Types of Valves Used in Petrochemical & Chemical Plants

Petrochemical and chemical plants use specialized valves designed for handling corrosive chemicals, high-pressure fluids, toxic gases, steam, hydrocarbons, slurry, and hazardous media. These valves are manufactured with high-grade materials and strict industrial standards for safety and reliability.

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1. Ball Valve

Widely used for quick shut-off applications in chemical and hydrocarbon pipelines.

Technical Details

• Quarter-turn operation

• Tight sealing capability

• Low pressure drop

• Fire-safe design available

• Anti-static construction for hydrocarbon service

Specifications

Parameter	Typical Range
Size	15 mm – 600 mm
Pressure Class	ANSI 150–2500
Temperature	-196°C to 650°C
Body Material	SS304, SS316, Duplex Steel
Seat Material	PTFE, Metal Seated

Applications

• Oil & gas pipelines

• Chemical transfer lines

• Solvent systems

• Fuel systems

Approximate Price

• ₹3,000 – ₹8,00,000

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2. Gate Valve

Used mainly for isolation in large pipelines carrying liquids, steam, and hydrocarbons.

Technical Details

• Full bore flow

• Minimal pressure drop

• Suitable for on/off service

• Available in rising stem and non-rising stem designs

Specifications

Parameter	Typical Range
Size	25 mm – 1200 mm
Pressure Class	ANSI 150–2500
Temperature	Up to 700°C
Material	WCB, WC6, WC9, Stainless Steel

Applications

• Steam lines

• Crude oil systems

• Process pipelines

• Utility systems

Approximate Price

• ₹5,000 – ₹10,00,000

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3. Globe Valve

Used where accurate throttling and flow regulation are required.

Technical Details

• Excellent throttling characteristics

• Higher pressure loss than gate valves

• Suitable for frequent operation

Specifications

Parameter	Typical Range
Size	15 mm – 400 mm
Pressure Rating	ANSI 150–2500
Temperature	Up to 650°C
Trim Material	SS316, Monel, Hastelloy

Applications

• Chemical dosing systems

• Steam regulation

• Cooling water control

• Process fluid regulation

Approximate Price

• ₹4,000 – ₹5,00,000

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4. Butterfly Valve

Commonly used in low-pressure large-diameter piping systems.

Technical Details

• Compact and lightweight

• Quarter-turn operation

• Suitable for slurry and water service

• Available in wafer, lug, and double-flanged types

Specifications

Parameter	Typical Range
Size	50 mm – 3000 mm
Pressure Rating	PN10 to PN40
Temperature	Up to 500°C
Disc Material	SS316, Duplex Steel

Applications

• Cooling water systems

• Air systems

• Chemical slurry lines

• Utility pipelines

Approximate Price

• ₹2,500 – ₹6,00,000

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5. Plug Valve

Widely used for corrosive and viscous fluid handling.

Technical Details

• Quarter-turn valve

• Bubble-tight shutoff

• Suitable for dirty and corrosive media

• Available in lubricated and sleeved types

Specifications

Parameter	Typical Range
Size	15 mm – 500 mm
Pressure Class	ANSI 150–900
Material	Carbon Steel, Stainless Steel
Lining	PTFE, PFA

Applications

• Acid transfer systems

• Hydrocarbon processing

• Slurry handling

• Chemical reactors

Approximate Price

• ₹6,000 – ₹4,00,000

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6. Diaphragm Valve

Used in highly corrosive chemical services.

Technical Details

• Leak-proof operation

• Excellent corrosion resistance

• Isolates actuator from fluid

• Ideal for sanitary and corrosive service

Specifications

Parameter	Typical Range
Size	10 mm – 300 mm
Pressure Rating	PN10 to PN25
Lining Material	PTFE, Rubber
Body Material	Cast Iron, SS316

Applications

• Acid plants

• Chlorine systems

• Pharmaceutical chemicals

• Water treatment plants

Approximate Price

• ₹2,000 – ₹2,50,000

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7. Check Valve (Non-Return Valve)

Prevents reverse flow in process pipelines.

Technical Details

• Automatic operation

• Protects pumps and compressors

• Available in swing, lift, and dual-plate types

Specifications

Parameter	Typical Range
Size	15 mm – 1200 mm
Pressure Class	ANSI 150–2500
Temperature	Up to 650°C

Applications

• Pump discharge lines

• Compressor systems

• Steam systems

• Chemical pipelines

Approximate Price

• ₹2,500 – ₹3,50,000

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8. Safety Relief Valve

Protects equipment and pipelines from overpressure.

Technical Details

• Automatic pressure release

• Spring-loaded mechanism

• High reliability for hazardous service

Specifications

Parameter	Typical Range
Set Pressure	Up to 400 bar
Temperature	Up to 700°C
Material	Alloy Steel, Inconel

Applications

• Pressure vessels

• Reactors

• Boilers

• Storage tanks

Approximate Price

• ₹8,000 – ₹7,00,000

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9. Needle Valve

Used for precise flow control of gases and liquids.

Technical Details

• Fine flow adjustment

• Small flow applications

• High-pressure capability

Specifications

Parameter	Typical Range
Size	3 mm – 25 mm
Pressure Rating	Up to 10,000 PSI
Material	SS316, Monel

Applications

• Instrumentation systems

• Gas sampling lines

• Pressure gauges

• Hydraulic systems

Approximate Price

• ₹800 – ₹50,000

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Common Valve Materials in Chemical & Petrochemical Plants

Material	Usage
Carbon Steel	General service
Stainless Steel 304/316	Corrosion resistance
Duplex Steel	Chloride environments
Monel	Acid service
Hastelloy	Highly corrosive chemicals
Inconel	High temperature applications
PTFE Lined	Aggressive chemical handling

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Common Valve Standards

Standard	Purpose
API 6D	Pipeline valves
API 598	Valve testing
ASME B16.34	Valve design
ANSI Classes	Pressure ratings
ISO 15848	Fugitive emission testing

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Valve Actuation Types

Actuator Type	Application
Manual	Small pipelines
Pneumatic	Fast process control
Electric	Automated plants
Hydraulic	Heavy-duty valves

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Important Selection Factors

• Chemical compatibility

• Corrosion resistance

• Pressure and temperature rating

• Fire-safe requirements

• Fugitive emission control

• Automation compatibility

• Maintenance accessibility