PSG. Installation and Operations Maintenance Manual. Parallel Side Gate Valve & Actuator

Transcription

1 G nstallation and Operations Maintenance Manual arallel ide Gate Valve & ctuator

2 age 2

3 B O CO. OCO O CVG O... 4 B. OO CO M OO C. OO HM COC WG O VG ) O OO OO VV BCO JM... 5 B. CO V. MC MBY MBY... 7 V. OB HOOG... 8 X G (1-7)... 9 X B CH 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 orque for 11 ¾ arallel lide Gate Valves t/bs orque for 13 ¼ arallel lide Gate Valves t/bs orque for 15 arallel lide Gate Valves t/bs Body Bolt orque Values G O age 3

4 ntroduction his manual describes special cautions that must be adhered to, in order to assure a long, trouble-free service life and Valvechnologies warranty. Valvechnologies, nc., as the leading manufacturer of metal-seated ball valves, manufactures arallel lide Gate valves. Valvechnologies 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. MO: 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 Valvechnologies, nc. valves should be directed to an authorized distributor or to the factory in Houston, exas. ailure to do so may void the warranty.. nstallation. eceiving and reparation Valvechnologies 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 Valvechnologies, nc. factory-trained 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 4

5 . 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. Valvechnologies 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 Valvechnologies, nc. 2. nsulation 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 nitial est 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.. Operation. Valve 1. ubrication and djustments he Valvechnologies 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. age 5

6 Valve osition ndication ll Valvechnologies, 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 Valvechnologies 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 months and replaced if oxidized or replenished should that be required. roper gearbox lubrication will minimize hand wheel torque requirements. V. Maintenance. isassembly rocedure: arallel lide Gate Valve O: ee ig. 1 & 3 for part identification 1. oosen the gland nuts (tem 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 two 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 6

7 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 two 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 Valvechnologies ball valve. hus the tand-off is the same as for a 4 bore Valvechnologies ball valve. 7. lace the stem (5) between the gates & use two 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 two 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 four 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 and add the remaining two bolts. 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), six 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 four yoke posts (21), torque per Valvechnologies bolting torque specification per Chart nstall two stop collars, if provided, onto the two 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 two yoke posts & clamp together. age 7

8 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. V. rouble hooting Malfunction ossible Cause emedial ction Valve won t cycle a) ctuator has failed a) eplace or repair actuator b) Valve packed with debris b) Cycle & flush valve to remove debris c) tem key has sheared c) etermine cause of shearing & correct/ replace keys d) Gate gap incorrect d) Call factory tem packing leaking a) Gland bolts loose a) ighten gland bolts b) acking damaged or missing b) hut down system & replace packing c) eal mis-aligned c) eplace & properly align Bonnet gasket leaking a) Bonnet Bolts loose a) ighten body bolts b) Body gasket damaged b) emove valve from service & replace body gasket c) Bonnet gasket seating faces in body or end piece damaged Valve gates leaking a) Valve no fully closed a) Close the valve c) eturn parts to Valvechnologies for rework b) ebris trapped in valve b) Cycle & flush to remove debris c) eat or ball damaged c) emove valve from service & repair or replace ball and/or seat age 8

9 X G age 9

10 G 1 age 10

11 G 2 G 3 G 4 age 11

12 G 5 G 6 G 7 age 12

13 X B CH age 13

14 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure Chart 1062 age 14

15 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure Chart 1062 age 15

16 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure Chart 1062 age 16

17 tem hrust (bs.) for arallel lide Gate Valves 8 eat.. ine ressure Chart 1062 age 17

18 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure Chart 1064 age 18

19 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure Chart 1064 age 19

20 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure Chart 1064 age 20

21 tem hrust (bs.) for arallel lide Gate Valves 11 3/4 eat.. ine ressure Chart 1064 age 21

22 tem hrust (bs.) for arallel lide Gate Valves 13 1/4 eat.. ine ressure Chart 1065 age 22

23 tem hrust (bs.) for arallel lide Gate Valves 13 1/4 eat.. ine ressure Chart 1065 age 23

24 tem hrust (bs.) for arallel lide Gate Valves 13 1/4 eat.. ine ressure Chart 1065 age 24

25 tem hrust (bs.) for arallel lide Gate Valves 13 1/4 eat.. ine ressure Chart 1065 age 25

26 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure Chart 1066 age 26

27 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure Chart 1066 age 27

28 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure Chart 1066 age 28

29 tem hrust (bs.) for arallel lide Gate Valves 15 eat.. ine ressure Chart 1066 age 29

30 orque for 8 arallel lide Gate Valves t/bs tem actor (0.0247) ine ressure Chart 1068 age 30

31 orque for 8 arallel lide Gate Valves t/bs tem actor (0.0247) ine ressure Chart 1068 age 31

32 orque for 8 arallel lide Gate Valves t/bs tem actor (0.0247) ine ressure Chart 1068 age 32

33 orque for 8 arallel lide Gate Valves t/bs tem actor (0.0247) ine ressure Chart 1068 age 33

34 orque for 11 3/4 arallel lide Gate Valves t/bs tem actor (0.0421) ine ressure Chart 1070 age 34

35 orque for 11 3/4 arallel lide Gate Valves t/bs tem actor (0.0421) ine ressure Chart 1070 age 35

36 orque for 11 3/4 arallel lide Gate Valves t/bs tem actor (0.0421) ine ressure Chart 1070 age 36

37 orque for 11 3/4 arallel lide Gate Valves t/bs tem actor (0.0421) ine ressure Chart 1070 age 37

38 orque for 13 1/4 arallel lide Gate Valves t/bs tem actor (0.0549) ine ressure Chart 1071 age 38

39 orque for 13 1/4 arallel lide Gate Valves t/bs tem actor (0.0549) ine ressure Chart 1071 age 39

40 orque for 13 1/4 arallel lide Gate Valves t/bs tem actor (0.0549) ine ressure Chart 1071 age 40

41 orque for 13 1/4 arallel lide Gate Valves t/bs tem actor (0.0549) ine ressure Chart 1071 age 41

42 orque for 15 arallel lide Gate Valves t/bs tem actor (0.0549) ine ressure Chart 1072 age 42

43 orque for 15 arallel lide Gate Valves t/bs tem actor (0.0549) ine ressure Chart 1072 age 43