PARALLEL SLIDE GATE VALVE AND ACTUATOR INSTALLATION, OPERATIONS MAINTENANCE MANUAL

Transcription

1 Certified to O Bingle oad Houston, X elephone: (713) ax: (713) ervice epartment mergency ager: VVCHOOG, C. G VV CO O, OO MC M age 1 of 54

2 able of Contents. ntroduction 4. nstallation 5. eceiving and reparation 5 B. Operators 5 1. ctuators 5 2. Manuals Operators 5 C. Orientation 5. hermal Concerns 6 1. Welding 2. nsulation 3. tress elieving 6 6 a) nstallation and Operation 6. nitial est 6. Operation 7. Valve 1. ubrication and djustments 7 B. ctuator 7 V. Maintenance 8. isassembly 8. e-assembly 9-10 age 2 of 54

3 V. rouble hooting 11 ppendix ll igures (1 7) ppendix B Charts 1062 tem hrust (B) for arallel lide Gate Valves 8 eat tem hrust (B) for arallel lide Gate Valves 11 ¾ eat tem hrust (B) for arallel lide Gate Valves 13 ¼ eat tem hrust (B) for arallel lide Gate Valves 15 eat orque for 8 arallel lide Gate Valves t/bs 1070 orque for 11 ¾ arallel lide Gate Valves t/bs 1071 orque for 13 ¼ arallel lide Gate Valves t/bs 1072 orque for 15 arallel lide Gate Valves t/bs 1091 Body Bolt orque Values 1092 Gland orque ign Off 58 age 3 of 54

4 ntroduction his manual describes special cautions that must be adhered to, in order to assure a long, trouble-free service life and Valvtechnologies warranty. Valvtechnologies, nc., as the leading manufacturer of metal-seated ball valves, manufactures arallel lide Gate Valves. Valvtechnologies valves are used in severe service applications by the world s leading power, petrochemical and refining companies. very valve is tested prior to shipping and is certified to have zero leakage. mportant he following procedures are written for the purpose of providing the customer with general information required for the proper operation and maintenance of its products. ny difficulties encountered in the operation or maintenance of Valvtechnologies, nc. valves should be directed to an authorized distributor or to the factory in Houston, exas. ailure to do so may void the warranty. age 4 of 54

5 . nstallation. eceiving and reparation Valvtechnologies metal-seated arallel lide Gate Valves are shown in ppendix, igures 1, 2 and 3 (ig. 1 is a full drawing O1BWH1-1; ig. 2 is an enlarged end view & ig. 3 is an enlarged side view with / balloons. he valves are shipped in a box or on a pallet in the open position (except fail close systems). rior to installation, the actuator and valve should be inspected to ensure there has been no shipping damage. ll shipping materials should be removed to allow a thorough inspection. Verify that no debris is in the valve bore. he valve should be cycled closed, then back to the open position, to ensure that the actuator is operational. lso observe the gates from each end to verify that there has been no damage to the coating. B. Operators 1. ctuators he valve will normally be configured with one of three types of powered actuator: hydraulic, pneumatic, or electric. he actuator will be factory mounted and adjusted on the valve. Manual gear drives are also used on some arallel lide Gates Valves. CO: ctuators should not be removed, adjusted (including limit switches or stops) or reinstalled except be Valvtechnologies, nc. factorytrained personnel. Valve must be retested for zero leakage after installation of actuator. MO: On electric operator valves, the valve should be manually cycled to the mid stroke position before cycling under power. 2. Manual Operators Manually operated valves may be fitted with gear operators. hey should be cycled and checked as above. C. Orientation ny orientation of the stem is acceptable and will depend solely on the user s piping or vessel configuration. age 5 of 54

6 . hermal Concerns CO: xcessive temperature, improper stress relieving techniques, or improper use in insulation may damage the valve and/or void the warranty. ee ppendix C: Welding and tress elieving Considerations. f actuator damage from excessive temperature (either operationally or during welding or stress relieving) is a concern, radiation shields are recommended. Valvtechnologies can recommend and provide a suitable design that is compatible with any specific valve/actuator design. 1. Welding CO: Valve should be open during welding operation. Care should be taken to minimize weld slag and splatter inside the valve and piping bore. rc strikes should not be made on the valve. ocalized stress relief is acceptable. Oven ( recommend this versus furnace, which implies direct flame) stress relief is not recommended without consulting Valvtechnologies, nc. 2. nsulation. nitial est a) tress elieving he valve must not be insulated during stress relieving. his is critical to the valve warranty and service life. b) nstallation and Operation nsulation is recommended for valves that will experience operation temperatures in excess of 400 degrees. CO: nsulation must not be applied above the bonnet flat, which is below the packing gland. ee ppendix, igure 4. fter installation, the piping system should be cleaned and flushed. his will ensure weld slag; tools and other debris are removed before cycling the valve. fter this process, the valve should be fully closed. t is good practice to cycle the valve several times to verify proper operation and to check the proper alignment of all automatic switched and valve position indicators. age 6 of 54

7 . Operation. Valve 1. ubrication and djustments he Valvtechnologies arallel lide Gate Valve requires O routine lubrication or maintenance. t is designed for severe service and long life. t is also designed to operate without requiring bonnet (where applicable: only 600 class) bolt or packing gland bolt re-tightening. However, should leakage occur from either the bonnet joint or stem packing as a result of unusual service conditions, re-tightening is permissible. n the case of bonnet bolts 600#, it is recommended that this procedure be performed while the system is depressurized. he required torque values for these bolts are given in Charts 1091 and 1092 in ppendix B. CO: ll torque values listed assume that weeney 505 (1000), or equivalent, is applied to nut face and threads. Other materials may result in as much as a 75% loss in bolt tension. Valve osition ndication ll Valvtechnologies, nc. products, unless specifically stated, are designed for clockwise rotation to close and counter-clockwise rotation to open. Open & Closed direction is indicated by the Bridge (19). B. ctuator he actuator on the Valvtechnologies arallel lide Gate Valve requires periodic maintenance. or electric, hydraulic and pneumatic systems, separate instructions accompanying these procedures will be provided with the original sales order depending on the actuator type and manufacturer. or worm gear actuators, the lubricant in the gearbox must be checked every three (3) months and replaced if oxidized or replenished should that be required. roper gearbox lubrication will minimize hand wheel torque requirements. age 7 of 54

8 V. Maintenance. isassembly rocedure: arallel lide Gate Valve ote: ee ig. 1 & 3 for part identification 1. oosen the gland nuts (item 12). emove the nuts and springs (11). 2. oosen the bonnet bolts (17). 3. lace 2 equal length bars under the bridge (14) and atop the bonnet (7) between the plate (14) & gland (6) with out touching the plate. 4. se the actuator (25) to drive the bonnet down enough to relieve the pressure on the segment rings (9). 5. nsert a drift pan into the holes in the side of the bonnet neck of the body (1) and the drive of the segment rings inward toward the stem (5). ee segment rings in ig. 5 of ppendix. ote the ring segments that have parallel ends must be removed first. 6. CO: Monitor the stem threads during the actuator operation during the following procedure. f screwed into the actuator, they can jam very tightly. emoval may not be possible. a. se the actuator to raise the gates (3) until they begin lifting the bonnet. he bonnet should be raised enough that it may be easily removed. b. f the stem threads approach the actuator, remove the actuator bolts (yoke cap screw 23). c. otate the actuator about the stem until a sizable gap appears between the actuator and mounting plate (22). d. nsert the blocks between the actuator and the mounting plate. e. epeat steps (a), & if necessary (c) & (d) until the bonnet is free to lift clear on the body. 7. emove the actuator, yoke posts (21), and gland plate & bonnet. 8. ull the gates up enough to permit installing 2 C-clamps (with padding to protect the coating) to squeeze the gates together. his is to preclude dropping the gates. 9. aise the stem further & install 2 more C-clamps in the vicinity of the main spring (4). 10. ully remove the stem and gates. age 8 of 54

9 B. e-assembly rocedure: arallel lide Gate Valve O: ee ig. 1 & 3 for part identification 1. osition the Valve in a suitable stand & verify that it is stable & secure. 2. lace the Belleville pring (tem 4) between the 2 gates (3). 3. rovide supports that result in parallel gates. 4. Measure the overall thickness of the sub-assembly. 5. Measure the seat (2) spacing in the body (1). 6. ubtract the measurements of step 5 from the measurements of step 6. he result is the tand-off. he correct tand-off range value is obtained from the tand-off tables for the same sized ball valve as the spring that is was taken from. he 8 gate valve uses a spring from a 4 Valvtechnologies ball valve. hus the tand-off is the same as for a 4 bore Valvtechnologies ball valve. 7. lace the stem (5) between the gates & use 2 C-clamps (with padding to protect the coating) to squeeze them together. 8. ower the stem/gate assembly into the body. 9. lide the bonnet (7) over the stem & into the body (1). 10. crew 2 pulling studs (18; only applicable on 600 class valves) into the bonnet. 11. lide the bonnet pressure seal (10) onto the bonnet. 12. lide the pressure seal spacer ring (8) onto the bonnet. 13. lace the segment ring (9) pieces into the body. ote that the 4 shorter pieces must be installed first, arranged as shown in ig. 5 of ppendix. he longer pieces with parallel ends must be installed last. t is essential that they be arranged so that they are all accessible through the knock-out holes in the valve neck. 14. n the case of the 600-class valve, replace the pulling studs with the bonnet bolts; & add the remaining 2 bolts. age 9 of 54

10 15. lide the gland packing (26) over the stem & into the bonnet. 16. lide the gland flange (6) over the stem & atop the bonnet. 17. nstall the gland studs (13), 6 gland springs (11) per stud & gland nuts (12). ote that the gland springs must be arranged in alternating orientation, per ig. 7 of ppendix to assure the correct balance between force & travel. ighten in a star pattern to the value given in Chart 1092 (Gland orque). 18. nstall the 4 yoke posts (21), torque per V bolting torque specification per Chart nstall 2 stop collars, if provided, onto the 2 yoke posts that will also guide the bridge (19). hese will be used to establish the upper travel limit, if necessary. 20. nstall the bridge around the 2 yoke posts & clamp together. 21. nstall the mounting plate (22) onto the yoke posts. 22. crew the nut onto the stem until it reaches the mounting plate. 23. lace the actuator atop the mounting plate & bolt it securely. 24. Cycle the valve while monitoring all aspects of clearance & operation. age 10 of 54

11 V. rouble hooting Malfunction ossible Cause emedial ction Valve won t cycle a) ctuator has failed b) Valve packed with debris c) tem key has sheared d) Gate gap incorrect a) eplace or repair actuator b) Cycle & flush valve to remove debris c) etermine cause of shearing & correct/replace keys d) Call factory tem acking eaking a) Gland bolts loose b) acking damaged or missing c) eal mis -aligned a) ighten gland bolts b) hut down system & replace packing c) eplace & properly align Bonnet Gasket eaking a) Bonnet Bolts loose b) Body gasket damaged c) Bonnet gasket seating faces in body or end piece damaged a) ighten body bolts b) emove valve from service & replace body gasket c) eturn parts to Valvtechnologies for rework Valve Gates eaking a) Valve no fully closed b) ebris trapped in valve c) eat or ball damaged a) Close the valve b) Cycle & flush to remove debris c) emove valve from service & repair or replace ball and/or seat age 11 of 54

12 X G age 12 of 54

13 age 13 of 54

14 age 14 of 54

15 age 15 of 54

16 age 16 of 54

17 age 17 of 54

18 age 18 of 54

19 age 19 of 54

20 X B CH age 20 of 54

21 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure CH 1062 age 1 of 4 ate:04/30/96 age 21 of 54

22 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure CH 1062 age 2 of 4 ate:04/30/96 age 22 of 54

23 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure age 23 of 54

24 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure CH 1062 age 4 of 4 ate:04/30/96 age 24 of 54

25 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure CH 1064 age 1 of 4 ate:04/30/96 age 25 of 54

26 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure CH 1064 age 2 of 4 ate:04/30/96 age 26 of 54

27 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure age 27 of 54

28 tem hrust (bs.) for arallel lide Gate Valves 11 3/4" eat.. ine ressure CH 1064 age 4 of 4 ate:04/30/96 age 28 of 54

29 tem hrust (bs.) for arallel lide Gate Valves 13 ¼ eat.. ine ressure CH 1065 age 1 of 4 ate:04/30/96 age 29 of 54

30 tem hrust (bs.) for arallel lide Gate Valves 13 ¼ eat.. ine ressure CH 1065 age 2 of 4 ate:04/30/96 age 30 of 54

31 tem hrust (bs.) for arallel lide Gate Valves 13 ¼ eat.. ine ressure age 31 of 54

32 tem hrust (bs.) for arallel lide Gate Valves 13 ¼ eat.. ine ressure CH 1065 age 4 of 4 ate:04/30/96 age 32 of 54

33 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure CH 1066 age 1 of 4 ate:04/30/96 age 33 of 54

34 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure CH 1066 age 2 of 4 ate:04/30/96 age 34 of 54

35 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure age 35 of 54

36 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure CH 1066 age 4 of 4 ate:04/30/96 age 36 of 54

37 tem actor orque for 8 arallel lide Gate Valves t/bs ine ressure CH 1068 age 1 of 4 ate:04/30/96 age 37 of 54

38 . tem actor orque for 8 arallel lide Gate Valves t/bs ine ressure CH 1068 age 2 of 4 ate:04/30/96 age 38 of 54

39 . tem actor orque for 8 arallel lide Gate Valves t/bs ine ressure age 39 of 54

40 . tem actor orque for 8 arallel lide Gate Valves t/bs ine ressure CH 1068 age 4 of 4 ate:04/30/96 age 40 of 54

41 tem actor orque for 11 ¾ arallel lide Gate Valves t/bs ine ressure CH 1070 age 1 of 4 ate:04/30/96 age 41 of 54

42 V. tem actor orque for 11 ¾ arallel lide Gate Valves t/bs ine ressure CH 1070 age 2 of 4 ate:04/30/96 age 42 of 54

43 V. tem actor orque for 11 ¾ arallel lide Gate Valves t/bs ine ressure age 43 of 54

44 V. tem actor orque for 11 ¾ arallel lide Gate Valves t/bs ine ressure CH 1070 age 4 of 4 ate:04/30/96 age 44 of 54

45 tem actor orque for 13 ¼ arallel lide Gate Valves t/bs ine ressure CH 1071 age 1 of 4 ate:04/30/96 age 45 of 54

46 V. tem actor orque for 13 ¼ arallel lide Gate Valves t/bs ine ressure CH 1071 age 2 of 4 ate:04/30/96 age 46 of 54

47 V. tem actor orque for 13 ¼ arallel lide Gate Valves t/bs ine ressure age 47 of 54

48 X. tem actor orque for 13 ¼ arallel lide Gate Valves t/bs ine ressure CH 1071 age 4 of 4 ate:04/30/96 age 48 of 54

49 tem actor orque for 15 arallel lide Gate Valves t/bs ine ressure CH 1072 age 1 of 4 ate:04/30/96 age 49 of 54

50 X. tem actor orque for 15 arallel lide Gate Valves t/bs ine ressure CH 1072 age 2 of 4 ate:04/30/96 age 50 of 54