- 2 - Table of Contents

Transcription

1 1 P 70 P

2 - 2 - Table of Contents 1 GENERAL HANDLING Reception and storing Installation into pipeline Supporting the valve Commissioning MAINTENANCE OF INSTALLED VALVE Gland packing Body joint Ball and seats Jammed or stuck valve REPAIR OF VALVE Removing the valve from the pipeline Disassembling the valve Inspection and maintenance of valve parts Ball Stellite seats Locked-up stellite seats PTFE seats Body Other parts RE-ASSEMBLING Cleaning and inspection of parts Installation of ball and seats Stellite seats Locked-up stellite seats PTFE seats Body joint between the body halves Fitting the body joint gasket Tightening the body joint bolts Gland packing Fitting the braided gland packing Fitting the gland packing strip SUPPLEMENTARY VALVE CONSTRUCTIONS, INSTALLATION Body with stellite bushing Ball with cylindrical pipe lining INSTALLATION OF THE ACTUATOR Hand lever VALVE PARTS Ordering spare parts Assembly drawings Metal seated valve Parts list Soft seated valve Parts list Valve stamping EQUIPMENT Tools Measuring devices Grinding compounds and belts Actuator removing tool

3 - 3-1 GENERAL The series P ball valve has flanges or welded ends, two symmetrical body halves, one-piece ball and stem with the ball supported by its seat rings. Standard valves are tight in both flow directions, because the differential pressure across the valve presses the ball against the down-stream seat. The same valve can serve as a throttling control valve and a tight shut-off valve. 2 HANDLING 2.1 Reception and storing Check that the valve has not been damaged during transportation. Store the valve properly before installation. Do not take it to the erection site until installation is due to commence. Do not remove the protection plates before installing the valve into the pipeline. The valve is always delivered in the open position. 2.2 Installation into pipeline Flush or blow the pipes clean before installing the valve. Impurities, sand and parts of welding electrodes might damage the ball surface and seats. There are three marks to indicate the open-closed position of the valve: - an arrow on the drive center of the actuator - a groove at the end of the ball stem - the keyway of the ball stem All are in the same direction with the flow opening. If you feel uncertain about the arrow, check by the groove and the keyway. Place the lifting ropes around the valve body. Never lift the valve by the actuator. (See Fig. 1). The valve can be installed in any convenient position. However, avoid installing it with the stem downwards, because in case of leakage through the gland packing, medium would run over the actuator.

4 - 4 - If possible, install the valve in such a position that the actuator can, if necessary, be detached without removing the valve from the pipeline. Be sure to use flange gaskets that are suitable for the operating conditions. Do not attempt to correct pipe misalignments by means of the flange bolts. The actuator must not touch the pipeline, as pipeline vibrations might damage it or cause incorrect operation. Fig. 1 How to lift a ball valve RIGHT WRONG

5 Supporting the valve A well supported pipeline minimizes strain in the valve, caused by the vibrations in the pipeline. For maintenance it would be preferable not to support the valve. However, if necessary, support it by the body with pipe clamps and supports. Do not fasten supporting structures to flange bolts or to the actuator. See Fig. 2. Fig. 2 How to support a ball valve 2.4 Commissioning Check that the pipeline is clean. Should the valve leak when the pipeline is pressure tested, possible reasons could be an insufficient quantity of testing liquid, or a very low pipeline pressure due to which the ball does not press tight against the seat. Therefore increase the differential pressure or assist the movement of the ball, for example by slackening the actuator installation brackets and gland nuts, then lightly knock the stem or body. If it is necessary to slacken the brackets, check that the open position does not change. The gland packing may leak after long storage. Tighten it uniformly by both nuts, see item

6 - 6-3 MAINTENANCE OF INSTALLED VALVE No regular maintenance is necessary. However, check the gland packing tightness at regular intervals. 3.1 Gland packing If the gland packing leaks after the nuts have been tightened to the values given in item 5.4.1, change the packing. The valve must not be under oressure during this operation. The change can be carried out without removing the actuator if cut packing rings have been used. Remove the old packing for instance with flexible removing tool, see Fig. 3. Install the new packing as instructed in item 5.4. Fig. 3 Removal of the gland packing with a removing tool 3.2 Body joint Should the body joint leak, tighten the nuts as per the torques given in item If the leaking continues, open the body and check the body joint gasket. Also check that the body joint sealing surfaces are level and undamaged, see item

7 Ball and seats A valve leakage exceeding the acceptable values can be due to the ball incorrectly located between the seats or damaged sealing surfaces caused by dirt, grit, etc. Stellite seated valves have a clearance between the ball and seats to prevent jamming of the ball due to thermal expansion. At low differential pressures or due to the weight of the actuator the force pressing the ball against the down-stream seat can be inadequate and the valve may leak. Therefore it will be necessary to swing the ball externally against the down-stream seat by means of distance washers located between the actuator and one of the brackets. Fig. 4 Swinging the ball by means of the actuator installation brackets pressure If damage to the down-stream sealing surface of the ball is suspected, try to stop the leakage by turn ing the ball through 180 degrees. If the leakage continues, then the down-stream seat or possibly both sealing surfaces of the ball are damaged. Turn the ball back to its original position and then turn the entire valve 180 degrees in the pipeline. Should the leakage still persist then it will be necessary to disassemble the valve and carefully check the sealing surfaces.

8 Jammed or stuck valve Jamming or sticking can be caused by accumulated medium between the ball and body. Turn the ball and throughly flush the valve inside. Another reason could be too small a ball clearance for the operating temperature. In such a case insulate the valve bodv properly. If the valve continues to stick then it will be necessary to dismantle the valve and check the ball clearance as stated in item REPAIR OF VALVE It may be necessary to remove and disassemble the valve if the above steps (item 3) do not resolve the problems. 4.1 Removing the valve from the pipeline Remove the valve with its actuator from the pipeline, then turn the valve to remove all flow medium. If the medium is toxic or corrosive, flush the valve TO AVOID ACCIDENTS. If the valve is going to be returned to the manufacturer for repairs do NOT disassemble it. 4.2 Disassembling the valve Disassemble the valve on a clean level surface of wood, cardboard or plastic. Place the valve standing on its flange. Support the actuator so that it cannot overturn when the installation bolts are removed. Fig. 5 Valve placed on a level surface for disassembly

9 - 9 - Remove the actuator installation bolts. Pull the actuator away from the stem either with a outpulling tool or by hand. The outpulling tool is shown in item Remove the installation brackets from the valve. Tap loose the key at the end of the ball stem. Remove any burrs from the keyway edges. Loosen the gland packing nuts. Remove the bolts that fasten the body halves. Lift the upper body half and place it standing on its flange. Fig. 6 Removal of actuator with the outpulling tool 4.3 Inspection and maintenance of valve parts Ball Check each part separately and determine steps to be taken. Lift the ball from the body onto a soft surface and clean it. Check the sealing surfaces of the ball and stem. Remove smaller scratches and impurities with emery cloth. File off any burrs from the stem keyway. If there are any deeper scratches on the sealing surfaces or if the ball is not fully spherical, it must be returned to the manufacturer for repair.

10 Stellite seats To check the backseal remove the stellite seats. Rotate the seat in its groove tapping with a chisel, until it moves freely. Turn the body upside down and hammer the end of the seat through the flow opening. If the seat is badly damaged and will not come out, weld a suitable flat iron bar onto it, which can then be hit through the flow opening. Change PTFE seals only if they are in a bad condition. Graphite backseals should always be changed Locked-up stellite seats If the seats are in good condition it is not necessary to remove them unless the back seal needs to be checked. Carefully grind off most of the metal from the locking points. Then chisel off the locking points by using a sharp single edged chisel. See Fig. 7. Remove the seats as instructed in item If the seats are locked-up with stellite bushing as described in item grind off the welding joint of the bushing, remove the bushing by pressing it into the body so that the seat will come out. See Fig. 8. Fig. 7 Grinding off the locking points Chiselling off the locking points

11 Fig. 8 Grinding off the welded joint in a stellite bushing PTFE seats Body PTFE seats need not be removed if they are still in a good condition unless it can be seen that medium has accumulated behind them. If the original seats are to be refitted remove them very carefully by means of a thin knife or screwdriver. Insert the blade between the metal clamp and seat, and from several points lift the seat from the groove. Body gasket must always be replaced during maintenance. Clean all sealing surfaces carefully. Do not round the sharp edges at the convergence point of the body joint as this could cause leakage. See Fig. 9. Fig. 9 Sharp edges of sealing surfaces sharp edges

12 Other parts Clean all other parts, i.e. packing gland, nuts and bolts, etc. After cleaning and inspection keep all parts well protected until re-assembling, especially the ball, seats and body joint surfaces. If the damage is so severe that the valvc cannot be repaired by changing the parts, return it assembled to the manufacturer for repairs. 5 RE-ASSEMBLING Re-assemble the Series P-valve so that the body half with a tongue in its flange lies underneath. Place this male part in an upright position, the body joint upwards, on a level surface. Then install the parts in the following order: (5.1) seats (5.2) ball (5.3) body joint between the body halves (5.4) gland packings In each of the above phases assemble a group of parts, the construction of which will vary slightly depending on the valve application. Detailed instructions and description of the construction of the groups of parts are given later. The last phase is to hammer the ball stem key into place. 5.1 Cleaning and inspection of parts Begin by checking the parts. Remove any burrs and scratches and clean again the internal parts. In PTFE-seated valves check that the sealing outer periphery of the seats is undamaged. 5.2 Installation of ball and seats In each size the bodies, balls and seats are interchangeable. Valves with stellite seats have hard chrome platcd or stellited balls; those with PTFE seats have polished balls of the basic material.

13 Stellite seats With PTFE strip as back seal Checking the ball clearance When installing new seats or a ball check the ball clearance as follows: Locate the ball seat into its groove without the backseal. Lift the ball into the male body half. Do not fit the body joint gasket. Lift the female body half into position. In order to keep the ball seat in position during this operation, place it slant ways in the groove or centralize it on the ball so that it slips into the groove when the upper body half is lowered into place. Tighten several of the flange bolts by hand. Move the ball to the closed position. Move the ball up and down by lifting and pushing the stem, the maximum distance possible, see Fig. 10. Then measure the ball clearance with a dial indicator, a T-gauge or two feeler gauges. Fig. 10 Measuring the ball clearance. Measure C taken with a dial indicator or T-gauge C Measure measured simultaneously 2 with two feeler gauges where "C" equals ball clearance or movement. feeler gauge

14 Assembly of the stellite seats Fig. 11 Stellite seats Locate the back seal in the seat groove as shown in Fig. 12. If necessary, fasten the PTFE strip with 3-4 small PTFE keys. Fig. 12 Cutting and fastening the back seal strip PTFE key Locate the ball seats into the groove and lift the ball onto the male body half. Fit the body joint gasket as instructed in item 5.3.

15 Locked-up stellite seats Locking the seat a) with a metal clamp which is peened over the seat shoulder by punching it at 4-8 points with a punch. Be careful not to deform the seat by excessive punching, b) with a stellite bushing pressed against the seat shoulder and welded at the flange-end of the valve as instructed in item 6.1. Fig. 13 Locking with a metal clamp Fig. 14 Locking with a stellite bushing Stellite seat Stellite bushing Weld There are three different ways to lock the seat, depending on the back seal material. These are described later. The thickness "t" of the filling cone, made of gasket sheet and required for pressing of the back seals, is calculated as follows: t ballclearancec 2 Fig. 15 Filling cone

16 Assembly by pressing Fig. 16 Assembly by pressing Filling cone Tighten the body halves together in a press or by tightening at least half of the flange bolts thus compressing seals into the grooves. At this stage it is sufficient to tighten the bolts to approx. 50 % of the final torque required, see Table 3. Disassemble the valve. Lock up the seats as instructed in item Lift the ball into the male body half. Fit the body joint gasket as instructed in item 5.3.

17 High temperature seats with graphite sheet as back seal Fig. 17 Locked-up high temperature seats Ball Seat Graphite seal High temperature seats are always locked up. Locate the ball seat with a graphite back seal into the body groove. Fit the ball and the female body half onto the male half. Check the clearance as instructed in item with the graphite seals fitted. Remove the upper body half, turn the ball to the open position and place the filling cone between the ball and seat. Replace the upper body half. Tighten, in a press or by the flange bolts, the body halves together as instructed in Disassemble the valve. Lock up the seats as per Fit the ball into the male body half. Fit the body joint gasket as instructed in item 5.3.

18 PTFE seats Assembly of PTFE seats The ball and seats are pre-pressed to ensure a good tighteness even at low differential pressures. The shape of the pre-pressed seats guarantees good valve sealing and tight shut-off ability. The pre-pressed edge must be unbroken. The clearance need not be checked as the inner parts, ball and seat will not be changed. Fit the ball into position on the male body half and fit the body joint gasket as instructed in 5.3. Fig. 18 PTFE seats Ball PTFE seat 5.3 Body joint between the body halves Fitting the body joint gasket The gasket is either a strip or a sheet depending on valve application.

19 Soft PTFE strip Fig. 19 Fitting the soft PTFE strip Fit the sealing strip following the shoulder of the male body half against the bushing on ball stem, see Fig. 19. Table 1 Dimensions of soft PTFE strip Valve size Strip ø Strip lenght mm (in) mm (in) mm (in) (1 1/2") ( 2") (2 1/2") (5/64") (5/64") (5/64") ( 12") ( 14") (16,5") (3") ( 4") ( 5") ( 6") (8") ( 10") ( 12") ( 14") ( 5/64") (5/64") (5/64") (1/8") (1/8") (1/8") (1/8") (1/8") (19") ( 25") ( 29") (36") (44") ( 55") ( 64") (72") Press the strip against the mounting bushing so that a part of it will extrude into the packing cavity when the body halves are mounted together. Cut the strip leaving about 5 mm extra to both ends.

20 Graphite sheet gasket Fig. 20 Cutting the graphite sheet gasket When fitting the gasket which comes supplied in a ring-shape, trim the ends as shown in the above figure. For large valves, 12" and larger, a straight strip can be cut from a sheet and bent following the shoulder of the male body half against the bushing on the ball stem. The thickness of the sheet is 0.4 mm (0.016") Tightening the body joint bolts After fitting the body joint gasket lift the female body half, complete with pre-installed seat, see item 5.2, onto the ball. Turn the body halves and align them so that the sealing surfaces do not form noticable steps between the body halves. Fig. 21 Guiding with mounting bushing Steps in the joint can cause leakage

21 Lubricate the flange and neck bolts, screw into place and tighten to the torques given in Table 2. If hexagon bolts are used as flange bolts the tightening is simpler if the bolts are inserted from below so that the nuts are screwed on from above the body joint flange. Neck bolts in valve sizes 100 mm (4") and smaller must be placed before installing the body halves. Center them so that the distance from the outer side of the nut to the shoulder of the bolt is equal at both ends. For unlubricated bolts the torque values must be multiplied by factor (~1,5). Table 2. Torques for bolts - lubricated UNC 5/16 3/8 1/2 5/8 3/4 7/ /4 1 1/2 Nm ft-lb Flange bolt tightening sequence to be as per the example below. Start opposite to the stem, initially to 10 % of the torque values given in Table 2. Then tighten in the same sequence to the final torques. Fig. 22 Flange bolt tightening sequence - a typical example Neck bolts

22 Gland packing Depending on application the gland packing is either braided PTFE or Grafoil strip. Table 3. Dimensions of thc packing box Shaft diameter Packing width, b Packing box depth, h mm (in) mm (in) mm (in) (1") (1 3/8") 6,35 6,35 (1/4") (1/4") (1") (1") (1 1/2") (2 5/32") (2 3/4") 6, (1/4") (5/16") (5/16") (1") (1 1/4") (1 1/4") (3 11/32") (3 3/4") (4") (5/16") (7/16") (7/16") (1 1/4") (2 5/32") (2 5/32") Fitting the braided gland packing The braided PTFE strip is generally used as gland packing. If no pre-cut rings are available, cut the braided strip as shown in Fig. 23 on the valve shaft. Cut vertically with a sharp thin knife. If a support ring is recuired, place it at the bottom of the packing box. Tap each packing ring in position, only by one, with a bush or with the packing gland. Locate eacho packing joint at 90 angle to each other and 45 to the flow opening.

23 No clearance must be shown between the ends of the packing ring. Tighten the non-pressurized gland packing three times: initially when the valve is assembled, then after it has been pressure tested, and finally before installing into the pipeline. Table 4 below gives the tightening torques and minimum allowed tightening margins. If the margin is too small add another packing ring. Tighten with a torque wrench. Fig. 23 Cutting a braided packing strip Fig. 24 Tightening margin of new gland packing Tightening margin Table 4 Tightening torques for gland packing Stem diameter Size of nut Torque Min. tightening margin allowed mm (in) Nm ft-lb mm (in) (1"-1 1/4") (1 1/2"-2 1/4") (2 3/4"-3 1/2") (3 3/4"-5 1/4") 3/8 UNC 1/2 UNC 5/8 UNC 3/4 UNC (3/8") (3/8") (1/2") (1/2")

24 Fitting the gland packing strip The material is usually graphite. It is also mentioncd in the valve parts list. Fig. 25 Making a gland packing ring from a strip Grafoil strip Support ring If no pre-pressed rings are available, make the packing ring by winding the strip onto the stem, to fit exactly the packing box diameter. With this type of packing a support ring is always necessary. Tighten the packing rings one by one as instructed in item Their thickness is normally reduced by about 50 %.

25 SUPPLEMENTARY VALVE CONSTRUCTIONS, INSTALLATION 6.1 Body with stellite bushing For applications where the standard body material would quickly wear out, the flow opening is stellite lined. Usually the ball is also stellited. Fig. 26 Installation of stellite bushing Size h mm (in) mm (in) (1 1/2) (2) (2 1/2) 4 4,5 4,5 (5/32) (11/64) (11/64) (3) (4) (5) (6) (8) (10) (12) (14) 4,5 4,5 4,5 5 5, (11/64) (11/64) (11/64) (13/64) (7/32) (1/4) (1/4) (1/4) Press the bushing into position so that the end which protrudes inside the valve is at the given distance "h" from the seat groove bottom. Tack-weld the flange end, without build-up, 4 to 8 tacks of about 10 mm each, depending on valve size.

26 Ball with cylindrical pipe lining This type of a ball is intended for applications where a straight flow opening is required. Fig. 27 Pipe lining of ball Welded seam Center boring The pipe is formed from thin plate and will not withstand pressure. The pressure is balanced by a small hole drilled through the bottom of the ball. The pipe lining is not fastened to the ball; the lining being joined by a longitudinal welded seam. 7 INSTALLATION OF THE ACTUATOR The Metso Automation drive center is suitable for various control units. Clean the stem bore. File off any burrs. Lubricate the stem bore and ball stem. Fasten the actuator brackets to the valve loosely. Insert the reducing bush in the actuator stem bore, if required. In the actuator stem bore there are two keyways at 90 angle from each other. The ball stem has a keyway parallel to the flow port of the ball. When mounting a cylinder actuator choose the actuator keyway that establishes the piston in its upper position (top end of the cylinder) when the valve is closed.

27 When installing a screw operator choose the actuator keyway that establishes the closed valve position when the handwheel is turned clockwise. Push the actuator onto the ball stem carefully. Any excess force may damage the sealing of the ball and seat, especially soft seats, e.g. PTFE. When there is a threaded hole at the end of the stem, the actuator can be pulled into position using a bolt. Locate the actuator as straight as possible with regard to the valve. Lubricate the fastening bolts and tighten them together with the bracket nuts. Adjust the open and closed positions of the ball by means of the adjustment screws in the actuator, see Fig. 28. The correct open position is obtained by means of the flow opening, and the closed position by means of the arrow marked on the actuator. No adjustments are necessary if the actuator was installed on the same valve previously. It is only necessary to drive the actuator to its open position and then twist the entire actuator. Turn the ball to the fully open position and tighten the bolts and nuts. Safeguard the stop screw at the top of the cylinder with a non-hardening sealant, e.g. Loctite 76. For required installation parts, see Fig. Nos. 29, 30 and 31 with parts lists. Fig. 28 Open and closed position of actuator Stop screw of closed position Stop screw of open position

28 Fig. 29 No bushing between valve stem and actuator bore Actuator Ball valve Fig. 30 Bushing between valve stem and actuator bore One or two keys, depending on wall thickness of bushing (5) Actuator Ball valve

29 Fig. 31 Stem extension for high temperature Parts list for Figures 29, 30 and 31 Item Qty Part 1 2 Bracket 2 4 x) Hexagon bolt 3 4 Hexagon nut 4 4 Washer 5 1 Bushing 6 1 Key 7 4 x) Washer x) = 8 pcs in size Hand lever When a hand lever is installed on the valve the ball stem has a shortened key, to avoid interference with the lower surface of the stop plate or the bearing bushing. Push the hand lever onto the ball stem, parallel to the flow opening of the ball.

30 Fit the stop plate, with the bearing bushing if required, onto the stem. Tighten preliminarily the stop plate fastening nuts. Determine the open and closed positions of the ball by twisting the lever against the open and closed position pins. Check the open position with the flow opening, and the closed position with the position of the lever relative to the keyway, and the body joint. Finally tighten the stop plate. A knob is fitted in the hand lever to facilitate locking of the valve in intermediate positions. Parts list Fig. 32 Installation of hand lever Item Qty Part 1 1 Stop plate 3 2 Hexagon nut 4 2 Washer 5 1 Bushing 6 1 Key (shortened)

31 VALVE PARTS 8.1 Ordering spare parts Please give the following details in your order sheet: - Valve type, given on the identification plate and in all related documents - Manufacturing number of valve, stamped on pipe flange - in flangeless valves on machined part of the welded end. - Parts code number. If valve s spare parts list is used, the name and quantity of the part, or - number of parts lists item number, quantitvand the name of the part, or - number of this manual, item number, quantity and the name of the part.

32 Assembly drawings Metal seated valve Metal seat Manufacturing number Parts list Item Quantity Part 1 1 Body half, male 2 1 Body half, female 3 1 Ball 4 2 Seat 5 1 Gland 6 2 Stud 7 Hexagon screw 8 2 Stud bolt 9 4 Hexagon nut 10 Hexagon nut 11 2 Hexagon nut 12 1 Key 13 2 Back seal x) 14 Gasket x) 16 Gland packing x) 19 1 ID plate x = Recommended spare parts

33 Soft seated valve PTFE seat Manufacturing number Parts list Item Quantity Part 1 1 Body half, male 2 1 Body half, female 3 1 Ball 4 2 Seat 5 1 Gland 6 2 Stud 7 Hexagon screw 8 2 Stud bolt 9 4 Hexagon nut 10 Hexagon nut 11 2 Hexagon nut 12 1 Key 13 2 Back seal x) 14 Gasket x) 16 Gland packing x) 19 1 ID plate x = Recommended spare parts

34 Valve stamping Name plate Casting code Material code Mfg. No Name of manufacturing Pressure rating of body Nominal size Pair No. of body halves Batch No. of body material Direction mark of ball opening Ball dia. below nominal one ( mm 100 ) Ball clearance of stellite-seated valve Stamped with letter-number combination, e.g. CL 0.55 Mark of pressure testing. Two marks on a stellite seated valve=tightness acc. to MSS SP-72 Tester s initials Seat material

35 EQUIPMENT 9.1 Tools No special equipment is needed to repair P-series ball valves. However, a special outpulling tool is recommended for the actuator removal, for dimensions refer to item 9.4. Series P ball valves are threaded to ANSI B standard, so American standard tools are to be used. For body and neck bolts it is recommended to use socket tools. 9.2 Measuring devices Measure the ball clearance either with a dial indicator, T-gauge or feeler gauges. In PTFE-seated valves the clearance for thermal expansion between the ball and seat is measured with feeler gauges. 9.3 Grinding compounds and belts For the ball and seats: Diamond or boric carbide paste - for pre-grinding, coarseness 28/20 µm - for finishing, 7/5 µm. Thin with thinner suitable for diamond grinding when necessary. For sealing surface of the stem: Grinding cloth with a coarseness of about Actuator removing tool Fig. 33. Actuator removing tool

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