FLUID HANDLING
CRANE
FLUID HANDLING
VALVE & ACTUATOR
OVERVIEW
TRAINING MANUAL
阀门和执行机构培训
A business of Crane Co.
FLUID HANDLING
1
DAY1 1. Introduction 2. Linear Valves 3. Check Valves 4. Control Valves DAY 2 5. Rotary Valves 6. Valve Testing 7. Actuators & Control Accessories 8. Valve & Actuator Sizing
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Orientation
Safety
Orientation
Safety
Alarms • • • •
Fire Tornado Hurricane Etc.
3
Orientation
Safety
Emergency Exits
Orientation
Safety
Assembly Areas
4
Orientation
Safety
Tripping Hazards
Orientation
Safety
Smoking
5
Orientation
Logistics
Bathrooms
Orientation
Logistics
Food and Drinks
6
Orientation
Logistics
Breaks
Orientation
Logistics
Cell Phones and Electronics
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Logistics
Orientation Internet Access
Introductions
Orientation • • • • • •
Name Work location Job role Years at Crane Work before Crane Hobbies
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Valve & Actuator Overview
Course Overview Valve & Actuator Overview • Basic information on common valves and actuators • Provides our employees with a better understanding of our products • Helps employees provide the best solutions to our customers.
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Terminal Objective Upon completion of this course, students will have basic knowledge of various types of valves and actuators, including: • • • • •
Component parts Industry applications Advantages and disadvantages Problems and potential causes Crane brands and products
Agenda Day 1 • • • •
Introduction Linear Valves Check Valves Control Valves
Day 2 • • • •
Rotary Valves Valve Testing Actuators & Control Accessories Valve & Actuator Sizing
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VALVE & ACTUATOR OVERVIEW
INTRODUCTION TO VALVES
Learning Objectives At the completion of this lesson, students will be able to: 1. 2. 3. 4. 5. 6. 7.
Define, ”valve.” List four categories of valves based on method of operation. List the three main functions for valves. Identify four types of end connections for valves. Define, “trim.” Define, “valve gasket.” Identify the materials used in the manufacturing of: • valve bodies • valve linings • valve gaskets • valve seats 8. Identify Crane brands that manufacture valves.
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Introduction
Definition
Valve A mechanical device that turns on and off, regulates, modulates or isolates the rate, volume, pressure or direction of liquids, gasses, slurries or dry materials through a pipeline, chute or passageway.
Define, ”valve.”
Introduction
Categories of Valves
1. Linear Motion 2. Rotary Motion 3. Check 4. Pressure Control
List four categories of valves based on method of operation. 12
Introduction
Categories of Valves
Linear Motion
Disc moves in a linear motion List four categories of valves based on method of operation.
Introduction
Categories of Valves
Rotary Motion
Disc moves in a rotary motion List four categories of valves based on method of operation. 13
Introduction
Categories of Valves
Linear and Rotary Motion Valve Comparison
List four categories of valves based on method of operation.
Introduction
Categories of Valves
Check
List four categories of valves based on method of operation. 14
Introduction
Categories of Valves
Pressure Control
List four categories of valves based on method of operation.
Introduction
Categories of Valves
Pressure Control
Pressure Relief Valve
Hot Water Heater
List four categories of valves based on method of operation. 15
Valve Functions
Introduction Three main valve functions
On/Off
Backflow Prevention
Control
List the three main functions for valves.
Introduction
Types of Connections
1. Flanged 2. Threaded 3. Socket Weld 4. Butt Weld
Identify four types of end connections for valves. 16
Introduction
Types of Connections
Flanged
Raised Face
Flat Face
Ring Type Joint (RTJ)
Identify four types of end connections for valves.
Introduction
Types of Connections
Flanged Raised Face
Identify four types of end connections nnecti tions ffor or val valves. lves 17
Introduction
Types of Connections
Flanged Flat Face
Identify four types of end connections nnections for valves valves.
Introduction
Types of Connections
Flanged Ring Type Joint (RTJ)
Identify four types of end connections i ffor valves. l 18
Introduction
Types of Connections Valve end
Threaded
Threaded pipe Identify four types of end connections for valves.
Introduction
Types of Connections Weld
Socket Weld
Valve end
Pipe
Identify four types of end connections for valves. 19
Introduction
Types of Connections Weld
Butt Weld
Valve end
Pipe
Identify four types of end connections for valves.
Introduction
Definition
Valve Trim Valve trim is a collective name for the replaceable parts in a Valve. A typical valve design includes a seat, stem, and sleeves needed to guide the stem.
Define, “trim.” 20
Introduction
Definition
Gasket & Packing Gaskets & packing are the seals used to prevent the leakage of a gas or fluids from valves. A gasket is a mechanical seal which fills the space between two or more mating surfaces, generally to prevent leakage from or into the joined objects while under compression.
Define, “valve gasket.”
Introduction
Knowledge Check
Why does a valve need to be sealed? • Hazardous emissions • Chemicals • Radioactive material • Gas • Negatively affect other system components • Steam leaks can cause burns
Define, “valve gasket.” 21
Valve Seals
Introduction Common types of gaskets
Flat
Spiral Wound
Ring Type Joint
Define, “valve gasket.”
Valve Seals
Introduction Types of valve stem seals
O-Ring
Stuffing Box
O-Ring / Stuffing Box
22
Valve Seals
Introduction Packing • Common to all gate and globe valves
Define, “valve gasket.”
Valve Seals
Introduction Packing Materials • Braided graphite • Teflon with aramid fibers • Solid Teflon • Laminated graphite
Define, “valve gasket.” 23
Valve Seals
Introduction Packing designs ͻ ͻ ͻ ͻ
Solid Die formed rings Rope Many others
Define, “valve gasket.”
Valve Seals
Introduction Example of installed packing
Define, “valve gasket.” 24
Introduction
Valve Materials
Valve bodies are commonly made from: ͻ ͻ ͻ ͻ ͻ ͻ ͻ
Brass Bronze Cast iron Steel Stainless steel Alloy steel Thermoplastics
Identify the materials used in the manufacturing of valves.
Introduction
Valve Materials
Other valve components are commonly made from: ͻ ͻ ͻ ͻ ͻ
Thermoplastics Resilient Material Graphite Glass ers Aramid Fibers
Identify the materials used in the manufacturing of valves. 25
Introduction
Knowledge Check
What are the four main categories of valves? • • • •
Linear Rotary Check Pressure Control
Introduction
Knowledge Check
What are three main functions of valves? • On/Off • Control • Backflow prevention
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Introduction
Knowledge Check
What are four types of valve connections? • • • •
Flanged Threaded Socket Weld Butt Weld
Introduction
Knowledge Check
What are some of the materials used to make… Valve bodies?
Other valve components?
ͻ ͻ ͻ ͻ ͻ ͻ ͻ
ͻ ͻ ͻ ͻ
Brass Bronze Cast iron Steel Stainless steel Alloy steel Thermoplastics
Thermoplastics Resilient Material Graphite Glass
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Introduction
Crane Brands
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
CRANE® The portfolio of CRANE® brand valves today is focused on delivering value. With a complete range of bronze, cast iron, cast steel Gate, Globe & Check valves, resilient-seated butterfly valves and ball valves, Crane has a valve for your needs.
Identify Crane brands that manufacture valves. 28
Introduction
Crane Brands
Aloyco® Aloyco® has supplied stainless and alloy steel valves for more than 70 years. The product line includes gate, globe, swing check and ball valves in sizes ½" -24", with flanged, socket weld, and threaded ends and pressure classes 150 to 600.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Center Line® Center Line® has been a market leader in resilient seated butterfly valves for more than 40 years, and we have earned a reputation as a supplier of superior valves at competitive prices. Center Line® Series RS provides repeatable tight shutoff in severe abrasive and corrosive environments Center Line® 200 single-piece stem design assures even torque distribution and resilient seat provides positive shut off
Identify Crane brands that manufacture valves. 29
Introduction
Crane Brands
Noz-Chek® The Noz-Chek® high performance, non-slam check valve minimizes the damaging effects of water hammer in fluid systems and eliminates valve chatter associated with conventional valves in reciprocating compressor service. The flow area is designed to provide minimal pressure drop across the valve. Noz-Chek valves provide a quick dynamic response, reducing reverse velocity.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Compac-Noz® Shorter face-to-face design for nozzle check valve offers an economic alternative to full-body with minimal sacrifice to performance characteristics • Sizes 12" - 60" • ASME B16.34 & API 6D, pressure classes 150 - 4500 • API 6A pressure classes 2000 - 15000 • Flanged, butt-weld ends, hub ends and specials
Identify Crane brands that manufacture valves. 30
Introduction
Crane Brands
Duo-Chek® Duo-Chek® valves have long been the standard for low-pressure drop flow reversal protection. These valves are made from cast iron, cast steel, stainless steel, and a broad variety of exotic materials. Duo-Chek offers retainerless designs to API 594 end-to-end dimensions in steel bodied wafer and lug style with a wide variety of trim materials including both metal and resilient seats. Valves come in sizes up to 88" and pressure ratings up to class 4500. Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Flowseal® Flowseal® Butterfly valves define high performance. Soft Seat, Fire Flow®, Metal Seat, and Mil-Spec valves up to 48" in pressure classes 150, 300 and 600, wafer or lugged style that include double dead end service capability.
Identify Crane brands that manufacture valves. 31
Introduction
Crane Brands
Jenkins® Jenkins® valves is the choice for mechanical contractors in North America. The complete range of products, including 600 CWPrated threaded and soldered end ball valves, make Jenkins the preferred supplier to this market place.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Krombach® Krombach manufactures large fabricated butterfly valves, triple offset valves, and check valves. These valves range in size from 3” to 136” and are typically used in applications such as steam / water isolations, condenser isolations, cooling tower isolations and seawater isolations. Krombach also makes soft seated and metal seated ball valves manufactured with precision to address rugged service in corrosive, abrasive and high temperature processes.
Identify Crane brands that manufacture valves. 32
Introduction
Crane Brands
Pacific® Pacific® Valves pressure seal bonnet and bolted bonnet valves are ideally suited for high pressure steam applications associated with power generation and in refining. Pacific Valve solutions for HF acid service have been approved for both of the major licensors' specifications for many years. Pacific wedgeplug valves are chosen for delayed coker isolation in high temperature slurry service.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Resistoflex® Resistoflex® is the largest plastic-lined piping products supplier in the world, with manufacturing and sales locations in North America, Europe, and Asia. Resistoflex invented the PTFE lined hose technology in 1953 for the aerospace and chemical industries, and in 1956 introduced the world’s first pipe and fittings lined with Teflon® PTFE. We also offer a full line of pipe and fittings lined with polypropylene, Teflon® PFA, and Kynar® PVDF.
Identify Crane brands that manufacture valves. 33
Introduction
Crane Brands
REVO® The REVO® brand is the standard for excellence and performance in actuator technology and is widely recognized in the process industries as a leader in quality and innovation. The REVO® range of rack & pinion actuators is ideal for operating quarter-turn valves, especially butterfly, ball and plug valves.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Saunders® Saunders® has led the way in providing solutions in industries where resistance to corrosion, abrasion, contamination, and troublefree operation are imperative. Simplicity in design coupled with over 75 years of cutting edge innovation has resulted in the Saunders® diaphragm valve’s ability to handle a wider range of fluids than any other valve type. Our core competencies in rubber and polymer technology uniquely position us to truly manage 'The Science Inside' the valve.
Identify Crane brands that manufacture valves. 34
Introduction
Crane Brands
Stockham® Customers in North America know the Stockham® brand for their dependable quality bronze, cast iron, cast steel, ball and butterfly valves. In Europe and Australia the Stockham legacy brand goes hand in hand with CRANE® and Duo-Chek® on our wafer check valves.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Triangle® The Triangle® brand of cast steel valves, originally from the UK, is now provided by our Sydney, Australia, site. Flanged and butt-weld cast steel multi-turn and swing check valves through 24" are available in pressure classes 150 to 600.
Identify Crane brands that manufacture valves. 35
Introduction
Crane Brands
Uni-Check® Uni-Check® manufactures swing check valves that are compact, lightweight, and economical. These wafer check valves are preferred because of their compactness, ease of installation and lower initial costs when compared to traditional flanged swing checks. Sizes available in 2" (50mm) to 36" (900mm), and pressure classes to meet ASME, BS, DIN, AS, JIS and ISO standards. A variety of materials are available including cast iron, cast carbon steel and many alloy steels.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
WTA® WTA® designs, develops and manufactures a full range of highquality Bellows Sealed Globe Valves, Strainers, Check Valves, Relief Valves, Change-Over Valves and Special Valves meeting stringent specifications required by the Chemical and Petrochemical Industries.
Identify Crane brands that manufacture valves. 36
Introduction
Crane Brands
Westlock Controls® Westlock is a global market leader in innovative and emerging technologies in the valve position monitoring, digital control & monitoring and smart positioning serving the global oil & gas, chemical, petro-chemical and general industry markets.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
XOMOX® XOMOX® was established in 1956 as the Continental Manufacturing Company. The principal product was the Tufline® fluorocarbonsleeved plug valve. The concept of the non-lubricated sleeved plug valve was developed owing to the advent of Teflon® by the E.I. du Pont de Nemours and Company.
Identify Crane brands that manufacture valves. 37
Introduction
Crane Brands
CRANE Fluid System Crane Fluid Systems is a leading brand of Crane Building Services & Utilities. Leading provider of valves, pipe fittings and engineered products for fluid handling applications in building services and general industrial markets.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
NABIC One of the UK's leading suppliers of gunmetal safety valves, NABIC has long been recognized as the industry standard for commercial and industrial hot water applications. In fact, our valves are ideal for hot water supply, heating, pump relief, bypass relief, outside installation and for use with difficult gases and liquids. Designed and tested to the latest British Standards with third party certified discharge capacities, NABIC valves are manufactured under an ISO 9001 quality assurance system.
Identify Crane brands that manufacture valves. 38
Introduction
Crane Brands
Hattersley For over 100 years the Hattersley brand has been synonymous with quality, reliability and excellent service. Hattersley offers a vast range of ball, butterfly, check, gate and globe valves. Where systems are designed for constant or variable flow, a range of commissioning valve solutions, is available for flow or pressure balancing.
Identify Crane brands that manufacture valves.
Introduction
Crane Brands
Sperryn Gas Controls Sperryn is a leading supplier of meter installation kits and emergency control valves for domestic, commercial and industrial applications. Using the latest design facilities and technologies, Sperryn regulators offer increased capacity, accuracy and lower pressure drops. Where applicable, fittings and control valves comply with the requirements of the relevant British Gas Engineering Standards.
Identify Crane brands that manufacture valves. 39
Introduction
Crane Brands
Viking Johnson Viking Johnson is a world leader in the manufacture and supply of couplings, flange adaptors, resilient seated valves, pipe repair and jointing solutions for the international water, wastewater, gas and industrial markets.
Identify Crane brands that manufacture valves.
Introduction
Summary
This is what we have discussed so far: • A “valve” is a mechanical device that turns on and off, regulates, modulates or isolates the rate, volume, pressure or direction of liquids, gasses, slurries or dry materials through a pipeline, chute or passageway. • Valves can be classified in four categories: • Linear • Rotary • Check • Pressure Control
40
Introduction
Summary
This is what we have discussed so far: • Three main functions of valves are: • On/Off • Control • Backflow prevention • Four types of valve connections include: • Flanged • Threaded • Socket Weld • Butt Weld
Introduction
Summary
This is what we have discussed so far: • Valve trim is a collective name for the replaceable parts in a valve. • Gaskets are the mechanical seals, or packing, used to prevent the leakage of a gas or fluids from valves. • Valves are manufactured using various materials including: • • • • • • •
Brass Bronze Cast iron Steel Stainless steel Alloy steel Thermoplastics
• • • •
Thermoplastics Resilient Material Graphite Glass
41
Introduction
Summary
This is what we have discussed so far: • Crane has a large variety of brands and products.
VALVE & ACTUATOR OVERVIEW
Gate Valves
42
Gate Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a gate valve, identify the major components. 2. Identify the following gate valve types: • Wedge • Parallel Slide • Bolted Bonnet • Resilient Seated • Knife • Slab
Gate Valves
Learning Objectives
At the completion of this lesson, students will be able to: 3. 4. 5. 6. 7. 8. 9.
Identify the three types of wedges. List advantages and disadvantages of gate valves. Identify typical applications for gate valves. Define, “thermal binding.” Define, “pressure locking.” Identify three types of gate valve bonnets. identify at least one likely cause for each given problem associated with a gate valve. 10. Given a list of gate valves, identify the Crane brand or brands that manufacture each of them.
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Gate Valves
Meet the Gate Valve
Introducing the gate valve • Simple construction • On/Off operation • Not recommended for throttling service • High flow coefficient • Easy to repair • Heavy duty design
Gate Valves
Meet the Gate Valve
Introducing the gate valve • Good for high temperature and high pressure service • Bi-directional flow • Easy & inexpensive to manufacture
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Gate Valves
Meet the Gate Valve
Valve materials and temperature limits 1000 F 538 C
500 F 260 C
Bronze
Cast Steel
Gate Valves Handwheel Nut
450 F 232 C
Iron
Components Handwheel
Gland Flange Packing Gland Packing Bonnet Bushing Stem T-Slot Disc Guide Body
Gland Eye Bolts Bonnet Studs Bonnet Nuts Bonnet Disc Seat Ring
Given a picture of a gate valve, identify the major components. 45
Knowledge Check Can you identify the parts of a gate valve?
Given a picture of a gate valve, identify the major components.
Meet the Gate Valve
Gate Valves Gate valve trim Stem
Disc
Seats
• Bronze
• Bronze
• Stainless steel
• Stainless steel
• Inserted or machined into the body • Bronze is the most common • Stainless steel
46
Gate Valves
Types of Bonnets
Threaded Bonnet • The threaded bonnet is screwed into the valve body with internal threads • This is a “no maintenance” type of valve • This the lowest cost valve
Identify three types of gate valve bonnets.
Gate Valves
Types of Bonnets
Union Bonnet • Connection provides external body threads with a heavy duty nut • Better for high temperature services • Do not loosen up with temperature changes • Stronger and more substantial product Identify three types of gate valve bonnets. 47
Gate Valves
Types of Bonnets
Bolted Bonnet • Bonnet is attached to the body using bolts • Joint has a gasket • Strong and easy to assemble and disassemble
Identify three types of gate valve bonnets.
Gate Valves
Types of Bonnets
Pressure Seal Bonnet • Incorporate "Bonnet take-up bolts" to pull the Bonnet up and seal against the pressure seal gasket. • Body-Bonnet joints seal improves as the internal pressure in the valve increases
Identify three types of gate valve bonnets. 48
Gate Valves
Types of Gate Valves
Let’s take a look at some common gate valves: • • • • • • •
Rising / Non-Rising Stem Wedge Parallel Slide Bolted Bonnet Resilient Seated Knife Slab
Identify various types of gate valves.
Gate Valves
Rising / Non-rising Stem
Identify various types of gate valves. 49
Wedge
Gate Valves Typical wedge gate valve
Identify various types of gate valves.
Wedge
Gate Valves
Gland
Yoke Stuffing box (packing)
Seat Ring
Bonnet
Wedge
Identify various types of gate valves. 50
Wedge
Gate Valves Types of wedges
Solid Wedge
Flex Wedge
Split Wedge
Identify three types of wedges.
Wedge
Gate Valves Solid wedge
Identify three types of wedges. 51
Wedge
Gate Valves Flex wedge
Identify three types of wedges.
Wedge
Gate Valves Split wedge
Ring - 2 x ½ Locking Pin
Bayonet Lock
Central part
Back Seat
Wedge plate lens
Identify three types of wedges. 52
Wedge
Gate Valves Split wedge
Wedge Plate with Bayonet Lock Identify three types of wedges.
Wedge
Gate Valves Split wedge
Identify three types of wedges. 53
Parallel Slide
Gate Valves
Identify various types of gate valves.
Parallel Slide
Gate Valves Design principle
Inner-gate space becomes pressurized
Forces disc against seat face Identify various types of gate valves. 54
Bolted Bonnet
Gate Valves Traditional Gasket
Leak Path
Leak Path
Identify various types of gate valves.
Pressure Seal Bonnet
Gate Valves Pressure Seal Gaskets
Identify various types of gate valves. 55
Pressure Seal Bonnet
Gate Valves Pressure Seal Gaskets
Draw Bolt Collar Segment Ring Body Gasket Thrust Ring Bonnet
25o
23.5o
Point formed in the bonnet of the PV Pressure Seal valve.
15o
Note: Not under pressure Identify various types of gate valves.
Resilient Seated
Gate Valves Resilient Seated Gate Valve • Suitable for use with water, neutral liquids and sewage • Clockwise or anti-clockwise closing • Handwheel option • Sea water version
Identify various types of gate valves. 56
Knife
Gate Valves Knife Gate Valve Good for slurries Broad size range High Cv Bidirectional or unidirectional available • Not a Crane product • • • •
Identify various types of gate valves.
Slab
Gate Valves Slab Gate Valve • • • •
Also called Through Conduit Used for oil and gas Good flow Piggable
Identify various types of gate valves. 57
Knowledge Check What are four types of gate valve bonnets? • • • •
Bolted Threaded Union Pressure Seal
Can you name three types of gate valve wedges? • Solid • Flex • Split
Gate Valves
Advantages & Disadvantages
Advantages for gate valves • Wide range of on/off applications where high Cv or Kv is needed • Lower thrust required to operate (Parallel Slide)
Disadvantages for gate valves • Not suitable for throttling applications except for specially designed knife gates • Potential for thermal binding in high temperature applications (Solid Wedge)
List advantages and disadvantages of gate valves. 58
Gate Valves
Applications
Solid Wedge • Isolation in process applications, potable water, and other liquid systems
Identify typical applications for gate valves.
Gate Valves
Applications
Flex Wedge and Split Wedge • High temperature/pressure steam and water in power plants • Where thermal binding is a concern
Identify typical applications for gate valves. 59
Gate Valves
Applications
Parallel Slide • High temperature/pressure steam and water in power plants where tighter sealing is needed
Identify typical applications for gate valves.
Gate Valves
Applications
Slab Gate Valve • Oil and gas platforms and pipelines
Identify typical applications for gate valves. 60
Applications
Gate Valves Knife Gate Valve • Low temperature and pressure • Pulp and paper and Oil Sands • Slurries, sludge, sewage
Identify typical applications for gate valves.
Knowledge Check Can you identify the following valves?
Wedge
Bolted Bonnet
Knife
61
Knowledge Check Can you identify the following valves?
Resilient Seated
Parallel Slide
Introduction
Slab
Definition
Thermal Binding Thermal binding takes place when a valve cools and the body shrinks more than the seated disc. The disc becomes, “bound” and may remain unserviceable until high temperature is re-obtained.
Define, ”thermal binding.” 62
Thermal Binding
Gate Valves
Thrust required to lift wedge
Thermal binding load
Thermal binding load
FLOW
FLOW
Upstream
Downstream Define, “thermal binding.”
Thermal Binding
Gate Valves Preventing thermal binding • After closing the valve, back off the stem a ¼ of a turn to allow for stem expansion • Install a bypass pipe and valve on the inlet and outlet sides of the body. This will allow warm up of both sides of the wedge
Define, “thermal binding.” 63
Introduction
Definition
Pressure Locking Pressure locking occurs when the pressure in the body cavity of a closed valve increases or when the pressure in the body bonnet area becomes higher than line pressure. The pressure forces the disc tightly into the valve seats, making the valve difficult to open.
Define, ”thermal binding.”
Title
Gate Valves Pressure Locking • Occurs when there is pressure in the body cavity.
• Temperature in the valve bonnet may increase in response to heat up during plant operation, ambient air temperature rise due to leaking components or pipe breaks. • The bonnet pressure could decrease by leakage past the seating surfaces or stem packing. • If this does not occur, the depressurization time may be longer than the needed time to operate the valve.
Define, “pressure locking.” 64
Pressure Locking
Gate Valves • Higher bonnet pressure causes the body to expand, moving the seats apart. • The stem pushes the disc further down and it “locks” into the seat.
Define, “pressure locking.”
Pressure Locking
Gate Valves Solutions: • Cycling the valve during start-up • Installing a pressure release system of the body cavity • Installing a automatic relief valve or a manual drain • Drilling an internal hole in the wedge face
Define, “pressure locking.” 65
Gate Valves
Problems and Causes
Valve doesn’t open or shut on demand Physical blockage, corrosion, broken actuator, broken stem, pressure locking, thermal binding
Valve partially strokes but doesn’t reach desired position Excessive stem load due to packing or seat friction, high stem to stem-nut friction, actuator problems
Identify at least one likely cause for each given problem associated with a gate valve.
Gate Valves
Problems and Causes
Packing leakage Normal packing wear, incorrect packing set, inadequate packing consolidation
Seat leakage Foreign material, seat/disc damaged, seat/disc repaired wrong, insufficient stem thrust
Body to bonnet leakage Wrong bolt torqueing, scratched sealing surface, wrong seal used, seal not properly installed
Identify at least one likely cause for each given problem associated with a gate valve. 66
Gate Valves
Problems and Causes
Pressure locking Pressure between discs or in bonnet much higher than up or downstream
Thermal binding Differential expansion and contraction between disc and body
Excessive packing friction Over tightened packing gland nuts, cocked packing gland follower
Bent or broken stem or disc attachment Excessive closing force applied, weak-link design calculation wrong
Identify at least one likely cause for each given problem associated with a gate valve.
Check Valves
Activity
Now it is time for you to identify gate valves manufactured by Crane Fluid Handling brands. 1. Place a valve photo under each brand name on the wall. 2. Pick an example gate valve from the valve directory on your computer for each brand. 3. For each valve selected create Team 1: a presentation with: Aloyco, Jenkins Team 2: • Product Name Krombach, Pacific Team 3: • Size Range Stockham, Triangle Team 4: • Materials Crane, Viking Johnson • Features Given a list of gate valves, identify the Crane brand or brands that manufacture each of them. 67
Gate Valves
Crane Brands
Given a list of gate valves, identify the Crane brands that manufacture each of them.
Gate Valves
Summary
This is what we have discussed so far: • • • • •
Wedges are available in solid, flex, and split. Thermal binding and pressure locking. Four types of gate valve bonnets. Possible causes for gate valves problems. Crane brands that manufacture gate valves.
68
VALVE & ACTUATOR OVERVIEW
Globe Valves
Globe Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a globe valve, identify the major components. 2. Identify the following globe valve types: • T-Pattern • Y-Pattern • Angle • Bellows Sealed • Change-Over 3. Identify three trim characteristics of a globe valve disc. 4. Identify three types of guiding for valve discs. 5. List advantages and disadvantages of globe valves. 6. Identify typical applications for globe valves. 7. Given a list of globe valves, identify the Crane brand or brands that manufacture each of them.
69
Globe Valves
Meet the Valve
Globe Valve • Called a globe due to round body shape • Heavy duty design • Easy to repair • Good for high temperature & high pressure service • Unidirectional flow • Can be used for regulating or throttling List advantages and disadvantages of globe valves.
Globe Valves
Meet the Valve
Globe Valve • Used for on/off service • Main type of control valve • Poor flow path • Generally not made in large sizes
List advantages and disadvantages of globe valves. 70
Components
Globe Valves Handwheel Nut
Handwheel
Yoke Bushing
Gland Flange
Gland
Gland Eye Bolts
Packing
Bonnet Studs
Bonnet Bushing
Bonnet Nuts
Stem Bonnet
Disc Stem Nut
Disc Body
Seat Ring
Given a picture of a globe valve, identify the major components.
Knowledge Check Can you identify the parts of a globe valve?
Given a picture of a globe valve, identify the major components. 71
Globe Valves
Valve Types
Let’s take a look at various types of globe valves. • T-Pattern • Y-Pattern • Angle • Bellows Sealed • Change-Over
Identify various types of globe valves.
Globe Valves
T-Pattern
• Most control valves are T-Pattern • Tight shut-off • Used for equipment isolation • Many options available
Identify various types of globe valves. 72
Globe Valves
Wye (Y)-Pattern
• More compact than T-Pattern • Smoother flow pattern (better Cv/Kv)
Identify various types of globe valves.
Globe Valves • •
• •
Angle
Ports are 90 degrees Offset Fewer Flow stream Direction Changes Higher Capacity Cavitation & Flashing Service vice
Identify various types of globe valves. 73
Globe Valves
Bellows Sealed
• For different types of media with inflammable, explosive, volatile, toxic, or aggressive characteristics, whose delivery must be prevented into the atmosphere • Designed in accordance with the Federal Emission Protection law
Identify various types of globe valves.
Globe Valves • • • •
Bellows Sealed
Two-part rising stem Stem coupling with bellows Anti-torque device and position indicator Full-size safety gland packing
Identify various types of globe valves. 74
Bellows Sealed
Globe Valves • Metal back seat with stroke limiter in open position • Bellows anti-vibration device
• • • •
Multiple wall Fully flushed stainless steel bellows Designed for 10,000 cycles Fully welded
Identify various types of globe valves.
Change-Over
Globe Valves
• Extremely low resistance coefficients • Compact weight-saving construction method • Offered in carbon steel, stainless steel, Low temperature carbon steel, and special materials 5
3 6
4
2
1
Identify various types of globe valves. 75
Change-Over
Globe Valves
• Plants are protected against undue excess pressure by switching over to the relevant standby safety valves • Full blow off capacity is maintained during switching • Hand wheels linked for tandem use by chain
Identify various types of globe valves.
Knowledge Check Can you name five types of globe valves?
T-Pattern
Y-Pattern
76
Knowledge Check Can you name five types of globe valves?
Bellows Sealed
Angle
Knowledge Check Can you name five types of globe valves?
5
3 6
4
2
1
Change-Over
77
Globe Valves
Disc Trim Characteristics
Three common trim characteristics:
Quick Opening
Linear
Equal Percentage
Identify three trim characteristics of a globe valve disc.
Globe Valves
Disc Trim Characteristics
Quick Opening • Maximum flow as soon as stem starts to open
Identify three trim characteristics of a globe valve disc. 78
Globe Valves
Disc Trim Characteristics
Linear • Equal volume and lift changes
Identify three trim characteristics of a globe valve disc.
Globe Valves
Disc Trim Characteristics
Equal Percentage • Like movements of the stem at any point of flow changes the flow an equal percentage
Identify three trim characteristics of a globe valve disc. 79
Disc Trim Characteristics
Globe Valves 100
% FLOW
75
50
25
0
25
50
75
100
% VALVE TRAVEL Identify three trim characteristics of a globe valve disc.
Guiding
Globe Valves Three types of guiding
Cage
Post
Stem
Identify three types of guiding for valve discs. 80
Globe Valves
Guiding
Cage Guiding • • • • •
Most common Best plug support Potential for galling More friction Not recommended for dirty fluids
Identify three types pes of guiding guid idin i g for valve discs discs.
Globe Valves
Guiding
Post Guiding • • • •
Guiding is near disc Smaller bearing surface More deflection Better in dirty fluid
Identify three types of guiding for valve discs. 81
Globe Valves
Guiding
Stem Guiding • • • • • •
Two stem bearings Cantilevered plug Low friction No galling Recommended for dirty fluids Can have plug vibration
Identify three types of guiding for valve discs.
Globe Valves Advantages & Disadvantages • Short stroke enhances process control capability • Selectable trims to optimize control • T-Pattern • Lowest Cv • Traditional design • Angle Pattern • Higher Cv • Used where change of direction is desired • Y-Pattern • Highest Cv List advantages and disadvantages of globe valves. 82
Applications
Globe Valves
• Throttling and flow regulation in a variety of fluid systems • Wide range of temperatures and pressures • Generally used for clean fluids • Angle Pattern used where change of direction is desired
Identify typical applications for globe valves.
Knowledge Check What are three trim characteristics? • Quick Opening • Linear • Equal Percentage
Can you name three types of guiding? • Cage • Post • Stem
83
Check Valves
Activity
Now it is time for you to identify the Crane brands that manufacture globe valves. Team 1: Aloyco, Crane Team 2: Jenkins, Krombach Team 3: Pacific, Stockham Team 4: Triangle, WTA, Viking Johnson Given a list of globe valves, identify the Crane brands that manufacture each of them.
Check Valves
Activity
Now it is time for you to identify the Crane brands that manufacture globe valves. 1. Identify all of the brands 2. For each brand: • Product Name • Size Range • Materials • Features
Given a list of globe valves, identify the Crane brands that manufacture each of them. 84
Gate Valves
Crane Brands
Given a list of gate valves, identify the Crane brands that manufacture each of them.
Globe Valves
Summary
This is what we have discussed so far: • • • • • • • •
Globe valve components Basic types of globe valves Trim characteristics of a globe valve disc Three types of guiding for valve discs Advantages and disadvantages of globe valves Typical applications for globe valves Problems and potential causes associated with globe valves Crane brands that manufacture globe valves
85
VALVE & ACTUATOR OVERVIEW
Diaphragm Valves
Diaphragm Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a diaphragm valve, identify the major components. 2. Identify two types of diaphragm valves. 3. List the materials available for diaphragm construction. 4. Identify the available linings for Crane diaphragm valves. 5. List advantages and disadvantages of diaphragm valves. 6. Identify typical applications for diaphragm valves. 7. Identify at least one likely cause for each given problem associated with a diaphragm valve. 8. Given a list of diaphragm valves, identify the Crane brand or brands that manufacture each of them.
86
Diaphragm Valves
History
Invention of the diaphragm valve • Invented in 1928 by P.K. Saunders • Main facility opened in 1939 in Cwmbran, South Wales
Diaphragm Valves
Meet the Valve
Named for its crucial component
Diaphragm Valve
Diaphragm
87
Diaphragm Valves
Meet the Valve
The Diaphragm Valve • 100% leak tight • Working parts are isolated • Wide choice of: • body materials • diaphragms • lining options • end connections • Yellow indicator with lip seal • Lubricated for life Identify various types of diaphragm valves.
Diaphragm Valves
Components
Position Indicator Bonnet
Diaphragm Compressor Liner Given a picture of a diaphragm valve, identify the major components. 88
Knowledge Check Can you identify the parts of a diaphragm valve?
Given a picture of a diaphragm valve, identify the major components.
Diaphragm Valves
Valve Types
Weir • Versatile & extensively used in Industrial applications • Can handle up to 15% solids • Perfect for on/off control involving corrosives
Identify various types of diaphragm valves. 89
Diaphragm Valves
Valve Types
Fire Hydrant • Bubble tight shut off • Fire tested and approved with the world’s leading safety agencies • For use on cruise liners, oil tankers, naval vessels and firefighting equipment in oil refineries
Identify various types of diaphragm phragm valves.
Diaphragm Valves
Valve Types
Straight Through • Low pressure drop • Smooth flow ideal for slurries
Identify various types of diaphragm valves. 90
Diaphragm Valves
Valve Types
HC4 - Aseptic • Class leading platform of Forged 2 Way , Standard Machined Block and Custom Designs to meet increasing demands for hygienic performance and regulatory compliance in Life Science process and utilities
Identify various types of diaphragm valves.
Diaphragm Valves
Title
Double acting stem
Identify various types of diaphragm valves. 91
Diaphragm Valves
Diaphragm Materials
Desired properties of a diaphragm • • • • •
High flex performance Good compression set properties Chemical resistance Abrasion resistance Anti-aging
Diaphragm Valves
Diaphragm Materials
Diaphragm construction Traceable multi layers of rubber and nylon reinforcement
Studs attached with bonding adhesive and mechanical anchorage
Rib around port area and across weir for leak tight sealing and lower closure torque List the materials available for diaphragm construction. 92
Diaphragm Materials
Diaphragm Valves
Diaphragm materials & life expectancy 10 Years • E3, 425 (EPM) • 226 Fluoroelastomer (Non FDA) • 214S & 214 with EPM Backing
7 Years •
Butyl, Nitrile & Neoprene
5 Years •
Natural Rubber
List the materials available for diaphragm construction.
Diaphragm Valves
Diaphragm Materials
Crane elastomer and polymer experience • 75 years of history and experience • Began rubber processing in 1932 • In-house rubber and polymer technologists • Developed first PTFE diaphragm in 1954 • All Diaphragms are developed, compounded, and made in-house
List the materials available for diaphragm construction. 93
Diaphragm Valves
Diaphragm Materials
Diaphragm material selection BEST
CORROSION & CHEMICAL RESISTANCE
PTFE/TFM FKM HYPALON NEOPRENE BUTYL/EP
NITRILE Q NATURAL
AA SOFT BEST
WORST
ABRASION RESISTENCE List the materials available for diaphragm construction.
Diaphragm Valves
Diaphragm Materials
Diaphragm material selection Natural Q
Water, effluent, abrasives
Natural AA
Abrasives, slurries, and dry powders
Butyl 300
Dilute acids and abrasives
EPM 425
Salts (acids water, etc.)
Nitrile C
Oils, fuels, no solids
Neoprene HT
Water, no oil
Hypalon 237
Strong acids, chlorine gas, sodium hypochlorite
Fluoroelastomer 226
Solvents, petrol unleaded, hydrocarbons
Silicone 500
Pharma, milk, toothpaste
PTFE 214/xxx
Strong acids and virtually all chemicals
PTFE 214S/xxx
As 214 and steam
PTFE 214K/xxx
Chlorine and chlorinated brine (PVDF backing) List the materials available for diaphragm construction. 94
Diaphragm Valves
Lining Materials
Available linings • Glass • Plastics • Elastomers
Identify the available linings for Crane diaphragm valves.
Diaphragm Valves
Lining Materials
Glass • More expensive than alternatives • Must be careful during installation and maintenance to avoid breaking
Identify the available linings for Crane diaphragm valves. 95
Diaphragm Valves
Lining Materials
Plastics • • • • •
Polytetrafluoroethylene (PTFE) Perfluoroalkoxy (PFA) Ethylene Tetrafluoroethylene (ETFE) Polyvinyldiene Fluoride (PVDF) Polypropylene (PP)
Identify the available linings for Crane diaphragm valves.
Diaphragm Valves
Lining Materials
Elastomers Hard Rubber Lined (HRL) • Ebonite Butyl Lined (BL) • IIR- Isobutylene Isoprene Soft Neoprene (NL) • Polychloroprene Soft Natural Rubber (AA) • Polyisoprene
Identify the available linings for Crane diaphragm valves. 96
Diaphragm Valves
Diaphragm Materials
Lining material selection BEST
CORROSION & CHEMICAL RESISTANCE
PTFE/PFA
GLASS
ETFE
HRL
NEOPRENE BUTYL
PP
AA NATURAL BEST
WORST
ABRASION RESISTENCE List the materials available for diaphragm construction.
Diaphragm Valves
Diaphragm Materials
Lining material selection Natural AA lining
Abrasive media, dry solids
Ebonite HRL lining
Salt water, Dilute Acids, Demineralised water
Butyl lining
Dilute Acids, Low permeation. Lime
Neoprene lining
Oils, Sea water, Sludge
Glass lining
Abrasives, strong acids, high temperature, HCL
Polypropylene lining
Water, Alkali solutions
ETFE lining
Medium abrasives, Strong Acids
PFA lining
Strong acids, Chlorinated solutions, Aromatics
Halar
Low cost for Dilute acids, Water treatment
PVDF
Chlorine
List the materials available for diaphragm construction. 97
Knowledge Check What are three available linings for Crane diaphragm valves? • Glass • Plastics • Elastomers
Diaphragm Valves
Advantages
Diaphragm valve advantages • • • • • • •
Operating mechanism not in contact with line media Valve operates first time even after long idle periods 100% leak tight Lined for excellent corrosion resistance Suitable for control In-line maintenance No seat wear
List advantages and disadvantages of diaphragm valves. 98
Diaphragm Valves
Applications
Aseptic • • • • • • • • • •
Fine Chemicals Chromatography Cosmetics Filtration Demineralization Fermentation CIP Yeast Food & Beverage Pills & Soap Identify typical applications for diaphragm valves.
Diaphragm Valves
Applications
Corrosive • • • • • • • • • • •
Sulphuric Effluent Treatment Potable Water Fire Fighting Pulp & Paper Basic Chemicals HCL Fuels Acids & Alkalis Organics Toxic Fluids Identify typical applications for diaphragm valves. 99
Diaphragm Valves
Applications
Abrasive • • • • • • • • • • •
Gold Mining Cement Copper Mining Ceramics Sugar Coal Slurry Phosphoric Sand Fertilizers Titanium Sewage Identify typical applications for diaphragm valves.
Diaphragm Valves
Applications
Industry • • • • • • • • • • •
Marine Iron & Steel Vegetable Oil Paints Manufacture Tanning Oil Production Automobile Air and Gas Effluent Dye Liquors Identify typical applications for diaphragm valves. 100
Diaphragm Valves
Problems and Causes
Seat leakage Foreign material, damaged diaphragm, corrosion or abrasion of weir
Diaphragm damage or leakage Normal aging, defective material, damage during maintenance, improper assembly, incorrect material for service application
Broken diaphragm attachment to compressor High cycling of valve, improper initial fit up
Flow obstruction Fluid system contains solids (slurries, rivers, lakes, seawater), tools or other debris left in system, parts from upstream components, low slurry velocity has allowed solids to settle out Identify at least one likely cause for each given problem associated with a diaphragm valve.
Diaphragm Valves
Activity
Now it is time for you to identify the Crane brands that manufacture diaphragm valves. Team 1: Weir Features Team 2: Fire Hydrant Team 3: Straight-Through Features Team 4: HC4 Aseptic Given a list of diaphragm valves, identify the Crane brands that manufacture each of them. 101
Diaphragm Valves
Summary
This is what we have discussed so far: • The diaphragm valve was invented in 1928 by P.K. Saunders • Four types of diaphragm valves are: • • • •
Weir Straight-Through Fire Hydrant Aseptic
• Crane has the following diaphragm lining options: • • •
Glass Plastics Elastomers
VALVE & ACTUATOR OVERVIEW
Check Valves
102
Check Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Describe the purpose of a check valve. 2. Given a picture of a check valve, identify the major components. 3. Identify the following check valve types: • Swing • Tilting Disc • Lift • Stop • Dual Plate • Nozzle • Flex • Floating Ball 4. List advantages and disadvantages of check valves.
Check Valves
Learning Objectives
At the completion of this lesson, students will be able to: 5. Identify typical applications for check valves. 6. identify at least one likely cause for each given problem associated with a check valve. 7. Given a list of check valves, identify the Crane brand or brands that manufacture each of them.
103
Title
Check Valves What is the purpose of a check valve?
• Check valves prevent fluid flow reversal. • Two typical reverse flow prevention applications exist: • At the outlet of a pump or compressor • At points where different portions of a piping system join a common header
• Check Valves: • protect equipment • prevent contamination • protect low pressure systems from high pressure surges
Describe the purpose of a check valve.
Check Valves
Title
Let’s take a look at different types of check valves: • • • • • • • •
Swing Tilting Disc Lift Stop Dual Plate Nozzle Flex Floating Ball
Identify various types of check valves. 104
Check Valves
Swing Check
Cover Studs
Bonnet Bonnet Gasket
Cover Nuts
Hinge Pin Body
Hinge Arm Disc Seat Ring
Disc Stud Nut
Given a picture of a check valve, identify the major components.
Knowledge Check Can you identify the parts of a swing check valve?
Given a picture of a check valve, identify the major components. 105
Swing Check
Check Valves
Identify various types of check valves.
Swing Check
Check Valves
Wafer Style • Wafer Pattern • PFA Lined Only • Sizes 3” thru 12”
Identify various types of check valves. 106
Swing Check
Check Valves Bronze
• Low velocity services, especially liquids and infrequent change of direction in backflow prevention • Generally used with gate valves because of similar flow characteristics
Identify various types of check valves.
Check Valves
Swing Check
Y Pattern • Good flow characteristics • Can be installed in both horizontal and vertical lines with upward flow • The 45o seat aids in back seating under low pressures • Screwed cap design allows for quick and easy removal Identify various types of check valves. 107
Check Valves
Tilting Disc
Identify various types of check valves.
Check Valves
Tilting Disc
Pressure Seal Bonnet Stop
Internal Disc Hanger Seat Ring
Disc
Body
Identify various types of check valves. 108
Lift
Check Valves
Identify various types of check valves.
Stop
Check Valves Yoke Sleeves
Handwheel Eye Bolts Stem Bonnet Joint Backseat Seat Ring Disc Body Identify various types of check valves. 109
Check Valves
Stop
How is the stop check valve different from a globe valve? • The valve stem is not connected to the disc • In the open position the disc is free to respond to the flow
Identify various types of check valves.
Check Valves
Stop
Y Pattern
Identify various types of check valves. 110
Dual Plate
Check Valves
Identify various types of check valves.
Dual Plate
Check Valves LIGHTWEIGHT PLATE DESIGN Increased seating & operation efficiency
LONG-LEG SPRING ACTION No seat scrubbing
INDEPENDENT SPRINGS Plates close independently
HINGE SUPPORT SLEEVE Reduces friction Independent plate suspension
Identify various types of check valves. 111
Dual Plate
Check Valves Opening
Top View Identify various types of check valves.
Dual Plate
Check Valves Opening
Top View Identify various types of check valves. 112
Dual Plate
Check Valves Closing
Top View Identify various types of check valves.
Dual Plate
Check Valves Closing
Top View Identify various types of check valves. 113
Check Valves
Dual Plate
Let’s see the Dual Plate check valve in action:
Identify various types of check valves.
Check Valves
Dual Plate
• Lightweight & Compact • Ease Of Handling & Installation • Spring Assisted Closure • Faster Response Time • Choice Of Spring Torques • Wide Range Of Body Configuration & Materials • Lower Life Cycle Cost Identify various types of check valves. 114
Dual Plate
Check Valves Available in large sizes
72” (DN 1800)
88” (DN 2200) Identify various types of check valves.
Check Valves
Dual Plate
Deceleration comparison
Identify various types of check valves. 115
Nozzle
Check Valves
Identify various types of check valves.
Nozzle
Check Valves Spring assisted closure
Axial disc movement with short stroke length
Identify various types of check valves.
Venturi nozzle-type (bore size reduction) 116
Nozzle
Check Valves Body + Integral Cone (single piece casting)
Seat
Disc Disc Rod Bearing
Spring
Guidance Housing
Identify various types of check valves.
Nozzle
Check Valves Venturi Effect
3
FAST
HIGH
SLOW
LOW
Velocity
Pressure
2 1 Identify various types of check valves. 117
Nozzle
Check Valves Pressure Differential
Higher Pressure
Lower Pressure
Spring Assist
Identify various types of check valves.
Check Valves
Nozzle
Identify various types of check valves. 118
Nozzle
Check Valves Compac-Noz
Body + Integral Cone (Single piece casting design)
Guidance Housing
Seat
Disc
Check Valves
Nozzle
Compac-Noz • • • • • • • • •
Engineered and sized for the application One piece body One moving part Short stroke length Choice of spring compression rates Anti-spinning device Tight shut-off Maintenance free design Lightweight & compact
List advantages and disadvantages of check valves. 119
Check Valves
Nozzle
Why use a nozzle check? • One piece body casting • One moving part • Minimizes water-hammer • Removes chatter • Minimizes pressure loss • Provides a quick response
List advantages and disadvantages of check valves.
Check Valves
Nozzle
Why use a nozzle check? • Suitable for reciprocating service • Stable behavior due to venturi design • Significant low-pressure loss • Choice of spring compression ratess • Anti-spinning device • Tight shut-off
List advantages and disadvantages of check valves. 120
Flex
Check Valves
Identify various types of check valves.
Flex
Check Valves Why use a flex check? • Quiet operation • Only one moving part • No pivot pins • No bearings • No mechanical hinges • No linkage mechanisms • No packing
List advantages and disadvantages of check valves. 121
Floating Ball
Check Valves
Identify various types of check valves.
Floating Ball
Check Valves Antique Snorkel
Plastic Ball
Identify various types of check valves. 122
Check Valves
Advantages/Disadvantages
Advantages
Disadvantages
• Prevents backflow • Maintains pressure • Most can be installed horizontally or vertically
• Can't be used with pulsating systems • Closing element may slam close causing damage and excessive wear
List advantages and disadvantages of check valves.
Check Valves
Typical Applications
Check valves can be used for: • All temperatures and pressures (metal designs) • Low to medium temperatures and pressures (lined valves) • Harsh or corrosive gasses, liquids, or slurries (lined valves) • High Cv needs (swing, tilting disc, dual-plate, or nozzle) • Boiler operations or other places for shut-off (stop) • Water-hammer concerns (dual-plate, nozzle) • Sludge or sewage (flex)
Identify typical applications for check valves. 123
Check Valves
Typical Applications
Check valves can be seen in industries such as: • Refining • Petrochemical and Chemical • Oilfield production • Water • Steam • Refining petro • Waste-water management systems • Manufacturing Given a list of check valve types, identify at least one typical application for each of them.
Check Valves
Problems and Causes
Valve doesn’t shut Physical blockage, corrosion, excessive wear, disc stuck in bonnet, missing disc, broken spring
Valve doesn’t open Physical blockage, corrosion seat leakage, foreign material, seat/disc damaged, seat/disc repaired wrong, excessive hinge pin/bearing wear
Flange leakage Wrong bolt torqueing, scratched sealing surface, wrong seal used, seal not properly installed
Identify at least one likely cause for each given problem associated with a check valve. 124
Check Valves
Problems and Causes
Worn or broken springs Valve not fully open due to overdesign or reduced flow, corrosion, embrittlement
Flow obstruction Fluid system contains solids (rivers, lakes, seawater), tools or other debris left in system, parts from upstream components
Water-hammer Rapid interruption of flow (check valve slam) results in pressure wave, misapplication
Excessive hinge pin, stem, bearing or sleeve wear Valve not fully open due to overdesign or reduced flow, backstop not long enough, upstream flow disturbances Identify at least one likely cause for each given problem associated with a check valve.
Check Valves
Problems and Causes
Disc nut broken/missing Valve not fully open due to overdesign or reduced flow, disc rotating, nut not pinned to disc stud
Flow obstruction Fluid system contains solids (rivers, lakes, seawater), tools or other debris left in system, parts from upstream components
Identify at least one likely cause for each given problem associated with a check valve. 125
Activity Now it is time for you to identify the Crane brands that manufacture check valves. Team 1: • Swing • Tilting Disc Team 2: • Lift • Stop Team 3: Dual Plate, Flex Check Team 4: Nozzle Given a list of check valves, identify the Crane brands that manufacture each of them.
VALVE & ACTUATOR OVERVIEW
Pressure Control Valves
126
PC Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a pressure control valve, identify the major components. 2. Identify the following pressure control valve types: • Safety Relief • Vacuum Relief • Pressure Reducing • Fixed Orifice Regulation • Differential Pressure • Pressure Independent 3. Identify typical applications for pressure control valves. 4. Identify the Crane brands that manufacture pressure control valves.
Valve Types
PC Valves
Let’s take a look at the following types of pressure control valves: • • • • • •
Safety Relief Vacuum Relief Pressure Reducing Fixed Orifice Regulation Differential Pressure Pressure Independent
Identify various types of pressure control valves. 127
Valve Types
PC Valves Safety Relief • Protects system from • Over pressure • Combined pressure and temperature ͻ Safety valves incorporate ͻ Safety Relief Valves ͻ Pressure Relief Valves ͻ Relief Valves ͻ High discharge capacity option ͻ Adjustable pressure setting
Identify various types of pressure control valves.
Valve Types
PC Valves Safety Relief • Enclosed chamber for hazardous services • Easing lever to check operation for nonhazardous services
Identify various types of pressure control valv valves. lves es 128
PC Valves Safety Relief Valve Adjusting Bolt
Components Cap Bonnet
Spring Spindle Disc Insert Set Screw
Nozzle
Given a picture of a pressure control valve, identify the major components.
PC Valves Safety Relief Valve • Some valves have outlet ports larger than inlet ports to give high discharge capacity Disc Seat
Components Manual Lever Pressure Adjuster
Outlet Inlet
Given a picture of a pressure control valve, identify the major components. 129
Valve Types
PC Valves Vacuum Relief • Spring-to-close device • Used when increase in vacuum must be limited • Opens to restore vacuum to original pressure setting
Identify various types of pressure control valves.
Valve Types
PC Valves Anti-Vacuum • Used on steam systems • Protects drying cylinders, tanks, etc. from collapse
Threaded
Flanged
Identify various types of pressure control valves. 130
Valve Types
PC Valves Anti-Vacuum
Identify various types of pressure control valves.
Title
PC Valves Pressure Reducing • Reduces distribution pressures to usable pressures at outlet • Maintains a constant outlet pressure regardless of fluctuating inlet pressures • Automatic operation
Identify various types of pressure control valves. 131
Components
PC Valves Pressure Reducing
Pressure Seal Inlet Chamber
Pressure Reduction Chamber Outlet Chamber
Seat Disc
Given a picture of a pressure control valve, identify the major components.
PC Valves
Components
Pressure Reducing Pressure Adjuster Distribution Pressure
Inlet
Stem moves disc between seat to maintain pressure
Reduced Pressure Outlet
Given a picture of a pressure control valve, identify the major components. 132
Valve Types
PC Valves Fixed Orifice Regulation (FODRV)
• Allows commissioning engineer to measure & regulate flow rate: • •
Differential pressure read across orifice Hand wheel position ignored for flow measurement urement
• Recordable set position • Double regulating feature allows commissioned position to be set • Accuracy ± 5% • Used for isolation
Identify various types of pressure control valves.
Valve Types
PC Valves Fixed Orifice Regulation g (FODRV) ( ) Test Points test points
FLOW Orifice Insert Identify various types of pressure control valves. 133
Valve Types
PC Valves Fixed Orifice Regulation (FODRV)
test points
Return Pipework to Terminal Unit Branch Return Pipework
Typical Installed Position
Identify various types of pressure control valves.
Valve Types
PC Valves Fixed Orifice Regulation (FODRV)
test points
Identify various types of pressure control valves valves. 134
Valve Types
PC Valves Differential Pressure (DPCV)
• Controls differential pressure within installed circuit • Simplifies the commissioning process • Control range can be set and is adjustable • Protects control valve authority
Identify Iden Id ent various types of pressure control valves.
Valve Types
PC Valves
Differential Pressure Adjuster
Differential Pressure (DPCV)
Diaphragm
Upper Chamber
Lower Chamber
FLOW Identify various types of pressure control valves. ves 135
Valve Types
PC Valves Differential Pressure (DPCV)
Typical Installed Position
Identify various types of pressure control valves.
Valve Types
PC Valves Pressure Independent Flow regulation with a setting dial Recordable set position Differential pressure control Two port control valve when actuator fitted • Constant flow regulator when actuator not fitted • Threaded or flanged • • • •
Identify various types of pressure control valves. 136
Valve Types
PC Valves Pressure Independent
Stem
Test Points Actuator Fixing FLOW Differential Pressure Control Identify various types of pressure control valves. s.
Valve Types
PC Valves Pressure Independent
PICV
Return pipework to terminal unit
Typical Installed Position
Identify various types of pressure control valves. 137
PC Valves
Applications
Pressure control valves are used • • • •
In process control plants Mainly for steam and water applications In situations were pressure needs to be regulated To protect tanks, cylinders, etc. from collapse
Identify typical applications for pressure control valves.
Activity Now it is time for you to identify the Crane brands that manufacture pressure control valves. Team 1: Vacuum Relief Team 2: DPCV/PICV Team 3: Safety Relief
Given a list of pressure control valves, identify the Crane brands that manufacture each of them. 138
PC Valves
Crane Brands
Given a list of pressure control valves, identify the Crane brands that manufacture each of them.
PC Valves
Summary
Let’s take a look at what we have discussed so far: 1. The major components of a pressure control valve. 2. We looked at examples of the following pressure control valves: • Safety Relief • Vacuum Relief • Pressure Reducing • Fixed Orifice Regulation • Differential Pressure • Pressure Independent 3. We reviewed some applications for pressure control valves. 4. We explored Crane brands that manufacture pressure control valves.
139
VALVE & ACTUATOR OVERVIEW IEW
Butterfly Valves
Butterfly Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a butterfly valve, identify the major components. 2. Identify the following butterfly valve types: • Concentric • Double Offset • Triple Offset 3. List three butterfly valve body designs. 4. List advantages and disadvantages of butterfly valves. 5. Given a list of butterfly valve types, identify at least one typical application for each of them.
140
Butterfly Valves
Learning Objectives
At the completion of this lesson, students will be able to: 6. Identify at least one likely cause for each given problem associated with a butterfly valve. 7. Given a list of butterfly valves, identify the Crane brand or brands that manufacture each of them.
Butterfly Valves
Meet the Valve
• A circular disc that rotates 90 degrees to open or shut • Disc and shaft are always in the flow stream • Used for on/off applications as well as throttling • Very Compact • Wide range of applications
141
Butterfly Valves
Components Stem
Gland Flange Packing Valve Body
Packing Gland
Bearing
Soft-Seat Disc Seal Retainer Given a picture of a butterfly valve, identify the major components.
Knowledge Check Can you identify the parts of a butterfly valve?
Given a picture of a butterfly valve, identify the major components. 142
Types
Butterfly Valves Concentric
Double Offset
Triple Offset 1
1 3 2
2
Identify various types of butterfly valves.
Butterfly Valves
Concentric
Concentric • A metal disc is centered in the waterway with the shaft on the centerline of the disc • The disc is either iron, stainless steel or aluminum bronze • The design is economical and seals bubble tight • Most common offering as Resilient Seated but available Teflon lined
Identify various types of butterfly valves. 143
Concentric
Butterfly Valves Concentric • Single-piece stem design with pinned shaft to disc connection
• Two-piece shaft with drive shaft and pilot shaft offers capability for special alloy or coated discs
Identify various types of butterfly valves.
Double Offset
Butterfly Valves Double Offset • Low weight • Low torque • Competitive initial cost • Tight shut-off • Long life • Less maintenance • Easy to install • Easy actuation
1
2
Identify various types of butterfly valves. 144
Butterfly Valves
Double Offset
Identify various types of butterfly valves.
Butterfly Valves
Double Offset
Identify various types of butterfly valves. 145
Butterfly Valves
Triple Offset
• Developed by Adams Valves in 1960. • Began marketing in the USA in the 1980’s. • Successful in fire safe design, tighter shut-off, and ¼ turn design. • TOVs gained widespread use in high temperature applications, including steam, due to metal to metal tight shut off. • Self releasing taper design • No sticking, galling, or rubbing • Less seat wear and longer service life Identify various types of butterfly valves.
Butterfly Valves
Triple Offset
• Saunders, div. of Alfa Laval, was purchased by Crane in 2001. • The Saunders TOV eventually became the Flowseal MS (also marketed as the Xomox 9000 TOV) • Krombach was acquired by Crane in 2008 and included the Tri-EX AK110 product offering through 112” diameter • Crane FKX9000 single piece cast body design is Crane’s newest offering insizes 3" up to 48“ (DN 80 up to DN 1200); pressure classes 150, 300 & 600 (PN 10, 16, 25, 40); and in Lug and Double Flanged Short & Long Patterns Identify various types of butterfly valves. 146
Triple Offset
Butterfly Valves
Seat Angle 25
o
Identify various types of butterfly valves.
Butterfly Valves Flexible seal ring • • • • •
Triple Offset Graphite
3 tightening laminations of stainless steel 2 laminations of graphite Triple safety against leakage Graphite laminations give elasticity Graphite provides lubrication and reduces wear and friction
Stainless Steel Identify various types of butterfly valves. 147
Triple Offset
Butterfly Valves
Identify various types of butterfly valves.
Butterfly Valves
Valve Body Types
Three types of butterfly valve bodies: • Wafer • Lug • Double Flange
List the three types of butterfly valve body designs. 148
Butterfly Valves
Valve Body Types
Wafer
List the three types of butterfly valve body designs.
Butterfly Valves
Valve Body Types
Lug
List the three types of butterfly valve body designs. 149
Butterfly Valves
Valve Body Types
Double Flange
Valve
List the three types of butterfly valve body designs.
Butterfly Valves
Advantages
Butterfly Valves • Typically 3” and larger (2” sizes available) • Lighter weight and lower cost • Easy installation • Simple quarter turn actuation • Simple lever operation up to 8”
List advantages and disadvantages of butterfly valves. 150
Butterfly Valves
Advantages
Butterfly Valves • Low torque • Bubble tight sealing with soft seats • Fire-tested models available • High temperature metal seats available
List advantages and disadvantages of butterfly valves.
Butterfly Valves
Disadvantages
Butterfly Valves • Not piggable • Disc disrupts flow
List advantages and disadvantages of butterfly valves. 151
Butterfly Valves
Applications
Concentric • Low temperature and pressure • Building utilities, HVAC (One-piece shaft) • Chemical, Flue gas desulphurization (Two-piece shaft) • Lined pipe applications
Given a list of butterfly valve types, identify at least one typical application for each of them.
Butterfly Valves
Applications
Double Offset • Medium temperature and pressure • Chemical, pulp and paper, oil refinery • Cryogenic applications • Power generation (metal seated)
Given a list of butterfly valve types, identify at least one typical application for each of them. 152
Applications
Butterfly Valves
Triple Offset • High temperature and pressure • Applications needing Class 6 with metal seat • Power/steam generation • Cryogenic applications
Given a list of butterfly valve types, identify at least one typical application for each of them.
Butterfly Valves
Problems and Causes
Valve does not open/shut on demand Physical blockage, corrosion, broken actuator, broken stem, missing or broken key
Valve partially strokes but does not reach desired position Excessive stem load due to packing or seat friction, actuator problems
Packing leakage Normal packing wear, incorrect packing set, inadequate packing consolidation, worn stem
Identify at least one likely cause for each given problem associated with a butterfly valve. 153
Butterfly Valves
Problems and Causes
Seat leakage Foreign material, seat or disc damaged, seat or disc installed wrong, insufficient stem torque
Valve to pipe joint leakage Wrong bolt torqueing, scratched sealing surface, wrong seal used, seal not properly installed
Valve cavitation or vibration Operating too near the valve seats
Identify at least one likely cause for each given problem associated with a butterfly valve.
Activity Now it is time for you to identify the Crane brands that manufacture butterfly valves. Team 1: Concentric Team 2: Double Offset Team 3: Triple Offset Team 4: Teflon Lined Given a list of butterfly valves, identify the Crane brands that manufacture each of them. 154
Butterfly Valves
Crane Brands
Given a list of butterfly valves, identify the Crane brands that manufacture each of them.
VALVE & ACTUATOR OVERVIEW
Ball Valves
155
Ball Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a ball valve, identify the major components. 2. Identify the following ball valve types: • Metal-seated • Soft-seated • Lined 3. List two primary ball designs. 4. Identify six ball valve body configurations. 5. Identify three typical types of stem seals for ball valves.
Ball Valves
Learning Objectives
At the completion of this lesson, students will be able to: 6. 7. 8. 9.
List advantages and disadvantages of ball valves. List typical applications for ball valves. Identify likely causes for problems associated with ball valves. Given a list of ball valves, identify the Crane brand or brands that manufacture each of them.
156
Meet the Valve
Ball Valves
• A ball with a hole that lines up with the inlet and outlet ports • Ball captured between two seats in the valve body • Rotates 90 degrees to open or shut • Normally used for on/off functions • Full Port design • Wide range of applications
Components
Ball Valves Belleville Washers
Secondary Seal Mounting Flange
Primary Seal
Body Joint Seals Tail Piece Ball
Soft Seat
Given a picture of a ball valve, identify the major components. 157
Knowledge Check Can you identify the parts of a ball valve?
Given a picture of a ball valve, identify the major components.
Valve Types
Ball Valves Types of ball valves
Metal Seated
Soft Seated
Lined
Identify various types of ball valves. 158
Valve Types
Ball Valves Metal Seated
Identify various types of ball valves.
Valve Types
Ball Valves Soft Seated
Identify various types of ball valves. 159
Valve Types
Ball Valves Lined
Identify various types of ball valves.
Valve Designs
Ball Valves Two types of ball valve designs
Floating
Trunnion Mounted
List two primary ball valve designs. 160
Valve Designs
Ball Valves Floating Cavity Relief Upstream Side
Seats Tighten
PRESSURE
Upstream Side
Downstream Side List two primary ball valve designs.
Valve Designs
Ball Valves Floating • Lower pressure classes • Limited to 12” bore size maximum • Pressure assisted sealing
List two primary ball valve designs. 161
Valve Designs
Ball Valves Trunnion
Cavity Relief Downstream Side
PRESSURE Seats Tighten Upstream Side
Downstream Side List two primary ball valve designs.
Valve Designs
Ball Valves Trunnion • • • • •
Higher pressure classes Largest bore size about 64” Seat is loaded against the ball Lower valve torque Double block and bleed capable
List two primary ball valve designs. 162
Body Configurations
Ball Valves
1pc Body-Flanged
1pc Uni-Body
2pc Body-Flanged
1pc Body-Top Entry
2pc Body-Threaded
3pc Body
Identify six ball valve body configurations.
Body Configurations
Ball Valves 1pc Body-Flanged
Identify six ball valve body configurations. 163
Body Configurations
Ball Valves 2pc Body-Flanged
Identify six ball valve body configurations.
Body Configurations
Ball Valves 1pc Body-Top Entry
Identify six ball valve body configurations. 164
Body Configurations
Ball Valves 1pc Uni-Body
Identify six ball valve body configurations.
Body Configurations
Ball Valves 2pc Body-Threaded
Identify six ball valve body configurations. 165
Body Configurations
Ball Valves 3pc Body
Identify six ball valve body configurations.
Ball Valves
Stem Seals
Three types of stem seals • O-Ring • Stuffing Box • Dual O-Ring Stuffing Box
Identify three typical types of stem seals for ball valves. 166
Ball Valves
Stem Seals
O-Ring • General purpose
Identify three typical types of stem seals for ball valves.
Ball Valves
Stem Seals
Stuffing Box • • • •
PTFE chevron (corrosion) or graphite (fire-safe) Live loaded capability Adjustable if leaking Typical for process industries
Gland Follower Design
Threaded Stem Design
Identify three typical types of stem seals for ball valves. 167
Ball Valves
Stem Seals
Dual O-Ring Stuffing Box • Fugitive emission • Graphite (fire-safe) • Typical for API-6D
Identify three typical types of stem seals for ball valves.
Ball Valves
Stem Seals
Crane patented stem seal
Identify three typical types of stem seals for ball valves. 168
Ball Valves
Advantages
• High flow coefficient (Cv or Kv) • Quarter-turn • High pressure and temperature • Cost-effective • Long service life
List advantages and disadvantages of ball valves.
Ball Valves
Disadvantages
• Not good for throttling • Significant torque to operate (floating)
List advantages and disadvantages of ball valves. 169
Applications
Ball Valves Metal Seated • High temperature and pressure • Autoclaves, delayed coker systems • Solids and slurries • Cryogenic applications
List typical applications for ball valves.
Applications
Ball Valves Soft Seated • Standard utilities including gas and water • General chemical industry • Fugitive emissions • Low temperature steam
List typical applications for ball valves. 170
Applications
Ball Valves Lined • Water treatment • Acids and corrosives • Chlorine
List typical applications for ball valves.
Ball Valves
Problems and Causes
Valve does not open/shut on demand Physical blockage, corrosion, broken actuator, broken stem
Valve partially strokes but does not reach desired position Excessive stem load due to packing or seat friction, actuator problems
Stem packing/seal leakage Normal wear, inadequate packing/seal loading, incorrect installation, incorrect packing set, inadequate packing consolidation, side loading
Seat leakage Foreign material, seat/ball damaged, seat/ball repaired/installed wrong
Identify likely causes for problems associated with ball valves. 171
Ball Valves
Problems and Causes
Seat leakage Foreign material, seat/ball damaged, seat/ball repaired/installed wrong
Body joint/Valve to pipe joint leakage Wrong bolt torqueing, scratched sealing surface, wrong seal used, seal not properly installed
Excessive packing/seal friction Over tightened adjustment nuts, incorrect installation
Damaged stem/stem to disc attachment Excessive loading, weak-link design calculation wrong
Identify likely causes for problems associated with ball valves.
Ball Valves
Problems and Causes
Valve cavitation/vibration Operating too near the valve seats
Flow obstruction Fluid system contains solids (rivers, lakes, seawater), tools or other debris left in system, parts from upstream components
Identify likely causes for problems associated with ball valves. 172
Activity Now it is time for you to identify the Crane brands that manufacture ball valves. Team 1: Crane & Jenkins Team 2: Krombach Team 3: Stockham Team 4: Xomox Given a list of ball valves, identify the Crane brands that manufacture each of them.
Ball Valves
Crane Brands
Given a list of ball valves, identify the Crane brands that manufacture each of them. 173
VALVE & ACTUATOR OVERVIEW
Plug Valves
Plug Valves
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of a plug valve, identify the major components. 2. Identify the following plug valve types: • Sleeved • Severe Service • Lined • Eccentric • Wedge • Lubricated
174
Plug Valves
Learning Objectives
At the completion of this lesson, students will be able to: 6. List advantages and disadvantages of plug valves. 7. Identify typical applications for plug valves. 8. Identify likely causes for problems associated with plug valves. 9. Define, “Cold Flow.” 10. Define, “Delayed Coking.” 11. Given a list of plug valves, identify the Crane brand or brands that manufacture each of them.
Plug Valves
Meet the Valve
• Tapered plug that rotates 90° to open or shut off flow • High flow coefficient • Cavity free • Maintenance free • Typically used for on/off applications • Top entry provides for in-line maintenance
175
Plug Valves
Meet the Valve
• Dates back to ancient times • Design is of unknown origin • Early plug’s made of wood or animal materials • Later designs were metal seated with lubricants to seal
Valve Types
Plug Valves Sleeved Plug
Identify various types of plug valves. 176
Components
Plug Valves Seal Adjustment Bolts
Top Cover
Primary Seal
Secondary Seal Sleeve
Plug Given a picture of a plug valve, identify the major components.
Knowledge Check Can you identify the parts of a plug valve?
Given a picture of a plug valve, identify the major components. 177
Introduction
Definition
Cold Flow Cold flow occurs when PTFE “flows” into areas of a valve where it is not desired.
Competitor’s Valve Without 360°° Port Lips Define, ”valve.”
Valve Types
Plug Valves Sleeved Plug
Integral Cast 360° Port Lips • Prevents sleeve turning • Prevents cold flow • Acts as a “scraper”
Cast Top and Bottom Stops • Prevents sleeve extrusion Identify various types of plug valves. 178
Valve Types
Plug Valves Sleeved Plug Sealing
Force
• Sleeve is compressed between body and plug taper
Primary Seal
Identify various types of plug valves.
Valve Types
Plug Valves Sleeved Plug Sealing
• Standard top seal acts as a stem seal as well as a cover bonnet seal • Standard top seal is a true secondary seal to atmosphere
Standard Top Seal
Identify various types of plug valves. 179
Valve Types
Plug Valves Cage designs • Cage protects sleeve during plug rotation • Ideal for high velocity and severe throttling applications
Identify various types of plug valves.
Valve Types
Plug Valves Throttling flow with a cage
Open
Throttle
Closed
Identify various types of plug valves. 180
Valve Types
Plug Valves Plug Trim designs
100%
50%
12.5%
Modified V-Port
Identify various types of plug valves.
Valve Types
Plug Valves Severe Service Sleeved Plug • Separate Plug/Stem • Live Loaded, Double Packed Stem • Optional Bleed Off Port • Shrink Seal in Both Packing and Cover • O-Rings at Cover • Additional testing and documentation Identify various types of plug valves.
181
Valve Types
Plug Valves Severe Service Sleeved Plug • Separate plug and stem
• Compensates for plug movement due to high pressure differentials while closed • Stem remains concentric with packing • Eliminates side loading of stem packing • Maintains stem seal to atmosphere during pressure differentials Identify various types of plug valves.
Valve Types
Plug Valves Lined Plug • Large seal area • Tight shut-off • Long life
Identify various types of plug valves. 182
Valve Types
Plug Valves XP Design Sleeved Plug • • • • •
Extending packing cover Patented “shrink seal” Independent plug adjustment Live loaded packing Optional bleed-off port
Identify various types of plug valves.
Valve Types
Plug Valves Eccentric Plug Manual Operation • • • • •
Bare shaft 2” drive t-key Lever Chain wheel Gearbox
Automated Operation • • • •
Electric Pneumatic Hydraulic Cylinder
Identify various types of plug valves. 183
Valve Types
Plug Valves Eccentric Plug Multi-Functional • Isolation • Regulation • Bi-directional
Identify various types of plug valves.
Valve Types
Plug Valves Wedge Plug • Wedge torque operator lifts, rotates 90 degrees, and re-seats plug on its protected seating surfaces • Open-close position indicator • Limit switches • Large stuffing box
Identify various types of plug valves. 184
Valve Types
Plug Valves Wedge Plug • Non-lubricated and tapered plug • Robust body with raised seating surfaces • Integrally cast body ribs • Seven body bosses
Identify various types of plug valves.
Introduction
Definition
Delayed Coking Delayed coking is one of the unit processes used in many oil refineries. A delayed coker heats a residual oil feed to its thermal cracking temperature in a furnace with multiple parallel passes. This cracks the heavy, long chain hydrocarbon molecules of the residual oil into coker gas oil and petroleum coke.
Define, “Delayed Coking” 185
Valve Types
Plug Valves Lubricated Plug • Used primarily in oil and gas or other applications where grease contamination is not a problem • Lower torque required than sleeve plug valves • Sizes ½” to 24” • Pressure Class 125 and 250
Identify various types of plug valves.
Plug Valves
Advantages
Plug Valves (all) • Simple design with few parts • They open and close easily (except large dimensions) • Maintenance and repair can be done at the place of operation • They have low flow resistance • They provide reliable leakproofness List advantages and disadvantages of plug valves. 186
Advantages
Plug Valves Sleeved Plug • Quarter Turn Operation • Inexpensive • Easy to actuate • Better at controlling emissions than a rising stem valve such as a gate or globe • Does not “drag” media thru stem packing
List advantages and disadvantages of plug valves.
Plug Valves
Advantages
Sleeved Plug Adjustable Seals • In-line and external seal • Can adjust while installed • ¼ Turn of adjustment screws
List advantages and disadvantages of plug valves. 187
Advantages
Plug Valves Full ported option available
• Full unobstructed flow • High Cv/Kv value • Piggable
List advantages and disadvantages of plug valves.
Plug Valves
Disadvantages
Plug Valves (all) • Because of high friction, first movement (opening-closing) requires a large amount of force • Large valves require a gearbox or an actuator • Valve transitions are narrowing flows due to conic plug 4. Generally, their costs are much larger than ball valves List advantages and disadvantages of plug valves. 188
Plug Valves
Applications
• Typically used for on-off but can be used for throttling (with cage) • Sleeved plugs • Limited pressure/temperature applications • Gas, crude oil, flare stacks • HF acid, acetic acid, desulfurization • Autoclaves • Pulp and paper • Severe service – chlorine, phosgene, MDI/TDI
Identify typical applications for plug valves.
Plug Valves
Applications
• Wedge plugs • On-off only • High pressure and temperature • Delayed coking • Lined plugs • Chemicals, corrosives • Water treatment • Eccentric Plugs • On-off and control • Sewage, sludge, slurries Identify typical applications for plug valves. 189
Activity Now it is time for you to identify the Crane brands that manufacture plug valves. Team 1: Sleeved, Severe Service Team 2: Wedge Team 3: Lined Team 4: Eccentric Given a list of plug valves, identify the Crane brands that manufacture each of them.
Plug Valves
Crane Brands
Given a list of plug valves, identify the Crane brands that manufacture each of them. 190
VALVE & ACTUATOR OVERVIEW
Valve Testing
Valve Testing
Learning Objectives
At the completion of this lesson, students will be able to: 1. 2. 3. 4.
Define, “Flow Coefficient.” State the purpose for a Flow Coefficient (Cv / Kv) test. Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. Given a scenario, identify the data required to calculate Flow Coefficient (Cv / Kv). 5. Using provided data, calculate Flow Coefficient (Cv / Kv). 6. State the purpose of shell and seat leakage testing.
191
Introduction
Definition
Flow Coefficient (Cv / Kv) The amount of water flow at 60 degrees F, in gallons per minute, at a pressure drop of one pound per square inch across a component.
Define, ”Flow Coefficeient (Cv/Kv).”
Valve Testing
Flow Coefficient (Cv / Kv)
• Flow Coefficient (Cv) is used in the United States • Flow Factor (Kv) is used in Europe • Kv = (.865)(Cv) • Both are used to measure the efficiency of a valve at allowing fluid flow • A valve with a high Flow Coefficient has less pressure drop than a valve with a low Flow Coefficient.
State the purpose for a Flow Coefficient (Cv / Kv) test. 192
Valve Testing
Flow Coefficient (Cv / Kv)
• Cv / Kv is one of the parameters used to size a valve • The values are determined by testing in a flow loop during the development of the valve and published for use by system designers • ANSI/ISA-S75-02 describes basic testing for Cv • EN 1267 describes the method for Kv
State the purpose for a Flow Coefficient (Cv / Kv) test.
Valve Testing
Flow Coefficient (Cv / Kv)
Basic flow test setup Valve to be tested set to desired position.
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. 193
Valve Testing
Flow Coefficient (Cv / Kv)
Basic flow test setup Valve to be tested set to desired position.
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test.
Valve Testing
Flow Coefficient (Cv / Kv)
Basic flow test setup Temperature confirmed to desired reading.
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. 194
Flow Coefficient (Cv / Kv)
Valve Testing Basic flow test setup
Valves adjusted to desired gallons per minute (GPM).
GPMs
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test.
Valve Testing
Flow Coefficient (Cv / Kv)
Basic flow test setup Readings taken to determine difference between upstream and downstream pressure.
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. 195
Flow Coefficient (Cv / Kv)
Valve Testing
Calculating flow differential (Cv) Specific Gravity (for fluid used)
Pressure Drop Across Valve Flow Rate (Gallons Per Minute – GPM) Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test.
Flow Coefficient (Cv / Kv)
Valve Testing
Calculating flow differential (Cv)
GPMs
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. 196
Valve Testing
Flow Coefficient (Cv / Kv)
Calculating flow differential (Cv)
Specific Gravity (obtained from known data)
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test.
Valve Testing
Flow Coefficient (Cv / Kv)
Calculating flow differential (Cv) Water
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. 197
Flow Coefficient (Cv / Kv)
Valve Testing
Calculating flow differential (Cv)
P1 - P2
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test.
Flow Coefficient (Cv / Kv)
Valve Testing
Calculating flow differential (Cv) 80 PSI
Water
60 PSI
60 Degrees F 225 GPM
Identify the steps needed to perform a Flow Coefficient (Cv / Kv) test. 198
Flow Coefficient (Cv / Kv)
Valve Testing
Calculating flow differential (Cv)
1.0 225 .05 GPM * .2236 8020 PSI PSI - 60 PSI
50.3
Using provided data, calculate Flow Coefficient (Cv / Kv).
Check Valves
Activity
It is time for you to calculate the Cv value for a valve. 120 PSI
Water
95 PSI
60 Degrees F 320 GPM
Given a scenario, identify the data required to calculate Flow Coefficient (Cv / Kv). 199
Check Valves
Activity
Use the information from the previous slide to solve the equation.
Using provided data, calculate Flow Coefficient (Cv / Kv).
Check Valves
Activity
Let’s check your work.
64
320 GPM *
1.0
.2.04
12025 PSI -PSI 95 PSI
Using provided data, calculate Flow Coefficient (Cv / Kv). 200
Check Valves
Activity
What is the same value for Kv?
Kv = (.865)(Cv) Kv = 55.36
Using provided data, calculate Flow Coefficient (Cv / Kv).
Valve Testing
Flow Coefficient Test
Flow Coefficient Testing at Kennesaw, GA Facility
201
Knowledge Check Why find the Cv or Kv values for a valve? It is one of the determining factors for sizing a valve.
What values are needed to calculate Cv? • Flow rate • Specific gravity of the fluid • Pressure difference
Valve Testing
Shell and Seat Leakage
ANSI/ISA-S75-02
202
Valve Testing
Shell and Seat Leakage
Basic steps for testing • Install the valve in the test fixture with sufficient clamping force to prevent leakage
State the purpose for shell and seat leakage testing.
Valve Testing
Shell and Seat Leakage
Basic steps for testing • Vent the valve while filling to remove air pocket • Pressurize the valve to the required pressure and hold for the required time • Verify that the leakage criteria is met
State the purpose for shell and seat leakage testing. 203
Valve Testing
Shell and Seat Leakage
ASME B16.34 Testing requirements • High Pressure Shell Test (1.5 times the rated valve pressure @ 100OF) • High Pressure Seat Closure Test (1.1 times the rated valve pressure @ 100OF) • Low-Pressure Seat Closure Test (60 – 100psi air) • Shell and seat closure tests to be performed for the times designated • A backseat test is required for gate & globe valves, except for bellows seal, that have the backseat feature
Valve Testing
Shell and Seat Leakage
ASME B16.34 Testing requirements Valves: Flanged, Threaded, and Welding-End Shell Test Duration
204
Valve Testing
Shell and Seat Leakage
BS EN 12266-1 Testing requirements • High Pressure Shell Test (1.5 times the rated valve pressure @ 20OC) • High Pressure Seat Closure Test (1.1 times the rated valve pressure @ 20OC) • Low-Pressure Seat Closure Test (4 – 7 bar air) • Shell and seat closure tests to be performed for the times designated • Seat closure tightness shall be agreed upon by the manufacturer and purchaser
Valve Testing
Shell and Seat Leakage
BS EN 12266-1 Testing requirements
205
Valve Testing
Shell and Seat Leakage
BS EN 12266-1 Testing requirements
Knowledge Check Why test a valve at 1.5 * its pressure rating? This ensures a safety margin.
206
VALVE & ACTUATOR OVERVIEW
Introduction to Actuators
Actuators
Learning Objectives
At the completion of this lesson, students will be able to: 1. 2. 3. 4.
Describe the purpose of an actuator. List two categories of actuators used by Crane. Define, “Thrust.” Define, “Torque.”
207
About Actuators
Actuators
Actuators are used for the automation of industrial valves to open or close them or move to a desired position.
Describe the purpose of an actuator.
Types of Actuators
Actuators
Crane uses two main types of actuators
Electric
Pneumatic (air)
List two categories of actuators used by Crane. 208
Actuators
Types of Actuators
An electric actuator and a valve together is called a motor operated valve or “MOV.”
List two categories of actuators used by Crane.
Actuators
Types of Actuators
A pneumatic actuator and a valve together is called an air operated valve or “AOV.”
List two categories of actuators used by Crane. 209
Introduction
Definition
Thrust The linear force needed to move the valve’s working element.
Force
Define, ”thrust.”
Introduction
Definition Force
Torque The rotary force needed to move the valve’s working element.
Define, ”torque.” 210
About Actuators
Actuators Why use an actuator on a valve?
• Large amount of thrust or torque required • Difficult access to the valve • Unique throttling or positional requirements • Integration into advanced operating systems • Emergency operation response
Describe the purpose of an actuator.
VALVE & ACTUATOR OVERVIEW
Electric Actuators
211
Electric Actuators
Learning Objectives
At the completion of this lesson, students will be able to: 1. Given a picture of an electric actuator, identify the major components. 2. Identify the following electric actuator types: • Multi-turn • Quarter-turn 3. Identify typical applications for electric actuators. 4. identify likely causes for problems associated with electric actuators. 5. Identify the Crane brands that manufacture electric actuators.
Electric Actuators
Actuator Types
Two types of electric actuators: • Quarter-Turn (worm or spur gear) • Multi-Turn (worm gear)
Quarter-Turn
Multi-Turn
Identify various types of electric actuators. 212
Actuator Types
Electric Actuators Spur Gear • Quarter-Turn actuators only
Spur Gears
Identify various types of electric actuators.
Actuator Types
Electric Actuators Worm Gear
Worm Gear
Stem
Motor
Worm Spring Pack Limit Switch
Torque Switch
Given a picture of an electric actuator, identify the major components. 213
Electric Actuators
Components Valve Stem
Worm Shaft Gear
Limit Switch Assembly
Worm Gear Motor
Worm Torque Switches Given a picture of an electric actuator, identify the major components.
Electric Actuators
Components
Drive Sleeve
Drive Sleeve
Bearings
Worm Gear
Given a picture of an electric actuator, identify the major components. 214
Electric Actuators
Components
Limit Switch
Given a picture of an electric actuator, identify the major components.
Electric Actuators
Components Torque Switch Pinion
Torque Switch Open Terminals Close Terminals Open Adjusting Screw
Close Adjusting Screw
Open Contact
Limiter Plate
Given a picture of an electric actuator, identify the major components. 215
Electric Actuators
Actuator Types
Worm Gear
Valve Stem
Worm Gear
Worm Identify various types of electric actuators.
Electric Actuators
Applications
Electric Actuators are ideal when: • Air supply is not available • Low ambient temperatures limit use of pneumatic actuators • Valves are in a remote location or difficult to access
Identify if typical i l applications li i ffor electric l i actuators. 216
Electric Actuators
Problems and Causes
Valve does not open or shut on demand Motor burn-up, broken gears, sheared key, motor overload tripped, broken stem or stem to disc connection
Valve partially strokes but does not reach desired position Limit or torque switch set incorrectly, high stem to stem-nut friction, motor overload trips
Excessive stem to stem-nut friction Degraded stem or wrong stem thread lubrication
Bent stem Limit or torque switch set wrong resulting in excessive closing force applied identify likely causes for problems associated with electric actuators.
Electric Actuators
Problems and Causes
Broken stem/stem-to-disc attachment Limit switches set wrong resulting in excessive loading into valve backseat
Sheared keys Wrong key material, set screw loose, bad installation
Motor overload tripping Low actuator efficiency, torque switch set to high, limit switch set wrong, broken/corroded rotor bars
Motor burn-up Torque switch set too high, excessive cycling, thermal overload failure, low supply voltage preventing motor from tripping torque switch
identify likely causes for problems associated with electric actuators. 217
VALVE & ACTUATOR OVERVIEW
Pneumatic Actuators
Pneumatic Actuators Learning Objectives At the completion of this lesson, students will be able to: 1. Identify the following pneumatic actuator types: • Diaphragm • Piston • Rack-and-Pinion • Vane • Scotch Yoke 2. Identify typical applications for pneumatic actuators. 3. identify likely causes for problems associated with pneumatic actuators. 4. Identify the Crane brands that manufacture pneumatic actuators.
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Pneumatic Actuators
Actuator Types
Diaphragm
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Diaphragm Diaphragm Actuator Stem
Diaphragm Plate
Actuator Spring
Spring Seat
Spring Adjustor Travel Indicator Disk
Indicator Scale
Identify various types of pneumatic actuators. 219
Pneumatic Actuators
Actuator Types
Piston • Used to automate rising stem linear valves • Capable of automating valves with long strokes • Simple and easy to maintain • Can handle higher supply pressures than linear diaphragm actuators
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Piston • Large volume results in actuators requiring more supply media volume to operate as compared to linear diaphragm or rotary actuators • Commonly used where moderateto-high supply pressures are available and long valve strokes are required
Identify various types of pneumatic actuators. 220
Pneumatic Actuators
Actuator Types
Piston Top Cylinder Pressure
Bottom Cylinder Pressure Fail Closed
Fail Open
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Rack-and-Pinion • • • • • •
Compact design Double acting Spring return / fail safe Constant travel torque Limited torque range Variable torque output for single acting actuators
Identify various types of pneumatic actuators. 221
Pneumatic Actuators
Actuator Types
Rack-and-Pinion
A
B
Open: Air at "A" causes counter-clockwise rotation. Close: Air at "B" causes clockwise rotation. Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Rack-and-Pinion
A
Open: Air at "A" causes counter-clockwise rotation. Close: Springs cause clockwise rotation and force air out Identify various types of pneumatic actuators. 222
Pneumatic Actuators
Actuator Types
Rack-and-Pinion
Racks (cylinders)
Pinions
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Torque Output • • •
The torque output remains constant throughout the valve stroke Both the forces generated by the pistons remain constant The distance between the pistons forces and the pinion remains constant
Identify various types of pneumatic actuators. 223
Pneumatic Actuators
Actuator Types
Rack-and-Pinion
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Torque Output • On the air stroke, the torque starts high but linearly decreases as more of the force generated by the piston is used to compress the springs • On the spring stroke the torque starts high but linearly decreases as the springs extend (re: Hooks Law) from their fully compressed position
Identify various types of pneumatic actuators. 224
Pneumatic Actuators
Actuator Types
Vane • Lightweight and Compact • One Moving Part • Dual Travel Stops • Fail Safe System • Economic
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Vane • High ratio of torque output per pound of actuator weight • Durable die cast aluminum housing
Identify various types of pneumatic actuators. 225
Actuator Types
Pneumatic Actuators Vane
• Most cost efficent design of double acting actuator • Few parts and easy to handle
B
A
Identify various types of pneumatic actuators.
Actuator Types
Pneumatic Actuators Vane • Constant travel torque
Closed
Open Travel
Identify various types of pneumatic actuators. 226
Pneumatic Actuators
Actuator Types
Vane
Paddle O-Ring
Bronze Bushing
Nylon Bearings
Paddle
Stroke Adjustment Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Scotch Yoke • Wide torque range • Can be used in conjunction with a linear cylinder or a linear diaphragm • Often used with ball and butterfly valves
Identify various types of pneumatic actuators. 227
Actuator Types
Pneumatic Actuators Scotch Yoke Single Acting
Closed
Double Acting
Open Travel
Closed
Open Travel
Identify various types of pneumatic actuators.
Pneumatic Actuators
Actuator Types
Scotch Yoke • • • •
Not normally economical for low pressure applications Large and heavy No constant travel torque Limited to valves which do not require more than 110 degrees rotation
Identify various types of pneumatic actuators. 228
Actuator Types
Pneumatic Actuators Scotch Yoke
Rotation
Travel
Air Inlet
Spring
Identify various types of pneumatic actuators.
Pneumatic Actuators
Applications
Pneumatic Actuators • Process control for maintaining flow, temperature, pressure, level, pH, etc. in any type of fluid system • On/off applications requiring low to mid torque or thrust • Applications where electrical power is not readily available
Identify typical applications for pneumatic actuators. 229
Pneumatic Actuators
Applications
Diaphragm • Linear control applications • On/off when stem thrust requirement is low
Identify typical applications for pneumatic actuators.
Pneumatic Actuators
Applications
Piston • Linear control applications • On/off when stem thrust requirement is high
Identify typical applications for pneumatic actuators. 230
Pneumatic Actuators
Applications
Saunder S360 • Smooth corrosion resistant profile optimizes cleanability in hygienic/pharma applications • High cycle life, lower air consumption and moree compact design versus diaphragm type • 316L Stainless Steel • Full 360° rotation of actuator head allows flexible installation and air port alignment
Identify typical applications for pneumatic actuators.
Pneumatic Actuators
Applications
Rack-and-Pinion • Compact for restricted space applications • Lower torque applications such as butterfly and ball valves
Identify typical applications for pneumatic actuators. 231
Pneumatic Actuators
Applications
Vane • Applications where torque to weight ratio is important • Medium torque applications such as plug valves • Applications where failure position is not critical
Identify typical applications for pneumatic actuators.
Pneumatic Actuators
Applications
Scotch Yoke • Applications where higher torques are required
Identify typical applications for pneumatic actuators. 232
Check Valves
Activity
Now it is time for you to identify different types of pneumatic actuators.
Identify various types of pneumatic actuators.
Knowledge Check
Vane Diaphragm
Piston
Scotch Yoke
Rack-and-Pinion
Identify various types of pneumatic actuators. 233
Activity Now it is time for you to identify the Crane brands that manufacture actuators. All Teams: Use the Valve Directory to Identify Crane Brands and Record findings as a group.
Given a list of actuators, identify the Crane brands that manufacture each of them.
VALVE & ACTUATOR OVERVIEW
Control Accessories
234
Control Accessories
Learning Objectives
At the completion of this lesson, students will be able to: 1. State the purpose of process loop controllers 2. Describe control system architecture 3. Identify the types of automation control accessories • Positioner • Limit Switch • Solenoid 3. Identify the Crane brands that manufacture control accessories
Control Accessories
Controllers
Why use a controller for a valve? • When installed as part of a control process, controllers help valves regulate: • • • • •
Flow Pressure Temperature Level pH
Identify various types of Control Accessories 235
Controllers
Control Accessories Basic process using controller
Identify various types of Control Accessories
Control Accessories
Control System
Distributed Control • Classic “point to point” I/O (Input / Output) • Bus networks
236
Control Accessories
Control System
Types of Fieldbus Networks
Control Accessories
Control Accessories
• Positioner • Limit Switch • Solenoid Valve
Identify various types of Control Accessories 237
Control Accessories • • • • • • •
Positioners
3-15 psi input 4-20 mA input Digital bus connected UL Listed FM Approved/Cenelec NEMA Explosion Proof
Identify various types of Control Accessories
Control Accessories
Positioners
3-15 psi pneumatic valve positioner • Normally used in conjunction with a separate I/P (Current to Pneumatic) Converter, which is old technology • Most users have changed to electro-pneumatic positioners, eliminating separate I/P converters • Some manufacturers offer a built-in I/P Converter. It is basically a pneumatic positioner with an internal I/P.
Identify various types of Control Accessories 238
Control Accessories
Positioners
4-20mA electro-pneumatic valve positioner • Built-in I/P Converter - basically a pneumatic positioner with an internal I/P. • Internal Electronics compares 4-20mA input signal with internal position feedback – normally received from a potentiometer or hall effect sensor • It then positions the actuator so that the two signals are equal
Identify various types of Control Accessories
Control Accessories
Positioners
Digital valve positioner • Divided into two categories: hybrid and fully digital. •
•
Hybrid positioners use an analog current signal command signal while superimposing over that signal a frequency that allows for bi-directional communications (HART Protocol) For fully digital positioners, the command signal is provided in a binary form that is coded and decoded by a communication protocol. (FOUNDATION Fieldbus and Profibus PA Protocols)
• Readily collect data about the valve to automatically alert users about how the valve and its assembly are performing to aid in diagnostics and maintenance
Identify various types of Control Accessories 239
Positioners
Control Accessories
Westlock ICoT SMART Valve Positioner • Output of 4-20 mA with HART® protocol or Foundation Fieldbus™ Protocol • Certifications: Atex, UL, CSA, FM, and Inmetro • Nonincendive, Intrinsically Safe, Explosion proof • Negligible bleed lapped spool manifold design with an MTBF of 333.33 years
Identify various types of Control Accessories
Control Accessories
Limit Switches
Limit Switches • SPDT, DPDT Mechanical um • SPDT Tungsten and Rhodium (hermetically sealed reed)) • Capacitive & Inductive Sensorss • Position transmitters • Bus Networks • UL Listed • FM Approved/Cenelec • NEMA • Explosion Proof Identify various types of Control Accessories 240
Control Accessories
Limit Switches
Westlock BEACON™ | Visual position indicator • Local mechanical indication of valve position with long-distance visibility, available in 2 and 3 ways
Identify various types of Control Accessories
Control Accessories
Limit Switches
Westlock Accutrak™ Rotary & Linear limit switches • Touch set cams provide quick calibration • Aluminum, Engineered Resin or 316 SST
•
Identify various types of Control Accessories 241
Control Accessories
Limit Switches
Westlock Quantum™ Integrated solution for control and monitoring process valves • It brings the same features of Accutrak™, but also combining Falcon II low-powered solenoids • Efficient and cost-effective method for both rotary and linear valves
Identify various types of Control Accessories
Control Accessories
Limit Switches
Westlock Intellis™ Field Networking, Position Monitoring & Control • It brings the same settings of Accutrak™ and Quantum ™, but also combining Digital Communications Protocols • Its use significantly reduces costs by eliminating “I/O”, significant reduction in dedicated wiring and installation (cable tray), and cost reduction educt o in eengineering g ee g aand d design. d
Identify various types of Control Accessories 242
Control Accessories
Limit Switches
Westlock Digital Epic • Hall effect / Magnetic sensor without mechanical contact • Output of 4-20mA with HART® or Foundation Fieldbus™ Protocol • Suitable for rotary and linear valves
Identify various types of Control Accessories
Control Accessories
Limit Switches
Westlock Pharma II| Nonincendive / Non Hazardous • Compact unit to monitor and control sanitary diaphragm valves • Meets the challenges and requirements of modern pharmaceutical and Biotechnology industries
Identify various types of Control Accessories 243
Control Accessories
Limit Switches
Saunders I-VUE • Intelligent valve sensor that offers continuous electromagnetic sensing technology with with 0.2mm accuracy • Enhanced diagnostics reducing maintenance cycles Saunders M-VUE • Compact intelligent valve sensor that offers one step contactless valve and sensor self-calibration • Solid State sensing technology with 0.3mm accuracy • Remote and local positioning Self-calibration feature reduces set-up time to 3mins Identify various types of Control Accessories
Control Accessories
• • • • • • •
3-way 4-way UL Listed FM Approved/Cenelec NEMA Explosion Proof NAMUR mounted
Solenoid Valves
Pilot operated spool type
Identify various types of Control Accessories 244
Control Accessories
Solenoid Valves
3-port/2-way solenoid valve pilot operated, normally closed with spring return actuator
Identify various types of Control Accessories
Control Accessories
Solenoid Valves
5-port/2-way solenoid valve pilot operated, normally closed with double acting actuator
Identify various types of Control Accessories 245
Control Accessories
Solenoid Valves
NAMUR direct mounting
Identify various types of Control Accessories
VALVE & ACTUATOR OVERVIEW
Valve and Actuator Sizing
246
VALVE & ACTUATOR OVERVIEW
Valve Sizing
Valve Sizing
Learning Objectives
At the completion of this lesson, students will be able to: 1. 2. 3. 4. 5. 6.
Identify key parameters needed to properly select and size a valve. Identify problems associated with incorrectly sizing valve. Recognize the importance of Flow Coefficient for sizing. Identify the formula for determining pressure drop. Identify the formula for determining flow rate. Define, “Choked Flow.”
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Valve Sizing
Parameters
Considerations when sizing a valve: • • • • • •
Pipe size Pipe material being used Valve shut-off pressure Service Media Temperature % of solids
Identify key parameters needed to properly select and size a valve.
Valve Sizing
Parameters
Considered when sizing a valve: • • • • •
Flow Rate at Maximum / Normal / Minimum Inlet Pressure at Maximum / Normal / Minimum Pressure drop at Maximum / Normal / Minimum Fluid Specific gravity Fluid Viscosity (if dissimilar to water)
Identify key parameters needed to properly select and size a valve. 248
Parameters
Valve Sizing Simplified Sizing for Liquids
Limitation: The pressure drop across the valve is less than 1/3 of the inlet pressure. If the pressure drop is greater then the “Complex Sizing” method must be used.
Identify key parameters needed to properly select and size a valve.
Sizing Formulas
Valve Sizing
Simplified Valve Sizing Formulas for Liquid ࢂ ࢘ ࡷࢂ ൌ ࡽ
ࡳ οࡼ
ࡽ οࡼ ൌ ࡳሺ ) ࢂ ࢘ ࡷࢂ
ࡽ ൌ ࢂ ࢘ ࡷࢂ
οࡼ ࡳ
Flow Coefficient (Cv) Pressure Drop Flow Rate ࢂ = Valve Capacity Coefficient - ANSI ࡷࢂ = Valve Capacity Coefficient - EN ࡽ = Flow in US Gallons/Minute or m3/hour οࡼ = Differential Pressure in psi or Bar ࡳ = Specific Gravity (Water = 1)
249
Sizing Formulas
Valve Sizing Solve for Flow Coefficient (Cv) ͻ ͻ ͻ ͻ ͻ
Flow rate = 248 gpm (56 m3/hr) Upstream Pressure = 96 psig (6.62 Bar) Downstream Pressure = 74 psig (5.1 Bar) Specific Gravity = .91 Cv = 1.16*Kv
ࢂ ࢘ ࡷࢂ ൌ ࡽ
Cv = 50.4 Kv = 43.33
Valve Sizing
ࡳ οࡼ
ࢂ = Valve Capacity Coefficient - ANSI ࡷࢂ = Valve Capacity Coefficient - EN ࡽ = Flow in US Gallons/Minute or m3/hour οࡼ = Differential Pressure in psi or Bar ࡳ = Specific Gravity (Water = 1)
Sizing Formulas
Solve for Pressure Drop ͻ Flow rate = 6650 gpm (1510 m3/hr) ͻ Cv = 1200 Kv = 1034.5 ͻ Specific Gravity = .88
οࡼ ൌ ࡳሺ
27 psi (1.87 Bar)
ࢂ
ࡽ ) ࢘ ࡷࢂ
ࢂ = Valve Capacity Coefficient - ANSI ࡷࢂ = Valve Capacity Coefficient - EN ࡽ = Flow in US Gallons/Minute or m3/hour οࡼ = Differential Pressure in psi or Bar ࡳ = Specific Gravity (Water = 1)
250
Sizing Formulas
Valve Sizing Solve for Flow Rate ͻ ͻ ͻ ͻ
Cv = 548 Kv = 472 Upstream Pressure = 380 psig (26.2 Bar) Downstream Pressure = 296 psig (20.4 Bar) Specific Gravity = .91
ࡽ ൌ ࢂ ࢘ ࡷࢂ
5265 gpm (1192 m3/hr)
οࡼ ࡳ
ࢂ = Valve Capacity Coefficient - ANSI ࡷࢂ = Valve Capacity Coefficient - EN ࡽ = Flow in US Gallons/Minute or m3/hour οࡼ = Differential Pressure in psi or Bar ࡳ = Specific Gravity (Water = 1)
Valve Sizing
Definition
Choked Flow A pressure drop condition where maximum flow rate through a valve has been achieved for a given inlet pressure.
Define, ”Choked Flow.” 251
Sizing Formulas
Valve Sizing
Simplified Valve Sizing Formulas for Gas Limitation: The pressure drop across the valve is less than 1/3 of the absolute inlet pressure. Choked flow is unlikely to exist at this pressure drop range. If the pressure drop is greater then the “Complex Sizing” method must be used.
Sizing Formulas
Valve Sizing
Simplified Valve Sizing Formulas for Gases ࢂ ൌ
ࡿࢍ Ԣࢎ ࡼ ૢǤ οࡼ
ࡷࢂ ൌ
ࡿࢍ Ԣࢎ ࡼ ૡǤ οࡼ
οࡼ ൌ
ࡿࢍ Ԣࢎ ሺ ) ࡼ ૢǤ ࢂ
ࡿࢍ Ԣࢎ οࡼ ൌ ሺ ) ࡼ ૡǤ ࡷࢂ
Ԣࢎ ൌ ૢǤ ࢂ ࡼ
Ԣࢎ ൌ ૡǤ ࡷࢂ
οࡼ ࡿࢍ
οࡼ ࡼ ࡿࢍ
Flow Coefficient (Cv)
Pressure Drop
Flow Rate
252
Valve Sizing
Check Valves
Swing Check • Opened and sustained in the open position by the force of velocity pressure, and closed by the force of gravity. • Seating load and resultant tightness is dependent upon back pressure. • Potential for water hammer • Minimum flow or velocity is required to fully open the disc
Valve Sizing
Check Valves
Swing Check • The minimum velocity required to hold a swing check valve in the wide open and stable position is expressed by the formula: • Sizing swing check valves on this basis may often result in the use of valves that are smaller than the pipe in which they are used, necessitating the use of reducers for installation.
253
Check Valves
Valve Sizing Tilt Disc Check
• The minimum velocity required to hold a tilt disc check valve in the wide open and stable position is expressed by the formula: 80
Valve Sizing
Check Valves
Stop Check • Stop Check Valves are as essential to safe operation of a boiler plant as safety valves or other safety devices attached to the boiler. • When more than one boiler is connected to the main steam header, a stop check valve should be installed in the pipeline between each boiler and the header. • Valve designed for steam application that operate between 100 psi (9 bar) and 375 psi (26 bar). • The Stop Check feature of this valve requires a minimum of 50 psi (3.5 bar) pressure differential between the piping system and the boiler to operate correctly. 254
Valve Sizing Stop / Lift Check
Check Valves Technical Data Bolted Bonnet Stop Check Valve Graphic representation of flow data determined by test
For details please see “TECHNICAL DATASHEET CRANE® - Cast Steel Valves Identify key parameters needed to properly select and size an actuator.
Valve Sizing
Engineered Check Valves
Engineered Check uses a sizing program to optimize the spring assist to the customer’s applications. The opportunity to use the sizing program as a selling tool should not missed or under-estimated. By correctly sizing the valve we can benefit the customer by: ͻ Reduce wear / Improved valve life ͻ Minimise reverse velocity (less waterhammer) ͻ Protect the pumping equipment ͻ Reduce pressure loss / Savings on running costs ͻ Educate the customer about our Check Valves.
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Valve Sizing
Engineered Check Valves
Customer should supply the details as above or on similar style data sheet.
Valve Sizing
Check Valve
Swing Check Valves • Relatively long response times under dynamic conditions • High reverse velocities resulting in slam effect and unwanted pressure surges
256
Valve Sizing
Check Valve
Spring assisted Dual Plate check valves (Duo-Chek®) • Design offering slimmer plates with less inertia than a single thicker disc (as in the Swing check type) • Spring pre-loading provides additional closing force at all angles • Enhanced response time as well as more reactive to changes in flow conditions
Valve Sizing
Check Valve
Nozzle check valves (Noz-Chek® & Compac-Noz®) • As flow decelerates, the spring overcomes decaying fluid force on the disc and triggers the valve to close • Low disc mass combined with spring loading and short displacement ensures rapid selfdampening response • Fastest response time, slam free and with minimal reverse velocity 257
Check Valve
Valve Sizing Check valve selection NOZ-CHEK with strong spring NOZ-CHEK with standard springs COMPAC-NOZ Check
DUO-CHEK II with strong springs DUO-CHEK II with standard springs Tilting disc check Conventional Swing Check
Identify key parameters needed to properly select and size an actuator.
VALVE & ACTUATOR OVERVIEW
Actuator Sizing
258
Actuator Sizing
Learning Objectives
At the completion of this lesson, students will be able to: 1. Identify key parameters needed to properly select and size an actuator. 2. Identify problems associated with incorrectly sizing an actuator.
Actuator Sizing
Considerations
Considered when sizing an actuator: • • • • • • • • •
Load requirements for the valve (torque and thrust) Available power supply Speed of operation needed Frequency of operation How valve is being used Double acting or fail-safe requirement Operating environment Manual override requirement Weight or size considerations
Identify key parameters needed to properly select and size an actuator. 259
Actuator Sizing
Considerations
Actuator Selection and Sizing Considerations
Identify key parameters needed to properly select and size an actuator.
Actuator Sizing
Considerations
Actuator Selection and Sizing Considerations • What are the load requirements for the valve regarding torque and thrust? • What power supply do you have available? • Is the speed of operation a consideration? • What is the frequency of operation? • How is the valve being used?
Identify key parameters needed to properly select and size an actuator. 260
Actuator Sizing
Considerations
Actuator Selection and Sizing Considerations • Does the valve require double-acting action or is it required to fail in a specific position? • What is the operating environment? • Is a manual override required? • Are there dimensional/weight considerations?
Identify key parameters needed to properly select and size an actuator.
Actuator Sizing
Considerations
Basic Actuator Sizing • Pneumatic Double Acting (DA) • Pneumatic Spring Return (SR) • Fail-Open • Fail-Closed
Identify key parameters needed to properly select and size an actuator. 261
Considerations
Actuator Sizing Valve Torque Characteristics Open
Closed
100%
Break Away
Open
Closed
Open
Closed
100%
100% 70%
Torque
Torque
Torque
65% 50%
30%
30% Running
0°
45°
90°
Ball Valve
Actuator Sizing
0°
45°
90°
0°
45°
90°
Plug Valve
Butterfly Valve
Considerations
Double Acting Actuator Torque Profile
262
Considerations
Actuator Sizing
Double Acting Actuator Torque Profile Scotch Yoke Double Acting
Closed
Actuator Sizing
Travel
Open
Double Acting Sizing
Double Acting Sizing 1. Determine max valve torque based on seat material, pressure drop, etc. Hydrodynamic torque must be included for butterfly valves 2. Apply the application safety factor 3. Apply the actuator manufacturer safety factor 4. Select an actuator (at the appropriate supply pressure) whose torque exceeds the max valve torque times the safety factors
263
Double Acting Sizing
Actuator Sizing
Typical Application Safety Factors (Sleeve Plug) Normal Service
F = 1.0
Chlorine Service
F = 1.5
Dry Service
F = 1.5
Vacuum Service
F = 1.5
Slurry / Abrasion
F = 2.0
Idle Time
F=*
* Variable from 1.0 to 1.5 depending on time between cycles.
Double Acting Sizing
Actuator Sizing
Actuator
Safety Factor
Torque
Plug valve Damper Ball valve Butterfly valve
0°
Rotation
90°
264
Actuator Sizing
Spring Return Sizing
ͻ Fail-Closed: Air to open, spring to close ͻ Fail-Open: Air to close, spring to open
Actuator Sizing
Spring Return Sizing
Scotch-Yoke Type
Single Acting
Closed Travel
Open
265
Actuator Sizing
Spring Return Sizing
1. Identify valve start & ending torques 2. Torque is not constant through out the stroke 3. Consider four primary torque positions a.Air Start b.Air End c.Spring Start d.Spring End 4. Actuator selected must be able to overcome both valve starting and ending torques on both air and spring ranges and torque in any intermediate position
Actuator Sizing
Spring Return Sizing
266
Actuator Sizing
Spring Return Sizing (in-lbs)
Actuator Sizing
Spring Return Sizing (in-lbs)
267
Actuator Sizing
Spring Return Sizing (Nm)
Actuator Sizing
Spring Return Sizing(Nm)
268
Actuator Sizing
Krombach MS Ball Sizing
Calculating valve torque Base Valve Torque Media (Service) Factors Cycle Frequency Factors (Default to 1.3) Valve Operating Torque Factors Break = 100% Run = 65% Seat = 92% Valve Torque 2.6 Media Service Factor 1.3 Cycle frequency Factor 203 ft/lbs 203
100% Break
132
65% Run
187
92% Seat
(275 Nm) (179 Nm) (253 Nm)
Actuator Sizing
Gate & Globe Sizing
Thrust (lbs) = [StA]*[LP] + [PL] + [SA]*[VF]*[DP] StA = Stem cross sectional Area LP = Line Pressure PL = Packing Load (estimated at 2000 lbs per inch of stem diameter for graphite packing) SA = Seat Area DP = Differential Pressure the valve is opening/closing against VF = VALVE FACTOR. 0.25 - Parallel seat 0.30 - Gate valve 1.10 - Globe valve
These formulas get you a baseline thrust value with no safety factor. You'll need to add an appropriate safety factor for your service
269
Gate & Globe Sizing
Sizing Electric Actuator Sizing
1. Electric actuator output capability is constant with position 2. Determine max valve torque/thrust based on seat material, pressure drop, etc. 3. Apply the application safety factor 4. Apply the actuator manufacturer safety factor 5. Select an actuator whose rated torque/thrust capability exceeds the max valve torque times the safety factors
Actuator Sizing
Problems and Causes
Valve partially strokes but doesn’t reach desired position Actuator not sized to handle all operational loads
Seat leakage Actuator undersized not producing sufficient torque or thrust to fully seat the valve
Bent or broken stem or stem to disc attachment Actuator oversized
Motor overload tripping Actuator not sized to handle all operational loads
Motor burn-up Actuator not sized to handle all operational loads
Control valve instability/lack of control Actuator design not adequate for specific valve and control application Identify problems and potential causes associated with actuators. 270
FLUID HANDLING
Notes
271
FLUID HANDLING
272