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Valve Selection for Instrumentation

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Valve Selection for Instrumentation Valve Selection for Instrumentation Doug Nordstrom Valve Product Manager Sarah Liston Valve Engineering Manager © 2014 Swagelok Company. Swagelok confidential. For internal use only Agenda • Considerations in Valve Selection • Overview and Attributes of different Valve Types – Ball – Plug – Needle – Diaphragm • Design features that impact valve performance – Ball – Needle © 2011 Swagelok Company – Confidential – For Internal Use Only Ball Valves © 2009 Swagelok Company Plug Valves © 2009 Swagelok Company Needle Valves © 2009 Swagelok Company Diaphragm Valves © 2009 Swagelok Company Typical Factors to Consider… 1. Seal integrity 2. Flow capacity and control 3. Actuation 4. Temperature limits 5. Chemical compatibility 6. Cost How do various instrumentation valves stack up with these factors? © 2009 Swagelok Company Typical Factors to Consider… 1. Seal integrity © 2009 Swagelok Company Typical Factors to Consider… 1. Seal integrity Two locations of leaks • Seat leaks • Shell (or Stem) leaks © 2009 Swagelok Company Typical Factors to Consider… 1. Seal integrity Three “types” of leaks • Surface finish leaks (path leak) • Scratches (path leak) • Permeation Helium Helium Gas Gas To HLT To HLT “path” leak “permeation” leak “Path Leak” “Permeation Leak” © 2009 Swagelok Company Permeation Response 1.E-06 PTFE (t=0.077cm) PEEK (t=0.043cm) 1.E-07 Zenite -6000L-N (3 pcs) (t=0.041, t=0.043, t=0.042 cm) 1.E-08 1.E-09 Permeation Rate (atm cc/s) (atm Rate Permeation 1.E-10 Permeation area = 0.47 cm2 1.2 atm He pressure applied 1.E-11 0 100 200 300 400 500 600 700 800 900 1000 Time (s) Permeation Leaks Short time behavior D = diffusion coefficient P A ∞ − D n2 π 2 t S = solubility constant Leak rate= D S He 1+ 2 cos(nπ ) exp A = permeation area ∑ 2 P = helium partial pressure L n=1 L He L = diffusion length (thickness) Big effect 1.E-06 L=.013 .020” 1.E-07 .029” .036” 1.E-08 1.E-09 Leak Rate (std cc/s) (std Rate Leak 1.E-10 1.E-11 0 30 60 90 120 150 180 210 240 270 300 Time (s) Bubbles vs. Leak rate Approximate time for Leak Rate (atm cc/s) one bubble (radius = 1mm) -2 0.4 seconds Slight scratches or a 10 (2.5 per second) leak path 10-3 4 seconds 10-4 40 seconds O-ring permeation 10-5 7 minutes 10-6 1.2 hours Plastics permeation 10-7 12 hours 10-9 2 months Metal permeation Typical Factors to Consider… 1. Seal integrity 1 N How soft is the seal? • O-rings O-ring • Plastics • Metal How smooth are the surfaces? 1 N Plastic 1 N Metal © 2009 Swagelok Company Typical Factors to Consider… 1. Seal integrity How much force is applied? Typical Factors to Consider… 1. Seal integrity Ability to adjust a valve in the field Ability for the valve to self-adjust to wear and temperature © 2009 Swagelok Company Typical Factors to Consider… 2. Flow capacity and control Is controlling flow value important? Or simple “On/Off” function? ¼” Valve Cv: • Ball Valve and Plug Valve ~ 1.5 • Needle Valve ~ 0.5 • Diaphragm Valve ~ 0.2 © 2009 Swagelok Company Typical Factors to Consider… 2. Flow capacity and control 1/2 Cv = q (SG / dp) 1 gallon per minute of water through a: • Ball valve would require in 0.7 psi • Needle valve would require 6.5 psi • Diaphragm valve would require 35 psi © 2009 Swagelok Company Typical Factors to Consider… 3. Actuation Ease of actuation © 2009 Swagelok Company Typical Factors to Consider… 3. Actuation Waterhammer 100 feet of water in a ¼” tube moving at 1 m/s results in a 175 psi spike when a valve shuts quickly! © 2009 Swagelok Company Typical Factors to Consider… 4. Temperature Limits O-ring temperature limits as compared to product temperature limits Plastics temperature limits Metal seal temperature limits © 2009 Swagelok Company Typical Factors to Consider… 5. Chemical Compatibility Compatibility charts © 2009 Swagelok Company Typical Factors to Consider… 6. Cost Product complexity • Threads • Number of parts • Seal materials © 2009 Swagelok Company Valve “Cheat Sheet” Cycle Temp Flow Life Range Flow Control Actuate Permeation Price Ball Plug Needle Diaphragm © 2011 Swagelok Company – Confidential – For Internal Use Only A Closer Look at Ball Valves © 2009 Swagelok Company Ball Valve Advantages • Full-port (high flow/small package) Not • Quarter-turn (easy to use) recommended • Lower torque than most other valves for throttling • Lower cost to automate than most other valves • Long service life • Design allows for the ability to replace the seats if a problem arises – Some allow seal replacement while the valve is inline © 2009 Swagelok Company – Confidential – For Internal Use Only Construction • Three-piece • Two-piece (screwed-end, end-entry) • Single-piece (top entry) • End-screw design © 2009 Swagelok Company – Confidential – For Internal Use Only Single-Piece, Packed Ball Valve – Single-piece body eliminates potential leak points – Virtually no dead space – Allows bi-directional flow – Adjustable – No elastomer seals © 2009 Swagelok Company – Confidential – For Internal Use Only Three-piece, Floating Ball Valve • Floating ball design compensates for: – Wear – Pressure changes – Temperature changes – Easy to rebuild seats • Flexing seat design ensures leak-tight seal in both low- and high-pressure systems. Bolted End-Screw © 2009 Swagelok Company – Confidential – For Internal Use Only Floating Ball Valve © 2009 Swagelok Company – Confidential – For Internal Use Only Trunnion Style, End Screw Design Ball Valve • Opposite of floating ball design – Ball cannot float – Seats compressed against ball using springs • Typically larger sizes and higher pressures © 2009 Swagelok Company – Confidential – For Internal Use Only Closer look at Needle Valves © 2011 Swagelok Company – Confidential – For Internal Use Only Needle Valve Advantages • Allows for regulation of flow • High temperature capabilities • Metal to metal sealing • Disadvantage – Flow path – Actuation time Also known as a “Globe Pattern” valve © 2009 Swagelok Company – Confidential – For Internal Use Only Needle Valves Types On/Off Flow Regulating Fine Metering © 2009 Swagelok Company – Confidential – For Internal Use Only Needle Valves Patterns Straight Angle Cross © 2009 Swagelok Company – Confidential – For Internal Use Only Integral Bonnet • Lowest number of components in the construction • Packing is typically above the threads • Adjustable spring loaded packing compensates for wear • Various stem tips for regulation or shut off performance • Rotating stem at seal point © 2009 Swagelok Company – Confidential – For Internal Use Only Screwed Bonnet • Bonnet is screwed into the valve body • Valves typically have non-wetted bonnet threads • Many screwed bonnets have non- rotatable stem tips to extend sealing life • Slightly larger in size and more components • Packing adjustments are more difficult, but possible © 2009 Swagelok Company – Confidential – For Internal Use Only Union Bonnet • Union bonnet eliminates accidental disassembly • Allows for higher pressures • No o-rings and grafoil packing allows for extreme temperature ratings • Various stem tips for shut-off or regulating performance © 2009 Swagelok Company – Confidential – For Internal Use Only Toggle • Designed for shut-off and fast actuation to full open position • High cycles in harsh applications • Ability to actuate more easily than other needle valves • Small, compact, and typically low number of components • Typically made with o-ring seals © 2009 Swagelok Company – Confidential – For Internal Use Only Needle Valve Considerations • Packing location (above or below the threads) • Stem rotation • Amount of flow regulation required • Soft seat – More robust seal, lower leak rates over time – More susceptible to contamination, wear, and temperature • Metal seat – Better compatibility – Higher temperature, sacrifice leak rate © 2009 Swagelok Company – Confidential – For Internal Use Only © 2014 Swagelok Company. Swagelok confidential. For internal use only.
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