Valve handbook

Other McGraw-Hill Handbooks of Interest Avallone and Baumeister MARKs' STANDARD HANDBOOK FOR MECHANICAL ENGINEERS Valve Handbook Bleier FAN HANDBOOK Brady et al MATERIALS Philip L Skousen HANDBOOK Valtek International Brink HANDBOOK OF FLUID SEALING Chironis & Sclater MECHANISMS AND MECHANICAL DEVICES SOURCEBOOK Czernik GASKET HANDBOOK Harris and Crede SHOCK AND VIBRATION HANDBOOK Hicks HANDBOOK OF MECHANICAL ENGINEERING CALCULATIONS Hicks STANDARD HANDBOOK OF ENGINEERING CALCULATIONS Lingaiah MACHINE DESIGN DATA HANDBOOK Parmley STANDARD HANDBOOK OF FASTENING AND JOINING Rothbart MECHANICAL DESIGN HANDBOOK Shigley and Mischke STANDARD HANDBOOK OF MACHINE 'DESIGN Suchy DIE DESIGN HANDBOOK Walsh MCGRAW-HILL MACHINING AND METALWORKING Walsh ELECTROMECHANICAL DESIGN HANDBOOK HANDBOOK McGraw-Hill New York San Francisco Washington D.C Auckland Bogota Caracas Lisbon London Madrid Mexico City Milan Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto Con ten ts Preface ix Acknowledgments xiii Chapter Introduction to Valves 1 1.2 1.3 1.4 1.5 1.6 1.7 The Valve The History of Valves Valve Classification According to Function 13 Classification According to Application 16 Classification According to Motion 16 Classification According to Port Size 17 Common Piping Nomenclature Chapter Valve Selection Criteria 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Valve Coefficients 21 22 Flow Characteristics 36 Shutoff Requirements 37 Body End Connections 47 Pressure Classes Face-to-Face Criteria 49 50 Body Material Selection 58 Gasket Selection Packing Selection 65 21 vi Contents Chapter Manual Valves 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 85 177 Introduction to Check Valves 177 Lift Check Valves 179 Swing Check Valves 188 Tilting-Disk Check Valve 192 Double-Disk Check Valves 198 Diaphragm Check Valves 204 9.1 9.2 9.3 9.4 9.5 429 429 Introduction to Valve Sizing 433 Valve-Sizing Nomenclature 439 Body Sizing of Liquid-Service Control Valves 458 Body Sizing of Gas-Service Control Valves 471 Pressure-Relief-Valve Sizing Chapter 10 Actuator Sizing 479 479 10.1 Actuator-Sizing Criteria 487 10.2 Sizing Pneumatic Actuators 10.3 Sizing Electromechanical and Electrohydraulic 497 Actuators 209 5.1 Introduction to Pressure Relief Valves Chapter 11 Common-Valve Problems 209 Chapter Control Valves Introduction to Control Valves Globe Control Valves 222 Butterfly Control Valves 261 Ball Control Valves 285 Eccentric Plug Control Valves 417 Chapter Valve Sizing Chapter Pressure Relief Valves 6.1 6.2 6.3 6.4 6.5 411 Chapter Smart Valves and Positioners 411 8.1 Process Control 8.2 Intelligent Systems for Control Valves 423 8.3 Digital Positioners Introduction to Manual Valves 85 Manual Plug Valves 87 Manual Ball Valves 101 Manual Butterfly Valves 111 Manual Globe Valves 132 Manual Gate Valves 147 Manual Pinch Valves 161 Manual Diaphragm Valves 170 Chapter Check Valves 4.1 4.2 4.3 4.4 4.5 4.6 vii Contents 221 221 305 Chapter Manual Operators and Actuators Introduction to Manual Operators and Actuators 7.2 Manual Operators 324 7.3 Pneumatic Actuators 335 7.4 Nonpneumatic Actuators 363 7.5 Actuator Performance 369 7.6 Positioners 370 7.7 Auxiliary Handwheels 376 7.8 External Failure Systems 384 7.9 Common Accessories 390 7.10 Electrical Equipment Certifications 403 321 321 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 499 499 High-Pressure Drops 503 Cavitation 526 Flashing 528 Choked Flow 529 High Velocities 530 Water-Hammer Effects 531 High Noise Levels 552 Noise Attenuation 573 Fugitive Emissions Chapter 12 Valve Purchasing Issues 595 595 12.1 Life-Cycle Costs 599 12.2 Spare Parts Bibliography 809 Appendix A Common Conversion Factors 813 Appendix B Fluid Data 837 viii Contents Appendix C Method 21-Determination of Volatile Organic Compound Leaks 857 Abbreviations of Related Organizations and Standards 885 Glossary 887 Index 709 Preface The editors at McGraw-Hill first approached me about writing this handbook nearly three years ago, after reviewing an article that I authored for The Valve Magazine They indicated that they were interested in having me author a valve handbook, using my common denominator writing style I liked the challenge that they proposed, and I accepted Now, after literally hundreds of hours, dozens of phone calls and facsimiles, and four drafts, the handbook is ready for the valve-using public When I began my career with Valtek International in 1975,I was like many who have started out in this industry: My only experience with a valve was taking a pair of pliers to a leaky faucet in the bathroom But spending three years in the engineering department at Valtek and then some 18 years as a technical communicator cured me of the notion that a process valve is just a larger version of a simple faucet True, the two are related in a number of ways and they both work by the same scientific principles However, the engineering design and complexity of process valves can be immense The process services they are installed in can sometimes be brutal-even capable of destroying a valve in hours if misapplied To me this is an exciting and dynamic industry, especially with the advent of smart technology, which has lifted the science and application of valves to a whole new level Twenty years ago, when I first picked up a drawing pencil (yes, computer-aided design was still a couple years away), if one wanted Ix ]I[ Preface to find basic information about valves, not much was readily available Unfortunately, if a person starting out in the valve business or process industry wanted to learn the basics about valves, instead of turning to a good reference handbook, he or she had to ask questions of more senior engineers or technicians More often than not, the individual might not have had the educational background or experience to even ask the right questions Hence, learning the basics of valves often took months and maybe even years to fully understand certain designs and principles It's not that valve books didn't exist; they did then and still today The problem is that such books not typically address the questions or level of understanding that most nonvalve experts ask A few valve books existed, but none began with the simple concepts of fluid dynamics and valve design to build a foundation of common understanding between the reader and the author Once this foundation is established, the more complex issues can then be addressed Those valve books in existence were primarily authored by one or several of the industry "gurus" or experts Many were product specific, such as those experts in severe service trims, packing boxes, or actuators Others had studied the adverse effects of process flow, such as those who extensively studied cavitation or noise Some handbooks were com.piled from aseries of "white papers" from a wide assortment of experts and brought together by an independent editor-a great method to put out a high level of knowledge quickly, but lacking in continuity and basics While most books concentrated on design and severe services, little information was provided about selection options, or about installing, starting up, troubleshooting, and servicing valves Over the years, I've had the opportunity to meet and work with many of these valve experts I have a great respect for their knowledge and pioneering efforts in the field of valves The knowledge that such experts impart is important to the entire industry Once understood by the user, it can help solve application and process control questions A problem inherent with many authors and some industry experts is their basic assumption that the reader knows as much as the authoror that at least the author and reader have the same high level of understanding or engineering background Although that may be fine for those experienced in the industry over some 10 or 20 years or with advanced engineering degrees, it leaves a great many people out of the loop of understanding I decided to write this book for those who need to know the essence of valves and know it quickly In this day of corporate turnarounds or internal reengineering, the ability to understand Preface xi a particular segment of process control-such as valves-cannot wait for a decade of experience Engineers and technicians responsible for valves need knowledge now-knowledge that is simple to understand and easy to apply After the basics are understood, the finer parts of this business can then be explored, some of which are explained in this handbook, as well as other valve books As a certified business communicator, one with years of technical writing and editing about valves, I have learned that the best approach to communication is to begin simply and write to a common denominator This means that if a principle or concept is written to a high school level, both the high school graduate and the engineer with a masters degree will understand it But if that same concept is written to a higher level, such as a 16th grade level, only the university graduate will understand it That's not to say that higher knowledge in this book is missing or "dumbed down." Rather, this higher degree of information is presented in a structured, simplified manner with no assumptions of knowledge made Because of this style, if the user reads this handbook from cover to cover, he or she may find some duplication of information This is because most handbooks, like encyclopedias and dictionaries, are used for reference purposes: they sit on a shelf until they are needed to answer a particular question or to explain a particular concept With common denominator style, the reader will be able to turn to any section of the handbook, read it, and understand the concepts without keeping a finger glued to the glossary or the index, or left wondering about a term With my experience in referencing valve books, I have learned one important fact: This industry is so large that no one book could ever hope to contain every fact, design concept, sizing equation, or principle about the thousands of different valve models available today If possible, the book would become a set of 20 volumes, and then be so massive that the user would find it extremely cumbersome As I accepted this challenge of writing a valve handbook for McGraw-Hill, I took the approach that a dozen basic designs and a handful of scientific principles represent the foundation of the valve industry Taking into account the dozens of valve manufacturers, each· design can have literally hundreds of particular features Rather than research and include them all, I have opted to take the most common features and have described them in detail A number of statements are made in the book describing the general design of a particular valve design or feature Because no one rule can be steadfast in this dynamic business, these general statements are by no means certain or definite Exceptions can always be found to these general statements xii Prtf'ao This also applies to any information in the handbook about in.taUation, quick-checking, troubleshooting, and servicing of a valve Th•• e sections are provided as general guidelines to the user, compUed from various users and manufacturers In no way can they possibly apply to every type of valve and are certainly not intended to replace th man· ufacturer's technical and maintenance literature By inc1udin thie information, I hope that these tips and ideas will provide the Ult' with a broader base of information than may be provided by the manufac· turer's literature alone The terminology used in the book is based upon my experi.nc and the advice of others With the wide diversity represented by th valv• ' industry, I found the same valve part or concept can be caUed by d\Nt, or four different names In the introduction of a new term, I hav._ included other common names for reference purposes How.v.r, I UM the first term consistently throughout the entire handbook Thi i not to say that the other terms are incorrect Rather, I believe that I con•••• tency of terminology makes the concepts and designs easier to understand Some of the information contained in this book has com to ••• through technical materials, training manuals, or white pap.n that 'I have collected over the years In addition, dozens of valve manufacturers graciously responded to my initial request for information aNi sent me boxes of material In some cases, I have relied upon my own knowledge and experience with valves, as well as my interview wi dozens of users over the years Overall, I was impressed with much 01 the recent material produced by valve manufacturers Many hav •• oM to great lengths to portray their products with simple, easy-to-undlrstand concepts Because my primary focus in valves has been control valv•• , I 1m indeed grateful to those experts in the manual, check, and pJ'lIlUJ'l relief valve industries who patiently explained the finer pointa of tMAr products to me I am also grateful for their review of my material, a well as their suggestions and criticisms One thing I have learned from authoring this handbook is that a great number of opinions exist among the valve experts of today Although I respect all opinions and arguments offered to me as part of this project, in some cases I had to act as referee when two opinions conflicted In such situations, the decision to promote one idea over another was based upon my judgment and the opinions of several leaders whose judgment I have come to trust Philip L Skousen AcknowledgIIlen ts Over the past two years, a great number of individuals have assisted the author with the preparation of this handbook, sharing their knowledge of particular portions of the valve industry, including the design, operation, troubleshooting, and service of a wide range of process valves These individuals have not only provided valuable input, but have also reviewed portions of the manuscript and recommended clarifications, which have been extremely valuable Many of these individuals also provided the photography, artwork, illustrations, graphs, and table data-greatly adding to the content of the handbook Special thanks to: Mark Peters of Accord Controls (Cincinnati, Ohio), a subsidiary of the Duriron Company; Tim Martin of Adams (Houston, Texas); Peter Amos and John Stofira of Advanced Products Company (North Haven, Connecticut); Roland Larkin and C H Lovoy of the American Flow Control, a division of American Cast Iron Pipe (Birmingham, Alabama); Bill Knecht of Anchor/Darling (Williamsport, Pennysylvania); Chris Buxton and Michelle Strauss of Anderson, Greenwood & Co (Houston, Texas), a subsidiary of Keystone International, Inc.; Richard H Stern of the Automatic Switch Company (Florham Park, New Jersey); Richard Weeks of Automax (Cincinnati, Ohio), a subsidiary of The Duriron Company; Dan Wisenbaker of Betis Actuators and Controls (Waller, Texas); Fermo Gianesello, Robert Katz, Herb Miller, Andrew Noakes, and Nicole Woods of Control Components Inc (Rancho Santa Margarita, California); Nancy Winalski of Conval Inc (Somers, Connecticut); xiii xiv Acknowledgments Walter W Mott of Copes-Vulcan (Lake City, Pennsylvania); Lew Babbidge and Cindy Sartain of the Daniel Valve Company, a division of Daniel Industries, Inc (House ton, Texas); Jean Surma of DeZURIK (Sartell, Minnesota); Rom Bordelon of Dresser Industries (Alexandria, Lousiana); Ken Senior of the DuPont Company-Polymers (Newark, Delaware); Dennis Garber of Durco Valve (Cookeville, Tennessee), a subsidiary of the Duriron Company; Philip R Vaughn of DynaTorque Valve Actuators and Accessories (Muskegon, Michigan); Bob Sogge and John Wells of Fisher Controls (Marshalltown, Iowa); Susan Anderson of Flowseal (Long Beach, California), a division of Crane Valves; Lee Ann McMurtrie of the Groth Corporation (Houston, Texas); James D Phillips of the Gulf Valve Company (Houston, Texas); Will Gavin of the Hydroseal Valve Company, Inc (Kilgore, Texas); Lou Gaudio and Valerie D Litz of ITT Engineered Valves; Ian W B Johnson of Kammer Ventile (Essen, Germany), a subsidiary of the Duriron Company; Domenic DiPaolo of Kammer USA (Pittsburgh, Pennsylvania), a subsidiary of The Duriron Company; Carter Hydrick of Keystone International, Inc (Houston, Texas); Robert Hoffman of Mueller Steam Specialty (St Pauls, North Carolina); Jime Holmes of Parker Electrohydraulics (Elyria, Ohio); Michael Fitzpatrick of Orbit Valve Company (Little Rock, Arkansas); Susan Anderson of Pacific Valves (Long Beach, California), a division of Crane Valves; Christ Letzelter of the Red Valve Company (Pittsburgh, Pennsylvania); Kevin Speed of Jordan Valve (Cincinnati, Ohio), a division of the Richards Industries Valve Group; Chris Warnett of Rotork Actuation (Rochester, New York); Pierre Brooking of Sereg Vannes (Paris, France), a subsidiary of The Duriron Company; Stephen R Gow of Spirax Sarco (Allentown, Pennsylvania); Frank Breinholt, Fred Cain, Candee Ellis, Alan Glenn, and Craig Heraldson of Valtek International (Springville, Utah), a subsidiary of the Duriron Company; Bill Sandler of the Valve Manufacturers Association of America (Washington, D.C.); Deborah Lovegrove and Tom Velan of Velan Valve Corporation (Williston, Vermont); Gilbert K Greene of the Victaulic Company of America (Easton, Pennsylvania); John J Murphy of Yarway (Blue Bell, Pennsylvania), a subsidiary of Keystone International Inc I would also like to thank my employer, Valtek International, for its valuable assistance and support during this two-year project Twelv~ years ago, as a technical communicator for Valtek, I was given the assignment to author a sizing and selection guide for control valves, working with a number of excellent engineers who helped guide me through that 200-page document It was during that time that I first envisioned a handbook that would explain valves in a simple, straight- Acknowledgments XV forward manner Valtek's parent company, The Duriron Company, Inc., took a special interest in this project-in partiular Duriron's chairman and CEO Bill Jordan Bill supported this project from day one and encouraged me to complete it, for which I am grateful And, finally, I'd like to thank my wife, Patty, for her general support and assistance with proofreading the manuscript Her insightful comments and objectivity helped make this handbook what it is I am also thankful for my three daughters-Lindsay, Ashlee, and Kristin-who saw a little less of their dad during this project and were very understanding (well, mostly understanding) when I needed to use the home computer It's all yours now, girls! Valve Handbook Introduction to Valves 1.1 1.1.1 The Valve Definition of a Valve By definition, valves are mechanical devices specifically designed to direct, start, stop, mix, or regulate the flow, pressure, or temperature of a process fluid Valves can be designed to handle either liquid or gas applications By nature of their design, function, and application, valves come in a wide variety of styles, sizes, and pressure classes The smallest industrial valves can weigh as little as lb (0.45 kg) and fit comfortably in the human hand, while the largest can weigh up to 10 tons (9070 kg) and extend in height to over 24 ft (6.1 m) Industrial process valves can be used in pipeline sizes from 0.5 in [nominal diameter (ON) 15] to beyond 48 in (ON 1200), although over 90 percent of the valves used in process systems are installed in piping that is in (ON 100) and smaller in size Valves can be used in pressures from vacuum to over 13,000 psi (897 bar) An example of how process valves can vary in size is shown in Fig 1.1 Today's spectrum of available valves extends from simple water faucets to control valves equipped with microprocessors, which provide single-loop control of the process The most common types in use today are gate, plug, ball, butterfly, check, pressure-relief, and globe valves Valves can be manufactured from a number of materials, with most valves made from steel, iron, plastic, brass, bronze, or a number of special alloys Introduction to Valves the walls of a canal to stop the flow or divert the flow to other channels, or when placed in a position between shut and fully open could regulate the amount of water entering the channel downstream As early as 5000 BC, crude gate valves were found in a series of dikes designed as part of ancient irrigation systems developed by the Egyptians along the banks of the Nile River Archaeologists have found that other ancient cultures in Babylon, China, Phoenicia, Mexico, and Peru also used'similar irrigation systems As early engineers examined these primitive process systems, they began to apply the technology to new uses For example, as early as 1500 BC, the tombs of Egypt were equipped with extensive drainage systems, which included siphons, bellows, and simple plug valves carved from wood Designed to bring water to the surface from underground wells, sophisticated saqqiehs in Egypt were equipped with simple wooden valves in the buckets used to transport the water The Romans, having conquered the Middle East, quickly saw the value of the Middle Eastern hydraulic engineering and expanded the concept into a series of aqueducts in Europe, which were used to sustain new cities that were located in areas away from major water sources These aqueducts included early pumps, piping, and waterwheels, as well as gate and plug valves made of wood, stone, or lead 1.2 The History of Val.•.•• 1.2.1 Earliest Use of the VaIN Prior to the development of even imple irrigation systems, crops cultivated by early civilizations were at the mercy of whims of weather, water levels of rivers or lakes, or the strength of humans and animals to transport water in primitive vessels Because of the unpredictability or hardship associated with thete methods, early farmers sought a number of ways to control the flow of nearby water sources The primary ideal of a valve most likely arose when these simple farmers noticed that fallen tree or debris diverted, or even stopped, the flow of streams; thus the concept arose of using artificial barriers to divert water into nearby fields Eventually, this idea expanded into simple irrigation using a planned series of ditches and canals, which by using gravity could transport, store, and widen the reach of the water source An important element of these early irrigation systems was a removable wooden or stone barrier, which could be placed at the entrance of each irrigation channel This barrier was the early progenitor of what we now commonly call the gate valve and could be wedged between 1.2.2 Historical Development of the Valve Generally, valves during the Middle Ages were crude, carved from wood, and used mainly as bungs in wine and beer casks Valve design changed very little until the Renaissance when modern hydraulic engineering principles began to evolve In an attempt to improve the performance of canal locks, Leonado da Vinci analyzed the stresses that would occur at different lock gates with varying heights of water on either side of the gate These early studies of the concept of pressure drop helped determine the basis for modern fluid dynamics, which is essential to understanding and calculating the performance of valves In 1712, Englishman Thomas Newcomen invented his atmospheric engine (sometimes called a heat engine), which used low-pressure steam to drive a piston forward When attached to a pivot beam, this simple engine could be used to lift water As Newcomen improved his machine, he introduced a simple iron plug valve, which could be used to regulate the flow of steam to the piston-the first known application of a throttling valve ... to Manual Valves 85 Manual Plug Valves 87 Manual Ball Valves 101 Manual Butterfly Valves 111 Manual Globe Valves 132 Manual Gate Valves 147 Manual Pinch Valves 161 Manual Diaphragm Valves 170... Pressure Relief Valves Chapter 11 Common -Valve Problems 209 Chapter Control Valves Introduction to Control Valves Globe Control Valves 222 Butterfly Control Valves 261 Ball Control Valves 285 Eccentric... Chapter Manual Valves 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 85 177 Introduction to Check Valves 177 Lift Check Valves 179 Swing Check Valves 188 Tilting-Disk Check Valve 192 Double-Disk Check Valves 198