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NAMEI POLYTECHNIC INSTITUTE

Engineering
Chapter 1
INTRODUCTION
Background of the Study
In order to control the flow and pressure within a system or process we need the
mechanical device called valve. Valve is found virtually in every industrial process,
including water and sewage processing, mining, power generation, processing of oil,
gas and petroleum, food manufacturing, chemical and plastic manufacturing and many
other fields. People in developed nations use valves in their daily lives, including
plumbing valves, such as taps for tap water, gas control valves on cookers, small valves
fitted to washing machines and dishwashers, safety devices fitted to hot water systems,
and poppet valves in car engines. However, valves may be operative manually and
directionally. Mechanically or manually valve may operate either by hand, lever, pedal
or wheel and directionally operated driven by changes in pressure, temperature, or flow.
These changes may act upon a diaphragm or a piston which in turn activates the valve,
Examples of this type of valve found commonly are safety valves fitted to hot water
systems or boilers. In this study presents the different assessment of strengths of valves
being manually operated and directionally. Understanding what is the most efficient
valve for overall system performance and how it is critical in achieving effective pumping
system operations to keep costs down and improve station reliability.
Marine Automation: Comparison of Mechanical Operated valve vs. Directional control valves. Page1
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Statement of the Problem/Objectives

General Objective:
This research paper has the objective are to discuss about the comparison between the
mechanical operated valve and directional control valve. For the student to understand
the topic and to know the purpose of each valve, and to know the difference between
the each valve, and how to use it properly.
Specific Objectives:
1. What is the different type of mechanical operated valve?
2. What are the advantage and disadvantage of mechanical operated valve and
directional control valve?
3. What is the purpose of Mechanical operated valve directional control valve.
4. What is the limitation special type of directional control valve in hydraulic and
pneumatic operation?
5. Which is much reliable in terms of industry usage and application?
Significance of the Study
The significance of the study is more on Marine Engineering; we should know the main
purpose and differences between the mechanical operated valve and directional control
valve, and also to know their ability, efficiency and durability.
Marine Engineers – This research tend to assist marine engineers to know the ability,
the purpose and advantage and disadvantage of the valve on the ship.
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Students of NAMEI - for the student of NAMEI, the researcher wanted them to know
the proper knowledge about the mechanical operated valve and directional control valve
that they may encounter in the near future.
Industry – to the MARINA the researcher goal is for them to make more education
syllabus concerning the ability, purpose of each valve and the advantage and
disadvantage of the mechanical operated valve and directional control valve. To
increase the numbers of students who know about the each system.
Faculty of NAMEI – For the Professors to have more knowledge that they can share on
the students and future Marine Engineers
Future Researchers – this study guides the researcher about the difference of
mechanical operated valve and directional control valve and more about each. Gives
the researchers appropriate knowledge they can use on their career.
Scope and Delimitation
The intention of this study is to gathered information about Mechanical Operated Valve
and Directional Control Valve and more about their ability, efficiency and durability in
each valve. This study was conduct in August 2019.The study is limited due some
factors, like what is the most common valve that we use in the ship, difference of the
mechanical operated valve and directional control valve, the advantage and
disadvantage of each valve.
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Chapter 2
THEORETICAL FRAMEWORK/DESIGN PROJECT
This chapter presents foreign literature relevant to the study and give us
information about how is purifier and clarifier operates on board a ship.
The researcher will utilize all the resources available such as books, articles,
computer, etc. to prepare his self in the study to be made. The sorted valid data and
information will be included in this study.
Review of Related Literature and Studies
According to hydraulic pneumatic
Mechanical operated valve mechanically operated valves apply forces by using cams,
wheels, rollers, etc., hence these valves are subjected to wear.
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Figure 2.1 Actuator
Actuator is a component of a machine that is responsible for moving and controlling a

mechanism or system, actuator requires a control signal and a source of energy. The
control signal is relatively low energy and may be electric voltage or current, pneumatic
or hydraulic pressure, or even human power. Its main energy source may be an
electric, hydraulic fluid pressure, or pneumatic pressure. When it receives a control
signal, an actuator responds by converting the signal's energy into mechanical motion.
Actuator is the mechanism by which a control system acts upon an environment. The
control system can be simple (a fixed mechanical or electronic system), software-based
(e.g. a printer driver, robot control system), a human, or any other input.
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Figure 2.2 Valve actuator
Valve actuator is a mechanical device that uses a power source to operate a valve.
This power source can be electric, pneumatic (compressed air), or hydraulic (the flow
of oil). There are two main types of actuators, one for each of the two main types
of valves that require them. They are rotary and linear.
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Figure 2.3 Hydraulic actuator
Hydraulic actuator consists of cylinder or fluid motor that uses hydraulic power to
facilitate mechanical operation. The mechanical motion gives an output in terms of
linear, rotatory or oscillatory motion. As liquids are nearly impossible to compress, a
hydraulic actuator can exert a large force. The drawback of this approach is its limited
acceleration.
The hydraulic cylinder consists of a hollow cylindrical tube along which a piston can
slide. The term single acting is used when the fluid pressure is applied to just one side
of the piston. The piston can move in only one direction, a spring being frequently used
to give the piston a return stroke. The term double acting is used when pressure is
applied on each side of the piston; any difference inpressure between the two sides of
the piston moves the piston to one side or the other.
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Figure 2.4 Pneumatic actuators
Pneumatic actuators enable considerable forces to be produced from relatively small

pressure changes. A pneumatic actuator converts energy formed by vacuum
or compressed air at high pressure into either linear or rotary motion. Pneumatic energy
is desirable for main engine controls because it can quickly respond in starting and
stopping as the power source does not need to be stored in reserve for operation.
Moreover, pneumatic actuators are safer, cheaper, and often more reliable and powerful
than other actuators. These forces are often used with valves to move diaphragms to
affect the flow of air through the valve.
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Figure 2.5 Electric Actuator
Electric actuator may provide the actuation force/torque in one of several

ways. Electromechanical actuators may be used to power a motor that converts
electrical energy into mechanical torque. Another approach is
an electrohydraulic actuator, where the electric motor remains the prime mover, but
provides torque to operate a hydraulic accumulator that is then used to transmit
actuation force in much the same way that diesel engine/hydraulics are typically used in
heavy equipment.
Electrical energy is used to actuate equipment such as multi-turn valves, or electric-

powered construction and excavation equipment.
Additionally, a brake is typically installed above the motor to prevent the media from
opening valve.
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Types of Valve Actuators
Each type of actuator is designed for a particular type of valve. Valves can be sorted by
their motion and their function.
Valve Motion
Rotary hydraulic valve actuators
Figure 2.6 Rotary hydraulic valve actuators
Rotary hydraulic valve actuators -- Rotary actuators are used for rotary motion valves
such as ball, plug, and butterfly valves through a quarter-turn or more from open to
close. The closing element is generally a disc or ellipse which turns about an angular
shaft.
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Figure 2.7 Linear hydraulic valve actuators
Linear hydraulic valve actuators -- Linear actuators move linear valves such as gate,
globe, diaphragm, and pinch valves by sliding a stem that controls the closure element.
Figure 2.8 Throttling valves
Throttling valves can be moved to any position, including fully open or fully closed,
within the stroke of the valve. Typically, valve actuators are added to throttling valves as
part of a control loop that includes a sensing device and circuitry.
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Directional Control Valves
Directional control valves perform only three functions:
 stop fluid flow

 allow fluid flow, and
 Change direction of fluid flow
These three functions usually operate in combination.
The simplest directional control valve is the 2-way valve. A 2-way valve stops flow or
allows flow. A water faucet is a good example of a 2-way valve. A water faucet allows
flow or stops flow by manual control.
A single-acting cylinder needs supply to and exhaust from its port to operate. This
requires a 3-way valve. A 3-way valve allows fluid flow to an actuator in one position
and exhausts the fluid from it in the other position. Some 3-way valves have a third
position that blocks flow at all ports.
A double-acting actuator requires a 4-way valve. A 4-way valve pressurizes and

exhausts two ports interdependently. A 3-position, 4-way valve stops an actuator or
allows it to float. The 4-way function is a common type of directional control valve for
both air and hydraulic circuits. A 3-position, 4-way valve is more common in hydraulic
circuits.
The 5-way valve is found most frequently in air circuits. A 5-way valve performs the
same function as a 4-way valve. The only difference is an extra tank or exhaust port.
(Some suppliers call their 5-way valves, “5-ported 4-ways.") All spool valves are five
ported, but hydraulic valves have internally connected exhaust ports going to a common
outlet. Because oil must return to tank, it is convenient to connect the dual tank ports to
a single return port. For air valves, atmosphere is the tank, so exhaust piping is usually
unimportant. Using two exhaust ports makes the valve smaller and less expensive. As
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will be explained later, dual exhausts used for speed-control mufflers or as dual-
pressure inlets make this configuration versatile.
Following are schematic symbols for commonly used directional control valves.
2-way directional control valves
A 2-way directional valve has two ports normally called inlet and outlet. When the inlet is
blocked in the at-rest condition, as shown in Figure 8-1, it is referred to as "normally
closed" (NC). The at-rest box or the normal condition is the one with the flow lines going
to and from it.
The boxes or enclosures represent the valve’s positions. In Figure 2-1, the active box
shows blocked ports, or a closed condition, while the upper box shows a flow path.
When an operator shifts the valve, it is the same as sliding the upper box down to take
the place of the lower box. In the shifted condition there is flow from inlet to outlet.
Releasing the palm button in Figure 8-1 allows the valve spring to return to the normal
stop flow condition. A 2-way valve makes a blow-off device or runs a fluid motor in one
direction. By itself, a 2-way valve cannot cycle even a single acting cylinder.
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Figure 2.9 2-way directional valve
Figure 2-2 shows a "normally open" (NO) 2-way directional valve. Energizing the
solenoid on this valve stops fluid flow.
Valve operators come in different types. Figure 2-3 shows a solenoid pilot operator
using solenoid-controlled pressure from the inlet port to move the working directional
spool. Figure 2-4 shows a cam-operated valve. A moving machine member usually
operates this type valve.
A 3-way valve has three working ports. These ports are: inlet, outlet,
and exhaust (or tank). A 3-way valve not only supplies fluid to an actuator, but allows
fluid to return from it as well. Figures 2-5 through 2-10 show schematic symbols for 3-
way directional control valves.
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Figure 2-10. Solenoid pilot-operated 3-way selector valve.
Figure 2-6 depicts an all-sports-blocked, 3-way, 3-position valve. A valve of this type
connected to a single-acting, weight- or spring-returned cylinder could extend, retract, or
stop at any place in the stroke.
Some 3-way valves select fluid flow paths as in Figure 2-9. Use a spool-type valve for
this operation. Another flow condition is the diverter valve shown in Figure 8-10. A
diverter valve sends fluid to either of two paths.
Figure 2-11. Palm-button-operated 3-way diverter valve.
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Figures 2-11 to 2-15 show different configurations available in 4-way directional control
valves. They range from the simple, two-position, single, direct solenoid, spring-return
valve shown in Figure 8-11, to the more complex three-position, double solenoid, pilot-
operated, spring-centered, external-pilot supply, external drain valve shown in Figure 8-
15.
Figure 2-12. 4-way, 2-position direct solenoid-operated spring return.
Lines to the boxes show flow to and from the valve, while lines with arrows in the boxes
show direction of flow. The number of boxes tells how many positions the valve has.
Figure 2-12 shows a single solenoid, spring-centered valve. This valve has a third
position but there is no operator for it. Use this spring-centered, single solenoid valve in
control circuits for special functions. In the past, to get this configuration, you only had to
wire one solenoid of a double-solenoid, three-position valve.
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Figure 2-13. 4-way, 2-position direct solenoid-operated spring centered.
Figure 2-13 shows another unusual 4-way configuration. This valve shifts from an
actuator moving flow path to center condition for certain special circuits.

Figures 2-16 through 2-20 show symbols of some 5-way air valves. Most spool-type air
valves come in a 5-way configuration. Because air usually exhausts to atmosphere, the
extra exhaust port is no problem.
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Figure 2-14. 4-way, 2-position direct solenoid-operated spring return.
Many valves use the two exhaust ports for speed control mufflers. Mufflers not only
make the exhaust quieter, but throttle the exhaust, which in turn controls cylinder speed
in a meter-out circuit.
Another example later in this section shows dual exhaust ports piped with different
pressures to save air. Also use dual inlet piping to make an air cylinder operate quickly
and smoothly.
Figure 2-15. 4-way, 2-position solenoid, pilot operated detected, line-mounted.
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Most air cylinders stroke from one extreme to the other. A two position, single solenoid,
spring return valve is sufficient for this operation. About 90% of air circuits use this type
of valve. To stop an air cylinder in mid-stroke, use the 3-position valve shown in Figures
2-19 through 2-21.
Figure 2-16.Line-mounted, solenoid pilot-operated, 2-position, spring returned 5-

way valve.
It is difficult — if not impossible — to accurately stop an air cylinder any place other than
at end of the stroke. When the cylinder moves slowly, a repeatable mid stroke position
of plus or minus an inch might be possible. The problem is, if the load on the cylinder
changes or there is any slight leak in the piping or seals, it will not hold position once it
stops.
Figure 2-17. Line-mounted, hand lever-operated, 2-position, spring-returned 5-

way valve.
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Three-position valves come in several styles, including: cylinder ports open as seen in
Figure 2-19; all ports blocked as seen in Figure 2-20; and pressure to cylinder ports as
seen in Figure 2-21.
Using2-wayvalves
Figures 2-18 show some uses for 2-way directional control valves.
Figure 2-19. 5-way, 3 positions, spring-centered solenoid, pilot-operated, cylinder ports

open-center condition, line mounted. One use is the blow-off function shown in Figure
2-22. A 2-way valve in Figure 2-23 operates a one-direction motor with an open
exhaust in the motor housing. The circuit in Figure 2-24 works well for electrically
unloading a pump for easy start up and/or reduced heat generation
Figure 2-19. 5-way, 3 position, spring-cantered solenoid, pilot-operated, all ports

blocked center condition, line mounted.
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Figure 2-25 shows a weight-returned, single-acting cylinder powered by a 2-way in
the at rest condition. At first sight it looks as if this circuit might work. Shifting the 2-way
valve, or extending, sends fluid to the cylinder cap end and it extends. The problem
comes when the 2-way returns to normal at the end of cycle. Instead of the cylinder
retracting after the solenoid de-energizes, it stays in the extended position. The cylinder
would only return if the valve, cylinder seals, or pipe connections leak.
Figure 2-20. 5-way, 3 positions, spring-centered pressure to cylinder ports,

exhausts blocked center condition, solenoid-pilot operated, line mounted.
Shows a circuit that operates a single-acting cylinder with 2-way valves. One (NO) and
one (NC) 2-way directional valve piped to the cap end cylinder port allows fluid to enter
and exhaust from it. Actuating both operators simultaneously extends the cylinder.
According to valve size and inlet air flow, the cylinder might not extend if just energizing
the (NC) valve. If the cylinder extends with only one valve actuated, it would be slow
and waste a lot of air.
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Figure 2-21. Blow-off. Figure 2-22. Running a one-direction fluid motor.
Figure 2-23. Unloading a pump.
Figure 2-24. Using one 2 way valve to operate a single-acting cylinder.
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Figure 2-25. Operating a single-acting cylinder with two 2-way valves.
Figure 2-25 shows four 2-way valves piped to operate a double-acting cylinder. A pair
of 2-way valves at each cylinder port gives a power stroke in both directions. Energize
and de-energize all four valves simultaneously to cycle the cylinder and keep from
wasting fluid.
Four 2-way valves may seem to be a complex and expensive way to operate a cylinder.
However, in the past few years, poppet type slip-in cartridge valves have been
operating large bore hydraulic cylinders this way. See chapter four on Cartridge Valves
for the advantages of these valves in high flow circuits.
Figure 2-26. Operating a single acting cylinder with four 2-way valves.
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Using 3-way valves
Figure 2-28 shows a 3-way valve, used to select Pr. 1 or Pr. 2. Use a spool type
directional control valve in this type of circuit. Spool valves normally take pressure at
any port without malfunction. Poppet design valves normally take pressure at the inlet
port only.
Since the example selector valve is solenoid pilot-operated, it is important to determine

which port has the higher pressure. Most solenoid pilot-operated valves take air from
the normal inlet port to operate the pilot section. If both inlet pressures are too low to
operate the valve, plumb an external pilot supply from the main air system. When it is
necessary to lock out one of two circuits while the other one operates, the hook up in
Figure 2-29 works well. While circuit one has fluid going to it, working on circuit two is
no problem. Use a spool type valve here also. Poppet valves usually only take pressure
at one port.
Figure 2-27. Pressure selector.
The most common limit valve is a miniature 3-way like the one shown in Figure 8-30.
This particular example is (NC). Contact with a machine member opens it. Except for
bleeder type control circuits, a limit valve requires at least a 3-way function.
Once this normally closed valve shifts, it passes a signal on to continue the cycle. In
normal condition, fluid in the control circuit exhausts through the exhaust port.
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Figure 2-28. Fluid diverter.
Figure 2-31 shows a single-acting cylinder with a 3-way valve powering it. Energizing
the solenoid, or extending, allows flow to move to the cylinder port and it extends. DE
energizing the solenoid or retracting lets the valve shift to home position and the
cylinder retracts from outside forces. The exhaust port on a 3-way valve lets fluid in the
cylinder escape to atmosphere. Figure 2-31. Operating a single-acting cylinder with one
3-way valve.
Figure 2-29. NC limit valve.
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To operate a double-acting cylinder with 3-way valves, use the hook up shown in Figure
2-32. With a 3-way directional valve at both ports, both extend and retract strokes of a
double-acting cylinder have force.
Some manufacturers use dual 3-way valves to conserve air. Piping between the valve
and cylinder ports wastes air. Every time a cylinder cycles, the lines to both ports fill and
exhaust. The longer the valve-to-cylinder lines are, the greater the air wastes. Mounting
air valves directly to the cylinder ports minimizes air waste. The higher cycle rate results
in greater savings.
Figure 2-30 a 3-way directional valve
Figure 2-30. Operating a double-acting cylinder with two 3-way valves.
Lowering pressure at the rod end port is another way to save air with dual 3-way valves
mounted directly to the cylinder port. As discussed before, reducing air pressure at the
cylinder uses less compressor horsepower. Usually, force required to return a cylinder
is minimal, so lower pressure at the rod port saves energy.
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Speed-control mufflers in the direct-mounted 3-way valves independently control the
extend and retract speed of the cylinder. This saves piping time and the cost of flow
control valves.
Figure 2-33 shows an air cylinder inching circuit. It is possible to inch an air circuit if
accuracy and repeatability are not important. An inching circuit’s repeatability is usually
not closer than ±1 in. if travel speed is slow. Faster travel speeds give less control.
Figure 2-31. Inching circuit for a double-acting cylinder with two 3-way spring-
centered valves.
A 3-way valve can replace a 2-way valve. To duplicate the 2-way function, block the
exhaust port of the 3-way valve. Blocking the exhaust of a 3-way is usually not
necessary for most 2-way applications. Using 3-way valves in place of 2-way valves
reduces inventory cost and saves time.
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Using 4-way valves
See Figures 2-34 to 2-36 for some uncommon uses of 4-way directional control valves.
Using directional controls in ways other than normal is a common practice. Make sure
the valve is capable of pressure in all ports before applying it to some of these circuits. If
the valve is solenoid pilot-operated, where does pilot supply come from? Also check
with the manufacturer if there is any doubt about the valve’s performance in an unusual
application.
To make a high flow 2-way valve from a 4-way valve try the circuit shown in Figure 8-
34. Connect pump flow to the normal inlet port and its outlet port, then connect the other
outlet port to the normal tank port and on to the system. In the at-rest condition there is
no flow through the valve.
Figure 2-32. Double flow capacity.
When the valve shifts, flow is from P through B to system and from A through T to
system. A valve rated at 10 gpm is now good for 20 gpm with little or no increase in
pressure drop. Make sure the valve is capable of backpressure at the tank port.
This piping arrangement comes in handy in hydraulic circuits, since most manufacturers
do not offer a 2-way valve. Also, a lot of 2-way hydraulic valves only stop flow in one
direction, so they are useless in a bi-directional flow line.
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For a full time regeneration circuit, pipe the 4-way as shown in Figure 2-35. Read
Chapter 17 for a full explanation of this regeneration circuit.
Figure 2-33. Full time regeneration.
Figure 2-36 shows how to pressurize both ends of the cylinder when a 4-way valve
centers. When a cylinder retracts to pick up another part, it often has to go too far to
make sure it is behind the part. Low backpressure from the check valve makes the
cylinder creep forward at low power so the cylinder is in contact with a part before the
next cycle starts.
Figure 2-37 shows the normal hook up of a 4-way directional valve. A double-acting
cylinder only needs one 4-way directional valve to extend and retract it. The three
sequences show a 4-way valve in action.
Figure 2-34. Low-pressure cylinder extends.
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Add flow controls or a counterbalance valve to complete the circuit when there is weight
on the rod. Note the port hook up is A to cap and B to rod.
Using this port connection arrangement consistently makes it is easy to wire the circuit
because the electrician knows A solenoid extends the cylinder while B solenoid retracts
it. Maintenance persons always know which manual override to push during trouble
shooting or setup.
Figure 2-35. Operating a double-acting cylinder with one 4-way valve
Most hydraulic directional control valves are 3-position. Valve center conditions perform
different functions in relation to the actuator and pump.
Figure 2-36. Inching circuit with pump unloaded, cylinder floating.
An all-ports open center condition directional valve unloads the pump and allows the
actuator to float as shown in Figure 8-38. This reduces heat build-up and allows
opposing forces to move the cylinder without building backpressure.
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To block the cylinder while unloading the pump, use the center condition shown in
Figure 2-39. Most hydraulic valves are a metal-to-metal fit spool design, so do not
depend on the cylinder setting dead still with a tandem center spool. If there are outside
forces on the cylinder, it will creep when the valve centers.
Figure 2-37. Inching circuit with pump unloaded, cylinder blocked.
If the cylinder needs to float while blocking pump flow, use the center condition shown in
Figure 2-40.
Figures 2-41 to 2-46 show several commonly used 4-way hydraulic valve center
conditions. The first four account for about 90% of all 3-position hydraulic valves in use.
The center condition of a 3-position valve can unload a pump, open actuator ports to
tank for free movement, block actuator ports to stop movement, give regeneration, or
work in combinations of these functions.
Figure 8-41 shows an all-ports-open center condition valve. The open center condition
unloads the pump and allows the actuator to coast to a stop or float. In the crossover or
transition condition it causes very little shock. Fixed volume pumps use this center
condition.
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Figure 2-38. Inching circuit with pump blocked, cylinder floating.
The all-ports-blocked center condition valve of Figure 2-42 appears to block the cylinder
ports. In actual use, leakage oil across the spool lands pressurizes A and B ports,
possibly causing a single rod cylinder to extend. This is not a good choice for stopping
and holding a cylinder as the symbol seems to indicate. To positively stop a cylinder,
use a valve with the cylinder ports hooked to tank, and pilot-operated check valves in
the cylinder line or lines. (See the section on “Check Valves as Directional Valves.”)
Figure 2-39. All ports open, center condition.
The float center valve of Figure 2-43 allows the actuator to float while blocking pump
flow. Pump output is available for other valves and actuators with this center condition.
It also works well for pilot-operated check valve locking circuits or with counterbalance
valves.
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Figure 2-40. Ports blocked center condition.
This is the normal center condition for the solenoid valve on a solenoid pilot-operated,
spring-centered directional valve.
Figure 2-41. Float center condition.
Figure 2-44 shows a tandem center valve. A tandem center valve lets the pump unload
while blocking the cylinder ports. The cylinder sits still unless there is an outside force
trying to move it. Any metal-to-metal fit spool valve never fully blocks flow. With external
forces working on the cylinder, it may slowly creep with the valve centered. This is
another common center condition for fixed volume pumps.
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Figure 2-42. Tandem center condition.
The regeneration center position of the valve in Figure 2-45 pressurizes and connects
both ports of a cylinder to each other. Connecting pressure oil to both cylinder ports and
to each other regenerates it forward when the valve centers. This valve is the pilot
operator for hydraulically centered directional valves or normally closed slip in cartridge
valves.
Figure 2-43. Regeneration center condition.
To unload the pump while blocking the cylinder from moving, use the valve shown in
Figure 2-46. However, the metal-to-metal fit spool will not lock the cylinder when there
are external forces.
Figures 2-47 to 2-48 show what is commonly referred to as the “crossover” or

“transition” condition of a spool. In some actuator applications it is important to know
what the valve port flow conditions are as it shifts. As shown in these figures, dashed
lined boxes show crossover condition. Normally discussions about crossover conditions
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cover “open” or “closed” types; in reality, the crossover condition may be a combination
of these and may be different on either side of center.
Figure 2-44. Pump unload, port B blocked, center condition.
Open crossover stops shock while the spool shifts, while a closed crossover reduces
actuator override travel. If the crossover condition is important to the circuit or machine
function, show it on the schematic drawing. Figure 2-49 shows an all ports blocked
center condition, solenoid pilot-operated valve, as a simplified and complete symbol. On
most schematics, the simplified symbol is sufficient. The solenoid slash and energy
triangle in the operator box show the valve has a solenoid operated valve piloting a
pilot-operated valve.
Figure 2-45. Open crossover or transition condition.
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Figure 2-46. Closed crossover or transition condition.
The boxes show the function of the main or working spool that controls the actuator. On
valves with other hardware added (here, pilot chokes and stroke limiters), it is better to
show the complete symbol. Both symbols in Figure 8-49 represent the same valve. The
complete symbol gives more information about the valve function and helps with
troubleshooting and valve replacement.
Figure 2-47. Solenoid pilot-operated valve with pilot chokes and stroke limiters.
Internal pilot supply (X) and external drain (Y).
The 5-way selector valve and shuttle valve in Figure 2-50 works where a 3-way selector
may not. The 3-way selector does fine when going from low to high pressure, but if
there is no air usage to allow expansion, it is almost impossible to go from high to low
pressure.
The 5-way and shuttle valve arrangement gives an exhaust path for high-pressure air
when shifting to low pressure. After the air exhausts to the lower pressure, PR.1, the
shuttle shifts and low pressure holds in the system.
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Figure 2-48. Pressure selector.
Figure 2-51 shows a pair of 5-way valves piped to act like a three way light switch.
Either valve moves the cylinder to its opposite position when activated.
Figure 2-52 shows the normal hook up of a 5-way valve. Normally, input air goes to the
center port of the side with three ports. A lot of air valve manufacturers call this #1 port.
In the at rest condition, air flows from #1 to #4 port and on to the cylinder rod end, while
#2 port exhausts the cylinder cap end through #3 port.
Figure 2-49. Operating an actuator from two locations.
After shifting the valve, or extending, air flows from #1 port through #2 ports to the
cylinder cap end. Flow from the cylinder rod end goes to #4 port and exhausts through
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#5 port. The exhaust ports often have speed control mufflers to reduce noise and
control the amount of exhaust flow. Speed control mufflers give individual meter-out
speed control in each direction of travel.Deenergizing the solenoid, or retracting, lets the
valve spring returns to its normal condition causing the cylinder to retract.In Figure 2-53,
the 5-way has a dual inlet instead of dual exhaust. Use a spool type valve for this hook
up, since it takes pressure at any port without malfunction.On most air circuits the
cylinder does little or no work on the retract stroke. Putting low pressure on the rod side
of the cylinder uses less compressor air without affecting the operation. This air savings
results in lower operating cost and leaves more air to run other actuators. Install flow
controls in the lines to the cylinder ports for individual speed control.
Figure 2-50. Operating a double-acting cylinder with one 5-way valve.
If the valve is solenoid pilot-operated, the supply to the pilot valve usually comes from
port #1. This means, with a dual pressure inlet, pilot supply must come from some other
source. On the circuit in Figure 2-53 a pilot line from system pressure goes directly to
the pilot valve. System pressure goes into the external pilot supply port and a plug shuts
off the internal pilot port. Changing the pilot line in the field with assistance from the
supplier’s catalog is quite easy.
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Figure 2-51. Air-saving circuit using a 5-way valve.
Figures 2-51 to 2-61 show another reason for using dual pressure inlets. They depict air
cylinder movement with conventional hook up. The cylinder pauses before raising and
drops rapidly when starting to retract.
Dual-pressure 5-way valves for air cylinder actuation
A vertical, up-acting air cylinder, with a heavy load, gives sluggish and jerky operation
when valves conventionally. Figure 8-54 shows a conventional 5-way valve hook up on
a cylinder raising a 600-lb load. This figure shows weight, cap and head end areas, and
pressures at both cylinder ports.
Figure 2-52. Cylinder at rest.
When the directional valve shifts, as seen in Figure 2-55, there is a pause before the
cylinder extends. The weight-to-cylinder force ratio and the rate of cylinder travel speed
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control the length of pause. The heavier the weight and the slower the cylinder speed,
the longer the pause. The delay could be three to four seconds in extreme cases.
The pause comes from weight pushing down along with force from air pressure on the
cylinder rod end. At the moment the valve shifts to extend the cylinder, down forces are
up to 1240-lb while up force is only 800 lb. As long as down forces exceed up force, the
cylinder will not move. The slower the air exhausts, the longer it takes to get enough
differential pressure across the cylinder piston to move it. The speed of exhausting air
controls how fast the cylinder moves once it starts.
Figure 2-53. Valve just shifted, cylinder pauses
Figure 2-54. Cylinder starts to move after rod-end pressure drops.
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When pressure in the head end of the cylinder reaches about 15 psi, as shown in Figure
2-56, the cylinder starts to move. It moves up smoothly and steadily as long as the load
remains constant. When the valve shifts to retract the fully extended cylinder, there is
another problem. Figure 2-57 shows the cylinder at rest at the top. Up force is 800 lbs.
from air pressure on the cap end, and down force is 600 lbs. from the weight.
Figure 2-55. Cylinder travels to end of stroke. Figure 2-56. Valve shifted to retract
cylinder, which drops rapidly.
When the directional valve returns to normal, as shown in Figure 2-58, down force
quickly changes to 1240 lb. Now the load drops rapidly until air pressure in the cap
compresses to approximately 120 psi. It takes about 120 psi on the 10-in.2 area to slow
the cylinder’s rapid retraction.Both pauses that occur when extending and retracting are
eliminated by using the dual-inlet feature of a 5-way valve.With a dual inlet pressure
circuit shown in Figure 2-59, the cap end port has 80 psi while the rod end port is only
15 psi. This sets a pressure differential across the piston before the valve shifts.
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Figure 2-57. Dual-pressure valve at rest. Figure 2-58. Valve shifts, cylinder starts
moving quickly.
When the valve shifts, as seen in Figure 2-60, down force is 720 lb. and up force is 800
lb. The cylinder starts to move almost immediately and continues moving smoothly to
the end.
In Figure 2-61 the valve shifts and the cylinder retracts. With the head end regulator set
at 15 psi, down force from air pressure and the load is almost offset by up force. The
load lowers smoothly and safely without lunging or bouncing, as fast as cap end air
exhausts. In figure 2-59 to 2-61, the cylinder strokes smoothly and quickly in both
directions with dual-pressure valve.
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Figure 2-59. Valve shifts to normal, cylinder moves with no lunge.
Check valves as directional valves
Normally a check valve is not thought of as a directional control valve, but it does stop
flow in one direction and allow flow in the opposite direction. These are two of the three
actions a directional control valve can perform. An inline check valve stops any chance
of reverse flow and is useful and/or necessary in many applications. Figure 8-62 shows
the symbol for a plain check valve.
Another application for a check valve is a relief function, which can be seen in Figure 2-
63. Heat exchangers, filters, and low-pressure transfer pumps often need a low-
pressure bypass or relief valve. A check valve with a 25-125 psi spring makes an
inexpensive, non-adjustable, flow path for excess fluid. It protects low-pressure devices
in case of through flow blockage. Pilot operated directional valves commonly use a
check valve in the tank or pump line to maintain at least 50-75 psi pilot pressure during
pump unload. Some manufacturers make a check valve with an adjustable spring, for
pressures up to 200 psi or more. Some check valves have a removable threaded plug in
them that may be drilled to allow controlled flow in the reverse direction. The symbol in
Figure 8-64 shows how to represent this in a symbol. A common use for a drilled check
valve is as a fixed, tamper proof, flow control valve. Fluid free flows in one direction, but
has controlled flow in the opposite direction. The only way to change flow is to change
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the orifice size. This flow control valve is not pressure compensated. Many of the
circuits in this manual show standard check valves in use. Hi-L pump circuits, reverse
free flow bypass for flow controls, sequence valves or counterbalance valves, and multi-
pump isolation, to name a few. Figure 8-65 shows some other applications for check
valves.
When the tank is higher than the pump or directional valves, always install some means
to block flow lines for maintenance. If the valves are not blocked, the tank must be
drained when changing a hydraulic component. Shut-off valves are the only option for
lines that flow out of the tank to a pump or other fluid using device. To avoid running the
pump dry, its shutoff should have a limit switch indicating full open before the electrical
control circuit will allow the pump to start. All return lines though, can have a check
valve piped as shown in Figure 2-65. A check valve with a low-pressure spring, called
an tank isolation check valve, on each return line allows free flow to tank, while blocking
flow out of it. A check valve in the tank lines makes shut off automatic and eliminates
chances of blowing a filter or wrecking a valve at startup.
Figure 2-60. Check valves in different circuit applications.
The backpressure check valve in the pump line maintains a minimum pilot pressure
while the pump unloads. Here it is in the line feeding the directional valves, other times
it is in the tank line. In either case it provides pilot pressure to shift the directional valves
when a new cycle starts.
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The circuit in Figure 2-65 also shows an anti-cavitation check valve for the cylinder with
a relief valve to protect it from over pressure. An external force can pull against the
trapped oil in the cylinder and cause damage or failure without relief protection. When
outside forces move the cylinder, fluid from the rod end goes to the cap end, but is not
enough to fill it. If a void in the cap of the cylinder is no problem then an anti-cavitation
check valve is unnecessary. However, this void can cause erratic action when the
cylinder cycles again, so install an anti-cavitation check valve. The anti-cavitation check
valve has a very low-pressure spring, which requires 1-3 psi to open, so it allows tank
oil to fill any vacuum void that might form. The anti-cavitation check valve has no effect
during any other part of the cycle.
Pilot-operated check valves
There are some circuits that need the positive shut off of a check valve but in which
reverse flow is also necessary. The following images show symbols of pilot-operated
check valves that allow reverse flow. Figure 2-66 shows the symbol for a standard pilot
to open check valve. Figure 2-67 shows a pilot-operated check with a decompression
feature. The symbol in Figure 2-68 shows a pilot-operated check valve with an external
drain for the pilot piston. Each of these pilot-operated check valves allow reverse flow,
but two of them have added features to overcome certain circuit conditions.
To hold a cylinder stationary, it must have resilient continuous non-leaking seals, no

plumbing leaks, and a non-leaking valve. Metal-to-metal fit spool valves will not hold a
cylinder for any length of time. As shown in Figure 2-69, a blocked center valve can
actually cause a cylinder to creep forward. Vertically mounted cylinders with down
acting loads always creep when using a metal-to-metal fit spool valve. Hydraulic motors
always have internal leakage so the circuits shown here will not hold them stationary.
Figures 2-70, 2-71, and 2-72 show a typical pilot-operated check valve circuit that
prevents cylinder creep.
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Figure 2-61. Blocked center directional valve, cylinder creeping forward.
The circuit in Figure 2-70 shows a horizontally mounted, non-leaking cylinder, positively
locked in place any time the directional centers. When using an on-off type solenoid
valve, a fast moving cylinder stops abruptly when the directional valve centers. Use a
proportional valve with ramp timers to decelerate the actuator and eliminate shock
damage.
Figure 2-62. Pilot-operated check circuit at rest with pump running.
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Notice the directional valve has A and B ports open to tank in the center condition. This
center condition allows pilot pressure to drop and the pilot-operated check valves to
close. Using a directional valve with blocked A and B ports in center condition, may
keep the pilot-operated check valves open and allow cylinder creep. If it is only
necessary to keep the cylinder from moving in one direction, one pilot-operated check
valve will suffice.
When solenoid A1 on the directional valve shifts, as seen in Figure 2-71, the cylinder
extends. Pump flow to the cylinder cap end builds pressure in the pilot line to the rod
end of the pilot-operated check valve, causing it to fully open. The pilot-operated check
valve in the line to the cap end opens by pump flow like any check valve. Energizing
and holding a directional valve solenoid causes the cylinder to move. Pilot operated
check valves positively lock the cylinder but are invisible to the electric control circuit.
When solenoid B on the directional valve shifts, as seen in Figure 2-72, the cylinder
retracts. Pump flow to the cylinder rod end builds pressure in the pilot line to the cap
end of the pilot-operated check valve, causing it to fully open. The pilot-operated check
valve in the line to the rod end opens by pump flow like any check valve. Energizing and
holding a directional valve solenoid causes the cylinder to move.
Figure 2-63. Pilot-operated check circuit with cylinder retracting.
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The following will describe how pilot-operated check valves can cause problems in
some applications.
Pilot-operated check valves
Figure 8-73 shows how using a pilot-operated check valve to keep a heavy platen from
drifting can cause problems.
Figure 2-64. Pilot-operated check valve on running away load, at rest, pump
running.
When a cylinder has a load, trying to extend it causes load-induced pressure. In the
example cited, a 15,000-lb platen pulling against a 26.51 square inch rod end area
gives a 566 psi load-induced pressure. This load-induced pressure holds against the
poppet in the pilot-operated check valve, forcing it closed. The pilot piston must have
sufficient pressure to open the poppet with 566 psi pushing against it. The pilot piston
on most pilot-operated check valves has an area that is three to four times that of the
poppet. This means it will take approximately 141-188 psi at the cap end cylinder port to
open the poppet for reverse flow.
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When the directional valve shifts, starting the cylinder forward, as shown in Figure 2-
74, pressure in the cap end cylinder port starts climbing to 150 psi. At about 150 psi the
poppet in the pilot-operated check valve opens and allows oil from the cylinder rod end
a free flow path to tank. The cylinder immediately runs away, pressure in cylinder cap
port drops, the pilot-operated check valve closes fast and hard, and the cylinder stops
abruptly. When the pilot-operated check valve closes, pressure at the cap end cylinder
port again builds to 150 psi, opening the check valve, and the process starts again. A
cylinder with these conditions falls and stops all the way to the work unless it meets
enough resistance to keep it from running away.
Figure 2-65. Pilot-operated check valve on running away load, cylinder extending,
and free fall.
With this circuit, system shock very quickly damages piping, cylinders, and valves.
Adding a flow control between the cylinder and pilot-operated check valve is one way to
keep it from running away. However, the restriction could cause fluid heating and slow
cycling, and would need frequent adjustment to maintain optimum control.
Placing a flow control after the pilot-operated check valve causes backpressure against
its pilot piston and could keep it from opening at all. With the flow control after the pilot-
operated check valve, use one with an external drain. When there is much
backpressure on the outlet of a pilot-operated check valve, it is best to use one with an
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external drain. It is best to control the cylinder shown here with a counterbalance valve.
See chapter five for the different types of counterbalance circuits. Even with some spool
type counterbalance valves, the cylinder still drifts. Adding an externally drained pilot-
operated check valve between the counterbalance valve and the cylinder holds it
stationary. The counterbalance valve keeps the cylinder from running away no matter
the flow variations, while the pilot-operated check valve holds it stationary when
stopped.
Figure 2-66. Pilot-operated check valve on running away load, cylinder stopping
on closed P.O. check.
A pilot-operated check valve with the decompression feature would not help in this
circuit. Figures 2-76 and 2-78 show another possible problem using a pilot-operated
check valve to keep a vertical down-acting cylinder from drifting. The cylinder in this
example has a heavy weight pulling against the rod side. A load induced pressure of
1508 psi plus 142 psi from pilot pressure acts against the poppet in the pilot-operated
check valve. This requires a high pilot pressure to open the pilot-operated check valve.
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Figure 2-67. Pilot-operated check valve on running away load, cylinder just
starting to extend.
It requires approximately 500 psi pilot pressure to open the pilot-operated check valve
with 1650 psi against the poppet. As pilot pressure builds to open the poppet, it also
pushes against the full piston area of the cylinder. This cylinder has nearly twice the
area on the cap side as the rod side, so every 100 psi on the cap side gives about 200
psi on the rod side. As pilot pressure builds to the 500 psi required, pressure against the
poppet in the pilot-operated check valve increases at twice the rate. Figure 8-77 shows
the start of this condition.
Figure 2-68. Pilot-operated check valve on running away load, cylinder still trying
to extend.
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In Figure 2-77, the cylinder rod end pressure is at 300 psi, which adds 570 psi to the
1508 psi load-induced pressure. The extra hydraulic pressure pushes harder against
the pilot-operated check valve poppet, making pilot pressure increase even more. As
pilot pressure increases, down force and rod end pressure escalates also. In Figure 2-
78, rod end pressure is at 3565 psi because pilot pressure continues to climb. In the
situation shown here, it is obvious the relief valve will open before reaching a pilot
pressure high enough to open the pilot-operated check valve. Even if pilot pressure
could go high enough to open the pilot-operated check valve, the cylinder runs away
and stops.
Figure 2-69. Pilot-operated check valve on running away load, cylinder still trying
to extend.
A pilot-operated check valve with a decompression poppet would not help in this
situation. Flow from the small decompression poppet is not enough to handle cylinder
flow. The cylinder would extend with a decompression poppet, but at a very slow rate. It
is best to control the cylinder in this example with a counterbalance valve. See chapter
five for the different types of counterbalance circuits. Even with some spool type
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counterbalance valves, the cylinder still drifts. Adding an externally drained pilot-
operated check valve between the counterbalance valve and the cylinder will hold it
stationary. The counterbalance valve keeps the cylinder from running away no matter
the flow variations, while the pilot-operated check valve holds it stationary when
stopped. Shown are circuits that require a pilot-operated check valve to have external
drain and/or decompression capabilities.
A standard pilot-operated check valve circuit usually has minimum backpressure at the
reverse flow outlet port. If there is a restriction causing high backpressure in the reverse
flow outlet port, a standard valve may not open when applying pilot pressure. The
reason this might happen is the pilot piston sees backpressure from the reverse flow
outlet port. If the pilot-operated check valve poppet has load induced pressure holding it
shut, plus reverse flow outlet port backpressure opposing the pilot piston, there is not
enough pilot piston force to open the check poppet.
If the reverse flow outlet port backpressure cannot be eliminated, then specify a pilot-
operated check valve with an external drain. Pipe the external drain to a low or no
pressure line going to tank. With an external drain pilot-operated check valve, the pilot
piston usually opens the check poppet to allow reverse flow.
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Figure 2-70. Pilot-operated check valve circuit with external drain function at rest,
pump running.
The schematic drawing in Figure 2-79 shows a cylinder with pilot-operated check valves
at each port and meter out flow controls downstream of the reverse flow outlet port. If
this circuit did not have externally drained pilot-operated check valves, the cylinder
would operate in jerks or not at all when the directional valve shifts. Backpressure from
the flow controls can push the pilot piston closed and stop the cylinder, then pressure
would drop and it would start again. This oscillating movement would continue until the
cylinder competes its stroke. With externally drained pilot-operated check valves, the
cylinder is easy to control at any speed.
Placing the flow controls in Figure 2-79 between the cylinder ports and the pilot-
operated check valve eliminates backpressure. This move eliminates the need for
externally drained pilot-operated check valves.In Figure 2-80, a running away load had
a drifting problem with only the counterbalance valve installed. Adding a pilot-operated
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check valve in front of the counterbalance valve stopped cylinder drifting. Using a
decompression poppet made it easy to open the main check poppet against the high
load induced pressure. The decompression poppet releases trapped fluid in the piping
between the pilot-operated check valve and the counterbalance valve allowing the main
check poppet to open.
Figure 2-71. Pilot-operated check on running away load with external drain and
decompression poppet with P.O. check for no leak holding, counterbalance valve
for smooth control of the extend stroke at rest, with pump running.
Notice the pipe between the pilot-operated check valve and the counterbalance valve is
at zero psi while the cylinder is held retracted. This pressure would have been about
1200 psi while the cylinder was retracting, but quickly drops to zero when the directional
valve centers. The reason for this pressure drop is leakage past the counterbalance
valve spool, which is the reason for adding the pilot-operated check valve. If the pilot-
operated check valve did not have an external drain, backpressure from the
counterbalance valve can force it shut when the cylinder starts moving. The external
drain and decompression features are both necessary in this holding circuit. Placing the
pilot-operated check valve in the line after the counterbalance valve would require
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neither an external drain nor decompression feature. However, the reason for installing
the pilot-operated check valve was to stop drifting. With the pilot-operated check valve
after the counterbalance valve, the counterbalance valve must have an external drain.
An external drain indicates there is internal leakage, so the drift problem may decrease -
- but would not go away.
Directional Control Valves (DCVs) are one of the most fundamental parts of hydraulic
and pneumatic systems. DCVs allow fluid flow (hydraulic oil, water or air) into different
paths from one or more sources. DCVs will usually consist of a spool inside a cylinder
which is mechanically or electrically actuated. The position of the spool restricts or
permits flow, thus it controls the fluid flow. A valve is a device that receives an external
signal (mechanical, fluid pilot signal, electrical or electronics) to release, stop or redirect
The fluid that flows through it. The function of a DCV is to control the direction of fluid
flow in any hydraulic system. A DCV does this by changing the position of internal
movable parts. To be more specific, a DCV is mainly required for the following purposes
to start, stop, accelerate, decelerate and change the direction of motion of a hydraulic
actuator.
To permit the free flow from the pump to the reservoir at low pressure when the
pump’s delivery is not needed into the system. To vent the relief valve by either
electrical or mechanical control. To isolate certain branch of a circuit.
Any valve contains ports that are external openings through which a fluid can enter and
exit via connecting pipelines. The number of ports on a DCV is identified using the term
“way.” Thus, a valve with four ports is a four-way valve A DCV consists of a valve body
or valve housing and a valve mechanism usually mounted on a sub-plate. The ports of a
sub-plate are threaded to hold the tube fittings which connect the valve to the fluid
conductor lines. The valve mechanism directs the fluid to selected output ports or stops
the fluid from passing through the valve. DCVs can be classified based on fluid path,
design characteristics, control methods and construction.
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Hydraulically operated.
A hydraulically operated Directional control valve works at much higher pressures than
its pneumatic equivalent. They must therefore be far more robust in nature so are
precision machined from higher quality and strength materials.
Generally specified using the number of ports and the number of switching positions. It
can be represented in general form as np/ns, where np is the number of ports
connected to the direction control valve and ns the number of switching positions.
In addition, the method of actuation and the return method can also be specified. A
hypothetical valve could be specified as 4-way, 3-position direction control valve or 4/3
DCV since there are four ports and three switching positions for the valve. In this
example, one port is called the pressure port which is connected to the pump; one port
is the tank port and is connected to the tank (or reservoir); and the two remaining ports
are called working ports and are connected to the actuator. Apart from characteristics of
valve the fluid suitable for valve, working temperature and viscosity also thought upon
before selecting a particular type of valve.
Gate valve is the most common type of valve that used in any process plant. It is a
linear motion valve used to start or stop fluid flow. In service, these valves are either in
Fully open or fully closed position. When the gate valve is fully open, the disk of a gate
valve is completely removed from the flow. Therefore virtually no resistance to flow. Due
to this very little pressure drops when fluid passes through a gate valve.
To achieve proper sealing, when the valve is fully closed, 360° surface contact is
required between disk and seats. Gate valves should not be used for regulation or
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throttling of flow because accurate control is not possible. The high velocity of the flow
in the partially open valve may cause erosion of the disc and seating surfaces and also
creates vibration and noise.
Globe valve is a linear motion valve used to stop, start, and regulate the fluid flow. The
globe valve disk can be removed entirely from the flow path, or it can completely close
the flow path. During opening and closing of globe valve, disc moves perpendicularly to
the seat.
Globe valve
This movement creates the annular space between the disk and seat ring that gradually
close as the valve closed. This characteristic provides the globe valve good throttling
ability required for regulating the flow.Leakage from globe valve seat is less as
compared to the gate valve, mainly due to right angle contact between the disk and seat
ring, which allows tighter seal between seats the disk.
Figure 2.72Gate Valve
Gate Valve Gate valve is a sliding type of valve. In gate valves, the closing member is a
metal gate. The gate slides down to close the valve. In fully open conditions, the flow
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area is equal to the area of the pipe and hence, there is negligible pressure drop across
the valve.
Gate valve should ideally be used as on-off valve. It is not advisable to use them as
throttling valves because in partly open conditions, erosion of gate might take place. In
partially open condition’s, due to vibrations, valve is exposed to quick wear and tear.
Also, during closing and opening, there is considerable amount of friction and hence,
opening and closing these vales quickly and frequently is not possible.
These valves find their use in petrochemical industry due to the fact that they can work
with metal-metal sealing.
Figure 2.73 Plug Valve
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Similar to ball valves, plug valves are also quarter turn type of valves. This valve
consists of a plug which can be either cylindrical or conical in shape. The plug has a
through slit which remains in-line with the flow in the open condition. When the plug is
turned by 90 Deg., this slit becomes perpendicular to flow and the valve gets closed.
Plug valves are well suited to handle fluids with suspended solids, slurries etcPlug
valves are primarily used for on-off applications. When used for throttling purpose, the
pressure drop through the valve is higher because of misalignment between flow
direction and the direction of the opening (slit).
Figure 2.74 Butterfly Valve
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Butterfly valves are most simple yet versatile valves. They are quarter turn operated
valves which are commonly used in multiple industries for varied applications. Quarter
turn operation ensures quick operating of the valve. In the open condition there is
minimum obstruction to the fluid flow through the valve as the flow passes around the
disc aerodynamically. This results in very less pressure drop through the valve.
Due to its unique mode of operation, the valve can be actuated easily without requiring
high torques and wear and tear. Due to lack of friction, use of bulky actuators can be
avoided. Another advantage offered by butterfly valve is their compact size. The valve is
quite compact, resembling a metal disc. This makes their installation very easy. They
can be used to handle slurries and fluids with suspended solids as there are no cavities
for deposition of solid particles inside the valve body.
Figure 2.75Globe Valve
Globe Valve Globe valve is a linear motion type of valves and is typically used in both
on-off and throttling applications. In globe valves, the flow of the fluid through valve
follows an S-path. Due to this, the flow direction changes twice which results in higher
pressure drops. Due to other advantages offered by them, they are widely used in
applications where pressure drop through the valve is not a controlling factor. These
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valves are generally not used beyond sizes larger than NPS 12 (DN 300) as enormous
forces are exerted on the stem to open or close the valve under fluid pressures. Globe
valves require high pressures on the seat to keep it closed when the fluid exerts
pressure from the bottom of the disc.
They are used for both on-off and throttling applications but special types of trims are
required for throttling applications where large pressure drops are involved. These
valves can be used in three configurations, depending upon the applications-
a. Tee pattern
b. Angle Pattern
c. Wye Pattern
When the disc is removed from the stem and allowed to rest on its own weight, globe
valves can be used as non-return valves. Machining of seats is easier and cheaper
compared to other types of valves.
Figure 2.76 Pinch valves
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Pinch valves consist of a plastic tube/sleeve which is made up of reinforced

elastomers. The sealing/ closing action is achieved by throttling or pinching this
sleeve/tube. Pinch valves are best suited for handling slurries and fluids having
suspended solids. Pinch valves offer many benefits over the other types of valves. They
can be used for handling corrosive fluids as there is no contact between the fluid carried
and the actual valve mechanism. Once suitable sleeve material is selected, this valve
can work with a variety of fluids. As fluid being carried does not come in contact with the
metal parts, these valves can be used for food grade applications also.
Generally, pinch valves are suitable for low pressure applications. When used with
abrasive slurries, they should be used as on-off valves; if used for throttling purposes,
the sleeve will get worn out.
Figure 2.77 Disc Check Valves
Disc Valve Disc check valves, also called as non-return valves allow the flow to pass
through them in only one direction and stop the flow in reverse direction. Because of
this unique directional property, disc check valves are essentially used for some critical
applications in the steam systems.
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Figure 2.78 Safety valve
Safety valve is a valve that acts as a protection of equipment from exploding or

damaging and it is mainly installed in pressure vessels such as chemical plants, electric
power boilers and gas storage tanks.
Safety Valve is a type of valve that automatically actuates when the pressure of inlet
side of the valve increases to a predetermined pressure, to open the valve disc and
discharge the fluid (steam or gas); and when the pressure decreases to the prescribed
value, to close the valve disc again. Safety valve is so-called a final safety device which
controls the pressure and discharges certain amount of fluid by itself without any electric
power support.
Safety valve supports not only the safety of energy industry but also the safety and
security of our life.
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Figure 2.79 Pilot-operated checks Valve
A pilot-operated valve along with its symbol is shown in Fig. 1.4. This type of check
valve always permits free flow in one direction but permits flow in the normally blocked
opposite direction only if the pilot pressure is applied at the pilot pressure point of the
valve. The check valve poppet has the pilot piston attached to the threaded poppet stem
by a nut. The light spring holds the poppet seated in a no-flow condition by pushing
against the pilot piston. The purpose of the separate drain port is to prevent oil from
creating a pressure build-up at the bottom of the piston. The dashed line in the graphical
symbol represents the pilot pressure line connected to the pilot pressure port of the
valve. Pilot check valves are used for locking hydraulic cylinders in position.
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Figure 2.80 shuttle valve
A shuttle valve allows two alternate flow sources to be connected in a one-branch

circuit. The valve has two inlets P1 and P2 and one outlet A. Outlet A receives flow from
an inlet that is at a higher pressure. Figure 1.5 shows the operation of a shuttle valve. If
the pressure at P1 is greater than that at P2, the ball slides to the right and allows P1 to
send flow to outlet A. If the pressure at P2 is greater than that at P1, the ball slides to
the left and P2 supplies flow to outlet A
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CONCEPTUAL FRAMEWORKS
Comparison of mechanical operated valve vs directional control valve
Directional control valve
I IV / advantage M/V DV / disadvantage
Construction of the Loss effectiveness they have short actuation

valve is complex movement
Higher flow rate in a Efficiency Smooth operation

Smaller package
It has a good closing Strength Closing and opening features
Figure 2. Research Paradigm
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Mechanical Operated Valve
IV / advantage MV DV / disadvantage
Increase half life Strength Low capacity
Increase half life
Easy to use Efficiency Long term
Relatively high Loss effectiveness Higher cost

actuator stiffness
Figure 2.82 Research Paradigm
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Definition of term
 2 way is a two port valve that turns the flow on or off

 3 ways is a three port valve that allows flow through the valve into a chamber, and
then out through the valve exhaust. The universal function can also be used as a
diverter valve.
 5/2 way is a five port, two position valve that will put a fluid or air into one end of a
double acting device as well as allowing the other end vent to exhaust.
 Zero Differential is solenoid valves that can operate under zero head pressure
(do not need a differential pressure drop across the valve to work). This is made
up of two categories, direct acting and coupled diaphragm.
 Direct acting are solenoid valves that are activated purely by the electromagnetic
forces in the valve and do not rely on the fluid pressure to assist. Hence they are
used where little or no fluid pressure is available such as vacuum service or low
pressure applications.
 Differential operated are solenoid valves that do rely on the fluid pressure to
assist in activating the valve. This helps in developing valves with larger orifices,
higher pressures and smaller coils.
 Normally closed (N.C.) means that when the solenoid valve is not energized the
supply pressure port is closed off. In the case of 3 way valves the downstream
port is open to the exhaust port.
 Normally open (N.O.) means that when the solenoid valve is not energized the
supply pressure port is open to the downstream port. In the case of 3 way valves
the downstream port is closed to the exhaust port.
 IP rating is an international standard to denote the degree of protection against
water and solid objects. All of our electrical coils with DIN plugs have an IP65
rating. The '6' denotes a complete protection against items as small as dust and '5'
is protection against low pressure jets of water from all directions.
 Flame proof relates to the electrical part of a solenoid valve only (usually the coil
and operator assembly) and is a way of making the valve safe to use in an
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 Explosive atmosphere. These valves must be installed in compliance to the wiring

standards for this type of approval and in a zone compatible to the approved code
and temperature rating.
 Accumulator - A container which stores fluids under pressure as a source of

hydraulic power. It may also be used as a shock absorber.
 Actuator - A device which converts hydraulic power into mechanical force and
motion. (Examples: hydraulic cylinders and motors.)
 Hydraulics - The engineering science of liquid pressure and flow.
 Hydrodynamics - The engineering science of the energy of liquid pressure and
flow.
 Hydrostatics - The engineering science of the energy of liquids at rest. (All the
systems covered in this manual operate on the hydrostatic principle.)
 Regenerative Circuit - A circuit in which pressure fluid discharged from a

component is returned to the system to reduce flow input re-quirements. Often
used to speed up the action of a cylinder by directing discharged oil from the rod
end to the piston end.
 Remote - A hydraulic function such as a cylinder which is separate from its

supply
Source. Usually connected to the source by flexible hoses.
 Reservoir - A container for keeping a supply of working fluid in a hydraulic
system.
 Restriction - A reduced cross-sectional area in a line or passage which normally
causes a pressure drop. (Examples: pinched lines or clogged passages, or an
orifice designed into a system.)
 Solenoid - An electro-magnetic device which positions a hydraulic valve.
 Valve - A device which controls either 1) pressure of fluid, 2) direction of fluid
flow, or 3) rate of flow.
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 Needle Valve - A valve with an adjustable tapered point which regulates the rate
of flow.
 Open Center Valve - A valve in which the inlet and outlet ports are open in the
neutral position, allowing a continuous flow of oil from pump.
 Pilot Valve - A valve used to operate another valve or control.
 Pilot Operated Valve - A valve which is actuated by a pilot valve.
 Poppet Valve - A valve design in which the seating element pops open to obtain
free flow in one direction and immediately reseats when flow reverses.
 Pressure Control Valve - A valve whose primary function is to control pressure.
(Includes relief valves, pressure reducing or sequencing valves, and unloading
valves.)
 Pressure Reducing Valve - A pressure control valve which limits outlet
pressure.
 Pressure Sequence Valve - A pressure control valve which directs flow in a
present sequence.
 Priority Flow Divider Valve - A valve which directs oil to one circuit at a fixed
rate and dumps excess flow into another circuit.
 Proportional Flow Divider Valve - A valve which directs oil to all its circuits at
all times.
 Relief Valve - A valve which limits the pressure in a system, usually by releasing
excess oil.
 Rotary Directional Valve - A valve designed in a cylindrical shape. When the
valve is turned, it opens and closes drilled passages to direct oil.
 Selector Valve - A valve which selects one of two or more circuits in which to
direct oil, usually operated manually.
 Shuttle Valve - A connecting valve which selects one of two or more circuits
because of flow or pressure changes in these circuits.
 Spool Directional Valve - A valve designed as a spool which slides in a bore,
opening and closing passages.
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 Thermal Relief Valve - A valve which limits the pressure in a system caused by
heat expansion of oil.
 Two-, Three-, Four-, or Six-Way Valve - A valve having 2, 3, 4, or 6 ports for
direction of oil flow.
 Unloading Valve - A valve which allows a pump to operate at minimum load by
dumping the pump's excess oil at a low pressure.
 Volume Control Valve - A valve which controls the rate of flow. Includes flow
control valves, flow di- diver valves, and bypass flow regulators.
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Chapter 3
OPERTIONAL FRAMEWORK
This chapter presents the research design, sample and sampling techniques,
research instrument, data gathering procedure and the statistical treatment of data.
Design
The method used by the researcher in this study was the use of questionnaires.
It was intended to focus and discuss the Comparison between mechanically operated
valve and directional control valve, and the advantages and disadvantages of using a
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mechanically operated valve and directional control valve system in a vessel

among thus, the validity of using mechanically operated valve and directional control
valve in vessels. It was concerned with the uses or services that are very much helpful
to man.
Respondents
The respondents answered the survey based on their knowledge and

experiences on board the ship. The sampling technique used in this study was non-
scientific and purposive. The respondents were fifty (50) Marine Engineers having
training at various training Center, from Intramuros Manila and MARINA. They were
chosen because the areas are accessible for all the kind of seafarers.
Research Instruments
The study made use of the following instruments:
Interview
Survey Questionnaires
The interview was used to obtain the respondents emotions and knowledge
about Comparison between mechanically operated valve and directional control valve.
The survey questionnaire consisted of (15) statements. These statements

pertained accurately and for the answers to be narrow rather than broad.
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Statistical Treatment of Data/Evaluation
The researcher approached some marine engineers in order to get their opinion
based on their knowledge and conducted to the study. The researcher asked and was
given permission by the school dean and their professor to conduct survey regarding
the study. It was signed and approved by the schools administration. The approached
Marine Engineers in order to get their opinion based on their knowledge and personal
experience. The researcher gave questionnaires regarding about the comparison of
mechanically operated valve and directional control valve. The questionnaires contain
question that can be answered by agree and disagree. The retrieval of questionnaires
follow as soon as they respondents filled up the surveys. The researchers offered their
outmost gratitude for the respondents. The data analysis collection was based through
the statistical tools to interpret the data gathered in the survey.
The researcher used the following statistical tools for the interpretation and
analysis of the gathered in the survey. Formula: %=F/N x 100 Where: F= frequency of a
purposes N= total number of respondents / total of responses Mean – the arithmetic
averages when all the scores were added and divided by the number of items was
obtained using the following formula: M=({ responses per item} x {scale value})/(number
of respondents{n}) Where: M= mean.
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Survey/Research Questionnaire
Comparison between Purifier and Clarifier ability, efficiency & durability
Respondent name Gender: M F
Company Yr/Exp
1-3 3-5 5-
Statement/Questions 1 2 3 4 5
1. If the directional control valve doesn’t work its harm the

machinery.
2. If the mechanically operated valve have damage the directional
control valve it continue operates
3. Is mechanically operated valve and directional control valve is
necessary to open both on board a ship
4. Directional control valve can operates without the help or
assistance of mechanically operated valve.
5. Mechanically operated valve will work without the help of
directional control valve.
6. The good maintenance and vigilant watch keeping will lessen the
damage to the equipment
7. Directional control valve can operates without the help or
assistance of mechanically operated valve.
8. Mechanically operated valve and directional control valve
always have the same time and situation in operating
9. There is time that only directional control valve works
without the mechanically operated valve.
10. While the mechanically operated valve operates it is
important also to open the directional control valve.
5-Strongly Disagree
4-Disagree
3-Maybe
2-Agree Respondent Signature
1-Strongly Agree
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Chapter 4
Results and Discussion
Findings, Data Results and Analysis
In this chapter the research will present, discuss and interpret data collected from
50 respondents, the Marine Engineering Students of STI – NAMEI about the Modern
Installation of Pneumatic Control Application Onboard, its Reliability and Dependability
based on Unmanned Machinery Space (UMS).
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Demographic Profile of the Respondents
Rank/Position on board ship Frequency Percentage

Chief Engineer 10 20%
Second Engineer 5 10%
Third Engineer 10 20%
Undefined 25 50%
Total 50 100%
Figure 4.1 Shows the Rank/Positions of the respondents
At present, how No. of Years Frequency Percentage

many years you 1-3 20 40%
are in the maritime
3-5 0 0%
industry as
5-Above 30 60%
Seafarer?
Total 50 100%
Figure 4.2 Shows how long have they been in Maritime Industry as Seafarers
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1. If the directional control valve doesn’t

work its harm the machinery.
Strongly Agree Agree Neutral Disagree Strongly Disagree
0%
20%
40%
20%
20%
Figure 4.3 Graph for directional control valve doesn’t work its harm the machinery.
2. If the mechanically operated valve have

damage the directional control valve it
continue operates
0%
20% 10%
20%
50%
Figure 4.4 Graph for the mechanically operated valve have damage the directional control
valve it continue operates.
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3. Is mechanically operated valve and

directional control valve is necessary to
open both on board a ship
0%
10%
20% 40%
30%
Figure 4.5 Graph for mechanically operated valve and directional control valve is necessary
to open both on board a ship
4. Directional control valve can operates

without the help or assistance of
mechanically operated valve.
0% 0%
10% 10%
80%
Figure 4.6 Graph for Directional control valve can operates without the help or assistance
of mechanically operated valve.
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5.Mechanically operated valve will work

without the help of directional control valve.
0%
10% 20%
30%
40%
Figure 4.7 Graph for Mechanically operated valve will work without the help of directional
control valve.
6. The good maintenance and vigilant watch

keeping will lessen the damage to the
equipment
0%
10%
10% 40%
40%
Figure 4.8 Graph for The good maintenance and vigilant watch keeping will lessen the
damage to the equipment
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Engineering
7. Directional control valve can operates

without the help or assistance of
mechanically operated valve.
0%
10% 10%
30%
50%
Figure 4.9 Graph for Directional control valve can operates without the help or assistance
of mechanically operated valve.
8. Mechanically operated valve and

directional control valve always have the
same time and situation in operating
0%
20% 10%
20%
50%
Figure 4.10 Graph for Mechanically operated valve and directional control valve
always have the same time and situation in operating
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9. There is time that only directional control

valve works without the mechanically
operated valve.
0%
20%
40%
10%
30%
Figure 4.11 Graph for There is time that only directional control valve works
without the mechanically operated valve.
10. While the mechanically operated valve

operates it is important also to open the
directional control valve.
0%
10% 20%
20%
50%
Figure 4.12 Graph for while the mechanically operated valve operates it is
important also to open the directional control valve.
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Strongly Agree Neutral Disagree Strongly Total

Agree Disagree
1. 10 10 10 20 0 50
2. 5 25 10 10 0 50
3. 20 15 10 5 0 50
4. 5 40 5 0 0 50
5. 10 20 15 5 0 50
6. 20 20 5 5 0 50
7. 5 25 15 5 0 50
8. 5 25 10 10 0 50
9. 10 5 15 20 0 50
10. 10 25 10 5 0 50
Figure 4.13 Tallies for the Survey
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Chapter 5
SUMMARY OF FINDINGS, CONCLUSIONS, AND RECOMMENDATIONS
This chapter presents the summary of findings, conclusion and recommendation. The
summary includes the major problem, the questions raised in the study, the research
design, and the research instrument, respondents in the study and the analysis and
interpretation of data.
Summary of Findings
This study was focused on the Comparison of Mechanical Operated valves vs

Directional control Valves
The major problem of this study is about the Mechanical Operated valves vs Directional
control Valves assessment of their strength, Availability and Efficiency.
1. Among the 50 Respondents if the directional control valve doesn’t work its harm the
machinery.20% Strongly Agree, 20% Agree, 20% Neutral, 40% Disagree, 0%
Strongly Disagree
2. Among the 50 Respondents If the mechanically operated valve have damage the
directional control valve it continue operates .10% Strongly Agree, 50% Agree,
20%Neutral, 20% Disagree, 0% Strongly Disagree
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3. Among the 50 Respondents Is mechanically operated valve and directional control

valve is necessary to open both on board a ship 40% Strongly Agree, 30% Agree,
20% Neutral, 10% Disagree, 0% Strongly Disagree
4. Among the 50 Respondents Directional control valve can operates without the help
or assistance of mechanically operated valve.10% Strongly Agree, 80% Agree, 10%
Neutral, % Disagree, 0% Strongly Disagree
5. Among the 50 Respondents Mechanically operated valve will work without the help
of directional control valve.20% Strongly Agree, 40% Agree, 30% Neutral, 10%
Disagree, 0% Strongly Disagree
6. Among the 50 Respondents The good maintenance and vigilant watch keeping will
lessen the damage to the equipment 40% Strongly Agree, 40% Agree, 10% Neutral,
10% Disagree, 0% Strongly Disagree
7. Among the 50 Respondents Directional control valve can operates without the help
or assistance of mechanically operated valve.10% Strongly Agree, 50% Agree, 30%
Neutral, 10% Disagree, 0% Strongly Disagree
8. Among the 50 Respondents Mechanically operated valve and directional control
valve always have the same time and situation in operating 10% Strongly Agree,
50% Agree, 20% Neutral, 20% Disagree, 0% Strongly Disagree
9. Among the 50 Respondents There is time that only directional control valve
works without the mechanically operated valve.20% Strongly Agree, 10% Agree,
30% Neutral, 40% Disagree, 0% Strongly Disagree
10. Among the 50 Respondents While the mechanically operated valve operates it is
important also to open the directional control valve.20% Strongly Agree, 50%
Agree, 20% Neutral, 10% Disagree, 0% Strongly Disagree
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Conclusions
The researcher concluded that almost Mechanical Operated Valves and
Directional Control Valves have the same uses on the ship, but Directional
control Valves is the most important because almost all new vessel now a day’s
only have Directional control Valves in their systems.
They also concluded that the uses of Mechanical Operated Valves can
also done by Directional Control Valves that’s why the Mechanical Operated
Valves now a day’s it’s important on board a ship. Because it’s working
automatically.
Recommendations
The researcher conducted the surveys and come out with the output on how they will
formulate the recommendations.
The researcher formulated the following recommendations.

1. Directional Control Valves are important in board ship.
2. Mechanical Operated Valves can automatically work.
3. They should keep the Directional Control Valve on the new vessel because same
of the valve in the ship can’t operate by the Mechanical Operated Valves.

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College of Marine

NAMEI POLYTECHNIC INSTITUTE

Statement of the Problem/Objectives

Significance of the Study

Scope and Delimitation

THEORETICAL FRAMEWORK/DESIGN PROJECT

Review of Related Literature and Studies

According to hydraulic pneumatic

Figure 2.1 Actuator

Actuator is a component of a machine that is responsible for moving and controlling a

Figure 2.2 Valve actuator

Figure 2.3 Hydraulic actuator

Figure 2.4 Pneumatic actuators

Pneumatic actuators enable considerable forces to be produced from relatively small

Figure 2.5 Electric Actuator

Electric actuator may provide the actuation force/torque in one of several

Electrical energy is used to actuate equipment such as multi-turn valves, or electric-

Rotary hydraulic valve actuators

Figure 2.6 Rotary hydraulic valve actuators

Figure 2.7 Linear hydraulic valve actuators

Figure 2.8 Throttling valves

Directional Control Valves

Directional control valves perform only three functions:

 stop fluid flow

These three functions usually operate in combination.

A double-acting actuator requires a 4-way valve. A 4-way valve pressurizes and

2-way directional control valves

Figure 2.9 2-way directional valve

3-way directional control valves

Figure 2-10. Solenoid pilot-operated 3-way selector valve.

Figure 2-11. Palm-button-operated 3-way diverter valve.

4-way directional control valves

Figure 2-12. 4-way, 2-position direct solenoid-operated spring return.

Figure 2-13. 4-way, 2-position direct solenoid-operated spring centered.

5-way directional control valves

Figure 2-14. 4-way, 2-position direct solenoid-operated spring return.

Figure 2-15. 4-way, 2-position solenoid, pilot operated detected, line-mounted.

Figure 2-16.Line-mounted, solenoid pilot-operated, 2-position, spring returned 5-

Figure 2-17. Line-mounted, hand lever-operated, 2-position, spring-returned 5-

Figure 2-19. 5-way, 3 positions, spring-centered solenoid, pilot-operated, cylinder ports

Figure 2-19. 5-way, 3 position, spring-cantered solenoid, pilot-operated, all ports

Figure 2-20. 5-way, 3 positions, spring-centered pressure to cylinder ports,

Figure 2-21. Blow-off. Figure 2-22. Running a one-direction fluid motor.

Figure 2-23. Unloading a pump.

Figure 2-24. Using one 2 way valve to operate a single-acting cylinder.

Figure 2-25. Operating a single-acting cylinder with two 2-way valves.

Since the example selector valve is solenoid pilot-operated, it is important to determine

Figure 2-27. Pressure selector.

Figure 2-28. Fluid diverter.

Figure 2-29. NC limit valve.

Figure 2-30 a 3-way directional valve

Figure 2-30. Operating a double-acting cylinder with two 3-way valves.

Figure 2-32. Double flow capacity.

Figure 2-33. Full time regeneration.

Figure 2-34. Low-pressure cylinder extends.

Figure 2-35. Operating a double-acting cylinder with one 4-way valve

Figure 2-36. Inching circuit with pump unloaded, cylinder floating.

Figure 2-37. Inching circuit with pump unloaded, cylinder blocked.

Figure 2-38. Inching circuit with pump blocked, cylinder floating.

Figure 2-39. All ports open, center condition.

Figure 2-40. Ports blocked center condition.

Figure 2-41. Float center condition.

Figure 2-42. Tandem center condition.