Process Technology Equipment
Chapter 5 Valves
Page 1
CHAPTER 5 Valves
Table of Contents
Contents
Page
Class Session Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
4
Lesson Plan
5
5.1 Types of Valves
5.2 Potential Valve Problems
6
11
5.3 Hazards Associated with Improper Valve
Operation
11
5.4 Process Technician’s Role in Operation and
Maintenance
13
Summary and Wrap-Up
14
Suggested Student Activities
14
End of Chapter Review Questions
14
Clicker Questions
Appendix
20
23
Process Technology Equipment
Chapter 5 Valves
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CHAPTER 5 Valves
Class Session Overview
Valves are piping system components used to control or stop the flow of fluids through a
pipe. Valves allow process technicians to achieve a desired flow rate or pressure which
may, in turn, be used to achieve a desired variable, such as tank level. Valve
classifications are based on the design of the internal components, how the valve is
operated, or the function of the valve.
Many different types of valves are used in the process industries. Process technicians
must be familiar with each of the different valve types, the valve components, and their
maintenance and operating characteristics. Process technicians are commonly required
to troubleshoot valve problems and determine the best solution to return the valve to
normal operating conditions, sometimes in the presence of various hazards associated
with piping and valves.
A process technician may be responsible for incidental (minor) maintenance and repair
of valves. Minor maintenance may include tightening valve packing or replacing a small
valve. The most critical repairs are performed by maintenance personnel with
specialized expertise. Additional process technician responsibilities include inspecting
for leaks, cleaning, greasing and lubricating stems, and monitoring the operation and
position of valves.
Class Preparation Checklist
1.
Familiarize yourself with the chapter content.
2.
Bring cutaways or other hands-on teaching aids if available.
3.
Copy and distribute any fill-in-the-blank handouts for today’s content.
4.
Safety Minute prepared or assigned
5.
Review the PowerPoint slides associated with this chapter (if used) and
make sure that your computer is correctly set up to navigate the slide deck
smoothly.
6.
Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
5.1 Describe the purpose, types, and components of valves in the process industry.
(NAPTA Valves).
5.2 Identify typical problems associated with valves (NAPTA Valves).
5.3 Describe safety and environmental concerns associated with valves (NAPTA
Valves).
Process Technology Equipment
Chapter 5 Valves
5.4 Describe the process technician’s role in typical procedures and safe valve
operation and maintenance (NAPTA Valves).
Process Technology Equipment
Chapter 5 Valves
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Class Agenda
Activity
Minutes
PPTs
1. Welcome to Class
1
1
2. Introduction and Agenda
2
2
3. Safety Minute
2
3
4. Objectives
2
4
5. Terms
6
5
6. Valves
1
6
7. Types of Valves
2
7
8. Gate Valves
1
8
9. Globe Valves
1
9
10. Check Valves
3
10
11. Ball Valves
1
11
12. Plug Valves
1
12
13. Butterfly Valves
1
13
14. Diaphragm Valves
1
14
15. Valve Components
3
15
16. Relief Valves
1
16
17. Safety Valves
1
17
18. Block Valves
1
18
19. Multiport Valves
1
19
20. Control Valves
1
20
21. Manual Valves
1
21
22. Potential Valve Problems
3
22
23. Hazards Associated with Improper Valve
Operation
1
23
24. Proper Body Position
1
24
25. Operating Overhead Valves
1
25
26. Safe Footing
1
26
27. Use of Valve Wrenches and Levers
1
27
28. Process Technician’s Role in Operation and
Maintenance
1
28
29. Inspecting for Leaks and Corrosion
1
29
30. Greasing and Lubricating
1
30
31. Monitoring
1
31
32. Summary and Wrap-Up
4
32
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Chapter 5 Valves
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Chapter 5 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Introduction and Agenda
Time: 2 minutes
Resources: Slide 2
Student Safety Minute
Time: 2 minutes
Resources: Slide 3
(Note to Instructor: Follow this procedure for the Safety Minute.)
Objectives
Time: 2 minutes
Resources: Slide 4
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Chapter 5 Valves
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Process technicians must also be able to describe safety and environmental concerns
related to different types of valves as well as understand and follow the procedures to
safely operate and maintain valves used in the process.
Terms
Time: 6 minutes
Resources: Slide 5
Valves
Time: 1 minute
Resources: Slide 6
Sample Instructor Script:
Valves are piping system components used to control or stop the flow of fluids through a
pipe. Valves allow process technicians to achieve a desired flow rate or pressure which
5.1 Types of Valves
Time: 2 minutes
Resources: Slide 7
Sample Instructor Script:
Many different types of valves are used in the process industries. The most common
valve types include:
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Chapter 5 Valves
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5.1.1 Gate Valves
Time: 1 minute
Resources: Slide 8
5.1.2 Globe Valves
Time: 1 minute
Resources: Slide 9
5.1.3 Check Valves
Time: 3 minutes
Resources: Slide 10
Sample Instructor Script:
Check valves are devices that prevent backflow (reverse flow in piping when the flow
stops). By eliminating backflow, these valves prevent equipment damage as well as
contamination of a process. All check valves are directional and must be placed in the
line correctly.
Process Technology Equipment
Chapter 5 Valves
5.1.4 Ball Valves
Time: 1 minute
Resources: Slide 11
5.1.5 Plug Valves
Time: 1 minute
Resources: Slide 12
5.1.6 Butterfly Valves
Time: 1 minute
Resources: Slide 13
5.1.7 Diaphragm Valves
Time: 1 minute
Resources: Slide 14
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5.1.8 Valve Components
Time: 3 minutes
Resources: Slide 15
Sample Instructor Script:
Valves have similar components, such as a closure device and a handwheel or
handle/lever attached to a valve stem. Other components include the following:
5.1.9 Relief Valves
Time: 1 minute
Resources: Slide 16
5.1.10 Safety Valves
Time: 1 minute
Resources: Slide 17
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5.1.11 Block Valves
Time: 1 minute
Resources: Slide 18
5.1.12 Multiport Valves
Time: 1 minute
Resources: Slide 19
5.1.13 Control Valves
Time: 1 minute
Resources: Slide 20
5.1.14 Manual Valves
Time: 1 minute
Resources: Slide 21
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5.2 Potential Valve Problems
Time: 3 minutes
Resources: Slide 22
Sample Instructor Script:
Process technicians are commonly required to troubleshoot valve problems and
determine the best solution to return the valve to normal operating conditions. The most
common valve conditions that a process technician may need to investigate are
blockage and leakage.
Valve leakage can occur either across the valve (within the pipe) or into the
atmosphere. Atmospheric leakage normally occurs through the valve stem packing or
flanges.
Leakage from the valve stem packing is addressed by tightening down on the packing
nuts to compress the packing so that it tightens around the stem. Flange leaks are
addressed by tightening the flange bolts. Because valve leakage can result in fire,
explosion, personnel exposure, and environmental impact, it is important to resolve
leaks as quickly as possible.
5.3 Hazards Associated with Improper Valve Operation
Time: 1 minute
Resources: Slide 23
Process Technology Equipment
Chapter 5 Valves
5.3.1 Proper Body Position
Time: 1 minute
Resources: Slide 24
5.3.2 Operating Overhead Valves
Time: 1 minute
5.3.3 Safe Footing
Time: 1 minute
5.3.4 Use of Valve Wrenches and Levers
Time: 1 minute
Resources: Slide 27
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5.4 Process Technician’s Role in Operation and Maintenance
Time: 1 minute
Resources: Slide 28
5.4.1 Inspecting for Leaks and Corrosion
Time: 1 minute
Resources: Slide 29
5.4.2 Greasing and Lubricating
Time: 1 minute
Resources: Slide 30
5.4.3 Monitoring
Time: 1 minute
Resources: Slide 31
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Summary and Wrap–Up
Time: 4 minutes
Resources: Slide 32
Suggested Student Activities
(Note to Instructor: Time permitting, do the activities listed below or possibly assign
them as homework. Be sure to remind students what to read for the next class.)
1. Given a hand valve (globe or gate), dismantle the valve and label all the separate
components.
2. Using a simulator or process skid unit, identify all the valve types in use.
End of Chapter Review Questions
1. What type of valve uses a disc and seat to regulate the flow of fluid through
the valve body?
A. Gate
B. Globe
C. Check
D. Butterfly
Process Technology Equipment
Chapter 5 Valves
2. What type of check valve has a disc-shaped flow control element that lifts up
off the seat as fluid flows through it and drops back onto the valve seat if the
fluid flow stops or attempts to flow in a reverse direction?
A. Lift check valves
B. Ball check valves
C. Swing check valves
D. Plug check valves
3. What type of check valves are especially well suited for use with fluids
containing solids or viscous materials and are available in horizontal, vertical,
and angle designs?
A. Lift check valves
B. Ball check valves
C. Swing check valves
D. Plug check valves