INDUSTRIAL VALVES:

TYPES, MOC, DESIGN & TESTING STDs., TPI

INSPECTION & REPORTING
PREPARED BY
GOUTHAM RATHINAM
B.E.(Mech.), CSWIP 3.1, NDT LII (LPT, MPT, RT, RTFI, UT)
 INDUSTRIAL VALVES
OPENING WITH A QUOTE
“Every day of your life ask yourself “How you’re living?”
“Remember & honour to those who gone before you & invested in you”
- Wisdom from a man on his death bed
 INTRODUCTION TO VALVES
• Definition: Mechanical devices, specifically designed to direct, start, stop, mix,
or regulate the flow, pressure and temperature of process fluid.

• Function of Valves:
1. Stopping and starting fluid flow.
2. Regulating the amount of flow.
3. Controlling the direction of fluid.
4. Regulating downstream pressure.
5. Relieving overpressure in the pipe or component.
 HISTORY OF VALVES
• 2560 BC : A special valve in the form of a hinged prism stone were used in the
construction of Great Pyramid of Giza for regulation of water.
• 1 BC : The Romans used lead piping and use of valves.
• 25 AD : A large bronze cock valve was found on Capri among the ruins of
Palace of Tiberius.
Romans used a primitive diaphragm valve, made of crude leather
that was manually closed over a weir, to control flow and
temperature of household bath water.
• 1681 : First safety valve was invented by Denis Papin.
• 1784 : It was believed butterfly valve was used by James Watt in his Steam
Engine design.
• 1840 : First valve patent granted in the US went to James
Robinson for his gate valve, or “stop cock”
• 1846 : The globe valve design is developed and patented by Walworth.
 HISTORY OF VALVES
•1875 : Groove-packed plug cock introduced by Dewrance & Co.
•1886 : Joseph Hopkinson introduced the parallel slide gate valve.
•WWI: Lubricated taper plug valve was developed by Sven Nordstrom.
•1907 : Frank P. Cotter developed a "simple self-sealing check valve.
•1929 : Modern diaphragm valve was developed by a South African engineer named
Saunders.
•1930s :Watts Regulator Co. introduced the first automatic temperature and pressure
relief valve.
•1945 : First ball valve was designed by Landis H. Perry.
•1953 : Fujikin developed its first patented product, the Needle Valve.
•1956 : Howard Freeman establishes Jamesbury Corp, Patented first bi-directional soft
seated Ball valve and the first pneumatic actuator produced in 1957.
•1975 : Neles metal-seated Neldisc butterfly valves are introduced to the process
industries. The revolutionary U-shaped metal seat and elliptic disc form a unique
triple-offset valve design, which is commonplace in many butterfly valve products
today.
CLASSIFICATION OF VALVES
 VALVE TYPES BY FUNCTION

• On/Off :
 Block Valve : Stop and start flow, (Ball, Gate, Plug &
Diaphragm).
• Regulating :
 Flow Control Valve : Control flow rate, (Globe, Butterfly, Needle,
Ball & Diaphragm).
 Protection :
• Non-Return Valve : Prevent flow reversal. (Check Valve)
• Pressure Relief Valve : Protection against over pressure in vessels
and piping system.
 VALVE TYPES BY MOTION
• Linear Motion Valves :
 Also known as Multi Turn Valves that have a sliding stem design that
pushes a closure element into the valve body which further regulates the
open and close positions. The closure device could be a disc, slat or
flexible material, like a diaphragm.
 Gate valves, Globe valves, pinch valves, diaphragm valves, three way
valves, angle valves belongs to linear motion valves.
• Rotary Motion Valves :
 Also known as Quarter Turn Valves are those valves that use a closure
element that rotates through a quarter turn (45 degree) to open or close
the flow (90 degree).
 Ball valves, Butterfly valves, Plug valves belong to rotary motion
valves.
 VALVE TYPES BY METHOD OF
OPERATION
• Manual Operation : There are 3 types of manual operation.
Handle : Handle is used for manual operation of gate and globe valves.
Lever : Lever is ordinarily used for manual operation of ball valves.
Gear : Gear-operated used for manual operation of butterfly and ball valves.
• Automatic Operation : There are two types of automatic operation.
Electric Actuator : The actuator is driven by electric power (AC or DC).
 Pneumatic Actuator : The actuator is driven by compressed air.
Hydraulic Actuator : The actuator is driven by hydraulic oils
• Auto response to system condition : Valves operating to maintain the system
temperature / pressure. They are pressure / temperature relief valves, check valves.
 PARTS OF A TYPICAL INDUSTRIAL
VALVE
• Actuator : Actuator operates the stem and closing element (disk) assembly. It may be
manual or automatic.
• Body : Body is the main pressure containing structure of the valve and contains the
valve's internal parts that comes in contact with the working fluid.
• Bonnet : Bonnet provides a leakproof closure for the valve body.
• Stem : Stem connects actuator/handle to the inside of the valve (disc) and transmits the
actuation force.
• Disc : Disk are closure member of the valve rests on the seat ring, connected to the
stem which slide or screwed up or down to throttle the flow using a actuator.
• Seat : Seat ring provides uniform leak proof tightness. Usually bevelled to allow
guiding during the final stage of closing.
• Stuffing Box : Stuffing box is a chamber that holds anti-seal material (packing).
• Packing : Packing is commonly a fibrous material that forms a seal between the
internal parts of a valve and the outside.
TYPICAL GATE VALVE
TYPICAL GLOBE VALVE
TYPICAL BUTTERFLY VALVE
TYPICAL BALL VALVE
TYPICAL CHECK VALVE
TYPICAL PRESSURE RELIEF VALVE
 INDUSTRIAL VALVES
MANUFACTURING STANDARDS & SPECIFICATION
ANSI : American National Standards Institute
ASME : American Society of Mechanical Engineers
ISA : International Society of Automation
• ANSI FCI 70-2: Control Valve Seat Leakage
• ANSI ISA S75.01.01: Flow Equations for Sizing Control Valves
• ANSI ISA S75.19.01: Hydrostatic Testing of Control Valves
• ASME/ANSI B1.20.1: Pipe Threads, General Purpose (Inch)
• ASME/ANSI B16.10: Face-to-Face and End-to-End Dimensions of Valves
• ASME/ANSI B16.11: Forged Fittings, Socket-Welding and Threaded
• ASME/ANSI B16.25: Buttwelding Ends
• ASME/ANSI B16.34: Valves - Flanged, Threaded, and Welding End
• ASME/ANSI B16.5: Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch
Standard
 INDUSTRIAL VALVES
MANUFACTURING STANDARDS & SPECIFICATION
API : American Petroleum Institute
• API STD 520: Sizing, Selection, and Installation of Pressure-relieving Devices Part I—Sizing and Selection
• API STD 526: Flanged Steel Pressure Relief Valves
• API STD 527: Seat Tightness of Pressure Relief Valves
• API STD 598: Valve inspection and Testing
• API STD 600: Steel Gate Valves - Flanged and Butt-welding Ends, Bolted Bonnets
• API STD 602: Gate, Globe, and Check Valves for Sizes DN 100 (NPS 4) and Smaller for the Petroleum and Natural
Gas Industries
• API STD 603: Class 150, Cast, Corrosion-Resistant, Flanged-End Gate Valves
• API STD 608: Metal Ball Valves
• API STD 609: Butterfly Valves: Double Flanged, Lug- and Wafer-Type
• API STD 622: Type Testing of Process Valve Packing for Fugitive Emissions
• API STD 624: Type Testing of Rising Stem Valves Equipped with Graphite Packing for Fugitive Emissions
• API STD 641: Type Testing of Quarter-turn Valves for Fugitive Emissions
• API STD 6FA: Standard for Fire Test for Valves
• API SPEC 6FC: Specification for Fire Test for Valves with Automatic Backseats
• API SPEC 6FD: Specification for Fire Test for Check Valves
 INDUSTRIAL VALVES
MANUFACTURING STANDARDS & SPECIFICATION
ASTM : American Society of Testing & Materials
• ASTM A105/105M: Standard Specification for Carbon Steel Forgings for piping applications
• ASTM A126: Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings
• ASTM A181/181M: Standard Specification for Carbon Steel Forgings for General purpose piping
• ASTM A182/A182M: Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges,
Forged Fittings, and Valves and Parts for High-Temperature Service
• ASTM A338: Standard Specification for Malleable Iron Flanges, Pipe Fittings, and Valve Parts for
Railroad, Marine, and Other Heavy-Duty Service at Temperatures Up to 650°F (345°C)
• ASTM A694/A694M: Standard Specification for Carbon and Alloy Steel Forgings for Pipe
Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service
• ASTM A727/727M: Standard specification for carbon steel forgings for piping components with
inherent notch toughness
• ASTM A961: Standard Specification for Common Requirements for Steel Flanges, Forged
Fittings, Valves, and Parts for Piping Applications
 INDUSTRIAL VALVES
MANUFACTURING STANDARDS & SPECIFICATION
BSI : British Standards Institute
EN : European Standard
• BS 1868: Specification for Steel check valves (flanged and butt-welding ends) for the
petroleum, petrochemical and allied industries
• BS 1873: Specification for Steel Globe and Globe Stop and Check Valves (Flanged and
Butt-Welding Ends) for the Petroleum, Petrochemical and Allied Industries
• BS 5351: Specification for steel ball valves for the petroleum, petrochemical and allied
industries (Superseded by BS EN ISO 17292, but used for full bore type)
• BS EN 12266-1: Industrial valves - Testing of metallic valves Part 1: Pressure tests, test
procedures and acceptance criteria - Mandatory requirements
• BS EN 12266-2: Industrial valves - Testing of metallic valves Part 2: Pressure tests, test
procedures and acceptance criteria - Supplementary requirements
 INDUSTRIAL VALVES
MANUFACTURING STANDARDS & SPECIFICATION
BSI : British Standards Institute
ISO : International Organization for Standardization
EN : European Standard
•BS EN ISO 5210: Industrial Valves - Multi-Turn Valve Actuator Attachments
•BS EN ISO 10434: Bolted bonnet steel gate valves for the petroleum, petrochemical and allied industries
•BS EN ISO 10497: Testing of valves - Fire type-testing requirements
•BS EN ISO 17292: Metal ball valves for the petroleum, petrochemical and allied industries
•ISO 5208: Industrial valves - Pressure testing of metallic valves
•ISO 5752: Metal valves for use in flanged pipe systems -- Face-to-face and centre-to-face dimensions
•ISO 15761: Steel gate, globe and check valves for sizes DN 100 and smaller, for the petroleum and
natural gas industries
•ISO 15848-1: Industrial valves — Measurement, test and qualification procedures for fugitive emissions
— Part 1: Classification system and qualification procedures for type testing of valves
•ISO 15848-2: Industrial valves — Measurement, test and qualification procedures for fugitive emissions
— Part 2: Production acceptance test of valves
 INDUSTRIAL VALVES
MANUFACTURING STANDARDS & SPECIFICATION
MSS : Manufacturers Standardization Society
• MSS SP 53: Quality Standard for Steel Castings and Forgings for Valves, Flanges,
Fittings, and Other Piping Component
• MSS SP 55: Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other
Piping Components - Visual Method for Evaluation of Surface Irregularities
 VALVE TERMINOLOGY
• Actual pressure drop: The difference between the inlet pressure and the outlet pressure of a
valve.
• Actuator: A device used to open/close or control the valve. Key types include electrical,
hydraulic, and pneumatic. Movement may be quarter turn or multi-turn.
• Actuator stem: A rod used in linear designed valves connecting the actuator with the stem of
the valve.
• Back seat: In linear valves, the area of the stem that enters the valve bonnet is sealed to prevent
process fluid from entering the packing box and to prevent deterioration of the sealing
materials.
• Ball valve: A quarter-turn valve with a spherical closing element held between two seats.
Characteristics include quick opening and good shutoff.
• Bellows: A sealing device that prevents line media leaking between the stem and the body.
• Blowdown: The discharge of process fluid to reduce the pressure in a piping system. This is
usually done through a pressure relief device.
• Breakout torque: The torque required to open or unseat a rotary valve.
 VALVE TERMINOLOGY
• Bubble-tight: When there is no measurable seat leakage over a certain period of time during test
conditions.
• Butterfly valve: A quarter-turn valve, which has a circular disc as its closing element. The standard
design has the valve stem running through the center of the disc, giving a symmetrical
appearance. Later more complex designs offset the stem, so that the disc “cams” into the valve
seat.
• Bypass valve: A valve smaller in diameter that is fitted in parallel to a larger main valve. Bypass
valves are used to reduce the differential pressure across the main valve before this main valve is
opened (as otherwise this larger, more expensive valve, may suffer damage to internal
components).
• Check valve: A valve that is designed to allow the fluid to flow in a given direction but closes to
prevent back flow. Types include swing check, tilting-disc check, and wafer check, non-slam
(piston type).
• Class: The class is used to describe the pressure rating of the piping system. For example, Class
150 lb, 300 lb, 600 lb, 900 lb, or API 3000, API 5000. This relates to the maximum allowable
design pressure that a flange of certain dimensions and made of a certain material can be used
with in a piping system.
 VALVE TERMINOLOGY
• Concentric butterfly valve: A butterfly valve with the disc installed in the center of the
valve.
• Control valve: A valve that regulates the flow or pressure of a fluid. Control valves normally
respond to signals generated by independent devices such as flow meters or temperature
gauges. Control valves are normally fitted with actuators and positioners. Pneumatically
actuated globe valves are widely used for control purposes in many industries, although
quarter-turn types such as (modified) ball and butterfly valves may also be used.
• Cryogenic valves: Valves suited for use at temperatures below 45 degrees Celsius. A
cryogenic valve should have a cold box as an integral part of the body to allow a vapor
barrier to form between the packing box and the liquified gas.
• Cv: The Cv of a valve is defined as 1 U.S. gallon of 60°F water during 1 minute with a 1 psi
pressure drop. Also known as the valve coefficient or the flow coefficient.
• Diaphragm valve: A bi-directional valve that is operated by applying an external force to a
flexible element or a diaphragm (typically an elastomer). Diaphragm valves may be used for
slurries (where other valve designs might clog) or in hygienic applications.
 VALVE TERMINOLOGY
• Direct-acting actuator: A diaphragm actuator that allows the actuator stem to extend.
• Double-acting positioner: A positioner that has the facility to supply and exhaust air on
both sides of the actuator piston or diaphragm at the same time.
• Double block and bleed: A valve configuration in which positive shutoff is achieved at
both the inlet and outlet sides. A small port is fitted to discharge fluid in the intermediate
space. Fitting a gas detector to the port provides assurance of the integrity of the upstream
seal. This configuration is often required to isolate high-pressure sections of a system to
facilitate safe maintenance, etc.
• Double disc check valve: A check valve with two semi-circular discs that are hinged
together and that fold together when the flow is in the correct direction and swing closed
when the flow is reversed. Also known as a split disc check valve.
• Drop tight: A bubble-tight test that involves a water-under-air test.
• Eccentric butterfly valve: A butterfly valve where the shaft that carries the closure disc is
slightly offset and creates an elliptical motion as it leaves the sealing surface. This effect
reduces friction and wear to the closure disc.
 VALVE TERMINOLOGY
• Elastomer: A polymer that is both flexible and resilient when used as a seal.
• End to end: The extremities of the valve. One connection to the other end connection.
• Extended bonnet: Used when the medium is at high or low temperatures, to avoid damage
to the sealing elements.
• Fail closed: An actuator facility such that in the event of power failure the valve will
move to the fully closed position.
• Fail open: An actuator facility such that in the event of power failure the valve will move
to the fully open position.
• Fail-safe: An actuator facility such that in the event of power failure the valve will move
to a predetermined position, which could be open, closed, or an intermediate position.
• Fire resistant.: The ability of a valve to withstand a fire and maintain the failure position.
Such a valve will be equipped with devices to achieve this status.
• Fire-safe: The ability of a valve to minimize the amount of process lost downstream or to
the atmosphere after a fire test.
 VALVE TERMINOLOGY
• Flat face: flange that has no raised face or a ring groove surface. These flanges are generally used
in lower piping pressure classes such as ASME 125 lb or 150 lb in cast iron and carbon steel. The
mating gasket will be flat and extend to the circumference with holes to accommodate the flange
bolting.
• Flat gasket: A circular, flat sheet with an inside and outside diameter.
• Floating ball: A ball valve where the closure ball is not attached to the body of the valve.
• Floating seat: A seat ring that is not attached to the valve body and can move to suit the closure
element and improve the shut-off.
• Float valve.: A valve that automatically opens or closes as the level of a liquid changes. The valve
is operated mechanically by a float that rests on the top of the liquid.
• Full-bore valve: Any valve where the closure element has the same inside diameter as the inlet and
outlet of the valve. Also called a full-port valve and has a lower pressure drop than a reduced bore.
• Full closed: The position of the valve when the closure element is fully seated.
• Full open: The position of the valve when the closure element is fully open allowing maximum
flow through the valve.
 VALVE TERMINOLOGY
• Full trim: The area of the valve’s seat that can pass the maximum flow for that particular size.
• Galling: The damage of two mating parts when microscopic portions impact and make a
temporary bond. When effort is made to separate these two surfaces, tearing of the two
components can occur. This usually happens when the two materials are the same or possess
several very similar mechanical characteristics.
• Gate valve: A multi-turn valve that has a gate-like disc and two seats to close the valve. The
gate moves linearly, perpendicular to the direction of flow. This type of valve is normally used
in the fully opened or fully closed position; it is not suited to throttling applications. Gate
valves provide robust sealing, and are used extensively in the petrochemicals industries. This
class of valve also includes knife gate valves, conduit gate valves, and wedge gate valves.
• Gland bushing or the packing follower: Located at the top of the packing box, it acts as a
barrier, protects the packing from the atmosphere, and transfers a force from the gland flange
bolting to the packing.
• Gland flange: Part of the valve used to compress and retain the internals in the packing box.
 VALVE TERMINOLOGY
• Globe valve: A multi-turn valve with a closing element that moves perpendicularly to the
valve body seat and generally seals in a plane parallel to the direction of flow. This type of
valve is suited to both throttling and general flow control.
• High-performance valves. A valve specifically designed for accurate throttling applications.
• Hydrostatic test: A test using water under pressure to detect any leaks through the body,
sealing joints, or closure element. Generally, this test pressure is 1.5 times the design
pressure at ambient temperature.
• Integral flange: A flanged connection that is either fabricated or cast to the body of the valve.
• Integral seat: A seat that is actually a machined part of the valve body and not one that is
inserted into the valve.
• Jacketed valve: Valve designed to incorporate a so-called jacket around the valve body.
Steam is introduced into the jacket to keep the fluids being controlled at the required
temperature.
• Lift check valve: A non-return valve that prevents back flow by having a free floating
element, either a ball or a poppet. The design incorporates a piston to damp the disc during
operation.
 VALVE TERMINOLOGY
• Limit stop. A device in an actuator that limits the linear or rotary motion of an actuator; can
be adjusted.
• Limit switch. An electromechanical accessory that is attached to an actuator and used to
identify the position of a valve’s closure element.
• Linear valve: A valve that has a sliding stem that pushes the throttling element up and down.
• Line blind: A pipeline shut-off device, whereby a flat disc is forced between two flanges.
Line blinds are less expensive than valves, but require much more time to operate.
• Lug body: A body of a flangeless wafer butterfly valve that requires bolts to pass through
the body to flanges on either side of the valve. These holes can be tapped to allow the line to
be dismantled without “dropping” the valve. Tapped lugged valves are sometimes called
“end of line” valves.
• Multi-ported: These valves include additional inlet/outlet ports, to allow fluids to be
directed. The ball and plug valve types are ideally suited to multiport designs.
 VALVE TERMINOLOGY
• Multi-turn: Category of valves (such as gate, globe, needle), which require multiple turns of
the stem to move the valve from the fully open to the fully closed position. Also known as
linear valves.
• National pipe thread: A tapered thread that is used for pressure connections for piping.
• Needle valve: Multi-turn valve that derives its name from the needle-shaped closing element.
The design resembles that of the globe valve. Typically available in smaller sizes, they are
often used on secondary systems for on/off applications, sampling, etc.
• Non-rising stem: A valve where the stem is threaded and the turning of a stationary operator
will result in the closure element rising to open and lowering to close.
• Normally closed. A valve that is normally closed during operation. In many cases these
valves are locked closed by using a mechanical device.
• Normally open: A valve that is normally open during operation. In many cases these valves
are locked open by using a mechanical device.
 VALVE TERMINOLOGY
• O-ring: An elastomer ring that forms a sealing material for the internals of a valve.
• Packing: A soft sealing material that is used to prevent leakage of process fluid from around
the stem. It is located in the packing box.
• Packing box: A chamber through which the stem passes. This chamber houses the packing
material, packing spacers, lantern rings, guides, and other seal accessories necessary to
prevent leakage of process fluid.
• Parallel gate valve: A gate valve that has a flat disc gate that slides between two parallel free
floating seats.
• PEEK: The abbreviation for polyether ether ketone. A robust soft seating material.
• Pilot valve: Small valve requiring little power that is used to operate a larger valve.
• Pinch valve: A valve in which a flexible hose is pinched between one or two moving external
elements to stop the flow. This valve is often used in slurry and mining applications, as its
operation is not affected by solid matter in the medium. It is also used with certain gases, as
the absence of possible leak paths to the atmosphere ensures good emission control.
 VALVE TERMINOLOGY
• Plug valve: This multi-turn valve derives its name from the rotating plug that forms the
closing element. The plug may be cylindrical or truncated. In the open position, the fluid
flows through a hole in the plug. Lubricated plug valves rely on a sealing compound injected
between the plug and the valve body, whilst sleeved plug valves are fitted with a “soft” insert
between the plug and the body.
• Poppet. A closure element in a check valve that is held in place by a spring.
• Positioner: A device that receives a signal—pneumatic or electric - from a controller and
compares it to the actual position of the valve. If the signal is not correct then the positioner
sends pressure to, or bleeds pressure from, the valve so that the correct position is achieved.
• Proximity switch. A limit switch that indicates the valve position without making mechanical
contact. The switch will use a magnetic or an electronic sensor to determine the valve
position.
• Psi: The abbreviation for pounds per square inch.
• psia.: The abbreviation for pounds per square inch absolute. The psia unit is used when the
pressure is expressed without taking into account ambient pressure.
 VALVE TERMINOLOGY
• Psig: The abbreviation for pounds per square inch gauge. The psig unit is used when the
pressure is expressed to standard atmospheric pressure (noted 14.7 psia).
• Quarter-turn: The 90◦ angle through which a valve’s closing element must move from the
fully open position to the fully closed position. Examples are ball, plug, and butterfly valves.
• Rack and pinion actuator: An actuator used in conjunction with quarter-turn valves. This
actuator will supply either a pneumatic or a hydraulic force to move a flat-toothed rack that
turns a gear to open and close the closure element.
• Reduced-port valve: A valve that has a smaller internal bore than those of the inlet and the
outlet. A reduced-port (bore) ball valve will have a greater pressure drop than a full-port
(bore) ball valve.
• Ring type joint: A flanged end connection with a circular groove on the mating face, where a
softer metal ring is placed before mating up to a similar flange face and bolting up. The
softer ring, usually oval or hexagonal, will deform when the flanges are bolted up and create
a tight seal. Ring type joint connections are used on higher-pressure piping systems, ASME
900 lb and above. The abbreviation is RTJ.
 VALVE TERMINOLOGY
• Screwed bonnet: A valve bonnet with male threads to join a valve body with female threads.
• Screwed end connections: End connections that have female national pipe thread (NPT),
which mates with male NPT on a pipe.
• Seating torque: The torque value produced by a rotary actuator to open or close the valve.
• Shaft: The rod that connects the closure element and the closure operator (handwheel or
actuator).
• Single-acting actuator: An actuator in which air is applied to one chamber. This air pressure
acts against and pushes a plate.
• Sliding gate valve: A gate valve that has a flat rectangular plate as a closure element.
Sometimes called a sluice valve and used for large bore irrigation and waterworks systems.
• Soft seat plug: An elastomer that is placed within a metal ring at the seating area of a globe
valve. This will provide a bubble-tight shut-off.
• Speed of response: The speed provided by an actuator to operate a valve. Sometimes called
the stroking speed.
 VALVE TERMINOLOGY
• Split body. Usually refers to a ball valve that comprises more than one piece and houses the
closure element.
• Stroke: The travel required by a valve, either linear type or rotary type, generally from fully
open to fully closed.
• Sub-sea valve: A valve that is designed for use in seawater. For example, installed in a
pipeline on the seabed.
• Swing check valve: A check valve with a single plate pivoted at the top and secured to the
body of the valve. The flow of the process fluid pushes the plate open and in the event of
flow reversal the plate swings to the closed position.
• Tank valve: A valve arranged for fitting at the bottom of a tank or process vessel.
• Three-way valve: A diverter type valve that has three ports and allows the flow path of the
process fluid to be switched, or two different flow paths to be combined.
• Throttling: The regulation of the process fluid by positioning the closure element of the
valve between open and closed to create the desire flow regime.
 VALVE TERMINOLOGY
• Through-conduit gate valve: A full-bore gate valve that has a very low-pressure drop and
allows for the passage of pipeline pigs or scrapers for cleaning, de-watering, batching, etc.
• Thrust: The force generated by any type of actuator to open, close, or position the closure
element of a valve.
• Trim: The trim of the valve is the parts of the closure element that are exposed to the process
flow, sometimes called the wetted parts.
• Trunnion mounted ball valve: A robust ball valve, where the closure element ball is
supported at the base by a shaft. This design is more common on larger valves and higher
ratings, because of the weight of the ball.
• V-ring packing: A stem packing that is V shaped in cross section. Radial forces that are
applied will force out the packing radially and create a tight seal against the wall of the
packing box and the stem/shaft.
• Wafer design: The construction of wafer design valves allows them to be “sandwiched”
between flanged sections of pipeline. The benefit is lower bolting requirements. Typically
used with certain butterfly and check valves.
 VALVE TERMINOLOGY
• Water hammer effect: The reaction when a valve is suddenly closed and a shock wave is
transmitted through the piping system. This is generally caused by under sizing of the piping
system. It is not only noise, but it can also cause mechanical damage to the piping system
and associated equipment.
• Weir: An obstruction in a diaphragm valve, against which the elastomer liner is compressed
to prevent the flow of the process fluid.
• Wellhead valve: Used to isolate the flow of oil or gas at the take-off from an oil or gas well.
The design is usually a plug or gate valve.
 VALVE SELECTION
• Valve Selection involves the following factors:
 Flow coefficient (Cv)
 Flow Characteristics
 Shut off Requirements
 Body End Connections
 Standard Classification or pressure class
 Face-to-Face Criteria
 Body & Trim Material selection
 Gasket Selection
 Packing Selection
PRESSURE CLASS IDENTIFICATION: MSS SP 86
 TYPES OF ACCEPTANCE TEST IN INDUSTRY
• Types of Acceptance Testing:
 Design Validation Testing (DVT)
Design validation testing (DVT) is an intensive testing program which is performed to deliver objective,
comprehensive testing verifying all product specifications, interface standards, original equipment manufacturer
(OEM) requirements, and diagnostic commands.
 User Acceptance Testing (UAT) : FAT & SAT
This may include factory acceptance testing (FAT), i.e. the testing done by a vendor before the product or system
is moved to its destination site, after which site acceptance testing (SAT) may be performed by the users at the
site.
 Operational Acceptance Testing (OAT)
Also known as operational readiness testing, this refers to the checking done to a product or system to ensure that
processes and procedures are in place to allow the product or system to be used and maintained.
 Contract & Regulation Acceptance Testing ( CRAT)
Product or system is tested against acceptance criteria as documented in a contract, before the system is accepted.
In regulation acceptance testing, a system is tested to ensure it meets governmental, legal and safety standards
• Valve industry usually involves DVT, UAT & CRAT. We are going to discuss only CRAT inspection scope.
 INSPECTION OF VALVES
• Documents required before start of the inspection at Vendor Location
 Purchase Order Or Contract Copy
 Valve Data Sheet, Approved Drawings, Offer List & Correlation on Name Plate or Tag
 Approved ITP/QAP
 MTCs & lab check test reports
 Applicable NDT & test procedures
 Type Test & Fire Test compliance
 NDT personnel qualifications
 Calibration certificates for measuring instruments & gauges
 INSPECTION OF VALVES
• Inspection Criteria for Block & Control Valves: Gate, Globe, Butterfly, Check, Ball
type are
 Inspection of Casting & Forgings.
 Pressure Testing of Valves: Shell, Back Seat, Low & High Pressure Closure.
 Fugitive Emission Testing.
 Cryogenic and Low Temperature Testing.
 Visual & Dimension inspection as per Data Sheet & Drawing.
INSPECTION OF CASTING & FORGING
• The inspection activities are
 Raw Material MTC & Heat Chart Review
 Material Identification, Sample drawing & mechanical testing as per material spec.
 NDT: Surface defects – Wet Fluorescent MPI for Forging & Casting
 NDT: Internal defects – RT or UT
 Hardness & Surface Roughness
INSPECTION OF VALVES : API STD 598
INSPECTION OF VALVES : API STD 598
INSPECTION OF VALVES : API STD 598
INSPECTION OF VALVES : API STD 598
VALVES FACE TO FACE DIMENSION STD (TYPICAL)
MOC OF BODY & BONNET (TYPICAL)
MOC OF TRIM (TYPICAL)
MOC & SPEC OF GASKET (TYPICAL)
TEMPERATURE LIMITATION OF PACKING
INSPECTION OF VALVES : API STD 598
 PSV TERMINOLOGY
• Accumulation: The pressure increase over the MAWP of the vessel, expressed in pressure
units or as a percentage of MAWP or design pressure. Maximum allowable accumulations
are established by applicable codes for emergency operating and fire contingencies.
• Actual discharge area or actual orifice area: The area of a pressure-relief valve (PRV) is
the minimum net area that determines the flow through a valve.
• Backpressure: The pressure that exists at the outlet of a pressure-relief device as a result
of the pressure in the discharge system. Backpressure is the sum of the superimposed and
built-up backpressures.
• Superimposed backpressure: The static pressure that exists at the outlet of a pressure-
relief device at the time the device is required to operate. Superimposed backpressure is
the result of pressure in the discharge system coming from other sources and may be
constant or variable.
• Built-up backpressure: The increase in pressure at the outlet of a pressure-relief device
that develops as a result of flow after the pressure-relief device opens.
 PSV TERMINOLOGY
• Blowdown: The difference between the set pressure and the closing pressure of a
pressure-relief valve, expressed as a percentage of the set pressure or in pressure units.
• Bore area/nozzle area/nozzle throat area/throat area: The minimum cross-sectional flow
area of a nozzle in a pressure-relief valve.
• Closing pressure: The value of decreasing inlet static pressure at which the valve disc
reestablishes contact with the seat or at which lift becomes zero as determined by seeing,
feeling, or hearing.
• Cold differential test pressure (CDTP): The pressure at which a pressure-relief valve is
adjusted to open on the test stand. The CDTP includes corrections for the service
conditions of backpressure or temperature or both.
• Curtain area: The area of the cylindrical or conical discharge opening between the seating
surfaces above the nozzle seat created by the lift of the disc.
• Opening pressure: The value of increasing inlet static pressure at which there is a
measurable lift of the disc or at which discharge of the fluid becomes continuous, as
determined by seeing, feeling, or hearing.
 PSV TERMINOLOGY
• Operating ratio of a pressure-relief valve: The ratio of maximum system operating pressure to
the set pressure.
• Overpressure: The pressure increase over the set pressure of the relieving device.
Overpressure is expressed in pressure units or as a percentage of set pressure. Overpressure is
the same as accumulation only when the relieving device is set to open at the MAWP of the
vessel.
• Set pressure: The inlet gauge pressure at which the pressure-relief device is set to open under
service conditions.
• Pressure-relief device (PRD): A device actuated by inlet static pressure and designed to open
during emergency or abnormal conditions to prevent a rise of internal fluid pressure in excess
of a specified design value. The device also may be designed to prevent excessive internal
vacuum. The device may be a pressure-relief valve, a non-reclosing pressure-relief device, or
a vacuum relief valve.
• Conventional pressure-relief valve: A spring-loaded pressure-relief valve whose operational
characteristics are directly affected by changes in the backpressure.
• Balanced pressure-relief valve: A spring-loaded pressure-relief valve that incorporates a
bellows or other means for minimizing the effect of backpressure on the operational
characteristics of the valve.
 PSV TERMINOLOGY
• Modulating pressure-relief valve: A pressure-relief valve that opens and flows in
proportion to the inlet pressure for some or all parts of the valve's operating range from
set pressure to overpressure at full lift.
• Pilot-operated pressure-relief valve: A pressure-relief valve in which the major relieving
device or main valve is combined with and controlled by a self-actuated auxiliary
pressure-relief valve (pilot).
• Non-reclosing pressure-relief device: A pressure-relief device which remains open after
operation. A manual resetting means may be provided.
• Relief valve: A spring-loaded pressure-relief valve actuated by the static pressure
upstream of the valve. The valve opens normally in proportion to the pressure increase
over the opening pressure. A relief valve is used primarily with incompressible fluids.
• Safety valve: A spring-loaded pressure-relief valve actuated by the static pressure
upstream of the valve and characterized by rapid opening or pop action. A safety valve is
normally used with compressible fluids.
 INSPECTION OF PSV

• Inspection Criteria for Pressure Relief Valves are

 Inspection of Forgings.
 Pressure Testing of PSV: Body & Nozzle
 Functional Testing of PSV: Set Pressure Test, Seat Tightness Test, Back Pressure Test
 Visual & Dimension inspection as per Data Sheet & Drawing.
INSPECTION OF PSV/PRV: API STD 527
INSPECTION OF PSV/PRV: API STD 527
INSPECTION OF PSV/PRV: API STD 527
INSPECTION OF PSV/PRV: API STD 527
 MOC OF PSV/PRV FOR SOUR SERVICE
• Duplex valves with bar stock nozzles and discs must meet NACE requirements.
ASTM A890 CE3MN UNS J93404
ASME SA 351 CD3MWCuN UNS J93380
ASME SA 351 CE8MN UNS J93380
 Z 6 CNDU 28.08 M, NF A 320-55 at 17 HRC MAX
ASTM A351 CK3MCUN (6Mo)
• Body, bonnet and cap, up to 815 °C cast materials:
ASME SA 351 CF8M with a minimum 0.04% carbon content and maximum 8% ferrite
content.
Alternatives are:
 ASME SA 351 CF8 SAME (with same chemical restrictions as CF8M)
 ASME SA 217 WC6 (up to maximum 593°C)
 ASME SA 217 WC9 (up to maximum 593°C)
 MOC OF PSV/PRV FOR SOUR SERVICE
• Wrought materials can also be used up to 815°C:
ASME SA 479 Grade 316H with a carbon content between 0.04% and 10%.
Alternatives are:
 ASME SA 479 Grade 304H (same chemical restrictions as 316H)
 ASME SA 479 Grade 347H (same chemical restrictions as 316H)
For the temperature range 530°C to 815°C:
 Bolting material: ASME SA 193 Grade B8 Class 2/ASME SA 194 Grade 8 – strain
hardened.
 Bellows material: INCONEL 625 Grade 2 (LCF) - annealed after forming /HAYNES
ALLOY 230/ ASTM B435 UNS N06230 is preferred above 650°C
• Spring material:
INCONEL X750
Above 232°C, 316SS springs not used. INCONEL X750 or chrome-plated springs
recommended.
 VISUAL & DIMENSIONAL INSPECTION
• Visually valves casing (if assembled) must be free from surface defects. If stripped, Valve
Trim or wetted parts must be carefully handled during inspection for dimension & PMI.
• Verification of Heat No. on Valve components.
• Dimensional Inspection Process Valve: Valve face to face, Body center to Actuator Top,
Body center to yoke Bottom, Body center to Actuator Center, Body center to Actuator
face, Actuator Length, Actuator Width.
• Dimensional Inspection PRV: Nozzle Center to Discharge Flange Center, Nozzle end to
Discharge Flange Center, Height.
 CODE STAMPS FOR VALVES
• ASME/ANSI B16.5 & 16.34 must carry ASME Stamp.
• ASME Section I approved valves carry the V stamp.
• ASME Section III valves (for nuclear applications) must carry the N, NV and NPT stamp.
• ASME Section IV (for heating boilers) valves carry the H stamp.
• ASME Section VIII (unfired pressure vessels in the process industry) valves must carry the
UV stamp.
• National Board must carry NB stamp.
 Q&A
SESSION
 THANK YOU FOR SUPPORT,
GIVING VALUABLE TIME & ENERGY