Training Manual Operations: July 1999-Rev.0

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Unit No. 3 - Valves
Module No. 7 : Piping systems
July 1999- Rev.0 Page 1/39

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UNITS IN THIS COURSE
UNIT 1 PIPING SYSTEMS
UNIT 2 PIPE FITTINGS
UNIT 3 VALVES

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Unit No. 3 - Valves

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TABLE OF CONTENTS
Para Page
3.0 COURSE OBJECTIVE 3
3.1 INTRODUCTION TO VALVES 4
3.2 VALVE IDENTIFICATION AND FUNCTION 5
3.3 VALVE PARTS 6
3.4 BLOCK VALVES 7
3.5 PLUG VALVES 11
3.6 BALL VALVES 12
3.7 THROTTLING OR REGULATING VALVES 13
3.8 CHECK VALVES
18
3.9 SPECIAL VALVES 22
3.10 STUFFING BOX AND VALVE PACKING 26
3.11 CONTROL VALVES 30
3.12 AUTOMATIC CONTROL VALVES 30
3.13 VALVE ACTUATORS 31
3.14 PNEUMATIC ACTUATOR OPERATION 32
3.15 ELECTRIC MOTOR ACTUATOR 35
3.16 HYDRAULIC VALVE ACTUATORS 36
3.17 SOLENOID / MAGNETIC ACTUATORS 37
3.18 VALVE INSPECTION 38

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Unit No. 3 - Valves
3.0 COURSE OBJECTIVE

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This course introduces the students to all major items of static equipment relating to
a plant site. Upon completion of the course the trainees will have a general
understanding of the following.
Equipment Terminology.
Theory of operation.
Equipment construction.
Hands on operation.
& Safety features.
Equipment interaction with the overall process.

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Unit No. 3 - Valves
3.1 INTRODUCTION TO VALVES

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A valve is a device installed in a piping system which controls the flow of a gas or
liquid. Valves have an opening through which gas or fluid can flow. They can close
off (isolate) the piping system to stop the flow and they can control the amount of
flow.
Processing systems handle different products at different pressures and

temperatures. So, there are many different types of valves A valves shape and
material depends upon the product and its operating pressure and temperature.
Valves carry the same rating system for pressure as flanges; i.e. 150-300-600 etc.
In a gas plant or refinery, valves will be made from the following materials:
Stainless steel.
Carbon steel. These are used for process fluids
Cast iron.
Brass. These are used for utilities / fire water

Bronze.
Plastic These are used for air chemical lines.

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Unit No. 3 - Valves

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3.2 VALVE IDENTIFICATION AND FUNCTION
Table 1 shows the four main types of valves and their function.
VALVE TYPE EXAMPLES FUNCTION
Block Valve Gate Valve To stop or start

the flow of a
Ball Valve fluid. Used in the fully open or
fully
closed position.
Throttling / Regulating Globe Valve To control how much fluid

Valve Butterfly Valve flows through a
valve. Used in
Needle Valve any position from
fully open to
fully closed.
Check / Non Return Ball Check Valve Allows fluid to flow in one
Valve Piston Check Valve direction
only. Fluid flowing in
Swing Check Valve the other
direction will close
the valve.
Safety / Relief Valve Balanced bellows To release excess pressure.

Pressure Safety To protect system from too
Valve (PSV) much
pressure.
Pressure Relief Valve
(PRV)

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Unit No. 3 - Valves
3.3 VALVE PARTS

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Figure 3-1 Major Valve Parts
The major parts common to most valves are as follows: See Figure 3-1
Body
Valve Disc (Opening Element).
Stem.
Handwheel / Handle.
Bonnet.
Packing Gland
BODY
The body is the part of a valve that is attached to the pipework flange. The gases or
liquids flow through the body when the valve is open.

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Unit No. 3 - Valves
VALVE DISC (OPENING ELEMENT)

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This is the part that opens and closes the valve. All valves have a valve disc in the
valve body. Valve discs are made in various shapes and sizes. They can move up
and down with the stem, or rotate around a central pivot point.
The valve disc stops or allows flow through a valve. We will discuss types of valve
disc further when we look at different types of common valves. When the valve is
closed the valve disc fits against the valve seat.
STEM
The stem raises or lowers the valve disc. In manually operated valves the stem is
usually threaded. In ball valves and butterfly valves the stem does not move up or
down. It turns inside the bonnet. In pneumatic and hydraulic valves the stem is a
smooth rod that moves up and down in the valve body.
HANDWHEEL / HANDLE
On a manual valve a handwheel or handle is attached to the stem. The handwheel

or handle allows the operator to turn the stem. The handwheel is held on the stem
by a handwheel nut.
BONNET
he bonnet is a separate housing that is bolted tightly to the top of the valve body.
The stem passes through the bonnet. The bonnet holds the stem in position.
PACKING GLAND
he packing gland is held in place by bolts or sometimes it is screwed into place. This
gland keeps the packing tight. Packing is a soft material inside the bonnet placed
around the stem to make a tight seal. The packing stops pressurised gas or liquid in
the valve from escaping to the atmosphere.
3.4 LOCK VALVES
The three most commonly used block valves in process systems are:
Gate Valve.
Plug Valve.
Ball Valve.

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Unit No. 3 - Valves
GATE VALVES

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There are two main types of gate valves used in the process system:
Rising stem gate valve.
Non-rising stem gate valve.
The valve disc in a gate valve is a wedge shaped disc or gate. It is attached to the
end of a threaded stem. The gate fits into a wedged shape seat in the valve body to
stop flow through the valve.
Turning the handwheel raises and lowers the valve disc. When the valve is fully
open the gate is positioned above the passage in the' valve body. This allows full
flow in both directions through the ports. There is little or no restriction and no
pressure drop across the valve.
When the gate valve is fully closed the gate fills the passage and it stops the flow
through the valve completely. Gate valves are only used in the fully open or fully
closed position to start and stop flow. You must turn the handwheel to many times to
move the valve to the fully open or fully closed position.
RISING STEM GATE VALVE
Figure 3-2 Rising Stem Gate Valve

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Unit No. 3 - Valves
Large gate valves normally have rising stems. When the handwheel is turned the

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stem rises out of the valve bonnet through the handwheel. The stem shows the
position of the valve disc and shows if the valve is fully open or fully closed. In small
gate valves the wheel and stem may rise together.
The threaded part of the stem is above the valve body. It is not in contact with the
fluid flowing through the valve. "this type of valve has less corrosion problems. The
rising stem gate valve requires more space and more head room.
NON RISING STEM GATE VALVE
Figure 3-3 Non Rising Stem Gate Valve
Some gate valves have a non rising stem. The stem does not come out of the valve
body. The valve disc moves up and down the stem. With this type of gate valve
there is more chance of corrosion as the valve stem is in contact with the liquid
flowing through the valve. This type of valve is used where there is not enough
space above the valve for the stem to rise out of the body.

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Unit No. 3 - Valves
Gate valves provide a good seal against flow. For this reason they are normally

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used as isolation valves in high pressure hydrocarbon pipelines. The gate valve is
the most commonly used valves in the petroleum industry.
If the gate valve is partially closed there may be vibration. This can cause noise and
possible damage to the valve disc and the seating surfaces. For this reason gate
valves should only be used for throttling (restricting flow) in an emergency.
There are three main types of gate designs for gate valves: (See Figure 3-4)
Solid Wedge Gate.
Split Gate (parallel disc).
Flexible Gate.
Figure 3-4 Gates for Gate Valves
SOLID WEDGE GATE
The solid wedge valve disc was the first type that was used in gate valves. It does
not allow for expansion or contraction of the valve body and stem material with large
temperature changes. This type of wedge is not used in high temperature processes
where there is thermal expansion and contraction of the valve body. (See Figure
3-4)

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Unit No. 3 - Valves
SPLIT GATE

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The split gate valve disc is split up the centre. This allows the element to expand or
contract. Therefore, the disc has a better fit in the valve seat over a wide range of
pressures and temperatures. The wedge can adapt itself to small amounts of
distortion caused by seat wear or piping strain. (See Figure 3-4)
FLEXIBLE GATE
Like the split gate valve disc the flexible gate valve disc is split up the centre. This
allows the element to expand and contract and to give a very tight seal in the valve
seat over a wide range of pressures and temperatures. This type of wedge is used
in high temperature processes. (See Figure 3-4)
3.5 PLUG VALVES
Figure 3-5 Plug Valve
The plug valve is one of the simplest types of valve. It is also known as a petcock or
a plug cock. Like the gate valve it is only used in the fully open or fully closed
position. The plug is a tapered round plug. It has a rectangular hole in the centre
that lines up with the ports in the valve body.

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The valve has a handle for manual operation. It is opened or closed by a quarter

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turn of the valve handle. When the valve handle is pointing in the direction of the
pipe the valve is in the fully open position. When the valve handle is pointing across
the pipe the valve is in the fully closed position. .
A special grease is forced into and around the plug to act as a seal and a lubricant.
These valves are a simple design. They do not take up much space and do not
have high yokes, bonnets or valve stems. Normally these valves are manually
operated but they can be operated automatically if required.
3.6 BALL VALVES
Figure 3-6 Ball Valve
This type of valve is opened or closed by a ball. Like the plug and gate valves, the
ball valve is used only in the fully open or fully closed position. The ball has a hole
through the centre which is the same size as the valve ports in the valve body. The
valve moves from the fully open position to the closed position by moving the valve
handle a quarter of a turn.

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The position of the valve handle indicates whether the valve is fully open or fully

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closed. When the valve handle is pointing in the direction of the pipe the valve is in
the fully open position. When the valve handle is pointing across the pipe the valve
is in the fully closed position.
The ball is carefully machined so that it fits exactly into the valve seats. It gives a
very tight shut off with metal to metal seal. Ball valves are very good when they are
used in gas processes at high and low pressures and temperatures.
3.7 THROTTLING OR REGULATING VALVES
Throttling or regulating valves are used to control the amount of flow They can only
receive flow from one side. (Except the butterfly valves)
There are three main types of throttling valves that are used in the petroleum
industry.
Globe Valves.
Needle Valves.
Butterfly Valves.
GLOBE VALVES
Figure 3-7 Globe Valve

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Unit No. 3 - Valves
A globe valve is used to control the amount of flow. The valve can be operated in

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any position from the fully closed position to the fully open position. The valve disc is
globe shaped (circular). The valve operates by raising and lowering the valve disc
into a circular seat. There is no contact between the seat and disc ends when the
flow through the valve starts. Only a few turns of the handwheel are needed to fully
open or close the valve. (The gate valve needs many turns to open or close it.)
There are partitions inside a globe valve. The fluid flowing through the valve must
make two 90 degree turns. The flow is "under and over" to prevent wear to the seat.
Therefore, there is a high pressure drop in the valve. It is easier to control this kind
of flow.
Globe valves are usually smaller if they are hand controlled and need to be opened
and closed often. The direction of the fluid flow through the valve keeps the seat
and disc clean.
NEEDLE VALVES
Figure 3-8 Needle Valve
The needle valve is similar to the globe valve. It has a needle shaped plug and seat
instead of globe shaped ones.

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Unit No. 3 - Valves
When the valve is fully open the needle valve does not allow a full flow. This is

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because the hole in the seat is much smaller than the pipe flow area.. The threads
on the stem of a needle valve are very close together. This allows very exact control
of the flow because the needle can be adjusted very precisely. Needle valves are
used in small sizes, only up to 1 ". They are mainly used on instrumentation
systems.
BUTTERFLY VALVES
Figure 3-9 Flanged Butterfly Valve

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Figure 3-10 Lug Wafer Type Butterfly Valve
Figure 3-11 Wafer Type Butterfly Valve

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Unit No. 3 - Valves
Modern butterfly valves usually have rubber or elastomeric seats. These provide a

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tight shut off like any other valve.
This valve design is very good for installations where space considerations are
important. This type of valve is good for large piping systems since they can be
made at almost any size. Basically, the valve consists of the valve body, shaft and
butterfly disc, sealing gland and valve actuator
Because the design is simple, this valve works equally well in three different valve
bodies; flanged butterfly valve, the lug wafer butterfly valve and the wafer type
butterfly valve., (See Figures 3-9, 3-10, 3-11).
The butterfly valve moves from fully open to fully closed. in a quarter turn of the
valve handle. These valves are used to control the amount of flow. The sealing
mechanism is a circular disc made of rubber or metal. It is difficult to shut off the
flow if the sealing mechanism is made of metal; rubber gives a better seal. Butterfly
valves usually have some kind of automatic actuator because they are fairly hard to
close manually. Butterfly valves can be used for fluid flow in either direction.
The valve disc in a butterfly valve is a flat disc. The disc rotates around a central
pivot. When fully closed the flat disc fills the entire area of the valve body. The
butterfly valve offers very little resistance to flow when it is fully open. Butterfly
valves are used as low pressure control valves in gas and liquid pipelines.
GAUGE COCK VALVE
Figure 3-12 Gauge Cock Valve

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Unit No. 3 - Valves
A gauge cock valve is a special type of valve. It is used between a vessel and a

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vessel gauge glass. Its function is to isolate the gauge glass automatically if the
gauge glass begins to leak or break.
The gauge cock valve has a small metallic ball inside. If the gauge glass breaks, the
fluid inside the vessel will flow out through the valve and out of the gauge glass. The
fluid movement pushes the metal ball into the outlet hole of the valve. This closes
the valve and so stops the leak.
A gauge cock valve must always be in the fully open position when it is in service or
it cannot protect the system. If it is only part open the valve stem will stop the ball
from sealing off the outlet hole.
If the gauge glass must be isolated for cleaning etc. the gauge valve can be
manually operated.
3.8 CHECK VALVES
Check valves are also known as non return valves. This type of valve allows the
fluid to flow in one direction only.
All check valves operate in the same manner. The pressure of the fluid flowing in
one direction holds the valve open. Fluid pressure from the opposite direction closes
the valve against a seal. Most check valves are marked with an arrow to show the
direction of flow through the valve. There are four main types of check valve:
Swing Check Valve.
Horizontal Lift Check Valve.
Vertical Lift Check Valve.
Ball Check Valve.
Check valves are installed on the discharge lines of pumps and compressors.

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Unit No. 3 - Valves
SWING CHECK VALVE

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Figure 3-13 Swing Check Valve
Swing check valves are so named because of the way they work. They swing
open to allow flow in one direction. When they close they stop the flow from the
opposite direction. They are widely used in general industry as they offer little flow
resistance and they don't go wrong.
In a swing check valve the valve disc is attached to a hinged arm. The pressure
of gas or liquid flowing through the valve holds the disc open, allowing full flow. If
the flow stops or the pressure downstream of the valve becomes higher than the
pressure upstream of the valve, the hinged arm will swing down. The disc will
cover the passage and close the valve. The back pressure will press against the
disc to keep it tightly closed. None of the liquid or gas that has already passed
through the valve can flow back through the valve.
Swing check valves can be installed horizontally or vertically. Gravity will close the
valve if the flow stops. They are usually installed on the discharge lines of pumps
and compressors.

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Unit No. 3 - Valves
BALL CHECK VALVE

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Figure 3-14 Ball Check Valve
The valve disc in a ball check valve is a ball. This type of check valve is used -to
control the flow direction of heavy fluids. They are available in horizontal, vertical
and angle design. Ball check valves also work well where particles are present in a
fluid.
The ball in this type of check valve rotates. This ensures that the ball wears evenly
and makes a good seal on the valve seat. A certain pressure is required to open the
ball valve. When the pressure falls, the ball valve will close by gravity.

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Unit No. 3 - Valves
LIFT CHECK VALVES

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Figure 3-15 Lift Check Valve
Lift check valves are sometimes built in globe valve bodies. They are also called
piston check valves. (See Figure 3-15) They have a guided disc shaped plug which
is lifted by the pressure of the fluid. This type of check valve does not shut suddenly
as the swing check valve does. It is better for piping systems where the flow is
irregular or often changes direction. The disc is seated horizontally so the fluid must
change direction twice as it passes through the valve.

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Unit No. 3 - Valves
3.9 SPECIAL VALVES

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SAFETY AND RELIEF VALVES
Figure 3-16 Pressure Relief Valve
Figure 3-17 Safety Relief Valve

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Unit No. 3 - Valves

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A safety or relief. valve is a very important protective device. It is designed to
avoid accidents by relieving pressure when something goes wrong in the system.
Safety valves and relief valves respond to high pressure in a pipe system. These
valves relieve the pressure before it can cause an accident or damage.
Safety valves are used for protection on steam and gas production facilities.
Relief valves are generally used on liquid production systems.
Safety valves are commonly called PSV's (Pressure Safety Valves). Relief valves
are commonly called PRV's (Pressure Relief Valves).
A safety valve on a gas processing system is usually connected to a flare vent

system. The gas escapes to a flare where it is burnt. A safety valve on a steam
system will vent to the atmosphere.
Safety valves are set to open (pop) completely at a pre-set pressure. This pre-set
pressure can be adjusted. The safety valve will stay open until the pressure drops
back to the pre-set lower pressure. The valve should then shut immediately.
The outlet ports on safety valves and relief valves are always larger than the inlet
ports. This allows the excess pressure to flow through the valve faster and bring
the pressure down to normal quickly.
The safety valve is spring loaded. The spring is adjusted before it is installed. At
the pre-set pressure the spring loaded disc is forced open. It is designed so that
the flow pushes the disc fully open. It stays in the fully open position until the
pressure falls to below the pre-set pressure. The spring then snaps the disc to the
closed position where it is firmly seated.
The relief valve is normally spring loaded. When the pressure goes above the
pre-set pressure the disc does not go fully open immediately. The amount it
opens depends on the amount of excess pressure. The more excess pressure
there is, the more the valve opens.
When the pressure falls to the pre-set pressure, the valve will close gently. There
is no loss of liquid because the liquid that escapes is recycled to the suction of
the pump or inlet of the vessel it came from, These valves are generally used as
relief valves for the thermal expansion of liquids in pipelines.

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Unit No. 3 - Valves
Safety valves and relief valves are very important for the safe operation of a piping

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system. They are normally inspected and tested once a year or during plant turn
arounds.
RUPTURE DISCS
Figure 3-18 Rupture Disc
Figure 3-19 Ruptured Rupture Disc

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Unit No. 3 - Valves

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Figure 3-20 Rupture Disc Installation
Rupture discs (bursting discs) are another pressure relief device. A rupture disc is
designed to break if the pressure is too high. Different discs are designed for
different pressures. After they break they must be replaced.
DIAPHRAGM VALVE
Figure 3-21 Diaphragm valve
A diaphragm valve is not like the other valves. It does not have a valve disc. The
diaphragm valve uses a flexible diaphragm as its opening / closing element. When
the diaphragm is forced downward it completely closes the valve. When it is
completely open the diaphragm is out of the line of flow so it does not restrict it.
There is no valve stem in the flow path. No stem packing is required. These are
types of valve require less maintenance than the conventional valves.

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Unit No. 3 - Valves
The diaphragm is usually made of a rubberised compound so these valves are often

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used where highly corrosive materials are present. Figure 6-63 shows the three
position of a diaphragm valve.
Figure 3-22 Positions of a Diaphragm Valve
3.10 STUFFING BOX AND VALVE PACKING
The valve packing inside the stuffing box has two main functions. It keeps the
process fluid inside and the atmospheric atmosphere outside the pipe. The packing
also makes it easier to open or close a valve because it lubricates the valve stem.
The valve packing must be able to withstand the following:
High temperature.
Low temperature.
High pressure.
Vacuum.
Many different types of fluids.
Abrasive materials.
Compression forces.

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Good packing must be:
Good lubricant.
Compressible.
Long Lasting.
Tough.
Flexible.
One type of packing cannot handle all the processes or be suitable for all the
different types of valves. Because of the wide variety of valves and process fluids, a
wide variety of stuffing boxes and packings are used. Stuffing boxes are designed
to hold a number of different types and sizes of packing. Four of the most common
types are shown below:
PACKING NUT WITH GLAND
Figure 3-23 Packing Nut With Gland
This type uses ring type packing. The packing is secured and compressed by a
normal single packing nut with a free gland.

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Unit No. 3 - Valves
BOLTED GLAND

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Figure 3-24 Bolted Gland
This type compresses the packing into the stuffing box with a gland follower (See
figure 3-24). The follower has two eye bolts through These are tightened down by
the nuts to compress the packing.
LANTERN TYPE
Figure 3-25 Lantern Type Packing.
This type has two sets of packing in the gland separated by a lantern ring. The
lantern ring is connected to the outside of the valve by two holes with a threaded
inlet and outlet. This will allow the following:

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Unit No. 3 - Valves

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A cooling fluid can be circulated in and out of the gland so as to keep it cool.
Any excess fluids passing the lower packing can be piped away without any
leaking or loss.
A flushing fluid can be pumped in so as to flush out any corrosive or abrasive

materials before they reach the top packing. This ensures a good seal.
INJECTION TYPE GLAND
Figure 3-26 Injection Type Gland.
The injection type gland uses a sealing compound instead of packing material. The
compound, e.g., special grease is injected into the stuffing box. This grease acts as
a packing to seal the process fluid and to help the valve turn easily.
The operator must check the following on these types of valves:
Check the valve for leaking fluids.

Check the gland for tightness.
Check how much thread is showing through the nuts. This will tell you how
much life is left in the packing material
Check for the smooth operation of the valve
Check that the valve is lubricated.

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Unit No. 3 - Valves
3.11 CONTROL VALVES

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The function of a control valve is to control the amount of fluid which flows through
it. By controlling the flow of fluids we can also control other process variables, i.e.
pressure, temperature and liquid levels. The types of control valves are globe valves
and butterfly valves. They have a valve actuator attached.
Control valves are important in any piping system where you want automatic control.
Modern plants use a lot of automatic control from a centralised control room; so do
pipeline and tank farm operations.
Manually operated valves can control fluid flow in any piping system. Control valves
are specially designed to provide a variable resistance in a piping system. This is
called throttling.
Valves can be operated Manually or Automatically, Valves can be operated Locally

or by Remote Control
3.12 AUTOMATIC CONTROL VALVES
Automatic valves are made in the same wide range of valve body styles, materials,
pressure ratings and end connections as manual valves. However, there are some
differences and certain types of valve bodies are better than others. The most
common automatic control valve is the globe type, unbalanced contoured plug
valve. This is very good for throttling actions. A similar plug type globe valve is the
balanced tight shut off plug. This is also available with a balanced trim. (see Figures
3-27 and 3-28 ).
Figure 3-27 Unbalanced Contour Valve

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Unit No. 3 - Valves

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Figure 3-28 Balanced Tight Shut Off Plug
3.13 VALVE ACTUATORS
Valve actuators are devices that provide the force to move a valve. They open,
close, adjust or maintain a set valve position by pulling, pushing or rotating the valve
stem. There are a number of different types of valve actuators that can be used:
Manual Valve Actuators:
Handwheel: Gear operated.

Handwheel: l Chain operated.
Automatic Valve Actuators:
Pneumatic: Air driven.

Electric : Motor driven.
Hydraulic: Liquid driven.
Valve actuators are used on valves for the following reasons:
Remote Operation:
Valve actuators are used on valves so that the operator can open, close or control
the flow from the control room. An operator can control the valve from a safe
location, e.g., at ground level.

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Unit No. 3 - Valves
Valve Size:

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Large valves can be too large to be opened / closed by hand. A valve actuator is
quicker and easier. A valve actuator is more accurate for setting a desired flow rate.
Safety
A valve actuator gives a remote operation for valves that are in hazardous areas.
3.14 PNEUMATIC ACTUATOR OPERATION
Most control valves use a pneumatic valve actuator. Air pressure from the actuator
positions the valve stem. A pneumatic valve actuator is attached to a valve. The
valve stem connects the valve disc to a diaphragm inside the valve actuator.
Figure 3-29 Major Components of a Typical Control Valve
The actuator has a rod which connects the actuator diaphragm to the valve stem of
a globe or butterfly valve. The diaphragm moves by increasing or decreasing the air
pressure pushing on the diaphragm. The air pressure is increased or decreased by
the operator in the control room when he moves the valve controller.

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Unit No. 3 - Valves

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Figure 3-30 Typical Reverse Acting Diaphragm Actuator
In Figure 3-30 the air pressure from below the diaphragm is increased and it pushes
the diaphragm up to open the valve. To close the valve the air pressure against the
diaphragm is reduced and the diaphragm moves down. It is the spring that holds the
diaphragm down.

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Unit No. 3 - Valves

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Figure 3-31 Typical Direct Acting Diaphragm Actuator
In Figure 3-31 the air pressure from above the diaphragm is increased and it pushes
the diaphragm down to open the valve. To close the valve the air pressure against
the diaphragm is reduced and the diaphragm moves up. It is the spring that holds
the diaphragm up.
The position of the valve depends on the air pressure on the diaphragm. The valve
will move from the fully open position to the fully closed position with an air pressure
change of from 3 psig to 15 psig.
In most process systems there are fail safe control valves. These protect parts of
the system from too much pressure if something goes wrong. A large spring is
attached to the actuator rod and diaphragm. Its function is to fully open or fully close
the valve if the instrument air supply to the valve actuator cuts off.
In Figure 3-30 if the air supply fails the valve will close. In Figure 3-31 if the air
supply fails the valve will close, these are called "Air Fail Closed" control valves.

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Unit No. 3 - Valves
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Figure 3-32 Butterfly Valve with Actuator
3.15 ELECTRIC MOTOR ACTUATOR
Some valves use an electric motor as an actuator. These valves are called motor
operated valves or MOV's.
Figure 3-33 Motor Operated Valve
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Unit No. 3 - Valves
A motor operated valve has two main parts: the valve itself and a motor driven
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screw stem. The motor uses two bevelled gears to move the valve stem up and
down. The drive gear is attached to the shaft of the motor through speed reducing
gears. The stem gear is threaded in the centre. The valve stem is screwed through
the gear.
As the motor turns the stem gear, the valve stem threads itself inside the stem
gear. This threading action moves the stem up or down depending on the direction
of motor rotation.
A motor operated valve is also equipped with a handwheel. The handwheel allows
the valve to be manually operated if the motor should fail.
3.16 HYDRAULIC VALVE ACTUATORS
A hydraulic actuator uses the force of a pressurised liquid, (usually oil) to position
the valve stem.
In a hydraulic valve actuator a cylinder assembly is attached to a valve. A piston

inside the cylinder moves up and down. The piston is attached to the valve stem.
The pressure of hydraulic fluid in the cylinder causes the valve stem to rise or fall.
When the hydraulic oil is pumped to the top side of the piston the valve will close.
When hydraulic oil is pumped to the bottom side of the piston the valve will open.
Figure 3-34 Hydraulically Actuated Control Valve
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Unit No. 3 - Valves
3.17 SOLENOID / MAGNETIC ACTUATORS
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Figure 3-35 Solenoid Valve Operation
Solenoid operated valves are not very large. They are commonly used to shut off
instrument air supply to control valves. They are often used in emergency shutdown
systems (ESD's).
Solenoid valves use the principle of electromagnetism to operate. As long as the coil
is energised, electromagnetism holds the core up. The valve remains open and
instrument air reaches the control valve. In an emergency the coil is deenergised.
Then the coil moves down and shuts off the instrument air to the control valve. The
control valve can be set up to open, close or remain in its position.
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Unit No. 3 - Valves
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Figure 3-36 Magnetic Valve Operation
Electromagnetic force from the coil holds the solenoid core down, allowing
instrument air to the , valve actuator. When power to the coil is shut off the solenoid
core moves up shutting off the instrument air supply to the valve actuator. At the
same time the system air is vented from the actuator (See Figure 3-36).
Control valves act in one of two ways:
Air pressure to close, "Direct Acting". An increase in air pressure closes the valve.
Air pressure to open, "Reverse Acting". An increase in air pressure opens the valve.
3.18 VALVE INSPECTION
Valves should always be checked regularly by the operators for flange stem or
bonnet leaks. A stem leak may indicate the valve needs new packing or the packing
nut needs tightening. Bonnet leaks may be caused by loose bolts due to strains in
the line over a long period of time. A flange leak may also be due to loose bolts.
No small leak should be overlooked or ignored as a small leak may develop into a
large leak.
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Unit No. 3 - Valves
You should lubricate valves regularly. Regular lubrication will prevent frictional wear
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(galling). Lubrication of the valves will also prevent the valves seizing.
Seizing occurs when metal to metal surfaces stick to each other because of heat
or pressure.
If any type of valve is left in one position for a long period of time, corrosion and
foreign particles may accumulate. This is especially true on stem threads.
Periodic checking and lubrication should be done regularly. Maintenance should
be told of leaking valves by the operations staff. Operations staff are the eyes of
the maintenance staff.
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Training Manual Operations: July 1999-Rev.0

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July 1999- Rev.0 Page 1/39

UNITS IN THIS COURSE

UNIT 1 PIPING SYSTEMS

UNIT 2 PIPE FITTINGS

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3.0 COURSE OBJECTIVE 3

3.1 INTRODUCTION TO VALVES 4

3.2 VALVE IDENTIFICATION AND FUNCTION 5

3.3 VALVE PARTS 6

3.4 BLOCK VALVES 7

3.5 PLUG VALVES 11

3.6 BALL VALVES 12

3.7 THROTTLING OR REGULATING VALVES 13

3.8 CHECK VALVES

3.9 SPECIAL VALVES 22

3.10 STUFFING BOX AND VALVE PACKING 26

3.11 CONTROL VALVES 30

3.12 AUTOMATIC CONTROL VALVES 30

3.13 VALVE ACTUATORS 31

3.14 PNEUMATIC ACTUATOR OPERATION 32

3.15 ELECTRIC MOTOR ACTUATOR 35

3.16 HYDRAULIC VALVE ACTUATORS 36

3.17 SOLENOID / MAGNETIC ACTUATORS 37

3.18 VALVE INSPECTION 38

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3.0 COURSE OBJECTIVE

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& Safety features.

Equipment interaction with the overall process.

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3.1 INTRODUCTION TO VALVES

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Processing systems handle different products at different pressures and

Brass. These are used for utilities / fire water

Plastic These are used for air chemical lines.

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VALVE TYPE EXAMPLES FUNCTION

Block Valve Gate Valve To stop or start

Throttling / Regulating Globe Valve To control how much fluid

Safety / Relief Valve Balanced bellows To release excess pressure.

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3.3 VALVE PARTS

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Figure 3-1 Major Valve Parts

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VALVE DISC (OPENING ELEMENT)

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On a manual valve a handwheel or handle is attached to the stem. The handwheel

3.4 LOCK VALVES

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Rising stem gate valve.

Non-rising stem gate valve.

RISING STEM GATE VALVE

Figure 3-2 Rising Stem Gate Valve

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NON RISING STEM GATE VALVE

Figure 3-3 Non Rising Stem Gate Valve

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