V&A Handouts

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

2

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

7

Logistics

Orientation Internet Access

Introductions

Orientation • • • • • •

Name Work location Job role Years at Crane Work before Crane Hobbies

8

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.

9

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.”

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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.”

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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

26

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

27

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.

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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.

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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.

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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.

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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

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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.

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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.

218

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.”

247

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.

255

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