Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.

2
SC-GCM-95 CM Issue 2 © Copyright 2005 Spirax-Sarco Limited

Module 12.2
Isolation Valves -
Rotary Movement

The Steam and Condensate Loop 12.2.1

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Rotary Movement Valves

Rotary movement valves, often called quarter-turn valves, include ball valves and butterfly valves.
Regardless of the type of rotary movement valve, the obturator rotates about an axis perpendicular
to the direction of flow. Fluid may flow through the obturator, as is the case with ball valves, or
around it, as with butterfly valves. Rotary movement valves tend to have a simple operating
mechanism and are therefore easy to automate and maintain.

Ball valves
Ball valves were developed during World War II and were initially intended for use in aircraft
fuel systems, where weight and space are at a premium. They consist of a body which houses a
rotating ball which has an orifice or bore machined directly through it. The ball is located in the
body by two sealing rings.
Rotation of the ball through 90° opens and closes the valve and allows fluid to flow directly
through the orifice. In the closed position, the blank sides of the ball block the inlet and the
outlet preventing any flow. There are two basic designs of ball valves – the floating ball design,
which relies on the valve seats to support the ball, and the trunnion mounted ball, which uses a
trunnion to support the ball. Trunnion mounting is used on larger valves, as it can reduce the
operating torque to about two-thirds of that provided by a floating ball.
Conventionally, the handle that is attached to the ball is in-line with the axis of the pipe when the
valve is open; conversely, if it is at right angles to the pipe axis, this indicates that the valve is
closed.

End view of the ball within the valve at different

stages of rotation

Stem seals Valve Valve Valve

Stem fully open ½ open fully closed

Ball

Fluid passes
freely through
the orifice
Seals
Fig. 12.2.1 Ball valve (shown in its open position)

Ball valves are available as reduced bore or full bore. Full bore valves have an orifice that is the
same size as the diameter of the pipe, whereas in reduced bore valves, the orifice diameter is less
than that of the pipe. Full bore valves cost more than reduced bore valves, and they should be
used where the pressure drop across the valve is critical or where ball valves are used upstream
of flowmeters. Full bore valves can be used in flowmeter applications to minimise fluid turbulence
upstream of the measuring device.
In order to insert the ball into the body, three different types of assembly exist. Not only does the
type affect the ease of assembly, but it also influences the maintainability of the valve.

12.2.2 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

o Two and three piece valves - The body of the valve is split in one or two places in the same
plane as the valve flange, and these pieces are bolted together. This has the advantage of
simplified, in-line maintenance.
o Top entry valves - The ball is inserted through a bonnet in the top of the valve. This facilitates
in-line maintenance.
o Single piece valves - The ball is enclosed in the body by an insert fitted along the valve’s axis.
This eliminates the possibility of body joint leakage and any chance of disconnection whilst in
service, but when maintenance is required, the whole valve has to be removed from the
pipeline.

(a) Single piece ball valve

(b) Three piece ball valve

(c) Two piece ball valve

Fig. 12.2.2 Single piece (a) three piece (b) two piece (c) ball valves

The Steam and Condensate Loop 12.2.3

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

The choice of seat material determines the conditions for which a particular ball valve is most
suited. Although new seat materials are continually being developed, Table 12.2.1 lists some of
the more common materials in use today.
Table 12.2.1 Common ball valve seat materials
Application Seat material Maximum operating temperature
PTFE 200°C
Low temperatures
Carbon reinforced PTFE 230°C
High pressures Polyetheretherketone (PEEK) 250°C
High temperatures Metal 1 000°C

Ball valve options

Ball valves can be produced with a number of options to meet the demands of a wide variety of
applications:
o Actuators - Ball valves, and indeed all rotary valves, are suitable for automation. This is usually
accomplished by using either an electrically or pneumatically operated actuator. The actuator
is connected to the valve through a linkage kit. Although not essential, an ISO standard mounting
pad enables the linkage kit to be installed without dismantling the valve, which maintains
valve integrity. Refer to Module 6.6 for more information on actuators.
o Firesafe - As ball valves are commonly used in gas and oil pipelines, it is essential that the
valves used in such applications are firesafe. A valve is considered firesafe if, when exposed to
fire conditions, it will continue to provide minimal leakage through the seat and stem, and
provide effective shut-off during or following a fire or exposure to excessive temperatures.
Standards relating to fire-safety are set out in BS 6755 and API RP 6FA.
The main concern is that burning temperatures will destroy soft seats and seals; a number of
methods have been developed to overcome this. One approach is to include secondary metal
sealing surfaces behind the polymeric seats as an integral part of the body. When exposed to
burning temperatures, the seat begins to deform and the pressure of the process media displaces
the ball so that it extrudes the polymeric seat (Figure 12.2.3(b)). When the seat has been
completely destroyed, the ball will seat against the body metal sealing surface, providing a
tight shut-off (Figure 12.2.3(c)).

PTFE
Body seal
Ball

(a) (b) (c)

PTFE seal intact PTFE seal melting PTFE seal destroyed and
a metal-to-metal seal
is established
Fig. 12.2.3 Operation of a firesafe ball valve

In addition to the inherent safety of the seating mechanism, the stem seal must also be capable
of preventing leakage to atmosphere under ‘fire’ conditions. This can be achieved by using
high temperature seals made from flexible graphite or Grafoil®; alternatively, a bellows sealed
arrangement can be used (see Figure 12.2.4).

12.2.4 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Flexible linkage from drive to valve

Bellows

Fig. 12.2.4 A bellows sealed ball valve

o Clean steam valves - A number of applications exist that require the valve to be of a ‘clean’
design; these include steam applications where there is direct injection of steam into the
product and process fluid lines in the biotechnology, food and electronics industries. The main
area of concern in such applications is the space between the body and the ball; process fluid
may accumulate in these spaces leading to contamination and corrosion. This can be overcome
by inserting cavity fillers in these spaces. The cavity filler may be an integral part of the seat or
a separate component in the valve assembly. Furthermore, ball valves used in clean steam
applications should be made from stainless steel with a good surface finish (less than 81
microns Ra is recommended).

o Throttling applications - When ball valves are used in throttling applications, high velocity
flow can impinge against a localised area of the ball and seals, causing premature deterioration
of the seating material. Modifications to the standard design are required for ball valves to be
used for throttling; these include the use of metal seats, hard coatings and, sometimes,
modifications to the ball, to give a characterised flow pattern.

The Steam and Condensate Loop 12.2.5

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Butterfly valves
Although there are many different designs of butterfly valve, they all consist of a disc that rotates
on a shaft at right angles to the fluid flow. When open, the disc is edge-on to the flow and the
fluid passes around it, offering limited resistance. In the closed position, the disc is rotated against
a seat in the body of the valve.
Butterfly valves usually take up little more room than a pair of pipe flanges, and are therefore
an attractive alternative to the ball valve where space is limited. In fact, some butterfly valves
are designed specifically for insertion between pipe flanges, these are known as wafer butterfly
valves.

Fig. 12.2.5 Butterfly valves

The main disadvantage of butterfly valves is that the shut-off is not as tight as that achieved by
other valve types. This can be alleviated to an extent by offsetting the axis of rotation of the disc
and using pressure assisted seats. By using an offset axis of rotation, a ‘camming’ action is generated,
which means that the disc creates a tight seal with the seat during the last few degrees of shut-off.
These high performance or eccentric-type butterfly valves have improved shut-off capabilities
and their design enables them to be used for throttling.
For steam applications, butterfly valves have largely been superseded by ball valves. Butterfly valves
are more commonly used in liquid systems or where space is limited. The compactness of butterfly
valves means less material is required and they are therefore ideal where the application specifies
the use of costly materials, for example, in seawater applications where nickel is specified.

12.2.6 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Selection and sizing of isolation valves

A process fluid must be fully contained in a properly designed piping system to avoid endangering
personnel and the environment, and contamination of the fluid itself. The pipeline system can
have many potential leak paths, such as pipe joints, seams, equipment connections and, most
importantly, valves. Valves can be one of the biggest contributors to plant problems if they are
wrongly selected or are poorly designed or manufactured. Furthermore, a valve, when selected
correctly for the application should last at least the life of the plant, if maintained properly.
When selecting an isolating valve for a particular application, a number of factors need to be
considered; these are shown in Table 12.2.2, along with the valve selection parameter that is
affected.
Table 12.2.2 Factors affecting the selection of an isolation valve
Factors affecting the selection
Areas of concern Affected parameter
of an isolation valve
Fluid – liquid or gas
Pressure Type of valve
Temperature Material of construction
Process medium
Flowrate Maintainability
Corrosive Valve size
Abrasion
Speed of operation
Fails – safe
Functional requirements Type of valve
Frequency of operation
Emission loss to atmosphere
Manual
Pneumatic
Type of valve
Method of operation Electric
Type of actuator
Electropneumatic
Hydraulic
Valve size
Pipeline material End connections
Pipeline Pipeline size Type of valve
Pressure loss Material of construction
Availability
Firesafe
Special requirements Free draining Cost
Type of valve
Antistatic

Table 12.2.3 summarises the main characteristics of the different types of isolation valve.
Table 12.2.3 Typical sizes and operating ranges of isolation valves
Pressure Temperature Pressure
Size
range range drop1
Valve type Min. Max. Min. Max. Min. Max.
bar
(mm) (mm) (bar) (bar) (º C) (º C)
Gate 3 2 250 >0 700 -196 675 0.007
Globe 3 760 >0 700 -196 650 0.590
Diaphragm 3 610 >0 21 -50 175 0.021
Ball (full bore) 6 1 220 >0 525 -55 300 0.007
Butterfly 50 1 830 >0 102 -30 538 0.120
1 Note: Typical values for a DN150 bore valve passing saturated steam at 24 bar, flowing at 40 m / s.

The Steam and Condensate Loop 12.2.7

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Table 12.2.4 summarises the applications of the most common isolating valve types in use today.
Table 12.2.4 Applications of isolating valve types
Valve type General applications
Shut-off/ regulation
Globe valve of liquid / gas flow.
Steam and condensate
applications.
Used fully open or fully
closed for on /off regulation
on steam, gas and other
Piston valve fluid services. Typically
used on fluids that cause
excessive seat wear.
Normally used fully open
or fully closed for on /off
Gate valve regulation on water, oil,
gas, steam and other fluid
services.
Shut-off and regulation in
larger pipelines in
Butterfly valve waterworks, process
industries, HPI, power
generation.
Wide range of applications
in all sizes, including HPI.
Ball Valve
Steam and condensate
applications.
Actuation Remarks
Usually manual, but may be: Usually applied to higher
- Electric pressure or high volume
- Manual systems, due to cost.
- Hydraulic Less suitable for viscous
- Pneumatic or contaminated fluids.
Usually manual, but may be: Usually used where the
- Electric valve body is to be
- Manual permanently installed and
- Hydraulic maintenance needs to
be minimised.
Not recommended as a
Usually manual, but may be: throttling valve. Solid
- Electric wedge gate is free from
- Manual chatter and jamming.
- Hydraulic Parallel slide valve used in
steam systems.
Relatively simple
Handwheel construction. Can be
Electric motor produced in very large sizes.
Pneumatic actuator Eccentric design essential
Hydraulic actuator for steam systems.
Air motor Typically used on liquid
systems.
Handwheel
Electric motor Can handle all fluid types.
Limited maximum pressure
Pneumatic actuator
Hydraulic actuator rating.

Table 12.2.5 is a generalised guide to the selection of isolation valves for particular steam and
condensate applications. It should be noted that the choice of isolation valve is subjective and
different industries and those in different geographical regions have their own unique preferences.
Table 12.2.5 Selection of valves for steam/ condensate isolation purposes
Note: In this table, bellows sealed refers to a bellows sealed globe valve and globe refers to a standard, gland
packed globe valve.
Standard Dead tight Energy and
Application Choice Zero emissions
application shut-off maintenance savings
<DN50 Ball < DN25 Piston < DN25 Piston Bellows sealed
1st
>DN50 Globe >DN25 Ball >DN25 Ball Globe
Trap sets
< DN50 Ball
up to 100 mm < DN25 Piston
2nd >DN50 Bellows Bellows sealed Bellows sealed
>DN25 Ball
sealed
Mains and 1st Globe Ball Piston Bellows sealed
equipment
< 50 mm 2nd Ball Piston Bellows sealed Piston
Mains and 1st Bellows sealed Bellows sealed Bellows sealed Bellows sealed
equipment
50 mm - 100 mm 2nd Globe Ball Ball Ball
Mains and 1st Bellows sealed Bellows sealed Bellows sealed Bellows sealed
equipment
> 100 mm 2nd Globe Globe Globe Globe
Automated 1st Bellows sealed Bellows sealed Bellows sealed Bellows sealed
mains and
equipment 2nd Globe Ball Ball Ball

12.2.8 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Once the most suitable type of valve has been chosen, it is necessary to choose the correct size.
Valves are typically sized according to the pipeline size. It is however advisable to check that the
pressure drop across the valve (when it is fully open) is within acceptable limits. The pressure
drop is a function of the valve flow coefficient (or Kvs value), the flowrate and the inlet pressure.
Specification sheets usually contain data about the Kvs value when the valve is fully opened.
With knowledge of the typical operating pressure, and the mass flowrate, it is possible to determine
the pressure drop across a chosen valve. Alternatively, if the maximum acceptable pressure drop
is known, it is possible to select a suitable valve size. Although there are many formulae and
charts available to predict the relationship between flowrate and pressure drop, the following
simplified empirical formula (Equation 3.21.1) produces reliable results for steam and is therefore
commonly used:

V . Y 3  F

 Equation 3.21.2

Where: ms = Mass flowrate in kg / h

Kv = Valve flow coefficient
P1 - P2
c = Pressure drop ratio =
P1
P1 = Upstream pressure in bar absolute
P2 = Downstream pressure in bar absolute

This formula forms the basis of the chart shown in Figure 12.2.7, which was first introduced in
Block 3, Module 21.
If the isolating valve is to be used in a liquid system, the pressure drop across the valve is determined
using the following equation:

. Y   '*3 Equation 6.3.1

Where: Kv = Valve flow coefficient (m³ / h bar)

V = Flowrate in m³ / h (m³ / h)
G = Relative density of liquid (non-dimensional)
DP = Pressure drop across the valve in bar (bar)

Rearranging the formula gives:


'3 * ⎛⎜ . ⎞⎟ Equation 12.2.1
⎝ Y⎠

The Steam and Condensate Loop 12.2.9

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

This sizing chart is empirical and should not be used for critical applications
0.8
Inlet pressure bar a (absolute) 1

2
Cr
3 Pr itic
es al
pre
4 su ss
re ure
5 dr dro
op pl
ba ine
8
r

10

20
0. 2 3

0.
0.
0.

5
1
3
1

30
40
50

10
20
80 30

20

30
Steam flow kg/h (÷ 3 600 = kg/s)

40
50

80 0.4
100
Kv
= 1.0
200
1.6
300 2.5
400
4.0
500
6.3
Kv
800 = 10
1 000
16
25
2 000
40
3 000
63
4 000 Kv
= 10
5 000 0
16
0
8 000 25
0
10 000
40
0

20 000

30 000
40 000
50 000

80 000
100 000
Fig. 12.2.6 Saturated steam sizing chart

12.2.10 The Steam and Condensate Loop

 Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

1 000
5)) In what book of the Bible do you
y find these words,
I am the living bread which came down from heaven 200

500
400 100
Kv 0
0
300 10
200 50
5000
40 40
300 30
100
by
y a whirlwind?200
20

50 100
40 10
30
50
40
20 30 5
4
20
3
10
10 2
Water flow m³ /h

Water flow l/s

4 5
4 1
3 3

2 2
0.5
0.4
1 0.3
1
0.2
0.5
0.4
0.5
0.3
0.4 0.1
0.3 0.2

0.2 0.1 0.05

0.04
5 0.03
0.1 0.0 4
0.0
3 0.02
0.0
2
0.05 0.0
0.04 0.01
0.03 1
0.0
0.02 0.005
0.004
0.003
0.01
1 2 3 4 5 10 20 30 40 50 100 200 300 500 1 000 2 000 4 000

Pressure drop kPa

Fig. 12.2.7 Water sizing chart

The Steam and Condensate Loop 12.2.11

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

Questions

1. Which of the following situations would warrant the use of a full bore ball valve?
a| Upstream of a flowmeter ¨
b| For isolation of plant when cost is an important consideration ¨
c| After a steam trap set ¨
d| The end of a steam main ¨

2. What is the main advantage of a three piece ball valve over a one piece ball valve?
a| Eliminates the chance of disconnections whilst in service ¨
b| Each piece can be selected individually to customise the valve to suit
a unique application ¨
c| Higher valve integrity ¨
d| Easier in-line maintenance ¨

3. Which application would a standard butterfly valve be most suitable for?

a| Temperature control ¨
b| In small mains applications ¨
c| Automated isolation of a large steam jacket ¨
d| In hazardous gas applications that require a dead tight seal ¨

4. What would be the Kv value of a steam isolation valve with a pressure drop of 0.3 bar?
Given that it is to be used upstream of a heat exchanger with a steam demand of
3 000 kg / h and a supply pressure of 5 bar g.
a| 70 ¨
b| 88 ¨
c| 100 ¨
d| 420 ¨

5. A bellows sealed globe valve is available in sizes DN25, DN32, DN40 and DN50
and the table below shows the corresponding Kvs values?

Size DN25 DN32 DN40 DN50

Kvs value 12 20 30 47

Choose the correct size globe valve if it is to be used downstream of a pressure

reducing station passing 500 kg / h of steam at 10 bar a, given that the
pressure drop across the chosen globe valve must be less than 0.1 bar.
a| DN25 ¨
b| DN32 ¨
c| DN40 ¨
d| DN50 ¨

12.2.12 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

6. Using selection tables determine the most suitable types of valve for use on a 150 mm
steam main to give a dead tight shut-off?
a| Bellows sealed globe valve / globe valve ¨
b| Ball valve / bellows sealed valve ¨
c| Ball valve / piston valve ¨
d| Bellows sealed globe valve / eccentric butterfly valve ¨

Answers
1: a, 2: d, 3: c, 4: b, 5: b, 6: a

The Steam and Condensate Loop 12.2.13

Block 12 Pipeline Ancillaries Isolation Valves - Rotary Movement Module 12.2

12.2.14 The Steam and Condensate Loop