Inspect Valves

INSPECT VALVES
PEW-404.01
The training materials contained in this module are the property of the Saudi Arabian Oil Company (Saudi Aramco) and
are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses. Any
material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given or
disclosed to third parties or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramcos
Professional Engineering Development Unit courses without the prior written permission of the Chief Engineer of Saudi
Aramco.
PEW-404.01
PARTICIPANT
DATE
REVISION DESCRIPTION
12/20/04
COMPLETE REVISION
REVISIONS
PAGE(S) AFFECTED
S.U. BASHA, S. CAVE, M. AKKAD
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MODULE COMPONENT
TABLE OF CONTENTS
PAGE
OBJECTIVES
Terminal Objective
Enabling Objectives
INTRODUCTION
IDENTIFY VALVES AND VALVE PARTS
Applicable Standards
Block Valves 1
Gate Valves
Plug Valve
Ball Valve
Throttling Valves
Butterfly Valve
Globe Valve
Needle Valve
Diaphragm Valve
Angle Valve
Automatic Control Valves
Check Valves
Swing-Type Check Valve
Lift Check and Ball Check Valve
Pressure Relief Valves
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TABLE OF CONTENTS
VERIFY VALVE IDENTIFICATION FROM MARKINGS

Valve Identification
Symbols for Metallic and Non-Metallic materials
INSPECT VALVES
New Valves (Vendor Inspection)
Field Installation inspection
Receiving Inspection
Field Tests
Field Installation Limitations
Existing Valve Inspection
Safety during inspection
Rebuilt or repaired valve
Frequently Occurring Problems
Operating Difficulties
Other Problems
Assurance Tests
Records
Valve Wall Retirement Thickness
Determining the tm for Valves
Thickness Measurement
Keeping Thickness Records For Retirement Decisions
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TABLE OF CONTENTS
EXERCISE #1. IDENTIFY VALVES

EXERCISE #2. IDENTIFY P&ID VALVE SYMBOLS
EXERCISE #3. IDENTIFY THE MAIN PARTS OF A GATE VALVE
EXERCISE #4. IDENTIFY THE MAIN PARTS OF A GLOBE VALVE
EXERCISE #5. MEASURE VALVE BORE SIZE AND FLANGE SIZE
EXERCISE #6. LOCATE SPECIFIC VALVES ON A PIPING AND
INSTRUMENTATION DRAWING
EXERCISE #7. INSPECT A DEFECTIVE VALVE
EXERCISE #8. DETERMINE VALVE WALL THICKNESS MINIMUM
EXERCISE #9. IDENTIFY MARKINGS ON A VALVE
EXERCISE #10. OBTAIN A DRAWING OF A VALVE
WORK AID 1.
TOOLS FOR INSPECTION OF VALVES
WORK AID 2.
TYPES OF VALVES
WORK AID 3.
PIPING AND INSTRUMENTATION DIAGRAM SYMBOLS
WORK AID 4.
DETERMINING TM'S FOR STEEL GATE VALVES STEPS
WORK AID 5.
HOW TO INSPECT A NEW VALVE
WORK AID 6.
HOW TO INSPECT A DEFECTIVE VALVE
WORK AID 7.
HOW TO INSPECT A REBUILT OR REPAIRED VALVE
WORK AID 8.
HOW TO INSPECT VALVE DURING A SCHEDULED T & I
WORK AID 9.
HOW TO MEASURE VALVE BORE SIZE AND FLANGE SIZE
GLOSSARY
102
ADDENDUM A.
APPLICABLE SAMSS
109
ADDENDUM B
FORMS SA-175
113
ADDENDUM C ASME B16.34 TABLE 3
118
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OBJECTIVES
OBJECTIVES
Terminal Objective
Upon completion of this module, the Participant will be able to inspect valves in
accordance with applicable standards.
Enabling Objectives
In order to accomplish the Terminal Objective, the participant will be able to do the
following
Identify valves and valve parts.
Verify valve identification from markings
Inspect valves
Note:
This training material has been developed using the latest available versions of applicable
Saudi Aramco and industry standards. However, these documents are regularly updated.
Therefore, it is the responsibility of the Inspector to ensure that he is conducting his
inspections according to the latest, updated version of these documents.
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INFORMATION
INTRODUCTION
In the petroleum industry, the primary responsibility of the inspector is to ensure plant
safety, ensure quality of materials, and achieve maximum plant reliability and efficiency.
The piping system makes up a major part of any petroleum processing operation. Proper
inspection and maintenance of the piping system is vital to Saudi Aramco interests.
There are many parts to a piping system. The valve is a very important part of the piping
system. The valve is a mechanical device that is used to control the flow of liquids and
gases through the piping system.
Valves are manufactured in a wide range of sizes, types, styles, and materials. This is
due to the wide range of system products and operating temperatures that may be
present in piping systems.
This module shows you how to identify different valves and their component parts. This
module also shows you how to inspect these valves.
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IDENTIFY VALVES AND VALVE PARTS

For an inspector to do a better job, he must have a good basic understanding of the
equipment that he will be inspecting. In the case of valves, the inspector must be able to
identify the type of valve and its function within the piping system. He should be able to
identify the parts of the valve and their function. The inspector should also be able to
identify the type of material used in the valve and the valve parts.
The most common mechanical device used in Saudi Aramco plants is the valve. Valves
in any piping system serve four basic functions:
1.
Shut off or open a system to fluid flow
2.
Regulate or throttle any fluid flow
3.
Prevent backflow
4.
Relieve pressure
Valve installation may be in the normally-open position or the normally-closed position,

depending on the particular requirements. For example, an unloading valve at a storage
tank is normally closed. The valve would only be opened when the tank's contents are
required to be discharged. An example of a normally-open valve would be a pump
discharge valve.
For functions that require only a fully-open or fully-closed position during operation, the
gate valve is the valve of choice. When the flow has to be regulated or throttled by only
partial opening of the valve, the globe or angle valve is much preferred. Check valves
have only one main function to perform, and that is the prevention of backflow in any
system. A particular application for a check valve is on the discharge side of a pump.
Besides these three categories, there are many other valve types available, and each
type may have its own particular application. Often, two or more valve styles can fulfill
the same service requirements. For instance, ball valves and plug valves have different
body styles but are suitable for similar use.
The main categories of valves used in Saudi Aramco plants and piping service are as
follows:
Block valves
Throttle valves
Automatic control valves
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Check valves
Pressure relief valves
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INFORMATION
Valves come in a wide range of sizes from 1/4 inch to 42 inches and sometimes larger.
Valves are classified according to the pressure they can withstand. Valves come in
pressure class ratings of 150, 300, 400, 600, 800, 900, 1500, 2500, and 4500 pounds
per square inch (PSI).
Note: Class 800 is not normally tabulated ASME B16.34 designation, but it is an
intermediate class that is widely used for socket welding and threaded end
valves.
Valves are designed to meet specific operating needs. The type of process and the
characteristics of the process material will determine the type, class, size, and function
of the valve. Not only is there an assortment of various valve types, but there is also a
choice of materials, various pressure ratings, and finally the type of connection in a given
piping system. There is also a choice of the various types of manual, mechanical, and
automatic controlled operators. Some things that determine the type of valve used are:
Speed of operation required
Amount of positive shut-off required
Highly erosive or corrosive service
Temperature of the process material
Pressure in the piping system
Amount of vibration present
Available space
Expense
Applicable Standards
The inspector needs to be familiar with the following standards:
04-SAMSS-035
General Requirements for Valves
04-SAMSS-048
Valve Inspection and Testing Requirements
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INFORMATION
SAES L- 102
Regulated Vender List for Valves
SAES-L-108
Selection of Valves
ANSI/FCI 70.02
Control Valve Seat Leakage
ASME-B16.34
Valves - Flanged, Threaded and Welding End
ASME-B16.5
Pipe Flanges and Flanged Fittings
ASME-B31.1
Power Piping
ASME-B31.3
Process Piping
API-API-598
Valve Inspection and Testing
API 6A
Specifications for Well Head , Christmas Tree Equipment
API 6D
Specification for Pipeline Valves
API 609
Butterfly Valves Lug Type, Wafer Type
MSS SP 45
Bypass and Drain Connection Standard
MSS SP 25
Standard marking systems for Valves
04- SAMSS- 001
Gate Valve
04- SAMSS- 002
Globe Valve
04 -SAMSS -003
Additional Requirements Low Temperature Valves
04 -SAMSS -005
Check and Swing Valves
04-SAMSS-035
General Requirements for valves
04 SAMSS- 041
Expanded Plug Valves
04-SAMSS- 042
4 Way Diverter Valves
04-SAMSS-048
Valve Inspection and Testing Requirements
04 SAMSS- 049
Inspection and Test API Valves
04- SAMSS- 050
Gate Valves Through Conduit API Spec 6D
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04 SAMSS- 051
Ball Valves API 6D
04- SAMSS -052
Ball Valve API 6A
Form 175-043000
043601, 045600
INFORMATION
Valve Material Certification requirements, Forms 043600,
Block Valves
Block valves either allow flow or block the flow of fluid through a piping system. They are
normally operated either in the full open or full closed position.
Some of the most common block valves used at Saudi Aramco are:
Gate valve
Plug valve
Ball valve
High-performance butterfly valve
Gate Valves
About 75 percent of all valves in process plants are gate valves. Most valves in process
plants function as block valves. Block valves are required only to fully shut off or fully
turn on flow (See Figure 1). The gate valve is an optimum engineering and economic
choice for this on or off service.
Gate valves are available in the full range of pipe sizes, ASME/ANSI B16.34
pressure/temperature ratings, and materials that are encountered in process plant
applications. A gate valve is not suitable to throttle flow because it will pass the
maximum possible flow while it is only partially open. In addition, the valve seating
surfaces can erode rapidly from fluid flow when the valve is not in the fully open or fully
closed position.
Figure 1A shows a flanged gate valve in the fully-open position with the drawing symbol
below. Figure 1B shows a flanged gate valve in the fully-closed position with the drawing
symbol below.
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Figure 1. Flanged gate valve

Function
The off/on flow control of a gate valve is achieved by moving a gate into or out of the
fluid-flow stream. When the full-port gate valve is in the open (on) position, it provides a
full line size, unobstructed, straight through flow passage, and thus results in a
minimum-flow pressure drop.
In reduced-port type gate valves, the flow area is smaller than the line size, causing
slightly higher-pressure drops than a full-port valve. The gate valve shuts off flow by
forcing the gate against the valve body seating surfaces, which creates a pressure-tight
seal in both directions.
The typical gate valve in a process plant consists of 20 or more components (See Figure
2). The design of most of these components is standardized, but can vary in detail
according to purchaser preference. Seven of these components (the body, gate, bonnet,
stem, stem packing system, end connections, and seats) are especially significant and
can be obtained in a variety of designs. The selection of a particular component design
and/or material depends on both the service conditions and the economics for the
application.
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Figure 2. Main parts of a gate valve

Body Pattern
Most standard gate valves are available in either cast or forged steel body construction
up to about 100 mm (4 in.) NPS. Body castings are usually supplied for larger gate
valves because of the cost and difficulty associated with forging the relatively complex
shapes of gate valves in the larger sizes. There are three types of body patterns: full-port
and venturi-port or reduced ports.
Full Port
The line size flow area and resulting minimum pressure drop of the full-port valve
make it suitable for all process plant applications where a gate valve is required.
Its use is mandatory for systems where pipe scrapers must be employed.
However, a full-port valve is usually not the most economical selection, since
reduced-port- and venturi-type valves are less expensive. Per API 600, Steel
Gate Valves - Flanged and Butt-Welding Ends, full-port is specified for all flanged
valves.
Venturi or Reduced-Port
In the venturi- or reduced-port valve, the seat opening is one or more pipe sizes
less than the valve size. This reduces the valve cost due to the overall smaller
valve casting size. However, the reduced seat size increases valve pressure
drop, reduces its strength to absorb loads from the piping system, and does not
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permit use of pipe scrapers. Reduced-port valves are available only up to 100
mm (4 in.) in size and are the normal choice in small diameters. A reduced-port is
specified for valves that are specified to meet API 602, Compact Steel Gate
Valves.
Gates
There are several different gate designs. The solid- and flexible-wedge gates are the
most common. 04-SAMSS-001 defines gate-type requirements for different valve sizes
and ratings. For example, a flexible wedge is required for valves 100 mm (4 in.) NPS
and larger in ASME/ANSI classes 150 through 600.
Solid-Wedge Gate
The solid-wedge gate is the lowest cost and most widely used gate-type in
process plants. Solid-wedges are of one-piece construction and the seating
surfaces are precision machined with a wedge taper. A precision-dimensional
match between the gate and the body seating surfaces is required to obtain a
tighter seal. The solid wedge gate is favored for its strong and simple design, but
it is prone to sticking when used in services where extreme temperature changes
or gradients [T> 194C (350F)] cause the valve body to contract more than the
gate.
Flexible-Wedge Gate
The flexible-wedge gate is the second most widely used type. Although similar to
the solid wedge, the flexible wedge contains a deep annular groove in the gate,
midway between the two seating surfaces. This groove reduces the rigidity of the
gate and allows slight relative flexing between the seating surfaces. This flexing
allows the disc seating surfaces to accommodate some thermal movement or
dimensional misalignment between the gate seats and the body seats. For this
reason, the flexible-wedge gate is more suitable than the solid-wedge gate for
high-temperature applications and is less prone to gate sticking.
Bonnets
The valve bonnet is a pressure-retaining component that supports the valve stem and
operating mechanism and contains the stem-to-bonnet packing gland seal system. The
bonnet joint provides a pressure-tight closure between the process fluid and atmosphere
at the junction between the bonnet and the valve body. The primary bonnet types include
bolted, welded, pressure-seal, seal-welded, threaded, union, and screwed. Bolted and
screwed are the most common bonnet types.
Bolted Bonnet
A typical bolted bonnet is shown in Figure 3. The bolted bonnet uses flanged
construction to permit its removal from the valve body, thus giving complete
access to the valve stem, gate, and body seat for maintenance. Because of the
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bolted-flange gasket detail, this design is subject to the same potential leakage
problems as a normal pipe flange. Therefore, the bonnet should be treated in the
same manner as a pipe flange with regard to bolting and gasket selection. The
bolted bonnet is the most practical and commonly used design for process plant
gate valves, and is available in all sizes and ASME/ANSI pressure/temperature
ratings.
Figure 3. Bolted bonnet

Screwed Bonnet
The screwed-in bonnet, as shown in Figure 4, is threaded externally and screwed
into an internally threaded valve body. An alternative design is the screwed-on
bonnet, where the bonnet is internally threaded and screwed onto an externally
threaded body.
Although of low cost and simple design, the screwed bonnet has several
disadvantages. First, the threaded joint is susceptible to loosening when
subjected to vibration or through the application of stem torque on the gland.
Second, screwing the bonnet firmly to the body neck tends to distort the body
neck or bonnet. It is, therefore, more difficult to achieve and maintain a tight seal
with a screwed bonnet valve than with the other types. Therefore, this type of
bonnet should be considered for use only in small [50 mm (2 in.) or less], low
rating (Class 150 or less), bronze and steel valves in clean, non-corrosive, utility
type services.
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Figure 4. Screwed bonnet

Trim
API 600, Steel Gate Valves, Flanged and Butt-welding Ends, defines gate valve trim as
follows:
the stem,
the body seat surface,
the gate seat surface,
the bushing or weld-deposit used for the backseat and stem hole guide, and
small internal parts that normally contact the service fluid, excluding the pin used in
making a stem-to-gate connection (the pin is specified to be an austenitic stainless steel).
Trim material is selected to prevent galling or metal wear of surfaces in sliding contact
with each other, and to minimize corrosion and erosion effects. API 600 lists 16 different
nominal trims by composition of seating materials and their associated hardness.
Stems
The stem raises and lowers the gate. It is designed to withstand the forces that are
generated during movement of the gate, which creates compression and tension in the
stem. However, the stem is not designed to resist the fluid forces that act on the disc.
A loose stem-to-gate connection is provided to permit the fluid forces that act on the gate
to be transmitted to body gate guides, which are provided for that purpose. The stem is
provided with some form of threading, which, upon turning, causes it to drive the gate up
or down. Gate valves can have either a non-rising stem or a rising stem. Figure 5 shows
a non-rising-stem gate valve.
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Figure 5. Non-rising stem Gate valve

The rising-stem gate valve is preferred at Saudi Aramco because the operator can easily
tell if the valve is open or closed by the position of the stem. For example, the stem in
Figure 6 is up. This indicates that the valve is open. If the stem were all the way down, it
would indicate that the valve was closed.
A rising-stem gate valve takes up more space than a non-rising-stem gate valve. If
space is limited, the non-rising-stem gate valve can be used.
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Figure 6. Rising-stem gate valve

Stem Packing System
A stem packing system provides a seal between the stem and the valve bonnet. The
system, as shown in Figure 7, consists of a stuffing box, packing (with or without lantern
ring), gland follower, and packing gland bolts and nuts.
The seal that is formed when the packing is simultaneously forced against the valve
stem and bonnet prevents leakage. This is accomplished by tightening the packing gland
nuts that force the gland follower down and compresses the packing.
A lantern ring is sometimes used where a condensing chamber, injection of sealant, or
purging into the stuffing box is required. The packing system consists of several rings of
resilient, pliable material installed in the stuffing box. Wire is inserted in some packings
to increase their ability to resist extrusion, and to serve as a sacrificial electrode to
prevent depletion of valve stem chrome content or stem pitting that can occur when
packing areas are not completely dry.
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Figure 7. Stem packing system with lantern ring

Seats
The extent to which tight shutoff is accomplished depends directly on the sealing ability
of the seating surfaces, consisting of body seats and gate seats. The ability of two
contacting surfaces to form a seal is a function of the degree of surface conformability
between them. Perfect contact, (i.e., no voids), gives zero leakage, but this cannot be
achieved in practice since an absolutely smooth surface with 100% conformability
cannot be attained. The problem therefore is to achieve sufficient conformability to keep
the leakage rate within acceptable limits. There are two general categories of valve
seats: the hard seat with metal-to-metal contact, and the soft seat with a metal-to non
metal primary contact.
Hard Seats
Hard seats are more economical, can be used at higher pressures and
temperatures, and are the most common seat design used in gate valves. The
body-seating surface may be designed as a separate seat ring, which is threaded
or welded into the valve body, or be integral with the valve body. Figure 8
illustrates the integral seat design. Integral seats will typically be used only for
small size valves. 04-SAMSS-001, Gate Valves, specifies seat ring design
requirements.
Soft Seats
Soft seats provide better shutoff, approaching zero leakage. However, the soft
seat materials that are used (such as Teflon or Viton) limit the maximum-use
temperature of the valve to a level that is much lower than the valve ASME/ANSI
pressure class. When a soft seat is used in a gate valve, the soft seat material
will typically be inserted into a groove that has been machined into the valve
body-seating surface.
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Figure 8. Integral seat

Advantages of Gate Valves
They have good shut-off characteristics.
They are bidirectional.
The pressure loss through the valve is minimal.
Disadvantages of Gate Valves
Gate valves are not quick opening or closing valves. Full-stem travel to open or
close a gate valve requires many turns of its hand wheel or an actuator.
Gate valves require large space envelope for installation, operation, and
maintenance.
The slow movement of the disc near the full-closed position results in high-fluid
velocities, causing scoring of seating surfaces, referred to as wire drawing. It also causes
galling of sliding parts.
Some designs of gate valves are susceptible to thermal or pressure binding,

depending upon the application.
In systems experiencing high-temperature fluctuations, wedge-gate valves may

have excessive leakage past the seats due to changes in the angular relationship between
the wedge and the valve seats caused by piping loads on the valve ends.
Repair or machining of valve seats in place is difficult.
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Plug Valve
Plug valves usually function as block valves to fully shut off or fully open flow. They are
well suited for conditions where quick on/off and/or bubble-tight shut-off are required.
Figure 9A shows a plug valve. Figure 9B shows the P&ID symbols for a threaded plug
valve. Notice that the plug valve is operated by a handle instead of a wheel. The plug
valve operates much faster than a gate valve. Only 1/4 turn of the handle will change the
plug valve from fully closed to fully open.
Most plug valve styles are available in the full range of pipe sizes and materials that are
needed in process plant applications. Soft-sealed styles with full cylindrical plugs are
suitable for double-block and bleed applications.
The soft-seal types, however, may have lower temperature/pressure ratings than those
given in ASME/ANSI B16.34 for steel valves, because of the lesser physical properties
of the soft-seat materials. Soft-seal plug valves are not normally used for throttling
service, since the soft seals are subject to erosion or distortion/displacement caused by
fluid flow when the valve is not in the fully open or closed position. A plug valve is a good
choice as a block valve when used within the limitations noted above, and when bubbletight shutoff or quick on/off operation is required.
Figure 9. Plug Valve
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Function
The plug valve utilizes a cylindrical and usually tapered plug to provide quarter-turn
operation from fully open to fully closed. A hole is provided through one axis of the plug,
connecting the inlet and outlet ports of the valve body for straight-through flow, when in
the open position, and completely blocking flow when rotated 90 to the closed position.
In the closed position, tight shutoff is obtained either by sealant injected into the
plug/body cavity interface, or by resilient, seat-to-metal seat-sealing contact (as in a softseated ball valve).
A plug valve has seven main parts that are listed below: (See Figure 10)
Hand lever
Port
Body
Stem
Bonnet
Packing
Plug
Figure 10. Main parts of a plug valve.
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Types
There are three basic plug valve-types: the lubricated, non-lubricated, and soft-sealed
fire safe. Non-lubricated, non-fire safe plug valves have few applications in process
plants and will not be discussed.
Lubricated Plug Valve
A lubricated plug valve depends on injection of a sealant to prevent leakage
around the plug through the interface between the plug and the body cavity. The
sealant is injected through a pressure fitting into the body cavity and distributed
across all seating surfaces via grooves in the plug. The sealant material must be
compatible with the process fluid, resist breakdown at maximum design
temperature, and retain its fluidity and lubricating properties at minimum design
temperature.
Lubricated plug valves can provide good long-term performance if adequate
maintenance attention can be ensured. With its substantial secondary metal-tometal seating and capacity for restoring tight shutoff by sealant injection, this
valve-type is inherently fire safe with respect to through-leakage. However,
appropriate high-temperature stem packings, gaskets, and supplementary seals
must be provided to ensure fire safe integrity against external leakage.
Soft-Sealed, Fire safe Plug Valve
Fire safe plug valves use a narrow-band primary-seal ring of a soft, resilient
material (such as Teflon) in the annulus between the plug and body cavity to
prevent leakage. A fire-safe soft-sealed plug valve also has a secondary metalto-metal backup seal. This assures positive shut-off capability if the soft seal is
damaged by fire. The maximum temperature limit of the valve is limited by the
soft seal material.
Body
Plug valves are typically of the one-piece body design, with top or bottom entry. Body
styles include the short pattern, regular (reduced-port) pattern, venturi pattern, and the
round-port full-bore pattern.
The short pattern design has the same face-to-face dimensions as Classes 150 and 300
flanged steel gate valves. This pattern is advantageous when replacing existing gate
valves or when there are space restrictions.
Regular pattern (reduced-port) designs have a smaller plug-port area than do full-bore
valves, are less expensive, and represent the most commonly available style. They may
be used in cases where pressure drop is not critical and the service application does not
require scraping.
Venturi-pattern designs provide maximum weight and cost savings, because they have
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the smallest port area for a given nominal valve size. Their use restrictions are the same
as for regular pattern valves. The round-port full-bore pattern is the most expensive for a
given nominal size, but is required where pressure drop is critical or where scraping will
be required.
Plug Styles and Seating Mechanisms
The plug opens or closes the flow path through the valve. A full or reduced-bore hole
through one axis of the plug permits straight-through flow when aligned with the
longitudinal valve axis and flow is blocked when the plug is rotated 90 to the closed
position.
Common plug configurations are the full cylindrical (usually tapered), and eccentriccylindrical segment styles. The most common style is the full-cylindrical tapered plug,
with sealant grooves for the lubricated-type valve or resilient-seat inserts for the softseal-type valve. This configuration is best suited to the constant wedge- seating
mechanism used with lubricated plugs and to the lift-off, turn and reseat design used for
some non-lubricated types.
Seats
The degree of closure afforded by a plug valve depends on the sealing capability of the
plug and body seats. Where tight closure is required, lubricated or soft-seal fire safe plug
valves may be used within the temperature limits of the lubricant or soft-seal material.
For lubricated plug valves, the sealant provides the seal. The second style uses metal
seats with resilient inserts, required for fire safe applications.
Sealant Seating (Lubricated Plugs)
For lubricated plug valves, the sealant is the sealing mechanism as well as the
lubricant for the metal-to-metal seating interfaces. Bubble-tight shutoff can be
obtained when sealant is initially injected. However, sealant pressure will
dissipate with time via slow leakage through the seating interface and periodic
sealant injection is required to maintain tight shutoff, particularly at higher
temperatures. The sealant must be chemically compatible with the process fluid
and have appropriate viscosity for the intended operating temperature.
Advantages of Plug Valves
Simple design with few parts.
Quick to open or close.
Can be serviced in place.
Offers minimal resistance to flow.
Provides reliable leak tight service. Seal can be maintained by injection of sealant or
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by replacement of sleeve, in addition to utilizing the wedging action of a
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tapered plug.
Multiple port design helps reduce number of valves needed and permits change in
flow direction
Disadvantages of Plug Valves
Requires greater force to actuate, due to high friction.
NPS 4 (DN 100) and larger valves require use of actuators.
Reduced port, due to tapered plug.
Typically, plug valves may cost more than ball valves.
Ball Valve
Ball valves usually function as block valves to fully shut off or fully open flow. Ball valves
are well suited for conditions where quick on/off and/or bubble-tight services are
required. The ball valve is available in the full range of pipe sizes and materials that are
needed in process plant applications.
Figure 11A shows a ball valve. Figure 11 B shows the drawing symbol for a ball valve.
Notice that the ball valve is operated by a handle instead of a wheel. The ball valve, like
the plug valve, requires only 1/4 turn of the handle to change the valve from fully closed
to fully open.
Figure 11. Ball valve
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Soft-sealed ball valves are usually suitable for double-block and bleed applications.
However, it is important to note that pressure/temperature ratings for ball valve soft
seats, above ambient temperatures, are usually lower than the ASME/ANSI ratings for
steel valves. This is because of the lower physical properties of the soft-seat materials.
Soft-sealed ball valves are not normally used for throttling service because the valve soft
seats are subject to erosion or distortion/displacement caused by fluid flow, when the
valve is not in the fully open or fully closed position.
The soft-sealed ball valve is a good choice as a block valve when used within the
limitations previously mentioned and when bubble-tight shutoff, double-block and bleed
capability, or the quick on/off feature is required. Where such capabilities are not
required, the ball valve is usually not the best choice in most sizes, because of its higher
cost relative to gate valves.
Function
The ball valve is quick-opening and requires only a quarter-turn from fully opened to fully
closed. A ball is used to permit or block flow. A hole, provided through one axis of the
ball, connects with the inlet and outlet ports of the valve body. With the ball in the open
position, straight-through flow is accomplished. When the ball is turned 90, flow is
blocked. In the closed position, tight shut-off is obtained by resilient, seat-to-metal ballsealing contact, and to a lesser degree, by metal-to-metal contact in metal-seated
models.
A ball valve has seven main parts, which are listed below: (See Figure 12)
Handle
Ball
Stem
Seats
Packing
Body
Seal
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Figure 12. Main part of ball valve

Major Ball Valve Types
There are two basic seating types for process service applications: the non-resilient,
seated (metal, carbon-graphite, etc.) and the soft-sealed, fire safe-type. Only the softsealed, fire safe design will be discussed, since that is the type that is required most
often.
Fire safe ball valves utilize a narrow-band primary-seal ring of a soft, resilient material
(such as Teflon) in the body seats to prevent leakage through the annulus between the
ball and body cavity. Fire safe ball valves also include a secondary, metal-to metal seal
(Figure 13) to assure a positive shutoff capability in the event of fire or other damage to
the soft seals. They also require high-temperature stem packings, cover gaskets, and
external bolting materials to minimize external leakage in a fire situation.
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Figure 13. Seat rings

Body
The body of a ball valve supports the ball, stem, and operating mechanism. There are
several body designs available, but all fall into the two basic categories of one-piece or
multi-piece designs.
Multi-piece Body
In the multi-piece body design, the valve body is circumferentially divided into
pieces, thereby permitting the ball and seats to be installed or removed by
disassembling the body.
The body segments are fastened together by flanging, screwing, or with long
through-bolts. However, the exposed through-bolt arrangement is not
recommended for fire safe valve applications, as direct flame impingement can
cause bolt relaxation and substantial external joint leakage. The multi-piece body
is acceptable for use in all utility services, but must be certified fire safe for use in
hydrocarbon services. The vendor should certify that the body joint(s) are
capable of withstanding full-pipe stresses with no resultant joint leakage.
One-piece Body
There are three basic one-piece body designs: the end-entry, top-entry and
sealed (welded) designs.
In the end-entry-type, the ball and seats are installed axially and retained by an
axial retaining ring. One desirable feature of this design is the ability to eliminate
one external leakage path by eliminating one body joint, usually required on other
types for ball and seat installation. However, this configuration has a safety
hazard in that faulty retention of the ball could result in blowout when the
downstream flange of the valve is disconnected under pressure, unless the
retaining ring design can be locked in.
In the top-entry body-type, the ball and seats are fit into the top of the valve and
retained by a cover or bonnet. This body construction permits inline maintenance
of the valve to the extent of replacing the ball or seats. This is a particular
advantage for valves that are butt-welded, seal-welded, or socket-welded into the
line.
The sealed-body design uses welded construction. The ball and seats are
positioned in the body before welding the body seams. While sealing a valve by
welding eliminates external leakage, it restricts inspection and maintenance of
the valve internals, in that cutting and re-welding of the valve body would be
required to provide internal access.
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Ball
The ball is the mechanism that either permits or prevents flow. A hole bored through one
axis of the ball connects the inlet and outlet ports of the body. By rotating the ball 90, it
is possible to fully shut off or permit flow through the valve. The port opening in valves of
the same size may vary significantly among manufacturers. For example, in the 6 mm
through 50 mm (1/4 in. through 2 in.) sizes, the port size can vary up to 13 mm (1/2 in.)
for a given size. Therefore, when a particular type of port (full or reduced) is required for
a specific application, it should be specified.
Seats
The ability of a ball valve to provide tight closure depends on the sealing capability of the
ball and body seat contact surfaces. In a ball valve, there is a metal-to-metal or metal-tononmetal primary-contact interface. The metal seating surface is always on the ball while
the nonmetallic seating surface, if any, is always on the body seat rings.
Two varieties of soft-seat rings are used in ball valves. In one variety, a metallic seat ring
contains the soft-seat material. In the other type, the ring is fabricated entirely of
nonmetallic material. The following paragraphs describe these rings, service-related
selection considerations, and fire safe features.
Advantages of Ball Valves
Provides bubble-tight service.
Quick to open and close.
Smaller in size than a gate valve.
Lighter in weight than a gate valve.
Multi port design offers versatility not available with gate or globe valves. It
reduces the number of valves required.
Several designs of ball valves offer flexibility of selection.

Can be used in clean and slurry applications.
High-quality ball valves provide reliable service in high-pressure and hightemperature applications.
Force required to actuate the valve is smaller than that required for a gate or
a globe valve.
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Disadvantages of Ball Valves

They are not suitable for sustained throttling applications.
In slurry or other applications, the suspended particles can settle and become
trapped in body cavities causing wear, leakage, or valve failure.
Throttling Valves
Throttling valves are used to regulate the flow, temperature, or pressure of the service.
These valves can move to any position within the stroke of the valve and hold that
position, including fully open or fully closed position.
Butterfly Valve
Butterfly valves are used to control and regulate or throttle the flow. They are
characterized by fast operation and low-pressure drop. They require only a quarter turn
from closed to full-open position.
Figure 14A shows a butterfly valve. Figure 14B shows the drawing symbol.
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Figure 14. Butterfly valve

Figure 15A shows the butterfly fully open. Figure 15B shows the butterfly throttled.
Figure 15C shows the butterfly fully closed.
Figure 15. Positions of butterfly valve

Butterfly valves are produced in sizes ranging from NPS 1 (DN 40) to over NPS 200
(DN 5000). They are usually manufactured in flanged, wafer, and lug, or single-flangetype designs. The welding-end style is a specially engineered valve for a specific
application. Threaded-end, grooved-end, and shouldered-end butterfly valves are also
available to satisfy the joint type selected for the piping system.
Butterfly valves are produced with metal-to-metal seats, soft seats, and with fully lined
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body and disc. The soft seats permit bubble-tight shut-off and the full lining enhances
erosion and corrosion resistance.
Butterfly valves are suitable for low-pressure and low-temperature applications as well
as high-pressure and high-temperature applications. The term high-performance
butterfly valve is intended to signify their suitability for moderate to high pressure and
temperature services. The butterfly valves have a low-pressure drop and high-pressure
recovery factor. They are suitable for low-pressure drop applications. These valves are
extensively used in large water transmission, distribution, and cooling water lines.
Construction of a Butterfly Valve
A butterfly valve has a short circular body, a round disc, shaft, metal-to-metal or soft
seats, top and bottom shaft bearings, and the stuffing box. The valve body may have
flanged ends, lugs, or wafer style. Configurations to be installed between pipe flanges.
The welding-end butterfly valves are usually large and have butt-welding ends.
Sometimes butterfly valves are manufactured in rectangular or square configurations.
The wafer-style butterfly valves are usually available in sizes NPS 12 (DN 300) or
smaller. The limitation on size is essentially imposed by the difficulty of holding the larger
weight valve in place between the flanges. The lug and flanged-end butterfly valves are
available in all sizes and pose no problem in installation between flanges except for the
normal problems associated with warped-flanged surfaces and uneven torquing of bolts.
A butterfly valve has seven main parts, which are listed below (See Figure 16):
Hand lever
Seat
Stem
Body
Neck bushing
Stem seal
Disc
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Figure 16. Main parts of a Butterfly valve

Types of Butterfly Valves
Low Pressure or Concentric Butterfly Valves
In low pressure and low temperature designs of butterfly valves, the disc and
shaft axes are concentric. In open position, the disc divides the flow in two equal
halves, with the disc in the middle and parallel to the flow. These valves are
provided with resilient seats. These valves are available as lined or unlined. Most
commonly used lining and seating materials include: Buna N, Neoprene,
Fluorcel, Hypalon, EPDM, TFE, Viton, among others. The application
temperature is limited by the temperature capability of the resilient material.
These valves are generally produced in Classes 150 and 300.
High-Performance or Eccentric Butterfly Valves:
The disc in high performance butterfly valves is offset from the center of the
valve, and the shaft is also offset from the center of the disc. The offsets provided
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allow the disc to move eccentrically uninterrupted away from or toward the valve
seat. Thus, the uninterrupted motion of the disc until it seats against the valve
seat prevents unwanted wear and tear of the valve seat and disc due to friction
and rubbing of the seating surfaces. Some butterfly valve manufacturers
produce high performance butterfly valves with triple offset, which enhances their
actuation and leak tightness.
Advantages of Butterfly Valves
The following summarizes the advantages of butterfly valves:
The compact design requires considerably less space, compared to gate,
globe, or other valves.
Light in weight.
Quick acting; as a quarter-turn valve, it requires less time to open or close.
It is available in large sizes, ranging from NPS1 to over NPS 200 (DN 5000).
They have low-pressure drop and high-pressure recovery.
Provide bubble-tight service.
Disadvantages of a Butterfly Valve
Throttling service is limited to low differential pressure.
Throttling is restricted to a 30- to 80-degree disc opening. Location of valve,
pipe routing, free, and closed discharge are to be considered while using a
butterfly valve in a throttling application.
Cavitation and choked flow are two potential concerns.
The disc movement is unguided and affected by flow turbulence.
Typical Applications of Butterfly Valves
Concentric or low-pressure and low-temperature butterfly valves, the high-performance
butterfly valves, cover a wide range of applications. These applications include:
Cooling water, air, gases, and other similar applications, such as fire protection,
circulating water,
Corrosive services requiring lined valves
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Food processing, chemical, and pharmaceutical services

Slurry and similar services
High-pressure and high-temperature water and steam services
Throttling service involving low differential pressures, as in cooling water or air
supply systems
Vacuum service
Globe Valve
Conventional globe valves may be used for isolation and throttling services. Although
these valves exhibit slightly higher pressure drops than straight through valves (e.g.,
gate, plug, ball, etc.), they may be used where the pressure drop through the valve is not
a controlling factor.
Figure 17A shows a flanged globe valve fully open with the drawing symbol below.
Figure 17B shows a globe valve in the throttled position. Figure 17C shows the drawing
symbol for a globe valve
Figure 17. Globe valve

Globe valves are extensively employed to control flow. The range of flow control,
pressure drop, and duty must be considered in the design of the valve to avert
premature failure and to assure satisfactory service. Valves subjected to high-differential
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pressure-throttling service require specially designed valve trim. Generally, the maximum
differential pressure across the valve disc should not exceed 20 percent of the maximum
upstream pressure or 200 psi (1380 kPa), whichever is less. Valves with special trim
may be designed for applications exceeding these differential pressure limits.
Types of Globe Valves
Tee Pattern
Globe valves have the lowest coefficient of flow and higher pressure drop. They
are used in severe throttling services, such as in bypass lines around a control
valve. Tee-pattern globe valves may also be used in applications where pressure
drop is not a concern and throttling is required.
Wye Pattern
Globe valves, among globe valves, offer the least resistance to flow. They can be
cracked open for long periods without severe erosion. They are extensively used
for throttling during seasonal or startup operations. They can be strong through to
remove debris when used in drain lines that are normally closed.
Angle Pattern
Globe valves turns the flow direction by 90 degrees without the use of an elbow
and one extra weld. They have a slightly lower coefficient of flow than wyepattern globe valves. They are used in applications that have periods of pulsating
flow because of their capability to handle the slugging effect of this type of flow.
Construction of a Globe Valve
Globe valves usually have rising stems, and the larger sizes are of the outside screwand-yoke construction. Components of the globe valve are similar to those of the gate
valve. This type of valve has seats in a plane parallel or inclined to the line of flow.
Maintenance of globe valves is relatively easy, as the discs and seats are readily
refurbished or replaced. This makes globe valves particularly suitable for services, which
require frequent valve maintenance. Where valves are operated manually, the shorter
disc travel offers advantages in saving operator time, especially if the valves are
adjusted frequently.
A globe valve has ten main parts that are listed below:
Hand wheel
Bonnet
Stem
Stuffing box
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Disc
Packing
Seat
Gland follower
Body
Packing gland
PARTICIPANT
INFORMATION
Figure 18. Main parts of a globe valve

The principal variation in globe-valve design is in the types of discs employed. Plug-type
discs have a long, tapered configuration with a wide bearing surface. This type of seat
provides maximum resistance to the erosive action of the fluid stream.
In the composition disc, the disc has a flat face that is pressed against the seat opening
like a cap. This type of seat arrangement is not as suitable for high differential pressure
throttling.
The conventional disc, in contrast to the plug type, provides a thin contact between the
taper of the conventional seat and the face of the disc. This narrow contact area tends to
break down hard deposits that may form on the seats and facilitates pressure-tight
closure. This arrangement allows for good seating and moderate throttling.
In cast-iron globe valves, disc and seat rings are usually made of bronze. In steel-globe
valves for temperature up to 750F (399C), the trim is generally made of stainless steel
and so provides resistance to seizing and galling. The mating faces are normally heattreated to obtain differential hardness values.
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Other trim materials, including cobalt-based alloys, are also used. The seating surface is
ground to ensure full-bearing surface contact when the valve is closed. For lower
pressure classes, alignment is maintained by a long disc locknut. For higher pressures,
disc guides are cast into the valve body. The disc turns freely on the stem to prevent
galling of the disc face and seat ring. The stem bears against a hardened thrust plate,
eliminating galling of the stem and disc at the point of contact.
Advantages of a Globe Valve
Good shutoff capability
Moderate to good throttling capability
Shorter stroke (compared to a gate valve)
Available in tee, wye, and angle patterns, each offering unique capabilities
Easy to machine or resurface the seats
With disc not attached to the stem, valve can be used as a stop-check valve.
Disadvantages of a Globe Valve
Higher pressure drop (compared to a gate valve)
Requires greater force or a larger actuator to seat the valve (with pressure
under the seat)
Throttling flow under the seat and shutoff flow over the seat
Typical Applications of Globe Valves
Cooling water systems where flow needs to be regulated
Fuel oil system where flow is regulated and leak tightness is of importance.
High-point vents and low-point drains when leak tightness and safety are major
considerations.
Feed water, chemical feed, condenser air extraction, and extraction drain
systems.
Boiler vents and drains, main steam vents and drains, and heater drains.
Turbine seals and drains.
Turbine lube oil system and others.
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Needle Valve
Needle valves generally are used for instrument, gauge, and meter line service. Very
accurate throttling is possible with needle valves and, therefore, they are extensively
used in applications that involve high pressures and/or high temperatures. In needle
valves, the end of the stem is needle point.
Figure 19A shows a needle valve. Figure 19B shows the drawing symbol for a needle
valve.
Figure 19. Needle valve

A needle valve has six main parts, which are listed below:
Needle
Bonnet
Seat
Body
Stem
Hand wheel
Diaphragm Valve
Diaphragm valves are multi-turn, corrosion-proof valves used to control the flow of
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corrosive and dangerous system products. This is accomplished by changing the

position of a flexible diaphragm between the fully-closed and fully-open positions. As
such, they may be operated open, throttled, or closed. Figure 20A shows a diaphragm
valve in the fully-open position. Figure 20B shows a diaphragm valve throttling the flow.
A diaphragm valve is a pack less valve that uses a flexible diaphragm, which functions
as both a closure and a seal. When the compressor is screwed down, it forces the
flexible diaphragm against a seat, or dam, in the valve body and blocks the flow of fluid.
Figure 20C shows a diaphragm valve fully-closed.
All diaphragm valves are bidirectional. Diaphragm valves offer advantages in certain
low-pressure applications not possible with other types of valves. Their fluid passages
are smooth and streamlined, minimizing pressure drop. They are suitable for moderate
throttling applications, and they exhibit excellent leak-tight characteristics, even when
conveying liquids containing suspended solids. The fluid stream is isolated from the
working parts of the valve, preventing contamination of the fluid and corrosion of the
operating mechanism. Since there is no leak path around the valve stem, the valve is
virtually leak tight. This feature makes the valve indispensable where leakage into or out
of the system cannot be tolerated.
The maximum pressure that these valves can be subjected to is a function of the
diaphragm material and the service temperature. In addition, the rated design life of the
valve is influenced by the service conditions. Furthermore, the system hydrostatic test
pressure must not exceed the maximum pressure rating of the diaphragm.
Figure 20. Diaphragm valve
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Construction of a Diaphragm Valve

Diaphragm valves consist mainly of the following (See also Figure 21):
A rigid body formed with a weir placed in the flow path,
A flexible diaphragm which forms the upper pressure boundary of the valve,
A compressor which is used to force the diaphragm against the weir,
The bonnet and hand wheel which secure the diaphragm to the body and
actuate the compressor
Stem
Seat
Diaphragm valves are manufactured in a variety of end connections: welding end socket
or butt welding; flanged, screwed, or threaded; clamp ends or grooved ends; solvent
cement joint ends for themoplastic valves; and male sanitary threaded ends.
Figure 21. Main parts of a diaphragm valve

The valve body is available in two patterns: tee-pattern and angle pattern. Diaphragm
valves are available in a wide choice of body, diaphragm, and lining materials that are
suitable for service with a wide variety of chemicals.
For severe corrosive applications, diaphragm valves are made of stainless steel or PVC
plastics, or they are lined with glass, rubber, lead, plastics, titanium, or still other
materials.
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Adjustable travel stops are used to prevent excessive compression of the diaphragm.
The adjustable travel stop can be enclosed in a temper-proof housing. The temper-proof
housing prevents inadvertent mishandling after the travel length is set. It requires a
special tool to open the housing and to make an adjustment in the travel length. When
an actuator is required, it should be sized and tested by the valve manufacturer and
furnished with the valve as an assembled unit with settings made and verified in the
shop.
Types of Diaphragm Valves
Primarily there are two basic designs of diaphragm valves: weir and straight-through
types. The body interior and the end flanges can be lined to make the diaphragm valves
suitable for corrosive applications. Various lining materials can be used, depending upon
the application.
Weir-Type Diaphragm Valves
In weir-type diaphragm valves, a weir forms an integral part of the valve body.
The weir acts as the valve seat against which the diaphragm is compressed to
stop the flow. This type of diaphragm valve is generally produced in large sizes.
The raised weir reduces the amount of diaphragm travel from the fully open to
the fully closed position, thus reducing the amount of stress and strain in the
diaphragm.
Straight-Through Diaphragm Valves
Variations of the weir diaphragm valve are the straightway (Figure 22) and the
full-bore types. When the straightway valve is open, its diaphragm lifts high for
full streamline flow in either direction. When the valve is closed, the diaphragm
seals tight for positive closure even with gritty or fibrous materials in the line. The
full-bore type of valve is most extensively used in the beverage industry. It
permits ball-brush cleaning with either steam or caustic soda, without opening or
removing the valve from the line.
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Figure 22. Straightway type Diaphragm Valve

Advantages of Diaphragm Valves
Can be used as on-off and throttling service valves.
Offer good chemical resistance due to variety of linings available.
Stem leakage is eliminated.
Does not have pockets to trap solids, slurries, and other impurities. It is suitable
for slurries and viscous fluids.
These valves are particularly suitable for hazardous chemicals and radioactive
fluids.
These valves do not permit contamination of flow medium, thus they are
used extensively in food processing, pharmaceutical, brewing, and other
Disadvantages of Diaphragm Valves
The weir may prevent full drainage of piping.
Working temperatures and pressures are limited by the diaphragm material.
Generally, the pressures are limited to 200 psi (1380 kPa) and temperatures up
to 400F (204C).
The diaphragm may also limit the hydrostatic pressure.
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The diaphragm may experience erosion when used extensively in severe

throttling service containing impurities.
Diaphragm valves are available in limited sizes, usually NPS1 - 12 (DN 15 to
300)
Angle Valve
An angle valve is a globe valve, which is combined with the function of a 90-degree
elbow. Angle valves are used when a throttling valve is needed where the piping makes
a 90-degree turn.
Standard globe valves and angle valves come in class ratings from 150 to 600 and in
sizes from 1/2 inch to 12 inches.
Figure 23A shows an angle valve. Figure 23B shows the drawing symbol for an angle
valve.
Figure 23. Angle valve
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Automatic Control Valves

The automatic control valve is similar to a globe valve because it also is used to control
the rate of flow. However, unlike valves in a piping system that primarily serve to shut
off, drain, fill, or divert, control valves are a part of an automated control system. Figure
24A shows an automatic control valve. Figure 24B shows the P&ID symbols for an
automatic control valve.
Automatic control valves are considered the final control element in an automated and
usually very sophisticated control loop. Aside from the control valve, the loop
consists of a transmitter that measures the variable to be controlled (usually pressure,
flow, level, or temperature) and a controller.
Following an error in the variable to be controlled (such an error being sensed by the
transmitter), the controller sends a signal change to the control valve which, in turn,
responds by altering the flow rate through the valve sufficiently to restore the desired
variable (such as pressure, for example).
As such, automatic control valve has no wheels, handles, or levers to operate. The top
of an automatic control valve has a diaphragm that moves the valve stem. An instrument
control system changes the pressure on the diaphragm to open, close or adjust the
valve. Automatic control valves are found throughout any large plant and are used to
control such things as temperature, flow, liquid level, and pressure.
Figure 24. Automatic control valve
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Check Valves
A check valve is used to prevent backflow. The system product is often required to flow
in one direction only. The check valve prevents the product from ever flowing in the
wrong direction
Swing-Type Check Valve

When the system product is flowing, a disc inside the valve is forced open allowing the
product to flow (See Figure 25). If flow direction changes (backflow), the disc swings
down onto a seat and the valve is closed.
An arrow on the valve body indicates the required direction of flow through the valve.
The valve must be installed with the arrow pointing in the normal direction of product
flow.
Figure 25. Check valve

A swing-type check valve has six main parts as follows (See also Figure 26):
Disc
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Pivot pin
Disc seat
Body
Pivot arm
Flange
INFORMATION
Figure 26. Main parts of a swing-type check valve
Lift Check and Ball Check Valve

The lift check valve and the ball check valve depend upon the force of gravity for
closure. If product flow in the proper direction should stop, gravity will force the ball type
and lift-type of check valves to close.
A lift-type or ball-type of check valve designed for horizontal operation will not function
properly in the vertical position. Figure 27A shows a lift-type of check valve for horizontal
installation, and Figure 27B shows a lift-type of check valve for vertical installation.
Figure 27C shows a ball-type of check valve for horizontal installation, and Figure 27D
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shows a ball-type of check valve for vertical installation.
Figure 27. Lift-type check valve

Another type of check valve is the piston type shown in Figure 28A. Figure 28B shows a
lift-type of check valve while Figure 28C shows a ball-type of check valve. The function
of all check valves, regardless of the type, is to prevent backflow.
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Figure 28. Cross-sections of a check valve

Advantages of Check Valves
They are self-actuated and require no external means to actuate the valve
either to open or close. They are fast acting.
Disadvantages of Check Valves
Since all moving parts are enclosed, it is difficult to determine whether the valve
is open or closed. Furthermore, the condition of internal parts cannot be
assessed.
Each type of check valve has limitations on its installation configurations.
Valve disc can stick in open position.
Pressure Relief Valves

A pressure-relief valve is a self-operating valve that is installed in a process system to
protect against over-pressurization of the system. When excess line pressure is
detected, the pressure-relief valve automatically opens and the excess pressure is
relieved.
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A pressure-relief valve is installed in a process system where excess pressure

constitutes a safety concern of the piping or equipment bursting, or where an abnormal
operating condition could damage the process product. Following the de-pressurization
of the process line to safe or normal limits, the pressure-relief valve automatically closes
again to allow for normal system operation. Pressure-relief valves can be used for both
gas and liquid services, although design varies with each.
Pressure-relief valves are divided into two families according to application. One is relief
valves and the other is safety valve
Note: For more information on pressure-relief valves, refer to next Module 404.02
Verify in-place testing of safety valves
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VERIFY VALVE IDENTIFICATION FROM MARKINGS

The inspector must be able to identify various types of valves, their drafting symbols,
and locate specific valves on a P&ID. Figure 29 shows a portion of a P&ID containing
piping and instrumentation legends and other information relevant to the P&ID.
The Piping Legend in Figure 29 shows the most commonly used symbols and
abbreviations for valves. The Instrumentation Legend in The legends and other
information relevant to the P&ID are always shown on the far right-hand side of every
P&ID.
Figure 29 shows that the title block is located in the lower right-hand corner of the P&ID
and indicates the drawing type, plant name and location, drawing index number, plant
number, and drawing number. The index number, plant number, and drawing number are
useful whenever you need to request a drawing from the Saudi Aramco Working
Drawing Files.
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Figure 29. P&ID
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Figure 30 shows some of the P&ID valve symbols on a larger scale. Each type of valve
has a specific symbol. Normally-closed valves are shown as a solid black shape on the
drawing.
Figure 30. P&ID valve symbols
Valve Identification
Valves are fully described in manufacturers' catalogs and are identified through a
numbering system that contains a full description of the valve in terms of type, pressure
rating, connecting end preparation, and the details of the various trim materials.
Sometimes a valve fails because it has the wrong pressure rating or the valve may not
be constructed of the proper materials for the service in which it is operating. In the case
of new work, the valve material should be verified, to prevent a possible future failure. In
either case, the inspector must be able to determine the pressure rating of the valve and
identify the valve body and trim materials.
On many valves and particularly those for high-pressure applications, the valve class
rating, body and trim materials, and other information are marked on a valve
Identification Plate. Figure 31 shows a typical valve Identification Plate.
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Figure 31. Identification on the valve

Valves are generally identified by manufacturer, class, and size. This information and the
type of metal used in the valve body is either cast or stamped into the valve body (See
Figure 32). In the case of check valves and globe valves, an arrow (==>) is cast into the
body of the valve to indicate required direction of product flow through the valve.
General marking requirements for valves are specified by ASME 16.34 and MSS SP-25.
Additional body and trim material identification is located in SAES-L-008.
Figure 32. Valve showing direction of flow
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Symbols for Metallic and Non-Metallic materials

The symbols for metallic and non-metallic materials are contained in SAES-L-108, MSS
SP-25 and ASTM specifications.
Figure 33. Symbols for Metallic materials

The following Figure 34 illustrates how a valve might be identified.
Figure 34. Valve identification for a gate valve
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INSPECT VALVES
It is the duty of the Inspector to verify that the proper material, classification, type and
installation of valves are in accordance with Saudi Aramco standards, industry standards
and project specifications. These standards are listed in the Applicable Standards
section.
Since valves are one of the most critical elements in all Saudi Aramco plants, the Valve
Inspector has a range of tasks to perform. The valve will be inspected for one of the
following reasons:
It is a new valve to be used in a critical service.

It is a valve that has been rebuilt or repaired. (Includes the valves that have failed and
is inspected to determine the cause of the failure and repairs required. And valves required of
scheduled periodic inspection.)
New Valves (Vendor Inspection)

The Inspector must verify that all valves are purchased from approved manufacturers
listed in SAES-L-102. Otherwise, the vendors must undergo a plant survey and an
engineering evaluation of their products with respect to their capability of meeting Saudi
Aramco specifications and applicable industry standards.
No Purchase Orders shall be placed on any Vendor unless the Vendor has undergone
and passed this technical evaluation.
The Inspector should verify that the selection of valves is normally limited to the
materials, types and sizes that are listed in SAMSS, Class 04, unless no suitable valve is
listed. In this case, proposed new valves must have a satisfactory in-service
performance history at two separate locations for at least two years each.
All vendors, where new or approved, shall implement and maintain an acceptable
Quality Program, equivalent to the ISO 9000 Series, which shall include clearly defined
and documented procedures for the relevant Quality Systems functions. The Quality
Program documents shall be made available to the Buyer's Representative for review
and audit.
The Inspector conduct his work by verifying that all valves are tested, examined and
qualified as specified in the Purchase Order. The purchase order shall include relevant
SAMSS. Testing and inspection shall comply with 04-SAMSS-048, Valve Inspection and
Testing Requirements. Saudi Aramco Inspection Requirements Form 175-043000, 175-
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043600 and 175-043601 (See Addendum), must be attached to the Purchase Order.
Note: Some of the Saudi Aramco Material System Specification standards that cover
valves are included in Addendum A.
The Inspector shall verify that flanged ends have dimensions per the latest revisions of
the standards listed in Figure 35.
Up to 24 inch, ASME Classes:
ASME B16.5
All Sizes, API 6A Classes:
API STD 6A
26 inch to 60 inch, Class 150 RF:
Std. Dwg. AD-036634
Std. Dwg. AD-036991
Std. Dwg. AD-036698
Std. Dwg. AD-036673
26 inch to 48 inch, Class 300 RJ:
Std. Dwg. AC-036484
Std. Dwg. AC-036437
Std. Dwg. AC-036442
Figure 35. Applicable standards for valve flanged ends

Flanges other than those listed above shall comply with ASME B16.47 Series A, unless
otherwise specified. Ring grooves shall comply with ASME B16.20. The gasket contact
surface of all steel raised face flanges shall have a smooth machine finish in the range
3.2 to 6.4 micrometers RA (Roughness Average).
In case of welding, the Inspector must verify that Welding procedures and welder
performance qualifications are approved in accordance with ASME B31.3.
Each individual valve shall be at least tested, examined and qualified as specified in the
industrial standard (such as API, ANSI, AWWA, MSS) referenced in the Purchase Order.
Nothing in this Specification shall be construed as waiving any mandatory requirement of
the referenced Standard.
Valves shall not be painted or externally coated before the shell pressure tests are
completed. Painted valves taken from the Vendor's warehouse or stores may be
retested without removal of paint. Internally epoxy coated valves shall be shell tested
before and after application of the coating. Internally lined valves shall be shell tested
after installation of the lining, unless specified otherwise by the Valves Standards
Committee Chairman.
Pressure Tests
When there is an industrial standard referenced in the Purchase Order, valves shall be
tested to the requirements of that standard (e.g., API, ANSI, MSS, AWWA). In addition
to tests per the applicable standard, testing shall comply with the following:
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For cast steel valves (all sizes and ratings), the shell hydrostatic test shall
consist of three parts:
a)
A primary pressure-holding period of a minimum of 3 minutes.
b)
The reduction of the pressure to zero.
c)
The secondary pressure-holding period of a minimum of 30 minutes.
When specified in the Purchase Order, cast steel valves shall be subjected to a
pneumatic high-pressure shell test of 110% above the maximum allowable
pressure at 100oF (38oC) per API STD 598 paragraph 3.5. The holding time shall
be a minimum of 15 minutes and no visible leakage is allowed.
For steel valves nominal pipe size (NPS) 14 and above, a high-pressure
hydrostatic seat test and a low-pressure 60-100 psig pneumatic seat test shall be
conducted, regardless of pressure rating.
For metal-seated ball valves and metal-seated high performance butterfly
valves, the maximum allowable leakage rates for closure tests shall be in
accordance with the requirements of API STD 598. The maximum allowable
leakage rates for metal seated through conduit gate valves shall be specified in
the Purchase Order.
Regardless of size, valves specified for flare system isolation service shall
receive low-pressure pneumatic seat tests at 5.0 psig. This test shall be
performed in lieu of the 60-100 psig test mentioned above.
When there is a governing industrial standard, but it does not specify test
durations or leakage acceptance criteria, API STD 598 requirements for
durations and leakage shall apply (See Figure 36).
When there is no referenced governing industrial standard, valve testing shall
be in accordance with the following requirements:
Valves NPS 2 and smaller, and non-metallic valves, shall be tested per
Vendor's procedure as approved by the Valve Standards Committee
Chairman.
Metallic valves larger than NPS 2 shall be tested in accordance with API
STD 598 requirements for shell tests and closure tests.
In addition, the Inspector verifies that all resilient soft-seated valves to have zero leakage
as demonstrated by hydrostatic seat valve.
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Figure 36. Valve leakage tests per API 598.
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Hardness Testing
The Inspector shall verify that hardness tests after post-weld heat treatment, when
required by specified service and/or material specification, are conducted by the Vendor
in accordance with ASTM E10 or ASTM E18.
Note: For more information on hardness testing, refer to PEW-401.02 Monitor Heat
Treatment and Hardness Testing module.
Impact Testing
When 04-SAMSS-003 is specified in the Purchase Order, the Vendor shall conduct
impact tests as required by the Specification.
Note: For more information on impact testing, refer to PEW-401.01 Identify Metals
module.
Nondestructive Testing
The Inspector has to verify that all non-destructive testing is conducted per the purchase
order. Acceptance of non-destructive tests shall be the authority of a Level II or Level III
NDT Technician.
Field Installation inspection
Receiving Inspection
The field inspector verifies all inspection documents and any mechanical damage
because of shipping. The Inspector shall verify proper shipment as follows:
All valves shall be completely drained of test fluid and thoroughly dried after
hydrotesting.
Valve end flanges and valve weld ends shall be fitted with plywood covers (See
Figure 37). The cover diameter shall be the same as the outside diameter of the
flange and shall be at least 10 mm thick for valves up to NPS 10 inch and 12 mm
thick for valves NPS 12 inch and larger.
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Figure 37. Valve end protection requirements (12-SAMSS-035)

The raised face portion of the flange and the ring joint groove shall be covered
with heavy grease. A heavy-duty moisture-proof disc shall be fitted between the
greased flange face and the cover. The disc shall have a diameter equivalent to
the inside diameter of the bolt holes.
The ends of threaded and socket weld end valves shall be protected with tight
fitting plastic caps.
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Field Tests
The valve shall be hydro-tested, as per SAES-L-108 and API-598 before it is installed in
the piping system. The field-testing includes the following:
Testing location shall be specified by proponent.
All new valves shall receive a body hydrostatic test prior to installation in the
line.
All new valves designated for isolation service (as specified by the Proponent)
shall be subjected to a high-pressure hydrostatic seat test prior to installation in
the line.
A low-pressure pneumatic seat test at 35 kPa (5 psig) shall be substituted for
the high-pressure hydrostatic seat test for flare system valves.
Buttweld and socketweld end valves in nominal pipe size (NPS) 1- inch and
smaller are exempt from the above field-testing requirements.
Test procedures, pressures, durations, and leakage acceptance criteria shall be
equal to those that the valves were originally purchased to.
Field Installation Limitations

The Inspector shall be aware of the specific valve limitation on different types of valves
as listed in SAES-L-108.
In addition, gate valves with back seats shall not be installed with their stems below the
horizontal except in the following cases:
Clean services
When they function as isolation valves in pressure relief and flare system
piping
When in utility or other similar non-critical services (firewater is considered to
be critical service).
Inside-screw-rising-stem (ISRS) and non-rising-stem (NRS) valves NPS 2 inch and
smaller shall not be used in hydrocarbon services.
Other limitations specific to valve types are listed in the next sections.
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Ball Valves
Welded body type ball valves shall not be used in sizes NPS 4 inch and larger,
except in underwater services.
Where appropriate, lever operated ball valves shall be equipped with a
handwheel or self-locking handle to prevent accidental operation.
Butterfly Valves
Concentric butterfly valves, such as the API STD 609 Category A type (typically
with internal rubber linings), are permitted only in non-hydrocarbon applications.
The use of high performance butterfly valves in hydrocarbon service shall be
limited to a maximum rating of Class 900.
Check Valves
Dual and single plate wafer check and swing check valves shall not be used in
reciprocating pump and compressor suction and discharge services or similar
pulsating services.
A non-slam internal-spring-assisted type check valve shall be installed at the
discharge of pumps and compressors, where un-acceptable level of slamming is
anticipated.
For parallel pump systems with individual pump discharge piping of NPS 20
inch and larger, a hydraulic analysis shall be conducted to verify that the selected
check valves have the correct dynamic response to prevent slamming and limit
pressure surge to an acceptable level. The analysis shall include consideration
of the "worst case" operating mode scenario.
For all sizes NPS 4 inch and above, a turbulence-free minimum distance of 5
pipe diameters upstream and 2 pipe diameters downstream of every check valve
shall be maintained. No pipefittings such as elbows, reducers, tees, etc., or flow
restricting devices such as orifices, control valves, etc., shall be installed in these
zones. Valves in intermittent service and valves in skid-mounted systems are
exempt from these requirements.
Check valves in sizes NPS 3 inch and above shall not be installed in vertical
lines, unless specifically approved by the Chairman of the Valve Standards
Committee. Valves in skid-mounted systems are exempt from this requirement.
Check valves in hydrocarbon service up to Class 600 shall have either a lugtype body with tapped bolt holes or a flanged body. In higher ratings, a flanged
body is mandatory. Wafer-type bodies are not permitted in any hydrocarbon
service.
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Spring-assisted non-slam piston check valves (also referred to as nozzle check

valves) shall be long-pattern with face-to-face dimensions in accordance with API
SPEC 6D. Short-pattern valves shall not be used without the review and
approval of the Chairman of the Valves Standards Committee.
Plug Valves (Hydrocarbon service only)
Flanged plug valves in hydrocarbon service shall be of the inverted lubricated pressure
balanced design, except that Class 150 valves NPS 6 inch and smaller may have a
standard plug with springs for balancing the plug.
Existing Valve Inspection

During visual inspection of existing valves, it is the duty of the Inspector to examine
valves for leaks through, corrosion, erosion, cracking, distortion, bulging, and other signs
of deterioration or equipment failure. Other methods of inspection or testing are usually
performed as a result of a visual inspection.
An inspector should always use a good light source when making a visual inspection.
Sources of good light are:
A three-cell flashlight
100-watt lamp bulb, with extension cord
Reflected sunlight from a mirror

Hidden surfaces and otherwise difficult to reach areas can often be inspected by using a
mirror and a good light source.
Safety during inspection

In general, before a valve is removed from the line, that section of the line containing the
valve should be blanked from all sources of harmful liquids, gases, or vapors. That
section of the line must be depressurized and purged of all oil, toxic or flammable gases,
and vapors.
All possible preparatory work should be done before the scheduled start of inspection.
The inspection tools needed should be checked for availability, proper working condition,
and accuracy. Equipment required for personal safety should be checked for availability
and condition.
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Rebuilt or repaired valve

A valve, that failed is dismantled and inspected to determine the cause of the failure. The
valve is checked for erosion, corrosion and mechanical damage.
During scheduled periodic maintenance inspections, valves in a critical service are
dismantled to permit examination of all internal parts. Body thickness is measured at
locations that were inaccessible before dismantling. Particular attention is given to
locations that show evidence of corrosion or erosion. Valves that operate in severe cyclic
temperature service are checked internally for cracks. After reassembly, the valve is
hydro tested.
Frequently Occurring Problems

When inspecting a valve, the inspector should be alert to the following problems which
commonly occur.
Leaks (Leaking of the process material into the environment)
General corrosion (Uniform loss of the original surface)
Pitting corrosion (Highly localized loss of the original surface)
Stress corrosion cracking (Small cracks caused by a combination of stress and

corrosion acting on a material)
Weld metal zone attack (Local corrosion of welds next to base metal)
Liquid/vapor transition corrosion (Corrosion in the area where a liquid changes to

vapor)
Erosion (Surfaces altered mainly by mechanical means such as abrasion, turbulent

flows and impingement)
Bulging, distortion, and mechanical damage
Broken valve hand wheel or handle
Damaged disc or seats
Stem broken internal to the valve
Damaged flange gaskets or flange face
Foreign material in the valve seating area or upper part of bonnet.
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Figure 38 is a sectional view of a flanged gate valve showing threaded in seat rings.
Areas where problems often occur are indicated and labeled.
When inspecting this valve look for loose seat rings, damaged seating surfaces,
damaged flange faces or gaskets, worn or damaged connection between the stem and
gate. Always inspect all areas that are exposed to the system product for corrosion or
erosion.
Figure 38. Common problem areas on a gate valve
Operating Difficulties
An accumulation of sludge or particles can foul a valve. When a valve is difficult to open
or close, it may be an indication of fouling. Figure 39 shows a valve that has an
accumulation of sludge at points A and B. If too much sludge is accumulated at point A,
the valve will not be able to close completely. If the accumulation is at point B, the
bonnet area, the valve will not be able to open completely.
Sometimes the sludge can be partially removed while the valve is on stream. However
this best method is to dismantle the valve. By dismantling the valve, all parts may be
cleaned and inspected. When badly worn parts are found they can be replaced.
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Figure 39. Sludge accumulation locations in a valve

Other problems that may cause a valve to be difficult to operate include corrosion of the
valve stem or stem threads and excessive tightening of the packing gland bolts. These
areas should always be checked when operation problems occur. See Figure 40.
Figure 40. Other problematic areas in a valve
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Other Problems
A common reaction to a leaky valve is to apply extra force in closing it, but this may
damage the valve. For example, a valve is leaking by the disc. If additional force is
applied to stop the leakage, the disc and seat would be jammed together, creating
excessive pressure on the yoke bushing and bonnet threads. Forcing the valve closed
could cause galling of the valve seats.
Moreover, if the valve were made of brass or any other soft metal, forcing it closed could
not only damage the seat and disc, it could also cause the stem to be bent or the bonnet
threads to be stripped.
Generally, leaking from a valve may be of less concern if it is coming from the stem.
Usually, change of the packing is all what is required.
Leakage through the packing gland is the most common type of valve leakage. The
packing inside the valve stuffing box is compressed by adjusting the packing gland, to
repair this type of leak. If adjusting the packing gland does not stop the leakage, the
valve must be re-packed.
The stem should be inspected for damage. A bent or worn stem can cause leakage even
though the packing is properly adjusted. The stem can be inspected by opening and
closing the valve. The stem should be observed to see if it wobbles back and forth,
which may be an indication that it is bent. On a rising stem valve, it is important to look
for signs of damage or corrosion when the valve is fully open. If there is no apparent
damage, the packing should then be adjusted.
Seat leakage may be caused by:
Improper seat interface.
Cracked seating surfaces.
Incomplete valve closure.
Operator error.
When examining the seating surfaces of butterfly valves, the most vulnerable point for
leakage is opposite the hinges of the disc.
Ball valves that operated for extended period in the partially opened position can
develop leak paths, cavitation damage and erosion. Cavitation occurs when bubbles
form in a liquid product and extend until the cavity collapses.
Pitting corrosion can be initiated by restricted fluid access. This form of pitting corrosion
is also called localized corrosion.
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Embrittlement can occur when in the presence of a severe metal ductility loss due to inservice environments.
Water hammer can also cause damage to valve and valve components. Water hammer
is caused by an abrupt flow change.
When inspecting gate valves that have been used for throttling measure the wall
thickness at the bottom of the valve between the seats. This is an area where serious
deterioration can occur because of turbulence. This is a particularly weak point because
of the wedging action of the disc when the valve is closed. This inspection area is
pointed out in Figure 41.
Figure 41. Turbulence-prone area in a valve

Visually inspect the seating surfaces for defects, which might cause a "passing" leak
when the valve is closed. These inspection areas are pointed out in Figure 42A.
Inspect the wedge guides in gate valves for corrosion and erosion both on the wedge
and in the body. These inspection areas are pointed out in Figure 42B.
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Figure 42. Wedge seating area in a gate valve

Swing check valves can be inspected by removing the cover or cap. The seating
surfaces on both the disc and the valve disc seat ring can be checked for erosion,
corrosion or mechanical damage by feeling them with your fingers. These inspection
areas are pointed out in Figure 43.
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Figure 43. Inspection areas in a swing check valve

The disc Flapper should be checked for freedom of rotation. The nut holding the disc
should be checked for security and the presence of a locking pin, lock washer or tack
weld. The arm should swing freely, and the pivot pin should be inspected for wear. These
inspection areas are pointed out in Figure 44.
Figure 44. Disc flapper inspection areas in a check valve

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Valve flanges should be visually inspected for distortion or dishing. Flange faces should
be cleaned and inspected for evidence of corrosive attack or mechanical damage. These
inspection areas are pointed out in Figure 45.
Figure 45. Flange faces inspection areas in a gate valve

Globe valves are inspected in much the same way as gate valves as the inspector
inspects the same parts of the valve. However, there are some differences between the
gate valve and the globe valve that should be pointed out.
Figure 46A shows a gate valve and Figure 46B shows a globe valve. In a gate valve, the
fluid flow is in a straight line, without bends. In a globe valve, the line of flow changes
direction. With the change of direction, turbulence occurs. Turbulence increases the
pressure drop across the valve. As a result, the globe valve has a higher pressure drop
than a gate valve. In addition, the increased turbulence in the globe valve makes it more
subject to erosion than a gate valve.
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Figure 46. Flow in a Gate and Globe valves

The disc and seat arrangements are different between the gate and globe valve. Figure
47A shows a gate valve disc and seat rings. Figure 47B shows a globe valve disc and
seat ring.
The seats in a gate valve are perpendicular to the line of flow. The seat in a globe valve
is parallel to the line of flow. Note, also, that the direction of flow through the globe valve
is from below the disc. The globe valve should not be installed such that the fluid flow is
from above the disc.
A gate valve has two seats, while the globe valve has only one. In a gate valve the disc
come down between the two seats. In a globe valve, the disc comes down onto the seat.
In a gate valve, there is considerable wear between the disc and seats due to friction. In
a globe valve there is very little wear between the disc and seat due to friction.
When a gate valve is partially open, only part of the gate is exposed to flow erosion.
When a globe valve is partially open, the entire disc is exposed to the flow.
Consequently, erosion of the disc in a globe valve is more uniform than in a gate valve.
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Figure 47. Valve seats in a Gate and Globe valves

The disc on a globe valve is free to turn. Liquid flowing between the seat and disc will
cause the disc to turn. Figure 48 shows the turning action of the disc in a globe valve.
Because of this turning action, point A on the disc will not always contact point A on the
seat ring. As a result, the wear due to contact friction between the disc and seat ring is
more evenly distributed in a globe valve.
Figure 48. Turning action of the disc in a globe valve
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Assurance Tests
After the valve has been repaired and reassembled, it should be hydrostatically tested:
Repairs that affect pressure-containing ability must be followed by a strength test of

the valve body.
A seat test should be performed on valves requiring tight shutoff if the trim has been
repaired or replaced.
A tightness (leak) test shall be conducted at operating pressure after gaskets and/or
packing has been renewed.
Records
When the inspection is complete, a worksheet is filled out defining any repairs to be
made. An entry is also made in the equipment record, and the plant logbook. Figure 49
is an example of an inspection worksheet.
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Figure 49. A typical Inspection Worksheet
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Valve Wall Retirement Thickness

Over a period of time, the valve body wall deteriorates due to erosion and corrosion.
Eventually the wall thickness decreases to a minimum allowable thickness and, at this
time, the valve should be replaced. This minimum allowable thickness is referred to by
Saudi Aramco inspectors as Retirement Thickness or Thickness Minimum. The two
terms have the same meaning and are abbreviated as (tm).
Determining the tm for Valves

Table 1 of API 600 specifies the tm values for steel gate valves. These tm values are
specified in inches. The same values are specified in metric increments in Table 1A. The
inspector can read the minimum thickness from these tables for steel gate valves of
any relevant size and rating.
Figure 50 shows a portion of Table 1. Find the tm for the shell wall of a 1.0-inch gate
valve with a 300-pound rating.
Figure 50. Part of Table 1 (API 600)
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The shaded portions of Figure 51 show that a 10-inch steel gate valve with a 300-pound
rating must have a minimum shell wall thickness of 0.75 inches.
Figure 51. tm determination for valves.
Thickness Measurement
Valve wall thickness is most often determined by Ultrasonic inspection methods (UT).
Actual UT results are compared to the tm to determine if the valve will be safe to operate
until the next scheduled Test and Inspection (T&I). The tm for pressure vessels, pipe,
and valves is the absolute minimum wall thickness allowed for the equipment to remain
in service. A valve must be repaired or replaced if, at the current rate of deterioration, its
thickness will be reduced below the tm before the next T&I.
If corrosion or erosion is anticipated, reference thickness measurements should be
made when valves are initially installed so that corrosion rate and metal loss can be
determined.
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Keeping Thickness Records for Retirement Decisions

The necessity of keeping complete records in a detailed and orderly manner is well
recognized. Properly maintained records will enable an evaluation of service life on any
piping, vessel, fitting, or valve. From these records the general condition of any piping
system can be determined. Such records, when properly maintained, form a permanent
record from which corrosion rates and probable replacement or repairs can be
determined. Figure 52 shows one method of recording thickness readings and other
relevant information.
Computerized record systems are used by most inspection units. A computer program
can be used to assist in a more complete evaluation of recorded information and to
determine the next proposed inspection date. At Saudi Aramco one such computer
program available for this purpose is called PIPE+, Version 3.5.
While the PIPE+ program is designed to evaluate corrosion rates and predict retirement
dates for piping and pressure vessels, it can also be used to evaluate valves. Saudi
Aramco programmers can modify the Pipe+ program by assigning 7,000 for the value of
S in the program formula and multiplying the result by 1.5.
Figure 52. Example of thickness reading records
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EXERCISES
EXERCISE #1. IDENTIFY VALVES

This exercise will familiarize you with the different types of valves used in the piping
systems at Saudi Aramco. Figure 53 contains pictures of assorted valves. From the list
of valve types below, label (with the valve type) the corresponding picture in Figure 53.
Valve Types
Gate
Plug
Ball
Butterfly
Globe
Needle
Diaphragm
Angle
Automatic control
Check
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Figure 53. Different valves for Exercise 1
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EXERCISES
EXERCISE #2. IDENTIFY P&ID VALVE SYMBOLS

This Exercise familiarizes you with the standard Piping and Instrumentation Drawing
(P&ID) symbols used by the drafting department at Saudi Aramco. Figure 54 is an
assortment if P&ID symbols. Match the valve from the list to the corresponding P&ID
symbol in Figure 54. Write the number of the valve in the blank provided adjacent to the
symbol.
Figure 54. P&ID valve symbols for Exercise 2
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EXERCISES
EXERCISE #3. IDENTIFY THE MAIN PARTS OF A GATE VALVE

This Exercise familiarizes you with the main parts of a typical gate valve. Figure 55 is a
cut-away drawing of a gate valve. Place the part number from Figure 55 next to the
correct part name in the blanks provided in the list below. Example: Hand wheel is part
number 1 and has been done for you.
Figure 55. Parts of a gate valve for Exercise 3
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EXERCISES
EXERCISE #4. IDENTIFY THE MAIN PARTS OF A GLOBE VALVE

This Exercise familiarizes you with the main parts of a typical globe valve. Figure 56
shows a cut-away drawing of a globe valve. Place the part number from Figure 56 next
to the correct part name in the list below.
Figure 56. Parts of a globe valve for Exercise 4
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EXERCISES
EXERCISE #5. MEASURE VALVE BORE SIZE AND FLANGE

SIZE
This Exercise gives you practice in measuring the inside diameter of a valve bore and
the outside diameter of a valve flange. The Instructor will demonstrate how to make
these measurements. After observing the Instructors demonstration, practice the
procedure and record your measurements in the space provided on this Exercise Sheet.
Tools Required For This Exercise
I.D. Transfer calipers
O.D. Transfer calipers
Steel rule
Equipment
Small bore flanged gate valve
Materials
Work Aid: Measure Valve Bore and Flange Size
Protective Equipment
Safety shoes, safety hat, safety glasses, coveralls.
Special Safety Hazards
None
Tasks
Bore Measurement
Using the I.D. transfer calipers, measure the inside diameter of the valve bore opening.
See Figure 57, Dimension (a).
Flange Measurement
Using the O.D. transfer calipers, measure the outside diameter of the valve flange. See
Figure 57, Dimension (b).
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EXERCISES
Note: The answers to this Exercise must be supplied by the Instructor after he selects
the specimen valve(s) for measurement.
Figure 57. Outside diameter of flange for Exercise 5
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PARTICIPANT
EXERCISES
EXERCISE #6. LOCATE SPECIFIC VALVES ON A PIPING AND

INSTRUMENTATION DRAWING
This Exercise gives you practice at locating specific valves on a Piping and
Instrumentation Drawing. Figure 58 is a portion of a P&ID for a De-propanizer. Arrows
have been drawn to point out certain valve symbols on the P&ID. Identify the specific
type of valve by placing the correct name of the valve in the space provided adjacent to
each arrow pointing to the valve symbol. Be sure to include the normal operating
position of the valve as indicated by the symbol.
Figure 58. P&ID for portion of a de-propanizer for Exercise 6
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PARTICIPANT
EXERCISES
EXERCISE #7. INSPECT A DEFECTIVE VALVE

This Exercise gives you practice in the visual inspection of a defective valve. The
Instructor will demonstrate the correct procedure to inspect a gate valve. Given a
defective gate valve, the Participant will perform an inspection of the valve, determine
the defects in the valve, and report the results of his inspection.
Tools Required for This Exercise
Inspection tools as required, (see Inspection Tools list in Work Aids)
Equipment
Defective gate valve.
Materials
None
Protective Equipment
Safety shoes, safety hat, safety glasses, coveralls.
Note: The answers to this Exercise must be supplied by the Instructor after he selects
the specimen valve(s) for this Exercise.
Inspection Steps
Review the plant inspection log and equipment inspection record to determine the
symptoms of the valve failure.
Remove any temporary repair materials, such as clamps, bands, plugs, etc., in order
to allow for a complete inspection of the valve.
Inspect the valve externally for any signs of corrosive attack or mechanical damage.
Inspect the flange faces for corrosion or mechanical damage.
Inspect the packing gland nuts, bolts, and follower for corrosion.
Check the adjustment of the packing gland follower.
83
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PARTICIPANT
EXERCISES
Check the valve for ease of operation.
Check the stem, seats, and gate for mechanical damage or corrosion/erosion.
Inspect the gate-to-stem connection.
Inspect the guides on both gate and body for corrosion or erosion.
Inspect the valve body internally for corrosion or erosion.

Complete the following Inspection Report; Record the results of your inspection; make
recommendations for corrective action.
Inspection Report
Valve: Type
Size
Class Rating_________________
Findings:
__________________________________________________________
__________________________________________________________
__________________________________________________________
Recommendations:
____________________________________________________
____________________________________________________
____________________________________________________
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PARTICIPANT
EXERCISE #8. DETERMINE

MINIMUM
VALVE
EXERCISES
WALL
THICKNESS
This Exercise allows you to practice looking up valve wall minimum thicknesses.
1.
6" - 600 psig rating:
Answer:__________ inches
2.
20 - 300 psig rating:
3.
8" - 900 psig rating:
Answer:_________ millimeters
4.
4 - 1500 psig rating:
85
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PARTICIPANT
EXERCISES
EXERCISE #9. IDENTIFY MARKINGS ON A VALVE

This Exercise gives you practice in interpreting markings on the valve and on the
Identification Plate. Figure 59 shows a valve and an Identification Plate. From the
information provided in Figure 59, fill in the blanks below.
Figure 59. Valve identification plate for Exercise 9
86
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PARTICIPANT
EXERCISES
EXERCISE #10. OBTAIN A DRAWING OF A VALVE

A defective valve has been removed from plant G77 for repair. The information on the
valve body is shown in Figure 60. Use this information to obtain a drawing of the valve.
Use Work Aid, Obtain A Drawing of A Valve to help you perform this exercise.
Note: The answers for this exercise depend on the Participant obtaining the correct
drawing for the valve specified.
Figure 60. Valve marking for Exercise 10
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WORK AID 1.
PARTICIPANT
WORKAIDS
TOOLS FOR INSPECTION OF VALVES
ULTRASONIC EQUIPMENT
PORTABLE LIGHTS, INCLUDING FLASHLIGHT
THIN-BLADED KNIFE
SCRAPER
ID AND OD TRANSFER CALIPERS
DIRECT-READING CALIPERS WITH SPECIALLY SHAPED LEGS
STEEL RULE
PIT DEPTH GAUGE MAGNIFYING GLASS WIRE BRUSH SMALL MIRROR
MAGNETIC PARTICLE EQUIPMENT LIQUID PENETRANT EQUIPMENT PAINT

OR CRAYON NOTEBOOK
88
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WORK AID 2.
PARTICIPANT
WORKAIDS
TYPES OF VALVES
Figure 61. Types of valves
89
PEW-404.01
WORK AID 3.
PARTICIPANT
PIPING AND
SYMBOLS
INSTRUMENTATION
WORKAIDS
DIAGRAM
Figure 62. P&ID Symbols
90
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PARTICIPANT
WORK AID 4.
WORKAIDS
DETERMINING TM'S FOR STEEL GATE VALVES

STEPS
1.
Determine the valve size, i.e. 6", 10".
2.
Determine the pressure rating of the valve, i.e. 300 psig, 1500 psig.
3.
Lookup tm in inches from Table 1 of API 600. Lookup tm in millimeters, if

required, from Table 1 A of API 600.
a.
Find the valve size in the first column from the left. The column heading
is:
Valve Size NPS
b.
Move to the right in the row for the correct valve size to the column with
the subhead:
Shell Wall Thickness under the correct heading for the pressure rating.
c.
Read the tm value from the table.
See the example below: tm = 0.75 inches for a 10: - 300 psig rated steel gate valve.
91
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PARTICIPANT
WORKAIDS
92
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WORK AID 5.
PARTICIPANT
WORKAIDS
HOW TO INSPECT A NEW VALVE
Many new valves do not require inspection. However, if the new valve will be used in a
critical service, then it should be inspected. When a new valve is to be inspected a
request for inspection will be issued along with a copy of the purchase order. Purchase
orders are not mandatory for carbon steel, bronze or brass gate valves that are 2 inch
size or smaller.
Steps
1.
Inspect the valve for any mechanical damage that may have occurred during
shipment.
2.
Inspect the valve flange faces, beveled ends or threads for mechanical damage
and/or corrosion.
3.
Measure bore size per ANSI B16.34 Table 3. (See Addendum C)
4.
Measure valve wall thickness per ANSI B16.34 Table 3. (See Addendum C)
5.
Verify that the material used in the manufacture of the valve is the same as
originally specified by the purchase order. If the material of construction is not the
same as specified, then report as Material not in accordance with description.
6.
Verify that the valve conforms to all other specifications of the purchase order.
7.
Witness a valve seat tightness test as specified by the Engineer.

Caution:
8.
The inspector should be sure to verify that the test pressure

is within the valve design test limit.
Record the results of the inspection. Report, in detail, any non-conformance with
specifications. Write an accurate description of material and dimensions in your
report. Make recommendations for corrective action as required.
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WORK AID 6.
PARTICIPANT
WORKAIDS
HOW TO INSPECT A DEFECTIVE VALVE
Steps required to determine the cause of failure:

Steps
Review the plant inspection log and equipment inspection record to determine the
symptoms of the valve failure.
Remove any temporary repair materials, such as clamps, bands, plugs, etc., in order
to allow for a complete inspection of the valve.
Inspect the valve externally for any signs of corrosion or mechanical damage.
Check the adjustment of the packing gland follower. If the follower has been adjusted
nearly all the way down then additional packing may be required.
Check the valve for ease of operation. If the valve is difficult to operate then the
packing may need to be replaced. Whenever the packing is replaced be sure to inspect the
valve stem in the area of the packing box for corrosion or possible wire drawing.
Check the stem, seats, and gate or disc for mechanical damage or corrosion/erosion.
Make sure the gate or disc is properly secured to the stem.
Inspect the valve body internally for corrosion or erosion. Give particular attention to
the area below the gate in gate valves. This area of the gate valve body is subject to
excessive deterioration if the valve has been used for throttling.
Check valves should be inspected to make sure that clappers, hinge pins, bolts, and
cotter pins are free from damage, wear, or corrosion and are functioning properly.
After the inspection is complete, analyze your findings and determine the cause of the
failure.
Record the results of your inspection. State the reason for the valve failure and make
recommendations for corrective action.
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PARTICIPANT
WORK AID 7.
WORKAIDS
HOW TO INSPECT A REBUILT OR REPAIRED

VALVE
Steps
If parts have been replaced, verify that the correct parts have been installed, including
correct metallurgy.
Make sure that the valve trim material is correct for the type of service.
Note: The original trim material will be marked on the identification plate:
Inspect any weld build-up area of the valve body for quality of workmanship and
adherence to Saudi Aramco welding standards. Check the built-up area for proper thickness,
using a U.T. meter.
Witness a hydrotest of the valve as specified by the Engineer. The test that is
performed depends on what repairs were made:
a.
Repairs that affect pressure containing ability must be followed by a

strength test of the valve body.
b.
A seat test should be performed on valves requiring tight shutoff if the trim
has been repaired or replaced.
c.
A tightness (leak) test shall be conducted at operating pressure after

gaskets and/or packing has been renewed.
Note: See Addendum-B for valve hydrostatic test pressures for the various valve
Class Ratings.
Record the results of your inspection and recommend corrective action if required.
95
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WORK AID 8.
PARTICIPANT
HOW TO INSPECT
SCHEDULED T & I
WORKAIDS
VALVE
DURING
Certain valves are scheduled to be dismantled and inspected during the scheduled plant
shutdown for a T&I.
Steps
Review the plant inspection log, equipment inspection records and T&l valve repair
sheets for information on the history of the valve.
Inspect the valve externally for any signs of corrosion or mechanical damage.
Inspect the bonnet bolting for corrosion and proper length.
Check the adjustment of the packing gland follower. If the follower has been adjusted
nearly all the way down then additional packing may be required.
Check the valve for ease of operation. If the valve is difficult to operate then the
packing may need to be replaced. Whenever the packing is replaced be sure to inspect the
valve stem in the area of the packing box for corrosion or possible wire drawing.
Check the stem, seats, and gate or disc for mechanical damage or corrosion/erosion.
Make sure the gate or disc is properly secured to the stem.
Inspect the valve body internally for corrosion or erosion. Give particular attention to
the area below the gate. This area of the gate valve body is subject to excessive deterioration
if the valve has been used for throttling.
Measure body thickness at all locations showing evidence of corrosion or erosion.
Inspect check valves to make sure that clappers, hinge pins, bolts, and cotter pins are
free from damage, wear, or corrosion and are functioning properly.
Record the results of the inspection and make recommendations for corrective action
if required.
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PARTICIPANT
WORKAIDS
Figure 63. Main parts of a flanged gate valve
97
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PARTICIPANT
WORKAIDS
Figure 64. Main parts of a welded-end gate valve
98
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WORK AID 9.
PARTICIPANT
WORKAIDS
HOW TO MEASURE VALVE BORE SIZE AND

FLANGE SIZE
This Work Aid will show you how to measure the inside diameter of a valve bore and the
outside diameter of a valve flange. The Instructor will demonstrate how to make these
measurements. After observing the Instructors demonstration, perform the STEPS in
sequence:
Tools Required:
Inside diameter spring transfer calipers
Outside diameter spring transfer calipers.

Equipment:
Small bore flanged gate valve
Materials:
None
Protective Equipment:
Safety shoes, safety hat,
Special Safety Hazards:
None
Figure 65A shows Outside Diameter (O.D.) transfer calibers. Figure 65B shows Inside
Diameter (I.D.) transfer calibers.
Figure 65. Spring transfer calipers
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PARTICIPANT
WORKAIDS
Bore Measurements Steps:
1.
Using the I.D. spring calipers, adjust the gap between the points until calipers
can be placed in the bore of the valve.
2.
Place the points of the calipers into the valve bore.
3.
Open the calipers until the points just touch the inside wall of the valve as shown
in Figure 66A.
Note: You will know when the calipers are correctly adjusted when the points
just touch but do not drag as you turn the calipers from side to side.
4.
Remove the calipers from the bore.

Note: Be sure not to disturb the adjustment when removing the calipers from
the bore.
5.
Measure the gap between the points with a steel rule as shown in Figure 66B.
Figure 66. Bore measurement
100
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PARTICIPANT
WORKAIDS
Flange Measurements Steps:
1.
Using the O.D. spring calipers, adjust the gap between the points until calipers
can be placed over the end flange of the valve.
2.
Place the points of the calipers over the valve flange.
3.
Close the calipers until the points just touch the outside edges of the flange as
shown in Figure 67A.
Note: You will know when the calipers are correctly adjusted when the points
just touch but do not drag as you move the calipers from side to side.
4.
Remove the calipers from the flange.

Note: Be sure not to disturb the adjustment when removing the calipers from
the flange.
5.
Measure the gap between the caliper points with a steel rule. See Figure 67B.
Figure 67. Flange measurements
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PARTICIPANT
GLOSSARY
GLOSSARY
actuator
The mechanical, hydraulic, electric or pneumatic device or

mechanism used to open, position, or close a valve.
automatic control
The control of fluid flow or of a process variable by the

combined use of a valve, actuator, and sensing device.
The valve is controlled in response to process changes
without operator intervention.
backflow
Fluid or gas flow, which is opposite to the direction of flow

for normal operation of the system process.
backseat
A seat on the bonnet, which contacts a corresponding

seating surface of the stem when the stem is fully
retracted.
body end
That portion of the valve body which is adapted for

connection to piping
body end port
The flow opening at the body end
body flange
The flange on a valve body to which the bonnet or cover is

bolted.
body plug
A threaded pipe plug designed to seal a tapped hole in the

body of a valve.
body seat
See seat
bolted bonnet
A valve construction in which the bonnet is bolted to the

valve body.
bonnet
A cover plate which is attached to the body by bolting.
bonnet
A valve body closure component which contains an

opening for the stem
bonnet bolting
The bolting that secures the bonnet to the valve body.
bonnet flange
The flange on a bonnet through which the bonnet is bolted

to the valve body.
bore
The inside diameter of the body end port
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PARTICIPANT
GLOSSARY
clapper
The closure member of a check valve.
closure member
That part of a valve which is positioned in the flow stream

to permit or to obstruct flow, depending on closure position.
It may also be called a disc, wedge, plug, ball, gate, or
other functionally similar component.
coke
A residue left after petroleum has been distilled to dryness.
cold working pressure
The maximum pressure at which a valve is allowed to be

used at ambient temperature.
composition disc
A valve closure member containing a non-metallic

component to seal off the flow.
compressor
In a diaphragm valve, a rigid member attached to

the valve stem to support the diaphragm and to
force it against the dam.
corrosion
The incremental deterioration of a metal by a

chemical or electrochemical reaction with its
environment.
critical service
A piping system or a portion thereof which handles a fluid

which would be extremely hazardous to anyone who might
come in contact with it. A service is determined to be
critical because of high temperature (650 degrees F or
higher), high pressure (500 psi or greater) or toxic or
corrosive nature of the fluid being handled.
diaphragm
A valve component consisting of a flexible sheet of

material arranged to contain a fluid. Mechanical or
pneumatic forces may be applied to deform the
sheet of material and restrict the fluid flow.
diaphragm actuator
A fluid powered actuator which uses hydraulic or

pneumatic fluid pressure acting on a diaphragm to
develop force to move the valve closure member
disc
See closure member
erosion
The incremental deterioration of a material caused

by the abrasive effect of a fluid flowing over the
surface of the material
flange
A circular collar designed to permit a bolted connection

between similar collars.
flange facing
The geometry of the mating surface of a flange.

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PARTICIPANT
GLOSSARY
flanged ends gate
Refers to a type of connection on a valve, used for joining

to other components with mating flanges.
gate
The closure member of a gate valve.
gland follower
The element used to compress the packing of a

mechanical joint.
gland
See packing gland and gland follower.
hammer Test
A test method in which a hammer is used to strike

components of a piping system to detect possible defects.
Such defects as areas of reduced wall thickness, burned
areas, loose joints, and Intergranular cracking may be
revealed.
handwheel
A valve component in the shape of a wheel which attaches

to the top of the valve stem and allows for manual
operation of the valve by hand.
hinge
In a swing check valve, The pivotal element that supports

the disc assembly relative to the to the body seat.
hinge pin
A pin which supports the disc of a swing or Tilting disc

check valve.
historical records
Any previous inspection, maintenance, or repair records on

the equipment.
holed-through Leak
A fluid leak through the wall of the valve body or at the

valve flanges into the surrounding atmosphere.
hydrotest
A nondestructive testing technique in which water is used,

under pressure, to test a valve for leaks. Refer to AES-A004 and API 598 for further information.
impingement
The action of solid particles in the fluid striking against the

valve wall at points where the direction of fluid flow
changes. This action causes increased rates of erosion
and corrosion.
Inside screw, RS
A type of gate or globe valve design where the stem has

both rotary and axial motion and rises as the stem is
turned. The stem threads are between the stem packing
and the closure unit.
inside screw, NRS
The disc rises on the threaded part of the stem instead of

the stem rising through the bonnet. The stem does not rise
or descend as the stem is turned.
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PARTICIPANT
GLOSSARY
leak
With respect to valves, there are basically two types of

leaks: 1. A "passing" leak which is a leak from one side of
the valve closure member to the other. 2. A "holed through"
leak which is a leak through the wall of the valve body or at
the valve flanges into the surrounding atmosphere.
mechanical damage
Any type of physical damage to equipment that is caused

by other than erosion or corrosion. Examples: scratching,
bending, gouging, warping.
NDT
Nondestructive Testing. It is the preferred method of testing

and inspection in the petroleum industry which allows
inspection while the equipment is in use. e.g. Visual (VT),
Penetrant (PT), Magnetic Particle (MT), Ultrasonic (UT),
Radiographic (RT), Hydrostatic, (HT).
NRS
Non-rising-stem
needle valve
A type of throttling valve which has a sharply tapered plug

allowing it to give very precise control of flow. Generally
used in instrumentation piping and chemical injection flow
control.
non-rising stem (NRS)
A valve stem that does not move into or out of the valve
body when the valve is actuated.
P&ID
Piping and instrumentation diagram.
PSI
Pounds per square inch,
PSIG
Pounds per square inch gauge.
packing assembly
A stem sealing system consisting of deformable material

of one or more mating deformable elements contained in
a chamber which may have manually adjustable
compression means to provide an effective seal
packing box
See packing chamber.
packing chamber
The part of the packing assembly containing the packing

used to seal against leakage around the stem or shaft.
Also call stuffing box or packing box.
packing
Deformable material which provides a seal around a

movable penetration through a pressure boundary.
packing gland
Element used to compress packing. Also called a packing

follower.
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PARTICIPANT
GLOSSARY
passing, leak
A "passing" leak is a leak from one side of the valve

closure member to the other.
plug
A closure member used in a plug valve.
plug type disc
A type of disc used in a globe valves; tapered plug disc

and cone shaped seat surface.
pneumatic
Moved or operated by air pressure.
pneumatic actuator
A device which converts pneumatic (air) pressure into

mechanical motion and force to move the valve closure
member.
positive shut-off
See tight-shut-off, TSO.
quarter turn valve
A valve whose closure member rotates approximately 90

degrees to move from full open to the full closed position.
raised face
The projecting annular surface on certain types and

classes of flanges which projects above the bolting ring
and provides the gasket compression area.
regulating valve
A valve designed to control the flow rate or fluid pressure

of the material flowing through the valve.
relief valve
An automatic pressure relieving valve which is actuated

when the internal pressure exceeds a set value (pressure)
designed for liquid service.
remote control
System for actuating a valve from a location distant from

the valve.
ring joint
A bolted flange design in which the adjacent flange faces

contain grooves designed to receive a shaped, continuous
ring arranged in such a way that the ring is compressed by
the mating flange grooves to provide a seal.
rising stem (RS)
A valve stem which moves into and out of the valve when
the valve is actuated.
scale
A coating, layer, or incrustation forming on the surface of

metals exposed to extreme heat or mineral rich fluids.
Example: sulfate and calcium that is deposited on the
interior of a boiler in which water is heated.
screwed end
See threaded end.
seat
That portion of a valve against which the closure member

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PARTICIPANT
GLOSSARY
presses to effect shut-off.

seat insert
Material inserted into the seat face to provide improved

sealing. Usually a resilient material.
seat ring
A separate piece inserted in the valve body to form a seat

against which the closure member engages to shut off
flow.
seating surfaces
The contacting surfaces of the closure member and seat

which effect valve closure.
shaft
See stem.
shell
the principal pressure containing portion of a valve which

has end ports adapted for piping.
slurry valve
A valve that is designed to handle solids entrained in

liquids.
solid wedge
A gate valve design using a one piece disc or wedge not

designed for flexibility.
split wedge
A two-piece wedge used in a gate valve with non-parallel

seats
stem
A valve component to which motion is imparted outside the

valve assembly to move the closure member inside the
valve.
stuffing box
See packing chamber.
system product
The type of fluid that is being processed and carried in the

piping system of a petroleum processing facility.
T&l
Test and Inspection. A scheduled plant shutdown for the

purpose of testing and inspecting the entire plant
processing and piping
thickness minimum (tm)
The minimum wall thickness allowed for a valve to remain

in service. (When a valve wall deteriorates to the minimum
thickness, the valve should be replaced.)
threaded end
Type of end on a valve, fitting, or pipe which permits parts

to be joined by engaging external and internal threads.
throttling
A reduction of flow through a valve by partial closure.
throttle valve
A type of valve which is used to regulate the flow of fluid

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PARTICIPANT
GLOSSARY
through the piping system.

(to) throttle
To reduce or control the flow of fluid through a valve.
tight-shut-off (TSO)
A complete shut-off of the flow without any leak-through

(passing) from the input port to the output port.
toxic
Poisonous to humans upon external or internal contact. Of

or related to poison.
trim
Functional parts of a valve which are exposed to the line

fluid. Usually refers to the stem, closure member, and
seating surfaces
valve
A device which isolates or controls fluid direction or flow

rate. Synonyms: stop, cock, faucet, tap.
valve body
The principal pressure containing shell of a valve which

has end ports adapted for piping
valve, port
The flow opening in a valve.
valve stem thrust
The force required to actuate a linear movement of a valve

stem.
valve stem torque
A torque required to actuate a rotary movement of the

valve stem.
wafer valve
A valve, designed to be installed between flanges, which

has a short face-to-face dimension in relation to the
pipeline diameter.
wedge
A gate valve closure member whose seating surfaces are

inclined to the direction of thrust so that can be
mechanically forced into sealing contact.
wedge gate valve
A gate valve design in which a wedge shaped closure

member is forced between angled seats to stop flow.
yoke
That part of a valve assembly used to position the stem nut

or to mount the valve actuator.
108
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PARTICIPANT
ADDENDUM
ADDENDUM A. APPLICABLE SAMSS
109
PEW-404.01
PARTICIPANT
ADDENDUM
04-SAMSS-001 Gate Valve

This specification, along with the purchase order, defines the minimum requirements for
steel, bolted bonnet, pressure seal bonnet, flanged and butt-welding end gate valves of
outside screw and yoke (OS&Y) construction. Included are nominal pipe sizes (NPS) 1
through 24 for Classes 150 through 2500, as covered by API STD 600, with the addition
of the following sizes:
26 through 60 inch Class 150
The valves covered by this specification shall be suitable for wet sour liquid or gaseous
hydrocarbon services with design temperatures between -18 and 400 C.
04-SAMSS-002 Globe Valves
steel, bolted bonnet, pressure seal bonnet, flanged and butt-welding end globe, angle
globe, "Y" pattern globe and globe stop check valves, of outside screw and yoke (OS&Y)
construction, in nominal pipe sizes (NPS) 1 and larger in Classes 150 through 2500.
Valves covered by this specification shall be suitable for wet, sour liquid or gaseous
hydrocarbon services with design temperatures between -18 and 400C.
04-SAMSS-003 Additional Requirements for Low Temperature Valves
This specification, along with the purchase order, defines the minimum additional
requirements for steel valves in services with minimum design temperatures in the range
of -18 deg C to -45 deg C. All requirements as stated in the specifications attached to
the purchase order remain fully applicable except as modified herein.
04-SAMSS-005 Check Valves, Swing Type
This specification, together with the Purchase Order, covers the minimum requirements
for steel, bolted bonnet, flanged and buttwelding end, swing check valves in 2 inches
nominal pipe size (NPS) and larger for ASME Classes 150 through 2500.
Valves covered by this specification shall be suitable for wet, sour liquid or gaseous
hydrocarbon services with design temperature between -18 and 400C.
04-SAMSS-041 Expanding Plug Valve
This specification together with the Purchase Order covers the minimum requirements
110
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PARTICIPANT
ADDENDUM
for steel, double block and bleed, non-lubricated plug valves with retracting soft seals
(expanding plug valves) in nominal pipe size (NPS) 2 through 36 inch for ASME Classes
150 through 900.
Valves covered by this specification shall be suitable for non-sour hydrocarbon services
between temperatures of -18 and 120C.
04-SAMSS-042 4-Way Diverter Valve
steel 4-way diverter valves with resilient seats for bi-directional meter prover systems in
nominal pipe sizes (NPS) 2 through 24 inch for ASME Classes 150 through 600.
Valves covered by this specification shall be suitable for non-sour hydrocarbon services
up to a maximum temperature of 120C.
04-SAMSS-049 Inspection and Testing Requirements for API SPEC 6A, 10000 PSI
Valves
This specification establishes the minimum quality control and testing requirements for
API SPEC 6A, 10000 PSI Valves and Chokes, 1-13/16 inch and larger, which may be
used in downstream of the wellhead and tree assembly.
04-SAMSS-050 Gate Valves, Through Conduit Type, API SPEC 6D
This Specification along with the Purchase Order covers the minimum requirements for
steel, soft-seated, full bore, slab gate, through-conduit type gate valves in nominal pipe
sizes (NPS) 2 inch and larger for ASME Classes 150 through 2500.
\Valves covered by this Specification shall be suitable for wet, sour liquid or gaseous
hydrocarbon services between -18 and 120C. For Low Temperature Service From
-45C to -18C, 04-SAMSS-003 should be applied.
04-SAMSS-051 Ball Valves, API SPEC 6D
soft-seated, steel, flanged and butt-weld end, trunnion-supported ball valves in nominal
pipe sizes (NPS) 2 inch and larger for ASME Classes 150 through 2500; and floating ball
valves up to and including NPS 4 inch in ASME Classes 150 and 300.
Valves covered by this Specification shall be suitable for wet, sour liquid or gaseous
hydrocarbon services from -18 to 120C. For Low Temperature Service From -45C to
-18C, 04-SAMSS-003 shall be applied.
111
PEW-404.01
PARTICIPANT
ADDENDUM
04-SAMSS-052 Ball Valves, API SPEC 6A

soft-seated, flanged end, trunnion-supported, full bore ball valves in nominal sizes 2-1/16
inches and above in API SPEC 6A Rated Working Pressures (ratings) up to 5000 psi.
Valves covered by this Specification shall be suitable for wet, sour liquid or gaseous
hydrocarbon services between -18 and 120C.
112
PEW-404.01
PARTICIPANT
ADDENDUM
ADDENDUM B FORMS SA-175
113
114
115
116
117
ADDENDUM C ASME B16.34 TABLE 3
118
119

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Inspect Valves

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INSPECT VALVES

S.U. BASHA, S. CAVE, M. AKKAD

VERIFY VALVE IDENTIFICATION FROM MARKINGS

EXERCISE #1. IDENTIFY VALVES

TOOLS FOR INSPECTION OF VALVES

PIPING AND INSTRUMENTATION DIAGRAM SYMBOLS

DETERMINING TM'S FOR STEEL GATE VALVES STEPS

HOW TO INSPECT A NEW VALVE

HOW TO INSPECT A DEFECTIVE VALVE

HOW TO INSPECT A REBUILT OR REPAIRED VALVE

HOW TO INSPECT VALVE DURING A SCHEDULED T & I

HOW TO MEASURE VALVE BORE SIZE AND FLANGE SIZE

ADDENDUM C ASME B16.34 TABLE 3

Identify valves and valve parts.

Verify valve identification from markings

IDENTIFY VALVES AND VALVE PARTS

Shut off or open a system to fluid flow

Regulate or throttle any fluid flow

Valve installation may be in the normally-open position or the normally-closed position,

Automatic control valves

Pressure relief valves

Speed of operation required

Amount of positive shut-off required

Highly erosive or corrosive service

Temperature of the process material

Pressure in the piping system

Amount of vibration present

General Requirements for Valves

Valve Inspection and Testing Requirements

Regulated Vender List for Valves

Control Valve Seat Leakage

Valves - Flanged, Threaded and Welding End

Pipe Flanges and Flanged Fittings

Valve Inspection and Testing

Specifications for Well Head , Christmas Tree Equipment

Specification for Pipeline Valves

Butterfly Valves Lug Type, Wafer Type

Bypass and Drain Connection Standard

Standard marking systems for Valves

04- SAMSS- 001

04- SAMSS- 002

Additional Requirements Low Temperature Valves

Check and Swing Valves

General Requirements for valves

Expanded Plug Valves

4 Way Diverter Valves

Valve Inspection and Testing Requirements

Inspection and Test API Valves

04- SAMSS- 050

Gate Valves Through Conduit API Spec 6D

Ball Valves API 6D

04- SAMSS -052

Ball Valve API 6A

Valve Material Certification requirements, Forms 043600,

High-performance butterfly valve

Figure 1. Flanged gate valve

Figure 2. Main parts of a gate valve

Figure 3. Bolted bonnet

Figure 4. Screwed bonnet

the body seat surface,

the gate seat surface,

Figure 5. Non-rising stem Gate valve