Instalation, Operation and Maintenance Manual

Transcription

1 POWER BALL VALVE Instalation, Operation and Maintenance Manual Rev. 1 1 of 23

2 INDEX PAGE 1.0 INTRODUCTION RECEIVING & PREPARATION FOR INSTALLATION RECEIVING INSPECTION QUALITY CONTROL DOCUMENTATION STORAGE UNPACKING, HANDLING & INSPECTION SAFETY AND WARNINGS INSTALLATION GENERAL SPECIAL INSTRUCTIONS FOR WELD END VALVES START-UP CHECKS GENERAL MAINTENANCE TROUBLESHOOTING CHART SOURCES OF OPERATIONAL PROBLEMS EXTERNAL PROBLEMS SMOOTHNESS OF OPERATION GENERAL OPERATION RECOMMENDED LUBRICATION GENERAL ASSEMBLY INFORMATION PACKING CHAMBER LEAKAGE GENERAL PACKING RING REMOVAL REPACKING WITH GRAPHITE PACKING RINGS Rev. 1 2 of 23

3 PAGE SEAT LEAKAGE GENERAL SEAT AND BALL REPAIR DISASSEMBLY EXPLODED ASSEMBLY OF SECURASEAL TYPE-R BALL VALVE GENERAL DISASSEMBLY OF SECURASEAL BALL VALVES CLEANING AND PRE-ASSEMBLY ASSEMBLY GENERAL ASSEMBLY PROCEDURE PROCEDURE FOR REMOVING ACTUATORS GEAR ACTUATORS PNEUMATIC ACTUATORS ELECTRIC ACTUATORS SPARE PARTS Rev. 1 3 of 23

4 1.0 GENERAL INTRODUCTION This manual has been prepared by Velan engineers, designers and maintenance personnel to assist you in obtaining many years of satisfactory service from your Sercuraseal Metal- Seated Ball Valves. It will also assist you in any repairs that the valves may need over the course of their lives. Velan Valve design and manufacturing incorporates many years of research and product development. We are constantly working to improve valve reliability and efficiency. Before installation and any major work, we recommend that you read this manual carefully to become familiar with our valves and service procedures. If you do not understand a procedure in the manual or are experiencing a problem which is not described in the manual, please contact Velan Field Engineering Services or an authorized local Velan representative for technical assistance. Before beginning any major work, we recommend that you carefully check the valve nameplate and record the valve figure number. This will ensure faster service when seeking technical valve assistance from Velan. Thank you for choosing Velan. Rev. 1 4 of 23

5 2.0 RECEIVING & PREPARATION FOR INSTALLATION 2.1 RECEIVING INSPECTION All valves must be examined for signs of damage that may have occurred during transportation. Any damage should be analyzed and a report should be issued. Serious damage should be reported the Velan Field Engineering Services Manager so that a suitable arrangement can be made for repairs. If possible, take digital pictures of the damaged area for the report. 2.2 QUALITY CONTROL DOCUMENTATION For valves purchased with Quality Control (QC) certification, inspect the package of documents to see that the Quality Control certificates are complete as per the purchase order. 2.3 STORAGE Valves should be stored in a suitably sheltered environment to prevent contamination by weather, dirt, or dampness. The valve is shipped with end protectors on the inlet and outlet, which should stay on the valve until it is ready for installation. NOTE: For actuators, please refer to the applicable manufacturers instructions for storage 2.4 UNPACKING, HANDLING & INSPECTION Extreme care should be taken when removing the valve from its container. Although the valve itself is very rugged, the actuator, controls and accessories, air supply tubing, etc., can be fragile, and therefore require extra care in handling. Rev. 1 5 of 23

6 WARNING: Do not use actuator lifting lugs to handle the valve/actuator assembly. The complete assembly must be handled using lifting straps placed underneath the bracket, as shown in the following sketch. Never handle the valve by the driver or the stem. LIFTING BELTS STEM AND DRIVER FIT BELT UNDERNEATH THE BRACKET Only store the valve in an area free from excessive exposure to dust, water, and mud. The valve should remain covered with protective end connection caps or taped coverings until it is ready for installation. Verify the Valve Serial Number against the Packing Slip. The valve serial number is located on the Valve Name Plate and on the valve body. This unique identification number should be recorded and must be used when ordering spare parts. Proper identification will speed up service. Prior to disposal of the shipping container, check the container for any loose pieces (i.e. spare parts, air set, etc.), which may have been shipped along with the valve. Contents of the shipping container should be verified against the Securaseal-Velan Packing Slip. Prior to installation, inspect the valve thoroughly. Look for any loose air fitting connections, loose fasteners, bent air supply line, or any other visual signs of damage. Remove the protective covers from the valve end connections. Using a suitable solvent, wipe the valve end connections to insure that they are free from any debris or visible foreign matter. Recommended solvents are clean or re-distilled acetone, or alcohol. Do not use chloride or fluoride bearing solvents. Flush the pipeline and clean before installing the valve. Debris allowed to remain in the pipeline (such as weld spatters, welding rods, bricks, tools, etc.) can damage the valve. Installation of valves with NPS 3 inch and larger require a hoist to assist installation. A nylon sling should be placed in such a way that the unit can be lifted vertically to its final destination. Rev. 1 6 of 23

7 3.0 SAFETY AND WARNINGS FOR SAFETY REASONS IT IS IMPORTANT TO TAKE THESE PRECAUTIONS Personnel making any adjustments on the valves should wear safety equipment normally used to work with the fluid in the line where the valve is installed. Before removing a valve from a line or re-packing a valve, line pressure must be relieved, with no exception. Velan Metal-Seated Ball Valves can be equipped with a variety of manual gear, electric motor, and hydraulic or pneumatic actuators. Generally, all pressure must be relieved from both sides of the valve before the actuator is removed. Rev. 1 7 of 23

8 4.0 INSTALLATION 4.1 GENERAL The installation area should be checked for adequate clearance to allow for proper servicing of the valve. Obstructions can prevent removal of the actuator and/or complete disassembly of the valve on line. Although the valve is normally supplied for operation in a horizontal line, with the stem vertical, it can be installed in any position. NOTE: Any orientation other than with the stem vertical is a compromise and should be specified during order quotation process. If you are unsure of a certain installation orientation, please contact Velan Field Engineering Services before installation. Open and close the valve to make sure that the disc position matches the actuator indicator. Adjust the stops, if necessary. Refer to the appropriate sections of the actuator manufacturer s manual. Ensure that the pipe openings are well suited to the size and shape of the valve. Do not attempt to pull any piping to the valve by over-tightening the valve end connection/piping studs during installation. Check the valve project drawing and the piping layout drawing to ensure correct position and direction of flow. The Valve Flow Direction Arrow Label is located on the valve bracket. High Pressure Low Pressure If bi-directional sealing is required, the Valve Flow Direction Arrow Label will show a secondary sealing direction (broken line arrow). This applies, for instance, when the valve is temporarily experiencing higher pressure on the side of the body end. Low Pressure High Pressure SPECIAL INSTRUCTIONS FOR WELD END VALVES Rev. 1 8 of 23

9 When installing a butt weld end valve, ensure that the valve is in the open position (even with fail closed actuators) and the inside bore of the valve body is coated with a suitable spatter guard. Ensure that the valve is installed properly in the piping system. Minimize any external pipe loads on the valve. Verify that the valve will be installed in the desired sealing direction. If you are using back-up rings, ensure that they are of the consumable type. Always keep the welding ground strap adjacent to the end being welded to prevent current flow through the valve. Weld valve in line using qualified welder and appropriate procedures. Use pre-heat according to the valve material and procedure requirements. The post weld heat treatment of the butt weld end valves must be localized. Take every precaution necessary to keep the intense heat away from the main portion of the valve (seats and ball). Do not cover entire valve with stress relieving blankets. The temperature of the main body section should not exceed the rated valve temperature. After welding, verify that the packing gland bolts and the body bolts are tightened as per Tables 3 & 4. Cycle the valve several times (minimum 3 times) to ensure smooth operation and re-torque bolts as required. 4.2 START-UP CHECKS Valve stroke is set at the factory and should not need adjustment prior to start-up. If the valve has a position indicator, check the calibration and tune to your system s sensitivity as required. NOTE: Refer to the actuator manufacturer s Instruction and Maintenance Manuals for position indicator details. Once the valve is installed successfully in the pipeline, cycle it several times (minimum 3 times) to insure smooth operation. Rev. 1 9 of 23

10 5.0 GENERAL MAINTENANCE 5.1 TROUBLESHOOTING CHART TABLE 1: TROUBLESHOOTING CHART SYMPTOM PROBLEM CAUSE RECOMMENDED REMEDY REFERENCE SECTION VALVE STEM Actuator has failed Repair or replace actuator as required 8.0 WON'T ROTATE Valve packed with debris Flush or clean valve to remove debris Shaft key sheared Replace shaft key, determine cause of shearing and correct PACKING Packing rings damaged Replace packing rings LEAK Packing rings worn out Replace packing rings Shaft damaged Repair or replace stem , 9.0 Packing chamber damaged Repair packing chamber Inadequate packing flange Tighten gland nuts to required torque Torque Gland bushing is binding values Loosen gland bolts, raise packing flange and readjust gland bushing VALVE SEAT Damaged seat faces Stack-Height repair or replacement LEAK Damaged ball Stack-Height repair or replacement OPENING/CLOSING Packing too tight Loosen packing to hand tight, re-torque TORQUE Shaft is bent or warped Replace shaft ,9.0 EXCESSIVE JERKY Actuator/shaft adaptor Remove actuator mounting and re-align 8.0 OPERATION mis-aligned Over-tightened packing Loosen packing to hand tight, re-torque For pneumatic actuator; Increase air supply pressure Air supply inadequate NOTE: When reporting a problem to Velan, please have the following information ready: Valve serial number - found on identification label and stamped on body. Figure number and tag number, stem orientation. Process media - slurry, oxygen, quench water, etc. Operating conditions - process temperature and pressure Length of valve operation (number of cycles) prior to problem. Exact description of event Rev of 23

11 5.2 SOURCES OF OPERATIONAL PROBLEMS EXTERNAL PROBLEMS Many external elements can affect a valve s overall performance. When a valve is malfunctioning, all possible external causes should be investigated prior to any valve disassembly. Here are some typical examples of external sources of problems: No power supply to valve actuator Inadequate power supply to valve actuator Loose pneumatic fittings Improper calibration of position indicator Improper signal from the Controller to valve position indicator Improper valve stroke adjustment Over compression of valve packing Misalignment of mating components SMOOTHNESS OF OPERATION Here are some examples of the cause of increase in torque to turn the valve: 5.3 GENERAL OPERATION Foreign debris depositing in packing area or behind seats Faulty or damaged valve parts Process caking up inside the valve Misalignment of mating components Valves should be inspected regularly, maintained during operation and serviced promptly when trouble arises. Valves that remain open or closed for long periods of time should be operated at least once a month (opened and closed minimum 3 times). If process does not allow complete open/closed cycling, try to cycle the valve partially (if possible). Test the torque of the gland bolts periodically (recommended once a month). If required, retorque to the torque values in Table 3 following the bolt tightening sequence. Check body and packing area periodically. If a minor leak is detected and deposits are found on the valve, clean the area using an air gun, as build up of process residue can aggravate problems. Any leakage should be monitored, documented and then closely investigated during shutdown periods. Rev of 23

12 5.4 RECOMMENDED LUBRICATION TABLE 2: RECOMMENDED LUBRICATION PART LUBRICATION APPLICATION FREQUENCY Anti-seize compound No.425-A (CRANE) or All threaded Equivalent Thin coat on all During valve Parts Felpro type C5A threads assembly only Hi-temperature anti-seize compound 5.5 GENERAL ASSEMBLY INFORMATION 1. It is important that all parts are cleaned and prepared before assembly. All rust and dirt should be removed with an emery cloth or a suitable solvent (re-distilled acetone, alcohol). Be careful that the lapped surfaces do not get damaged. 2. All threaded parts (cap screws, studs, nuts, bolts) must be well lubricated. Recommended lubricants can be found in Table Verify that all repaired parts meet specifications and that all replacement parts (e.g. packing rings, gaskets, etc.) match the engineering drawing and will fit into the valve. 4. All orientation marks assigned during disassembly must be observed so that correct orientation can be maintained during re-assembly PACKING CHAMBER LEAKAGE GENERAL All Velan SECURASEAL ball valves require four packing rings: two braided graphite packing rings and two graphite ribbon packing rings (see Figure 4) GRAPHITE RIBBON PACKING RINGS BRAIDED GRAPHITE PACKING RINGS [ANTI-EXTRUSION RING] FIGURE 4: PACKING ARRANGEMENT Rev of 23

13 If moisture or dripping from the packing chamber is noticed, the following points must be investigated before removing the packing: 1. Check if the packing flange is torqued down to the correct torque value as per the Table Check if the gland bushing is binding against the packing chamber wall or stem. If so, relieve the line pressure. Loosen the packing flange and realign the gland bushing. Retighten the packing flange by hand, making sure that it is even on both sides of the stem, then torque to the correct torque values by following packing compression procedure. 3. After re-tightening, cycle the valve three to five times and re-tighten the nuts to original torque values as per the Table 3. Loosen the nuts slightly, if the torque value is too high. 4. If steps 1 to 3 do not stop packing leakage, proceed with the removal and replacement of the packing rings. NOTE: Process residue can deteriorate valve components (i.e. corrosion of fasteners, and process build up in the area of live loading and packing chamber, etc.) and should be removed with an air gun during scheduled maintenance checks PACKING RING REMOVAL WARNING: Make sure all line pressure is relieved before any disassembly work is started. Failure to do so may result in personal injury. 1. Remove the packing flange nuts. 2. Lift packing flange and gland bushing as high as possible and secure. 3. Remove old packing rings using flexible removal tools. Removal tools have hooks, which screw into the packing rings. Removal of the packing rings is a difficult and timeconsuming operation. Care must be taken not to scratch the stem or the machined surfaces of the packing chamber during the operation REPACKING WITH GRAPHITE PACKING RINGS 1. Before re-packing, inspect the sealing surfaces of the stem, and the machined surfaces of the packing chamber for damage. Minor scratches can be removed by polishing the surfaces with a fine emery cloth. Verify that the stem is in the center of the gland bushing. If required, realign the stem by tapping it sideways using soft hammer. 2. Insert the first packing ring (braided graphite type, anti-extrusion ring) manually and place it as deep into the packing chamber as possible followed by one graphite ribbon. Refer to Figure 4 (packing arrangement). 3. Use a split packing adapter to push the packing ring to the bottom of the chamber. Rev of 23

14 4. Insert the third packing ring (the graphite ribbon type) as described in Steps 2 and 3. Follow with the fourth packing ring (the braided graphite type) 5. Place the gland bushing and the packing flange into position by hand tightening the nuts. The required torque for gland bolts is listed in table 4. Apply this torque in increments of 20% of the total torque to avoid mis-alignment of the gland bushing. NOTE: Ensure gland studs and nuts are well lubricated with anti-seize compound. TABLE 3: PACKING TORQUE VALVE STUD TORQUE SIZE SIZE 2800# 4500# 1 / 2 " ft-lb Nm ft-lb Nm 3 / 8 " / 4 " 1" 1 1 / 4 " 1 1 / 2 " 2" 2 1 / 2 " 3" 4" 3 / 8 " / 8 " / 8 " / 8 " / 2 " / 2 " / 4 " / 4 " / 4 " SEAT LEAKAGE Rev of 23

15 GENERAL A valve might be leaking if there is a pressure loss in the high-pressure line side after a valve has been properly closed. Leaks can develop from failure to fully close the valve, resulting in high velocity flow through a small opening. The hardfacing material (i.e. chrome oxide) is corrosion and erosion resistant, but grooves (wire drawing), pit marks (mechanical impact), or other surface irregularities may still appear on the mating surfaces. A leaking valve should be repaired as quickly as possible to prevent greater damage caused by the high velocity SEAT AND BALL REPAIR The extent of the damage should be determined at the time of disassembly. If the lapped surfaces are in good condition and only minor scratches are visible, then it may be possible to lap them out with a very fine lapping compound (600 grit or better). If there are any difficulties with determining whether the balls and seats can be refurbished, contact Velan Field Engineering Services. The coating, grinding, and lapping of seats and balls can ONLY be done by Velan trained personnel using specialized equipment. For further details on these operations, please contact our Field Engineering Services department. 6.0 DISASSEMBLY Rev of 23

16 6.1 EXPLODED ASSEMBLY OF POWER BALL VALVE 6.2 GENERAL Rev of 23

17 WARNING: Make sure all line pressure is relieved before any disassembly work is started. Failure to do so may result in personal injury. As general disassembly progresses, place matching marks on parts so that orientation can be maintained during valve reassembly. Work in a clean area, with room for collecting and protecting the valve parts as they are removed. Be prepared to note the condition of all parts during disassembly, looking for evidence of wear, leakage or interference. If possible, take digital pictures of any damaged areas for the file. 6.3 DISASSEMBLY OF POWER BALL VALVES Depressurize valve and follow safety instructions in section 3 when doing any work on the valve. Disassembly refers to components in exploded drawing in Section Remove the actuator as per instructions in Section Remove the valve from the pipeline. Make sure the valve disc is in the partially open position, to allow proper drainage of the process fluid and to prevent damage to the ball. Stand the valve on the body flange. 3. Move lock clip (31) from locked position. 4. Unscrew the self-locking nut (16C) from the stem threaded end. 5. Loosen lever socket head screw (17). 6. Disassemble the handle (33). 7. Remove the upper thrust washer (57B) 8. Remove the external retaining ring (24B). 9. Remove the lower thrust washer (57A). 10. Remove the internal retaining ring (24A). 11. Remove the retainer bushing (75). 12. Remove the load ring (46). 13. Remove seat B (09B). 14. Remove the ball (05). 15. Remove the gland nuts (16A). 16. Remove the gland studs (15). 17. Lower the stem (04) into the valve body cavity. Rev of 23

18 18. Remove the split yoke bushing (55). 19. Remove the upper stem bushing (07). 20. Remove the thrust bearing (29). 21. Remove the split gland bushing (12) by raising the stem, packing flange (11) and Belleville washer assembly (36). 22. Completely remove the stem in order to remove the packing flange and the Belleville washers. 23. Use the appropriate tools to extract the anti-extrusion rings and the packing rings (13). 24. Remove the lower stem bushing (07). 6.4 CLEANING AND PRE-ASSEMBLY 1. Clean all parts with an appropriate and safe solvent, such as clean or re-distilled acetone, or alcohol. 2. Inspect surface of the stem around the packing for any nicks and scratches. Use a fine emery cloth to clean up any scratches. Buff the surface using an emery cloth 3. Inspect the ball and seat surfaces. Light scale can be removed by applying light pressure through a fine emery cloth. Carefully scrape heavier deposits using a metallic edge. Slight scratches can be removed by lapping using 600 grit or finer lapping compound. Be careful to lap seat A to surface A of the ball, and seat B to surface B. The ball valve surface is indicated in the stem slot. 4. Inspect the backs of seats for scaling and damage. To remove scaling, place a fine emery cloth on a flat surface. Place the seat on top of the emery cloth. Rotate the seat over the emery cloth, and stop to inspect. Continue until all scaling and damage is repaired. 5. Inspect the seat sealing surfaces on the body. These surfaces should have no major scratches or scaling. Any scratches or scaling should be removed using a fine emery cloth. Avoid rubbing in one area for an extended period of time as it may create a depression, which can open a leak path. Lap seats using a 600 grit or finer lapping compound. Ensure that these surfaces are thoroughly cleaned and free of dirt and lapping compounds prior to assembly. 6. Inspect the load rings. Edges that contact the body and seats should be sharp and free of nicks and burrs. Damaged load rings should be replaced in order to maintain bi-directional sealing of the valve. 7.0 ASSEMBLY Rev of 23

19 7.1 GENERAL Ensure that all parts are thoroughly cleaned and prepared prior to assembly. All components should be inspected visually for any defects or damage. 7.2 ASSEMBLY PROCEDURE Assembly procedure refers to parts in exploded assembly drawing in section Insert carefully seat A into the body and lock seat A. Make sure that the seat is in the correct location. 2. Weld seat A into the body. Follow standard welding procedures. 3. Insert the lower stem bushing. 4. Install the packing rings into the packing chamber according to procedure in Section Insert the Belleville washers into the packing flange area. Make sure to insert the washers so that they meet on their outside diameters. 6. Insert the packing flange and 3 Belleville washers between the yoke. 7. Insert the stem through the body, packing flange, Belleville washers and packing rings. Verify that the cut feature is in front of the yoke arm. This is for safety blow-out of steam. 8. Insert the needle bearing (Make sure that bearing is well lubricated): a. Assemble the lower race (thicker). b. Assemble the needle bearing. c. Assemble the upper race (thinner). 9. Insert the split bushing on the top of the needle bearing. 10. Slide stem, needle bearing and split bushing into the split bushing guiding 11. Insert the upper stem bushing 12. Insert the lower thrust washer on the top of the split bushing 13. Assemble the external snap ting on the stem groove. 14. Lubricate the studs with an anti-seize compound in Table 2. Tighten the studs into the body. 15. Lubricate the nuts with an anti-seize compound as per Table 2. Following the bolting procedure in Section to tighten the nuts. CAUTION: Verify that the split gland bushing does not come in contact with the OD of the stem and ID of the split gland bushing. The packing flange must be horizontal. Verify that the shoulder of the split gland bushing does not come in contact with the body. 16. Close the valve. Insert the ball. 17. Insert seat B. Rev of 23

20 18. Verify that the load ring is flat and that its edges are sharp. Insert the load ring. 19. Insert the retainer bushing. 20. Insert the internal snap ring into the specific groove. 21. Assemble the name plates. If the valve is equipped with a lever a. Assemble the 2nd thrust washer. b. Assemble the lever. c. Tighten the lever standard nut. d. Assamble the lock nut. e. Tighten the stop pin. Or if the valve is equipped with an actuator a. If required, assemble the insulator gasket. b. Assemble the actuator. c. Assemble the lock washer and the socket head cap screw. Rev of 23

21 8.0 PROCEDURE FOR REMOVING ACTUATORS 8.1 GEAR ACTUATORS Securaseal ball valves can be equipped with a variety of manual gear actuators. Use the following procedure to remove a gear actuator from a valve on line. 1. All pressure must be relieved from both sides of the valve before removing the actuator. 2. Remove the hand wheel from the gear actuator. 3. Remove all actuator bolting from the bottom of the bracket. 4. Using a hoist and nylon slings, raise the actuator off the coupling. If the connection between the stem and driver is keyed, ensure the security of the keys prior to disassembly. Do not to lose or drop keys. Note the orientation of the keyways in the driver. 5. To repair or service the actuator, refer to the manufacturer s instruction manual. 8.2 PNEUMATIC ACTUATORS Securaseal ball valves can be equipped with a variety of pneumatic actuators. Use the following procedure to remove a pneumatic actuator from a valve on line. 1. All pressure must be relieved from both sides of the valve before removing the actuator. 2. Prior to disassembly, make sure that there is no air pressure in the pneumatic actuator. 3. Check if the actuator is supplied as Fail Open or as Fail Close. Make sure that the actuator has fully cycled to its fail position, meaning that the spring is not loaded. Failure to do so can result in serious injury! 4. Remove all actuator bolts from the underside of the bracket. 5. Using a hoist and nylon slings, raise the actuator off of the coupling. If the connection between the stem and driver is keyed, ensure the security of the keys prior to disassembly. Do not to lose or drop keys. Note the orientation of the keyways in the driver. 6. To repair or service the actuator, refer to the manufacturer s instruction manual. Rev of 23

22 8.3 ELECTRIC ACTUATORS Securaseal ball valves can be equipped with a variety of electric actuators. Use the following procedure to remove an electric actuator from a valve on line. 1. All pressure must be relieved from both sides of the valve before removing the actuator. 2. Disconnect the electrical wiring from the actuator. Failure to do so can result in serious injury! 2. Remove all actuator bolting from the bottom of the bracket. 3. Using a hoist and nylon slings, raise the actuator off of the coupling. If the connection between the stem and driver is keyed, ensure the security of the keys prior to disassembly. Do not to lose or drop keys. Note the orientation of the keyways in the driver. 4. To repair or service the actuator, refer to the manufacturer s instruction manual. Rev of 23

23 9.0 SPARE PARTS Please contact Velan Field Engineering Services or an authorized local Velan representative to order any Securaseal Ball Valve parts. For faster service, clearly specify all part types and quantities required. Please have the following information available when ordering spare parts: 1. Velan order number. (P.O.) 2. Valve figure number/tag number 3. Velan item number (if more than one item). 4. Securaseal-Velan Project Drawing number. 5. Your order number and item number. 6. Valve size, type, pressure class, and serial number. Rev of 23