Chattering is prevented by blowdown, which insure that the popping
press. and the position seating press. are different.
[Abnormal rapid reciprocating movement of the disc on the seat]
4.3 For one Ring Safety Valve Adjustment
The adjusting ring:
When the adjusting ring is in the raised position, the

escaping steam is directed right at the disc. The velocity of
the escaping steam exerts a great deal of upward force,
because most of the steam is aimed at the disc. This means
that system press, must drop will below the popping press, of
the valve before the spring can force the disc back onto its
seat. Therefore, raising the adjusting ring increase the
blowdown of the valve.
Lesson 9 Page 8
If the adjusting ring is lowered, the escaping steam is not

aimed directly at the disc with the adjusting ring in the
lowered position, the valve will close against higher system
pressure than it did when the ring was raised. As a result, the
blowdown of the valve decrease.
The function of the adjusting ring, then, is to adjust the blewdown of the
valve. The higher the ring, the higher the blowdown the lower the ring,
the lower the blowdown.
FIG: 9 8
4.4 THE TWO-RING HUDDLING Chamber Safety Valve:
Have two adjusting rings see (Figure 9-8).
An upper ring for:
1. Adjusts the blowdown of the valve.

2. Directs the escaping steam away from the disc.
The lower ring for:
1. Directs the escaping system at the disc.

2. Traps a cushion of steam to soften the metal to metal
contact as the valve closes.
Lesson 9 Page 9
The upper adjusting ring adjusts the blowdown of the valve by

adjusting the size has a wide, straight path to the outlet. With the
ring raised, little of the escaping steam acts on the disc, so the
valve can close at higher system press. (The valve thus has a
smaller blowdown). The a mount that the upper ring is raised is
important, if the ring is raised too much, it might allow so much
steam to escape without acting on the disc that the valve might not
able to lift all the way.
If the upper adjusting ring is lowered, the escape route for the steam is
narrowed, so more of the steam will act on the disc. Lowering the
upper ring also directs the steam downward and thus creates a force
called reactive force.
Reactive force : is a type of force that is equal to the original force, but
opposite in direction. Thus, the force of the pressurized gas or steam
that is directed downward by the upper ring will exert an up ward force
on the disc. When the upper ring is in its lower position, the
combination of the narrowed escape route and the reactive force
results in a greater blow down of the valve.
The lower adjusting ring aims the escaping steam directly at the disc
to insure a clean forceful popping action.
If set too high the space will be too narrow. Steam will not be able to
escape through the narrow space, and the blow down will be
increased. There is also possibility that the disc hit the lower ring.
If the lower ring set too low much of the steam escape with out hitting
the disc. As a result the valve might simmer too long before popping
open, or it might not pop open at all.
The second function of the lower adjusting ring is to trap a cushion

of steam that softens the metal to metal contact between the disc
and the seat when the valve closes. If the lower ring is set too low,
no cushion of steam is formed.
After the rings have been properly set, they are locked in place, by
tightening the ring pins that protrude through the valve body.
Lesson 9 Page 10
FIG: 9 9
5 SAFETY-RELIEF VALVES
As per (Figure 9 9).
Is a valve that is suitable for use as either a safety or relief valve,

depending on the application. Safety valves are commonly used in
refineries, on system that contain liquid vapor mixture, and in some
low pressure steam system.
The valve shown in (Figure 9 9) is a safety relief valve that acts

as a safety valve with the adjusting rings in one position and as a
relief valves with the ring in another position.
The construction is very similar to that of the nozzle reaction safety

valve. The valve has a nozzle shaped and upper and lower
adjusting rings.
The valve set up for service as a safety valve by adjusting the lower
ring to direct fluid against the disc, which will cause the valve to pop
open. In this position, the lower ring will also trap a cushion of gas
or steam to protect the valve from damage as it close.
- If the valve is to be used as a relief valve, the bottom-adjusting

ring must be lowered so that fluid is not directed against the
disc. That adjustment will allow the disc to open gradually
instead of popping open.
Lesson 9 Page 11
Adjustments to safety relief valves are made by the valve

manufacture before the valves are sent to the plant for installation.
Plant maintenance personnel do not normally make the adjustment that

converts safety relief valves from one type to the other.
FIG: 9 10
5.1 PILOT-ACTUATED RELIEF Valves
Are valves that have a separate sensing device that reacts to excess
pressure conditions. This arrangement allows excess press. to be
detected in one part of a system (such as a steam line) while the valve
protects another port of the system (such as the boiler).
Pilot actuated relief valves are also called power actuated

pressure relief valve (P.A relief valves), electromatic relief
valves, and pressure matic relief valves.
The valve consists of two major components: As per (Figure 9

10).
1. The valve it self.

2. A separate pilot device that senses changes in press. and
initiates the valve opening sequence
Lesson 9 Page 12
Electrical
relay Outlet
Pressure-
sensing tube
Disc
Solenoid
Spring Seat
A pilot valve
Disc Clearance
Valve Body
Inlet
FIG: 9 11
The valve component of a typical pilot actuated relief valve, is

shown in (Figure 9 - 11). The spring in this valve is below the disc,
the disc opens down ward, allowing the steam to escape through
the outlet at the upper past of the valve body. The valve also has a
disc guide, which is a sleeve that aligns the disc.
As shown in (Figure 9 11) there is a small opening between the disc

guide and the disc that allows system fluid to pass through from the
inlet to the bottom of the main disc. Because of this feature, system
pressure is exerted on both the top and bottom of the disc during
normal system operation. If system puss. Increase, it increase on both
sides of the disc. The valve will not open however, because the press.
on the top of the disc counterbalance the pressure on the bottom.
The opening of a pilot actuated relief valve is initiated by a separate

pilot device, such as the one shown in (Figure 9 11). The pilot device
consists of:
1. A pressure- sensing tube.
2. An electrical relay.
3. A solenoid.
4. A pilot valve.
The pilot device is set to open at a predetermined pressure. Increase in

system pressure is detected by the press. sensing tube.
When system press. reaches the predetermined level, the pressure

sensing tube activates the electrical relay. The electrical relay
closes an electrical circuit and energizes the solenoid. The solenoid
then lifts the pilot valve, and the excess pressure is relieved.
The excess pressure that is relieved by the pilot valve comes from
below the disc in the main valve. (The amount of press. that the pilot
valve is capable of relieving is greater than the amount that could leak
between the disc and the disc guide). When this press. is relieved, the
Lesson 9 Page 13
only press, remaining on the disc is the pressure that is above it. With
no press. below the disc to counterbalance it, the pressure above the
disc easily overcomes the spring tension, so the valve opens to release
system fluid through the out let above the disc.
When system press, returns to normal, the pilot valve close.

Pressure then builds up again below the main valve disc and helps
the spring to hold the disc closed.
Pilot actuated relief valve are used on gas and steam systems,
like safety valves, they pop open and they have a predetermined a
mount of blowdown to prevent chattering.
Pilot actuated relief valves are often used on systems that use
safety valves in such instance, the pilot actuated relief valves are
set to open at lower system press. than the safety valves. This type
of arrangement saves wear and tear on safety valves and prevents
the costly shutdowns that would be required for safety valves
repairs. By law, safety valves cannot be isolated from the systems
that they protect, because of the damage that might occur if the
systems were operated with out protection. There fore, whenever a
safety valve is damaged, its system must be shut down while
repairs are made. Pilot actuated valves, however, can be isolated
from a system, because they are not part of the system safeguards.
These valves can be used and then repaired, if necessary, with out
having to shut down the system.
6 Troubleshooting
FIG: 9 - 12
Lesson 9 Page 14
External inspection of this type of valve usually in valves checking the

following:
1. The lock wire on the adjusting ring pin.
2. Signs of leakage a round the Yoke or bonnet bolts and

the discharge piping bolts.
3. The temperature of the valve and the discharge piping.
4. Condition of the catch tray on the discharge piping.

(Figure 9 12).
5. Signs of possible leakage from the discharge piping out

let.
If a safety valve is suspected, a stethoscope is used to listen for a

hissing or whistling sound.
Another way to detect leak through is to go out side and check the
exhaust pipe form the valve.
The catch tray on the discharge piping collects condensate that

comes down the discharge piping when the valve is open. It should
be clean and dry. If not cleaned, then it is possible for condensate,
dirt, and corrosion particles coming down into the valve seat disc.
There may be some sure signs that the valve is leaking through
between the disc and seat. Two possible cause of such leakage
are:
1. The valve did not reseat correctly after its last popping.
2. Some kind of forcing material, like ash, dirt or rust particles, is

trapped between the seat and the feather. These can be
corrected by hand lifting the valve. Hand lifting clears foreign
material out of the valve and gives the feather a chance to
reseat properly.
The operator must know when a safety valve is to be hand lifted so

that he can compensate for the drop in system press. And keep it
from take emergency measures to raise press. Or to shut the
system down. Such an error would be costly and perhaps
dangerous.
Hand lifting a safety valve requires some important safety

precaution Ear protection, safety goggles or a full-face shield, and
gloves should all be worn.
Lesson 9 Page 15
FIG: 9 13
1. Whenever the valve hand lifting, a great deal of hot, pressurized

fluid is released, so the person lifting the valve should be as far
a way from the valve as possible. As a safety precaution, a hook
and lanyard are connected to lifting lever so that the valve can
be lifted from a distant (Figure 9 13).
2. The valve should be held open form only 2 or 3 seconds. If it is

held open any longer, the rush of steam could damage the
feather.
Before any work is started on a safety valve, it is important to get as

much information as possible about the valve. Atypical valve
nameplate provides these data.
Before a valve is disassembled, it should be cleaned to keep the dirt
and corrosion particles on the outside of the valve from getting inside
the valve and damaging it.
To maintain proper set points, the position of the compression screw,
the upper adjusting ring, and lower adjusting ring must be precisely
measured and recorded before these parts are removed from the
safety valve.
The parts of safety valve according to the order in which they are
removed:
1. Hand lifting assembly.

2. Cap.
3. Lock nut and lifting nut.
4. Compression screw.
5. Yoke nuts and yoke.
6. Spindle and feather.
7. Upper and lower adjusting rings.
Lesson 9 Page 16
Safety valve parts are cleaned with solvent and a brush or by dipping
directly in the solvent.
Lapping uses abrasives in the form of a lapping compound to restore

damaged surfaces.
When a lapping plate is used, the basic lapping motion is figure eight
motion.
Damage to a valve seat usually appears in the form of cracks or steam

cutting.
The basic difference between lapping a flat valve seat and lapping a
valve seat that is not flat is the shape of the lapping tool.
The action that can be taken when a valve seat that is a permanent
port of the valve body is severely damage are:
1. Use a special tool to restore the damage surface.

2. Mount the valve in a lathe and remachine the seat.
Extensive maintenance on a valve seat can also change the lift of the
valve. Lift adjustment can be made by moving the lift stop collar up (to
decrease the lift) or down (to increase the lift). A valve that dose not
have a lift stop collar for making lift adjustment might have to be
replaced.
Adjusting rings are subject to damage in the form of nicks, cracks, and
steam cutting, but this does not happen very often. The ring still require
careful inspection, however, because any damage might cause them to
fail when the valve is put back in service Damage adjusting rings are
always replaced.
The spindle must also be inspected carefully for cracks and other signs
of damage. The end of the spindle that fits into the feather must be
smooth and round. Because it acts like a ball and socket joint inside
the feather so that the feather can align itself properly with the valve
seat with out damaging the seat. Flat spots on that end of the spindle
can cause uneven contact and unwanted friction between the spindle
and the feather.
The correct position of the lower adjusting ring determined by a lapping

block laid flat against the valve seat is used as a reference point. The
ring is adjusted until there is full contact between the seating surface
and the lapping block. The ring is then turned and the notches are
courted. The ring is in the proper position when the number of notches
equals the number given in the notes made during disassembly.
Lesson 9 Page 17
The tip of the spindle is lubricated before it is screwed into the feather
because lubrication minimizes the friction caused be the side to side
motion when the valve is in operation.
Perfect contact between the feather and the valve seat is necessary in
order to prevent passing (steam leak through the valve between the
two port).
The exact position of the upper ring is measured first. Witness marks
can be made with an indelible marking pen and used as described in
the procedure for removing the compression screw. (to avoid damaging
the ring, a hammer and a punch are not used to make the witness
marks). The measurement can also be taken by laying rigid rule across
the lip of the valve body and then placing a second rule vertically with
one end-resting flat against the top of the upper ring. The
measurement is taken on the vertical rule at the pint where it intersects
with the horizontal rule. The measurement must be exact so that the
adjusting ring can be replaced in the same position during reassembly.
Method for testing the contact between the feather and the valve
seat:
Apply a thin layer of Prussian blue around the seating surface of the
feather and insert it into the valve seat. A thin uniform circle of blue on
the valve seat indicates correct fit.
When the compression screw has been turned the exact number of
time stated in the notes, its position is checked. The tips of the divider
used during disassembly are inserted into the witness marks. If the
tips of the divide fit precisely into the marks, position of the
compression screw is correct.
A safety valve should be tested after reassemble to make sure that it

has been reassembled correctly.
Popping set point can be adjusted by turning the compression screw.
A hydrostatic test is not a test of safety valve, it is a test of the system

that the safety valve protect.
The purpose of a hydrostatic test is to determine whether or not a

system can tolerate excessively high pressure in case of an
emergency.
Causes of a bent spindle are:
1. Careless handling.
2. Improper gagging.
Lesson 9 Page 18
Two methods used to test safety valves are:
1. Raise system pressure.

2. Use an auxiliary device to lift the spindle only for popping
adjustment.
6.1 Blue Check a Valve Seat
After lapping the valve seat, a blue check should be performed to make
sure that the meeting surface of the disc and seat fit together properly.
Apply alight, even coat of bluing and set the disc on the valve seat and
rotate it a quarter turn (in one direction only remove the disc and check
for an unbroken, even blue line around the disc seating area.
Gagging procedure:
1. Remove the hand lifting lever.

2. Remove the protective cap from the top of the spindle.
3. Align the gag spindle with the valve spindle.
4. Attach the gag jaws to the yoke.
5. Tighten the gag finger tight only. (A wrench in never used
on a gag, it might damage the valve by making the gag too
tight a condition called over gagging)
If a leaking safety valve is noted during a hydrostatic test the

system pressure reduced and then tightens the gag further.
After the hydrostatic test has completed, it is essential to remove

the gags from all safety valves because gagged valves can not
protect the system from over pressure conditions.
7 Safety Valve adjustment
Pop Press - Reset Press

Blow Down Present = 100 = %
Poping Press
Upper Ring: to adjust the blow down press.
If Blow down present more than 5% turn upper ring

Counter clock to decrease the blowdown present. -
If Blow down present less to increase turn clock wise the upper ring +
Lesson 9 Page 19
Lower Ring: to adjust the simmering of the safety valve.
To increase or decrease Popping Press. Tight or loose the nut. Each

nut flat increase the popping press 2 or 3 bars
One flat
Installation of safety valve should be a way 8 to 10 times of the pipe

diameter away from bend or elbow.
Use cast iron for lapping of the safety valve (Ring lap )
Never gag the safety valve until the boiler pressure retch 75% or
80% of the normal pressure.
Never gag all the S/V during the test leave one with out gag. This
one should be with hand lever on it safety.
(1) (3)
Blow Down (2) Long

Ok Short
Blow Down
Blow Down
Pop Reset Pop Reset Reset
For adjustment of the S/V:
1. Shattering from lower ring.

2. Simmering from lower ring should be left up.
3. Lower ring should be 3 to 5 notches from straight adage of the
or Nozzle of the S/V. Straight adage
Seat
Hand popping should be done before the test take place to clean
the seat and disc and should be done before the set pressure by 7
to 10% of the set pressure.
Release nut should be checked for final assembly if the pin in

position so it will restrict the movement of the spindle so the valve
will not close.
Lesson 9 Page 20
High pressure S/F adjustment:
1. Popping pressure (open).

2. Set pressure Near 1% (from the name plate).
3. Reset pressure
Blow down = (Pop Pr.) (Reset Pr.)/popping pursuer x 100 = %
Good Blow down = 3 to 5 % of the pop pr.
Blow Down
Percent % = 100
Pop Pr.
To increase the B/D take the upper Ring down.
Decrease the B/D take the upper Ring up 10 to 20 notches.

Secondary adjustment for B/D if the upper ring not work good for
adjustment then adjust caller for adjusting B/D opposite to upper
ring (Down to decrease the B/D and up to increase the B/D of the
Safety valve).
Lesson 9 Page 21

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Kingdom of Saudi Arabia

Saline Water Conversion Corporation

VALVES & VALVE MAINTENANCE

Course Code: VALVE & VALVE MAINTENANCE

Valves are extensively used in piping systems and on equipment to

1.1 FUNCTION OF VALVES

Function of Valves is to start, stop or regulate a flow of liquid or gas

1. Opening or closing a circuit.

1.2 VALVE CLASSIFICATION AND TYPES

Valves can be classified by function, by disc arrangement, by

The most common way to classify a valve is by the arrangement or

REGULATION OF FLOW. Many applications require that the flow of the

Fig. 1-1. Families of Valves.

A common method of classification is the method by which they actually

a. Fig. 1-2 shows the basic construction of a common valve type,

Fig. 1-2. How a valve operates.

c. If the closing element (named a disc) in the close position the

Valves are subjected to the effects of heat, pressure and corrosion, so it is

Manufacturing method relates closely to body design. Casting is well

Fabrication by welding may begin with plates, rings, forging, or even

The bonnet complicates manufacturer, increases valve size, and

Combination of the two basic motions is possible, too. A symmetric

Demanding special services have involved into almost separate

Service conditions and material choice are closely interconnected.

Bi-directionality of a valve is a large consideration with several types and

advantage of cost and maintenance effort if a valve has exactly the

Reparability and maintainability are factors in valve section. The cost of

Fig. 1-3. Valve Components.

System flow passes through the body of the valve. The

The seat can be :

In high temperature, high pressure system, a combination of threading

Materials used for seat construction:

* For low-pressure low temperature system valve seat may be made

Fig. 1-6. Threaded and Welded Seat Attachment

disc attached to the stem:

5. Bonnet: is attached to the valve body by bolting, threading, or

6. Stuffing box: is filled with a packing to prevent leakage.

7. A packing gland: Is to hold and compressed the packing in place to

8. Hand wheel or Operator: is control the movement of the disc inside

9. Bridge wall markings: is provide useful information indicates how

10. Service markings: indicates the maximum allowable pressure

* The smaller the valve, the finer the control.

1.6 VALVES APPLICATIONS :

In a gate valve, the disc is wedge-shaped with mating surfaces on two

Fig. 2-1. Gate Valve

2 GATE VALVE CONSTRUCTION

The exterior construction of most gate valves is similar. The body

The interior construction of gate valves varies, depending on the type

stop all flow.

PACKING Special material (made of asbestos, grease, neoprene each

GLAND After the packing is installed the gland compresses the

BACKSEAT In order to permit re-packing under pressure, some valves

BONNET The bonnet gasket is provided to eliminate leakage between

3 NON RISING-and RISING STEM

* Hard to tell if valve is opened or closed.

Fig. 2-2 Rising Stem

Fig. 2-3. Non-rising stem gate valve

3.1 NON RISING-STEM

The non-rising stem (NRS) configuration places the stem threads

Fig. 2-4. Rising stem gate valve with circular bonnet

Up to a steam working pressure of 250 psig, gate valves are usually

There are several types of gates:

a. Solid wedge gate As per Fig. 2-5.