32 PAMPHLET 94

5.3.2 Other Piping Systems

Nonmetallic piping systems including lined pipe, FRP, dual laminate FRP, PVC, CPVC,
polypropylene and other materials have been successfully used for many applications at
varying concentrations. The quality of the design and manufacture of dual laminate
piping is highly dependent on the utilization of a designer and manufacturer with
adequate expertise, therefore references and past experience should be strongly
considered when selecting a nonmetallic piping contractor.

Each application is unique and therefore the conditions (temperature, pressure, caustic
concentration, etc.) should be carefully considered before selection of the material of
construction.

5.4 VALVES

Valving for caustic service requires special attention by all associated with the
application, including the manufacturer, the supplier, the installer, the operator, and the
maintainer. An understanding by all involved of the following subsections will provide for
a successful application.

This section will discuss the types of valves currently in service, the criteria for selection
of valve features, valve selection tables and materials of construction tables. The
information presented is based on experience of the Institute’s membership and relevant
information furnished by valve manufacturers. There is no intention to exclude the use
of other valve types or materials provided there is adequate experience and sufficient
testing to ensure their safe operation.

5.4.1 General Caustic Service Valves

The types of valves commonly employed in caustic service are the globe, ball, plug,
gate, butterfly and diaphragm. Each type is available in several basic body patterns and
with different design features often unique to a particular service and/or installation.
Specific advantages and disadvantages are listed in the following section.

Globe Valves

Globe valves offer several important safety features, including tight shut off in both
directions (bidirectional seating) without trapping liquid inside cavities, multi-turn
operation that prevents quick (and sometimes accidental) opening and closing, and a
positive means to verify valve position (open or closed).

The recommended configuration includes a blow-out proof stem, a bolted bonnet

employing four bolts minimum, and a gland with outside screw and yoke (OS&Y) for
external packing gland adjustment. Either metal-to-metal seating employing hard-facing,
or soft-seating using a fluoropolymer insert will provide satisfactory service.

A bellows seal can be chosen for extended service life. Similar results may be achieved
with special stuffing box designs incorporating a live-loaded packing gland.
SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION
(CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM 33

Ball Valves

Ball valves can provide tight shutoff with minimum resistance to flow when fully open.
They are generally easier to operate than plug valves of equal size. The 1/4-turn stem
movement lends itself to an inherently more reliable stem seal design than the rising
stem valve. Ball valves should incorporate a blow-out proof stem design and a means to
externally adjust the stem seal. The sealing material generally is a fluoropolymer resin,
although fluoroelastomer O-rings are sometimes employed as the outer secondary seal.
Glass reinforced fluoropolymer seals should not be used in caustic service.

Ball valves may be furnished either full-bore or reduced-bore. Flanged valves may have
either a long (standard) or short body pattern. Full-bore ball valves have openings
throughout the length of the valve with a diameter equal to their nominal pipe size. If the
ball valves are to be insulated, the stem should be extended to accommodate the
thickness of the insulation.

Two designs of ball valves generally used are the metal bodied type with fluoropolymer
resin seats and the fully lined type utilizing a fluoropolymer resin-lined body and
overmolded ball. Selection should be based on a complete understanding of the
pressure, temperature, and concentration of the application.

Plug Valves

Plug valves can be used for caustic service and have generally provided satisfactory
service. Their primary drawback is a need to balance turning torque and shutoff sealing
capability. Like the ball valve, this valve can provide tight shutoff and, with the 1/4-turn
stem movement, lends itself to an inherently more reliable stem seal design than the
rising stem valve and if insulated, the stem should be extended to accommodate the
thickness of the insulation.

Plug valves have an inherent blow-out proof stem design and should be provided with a
means to externally adjust the stem seal. The sealing material generally employed is a
fluoropolymer resin. Two designs of plug valves generally used are the metal type with
a fluoropolymer resin sleeve body and metal plug, and the fully lined type, utilizing a
fluoropolymer resin-lined body and overmolded plug.

While these valves provide good shutoff sealing, they require substantial torques to
operate them. This torque requirement tends to increase as the valve liner ages or
deforms. The use of gear operators on 4 inch (10.2 cm) valves and larger is strongly
recommended. In some cases, gear operators may be needed on 3 inch (7.6 cm)
valves, as well.

Gate Valves

Gate valves have provided satisfactory service in caustic applications. Gate valves
utilizing a rising stem design may require additional maintenance and packing
adjustments to avoid shaft leakage.

Material selection should be based on the specific application, with regards to the
concentration and temperature. Metal-to-metal seating or soft-seating using a
fluoropolymer resin insert will provide satisfactory service.