Installation, Operation and Maintenance

Transcription

1 Plug Valve Specialists Strong Company Good Company Doc. No. 3ZQM-E-02 Approved by H.S.KIM Rev. No. C Checked by Y.J.KANG Issued 10,19,2015 Prepared by H.E.KO Non lubricated Lined Plug Valve Installation, Operation and Maintenance 3Z CORPORATION 254 SIHWA VENTURE-RO, SIHEUNG-SI, GYEONGGI-DO, SOUTH KOREA (TEL) (FAX) z@3zvalve.com Web:

2 0. General Introduction 0-1. Introduction This manual is designed including the explanation of storage installation test maintenance for all of the lined plug valve supplied by 3Z. You must comply with this manual to maintain and manage the lined plug valve for a long time. Contents 1. Specification & Availability 3 2. Exploded View of Lined Plug Valve Storage & Installation 5 5. Operation 6 6. Maintenance and Repair The Value of Valve Torque Gear Operator User safety All of the person in charge must fully aware of the contents described here, understand and practice exactly. But the matters of instructions of this manual are not fully explained for all about any unforeseeable accident that can occur in lined plug valve, related equipment, and a variety of working process, so when you act by the contents of this manual,,you must handle properly p depending on the common sense and experience of the relevant worker situationally. The procedures and orders of this manual are composed of maintenance of lined plug valve to assist the user. Please read the notes below. CAUTION Never do not attempt to repair the valves or components during under pressure. It can lead to serious injury or death. WARNING NOTICE Please read the instructions before repairing the valves. If you do not follow the instructions of this manual, you can lead to serious injury or death. -2- The instructions of this manual are explain the valves what are produced currently. If you need to repair the discontinued valve, please contact with 3Z service center, and make certain that the correct repair method and instruction.

3 1. Specification & Availability 1-1. Specification 3Z lined plug valves have the specifications as following table. Fig Rating Size 0.5 ~ ~ 8 Size for CE 15~350 15~200 Temperature -46 C C ~ 204 CC Connection Design Flange ASME B16.34, API 599, API 6D End To End ASME B16.10 Dimension of Flange ASME B Available Materials The main materials used in the 3Z lined plug valves are used in a following temperature range. Component Materials Operating Temperature ( C) ASTM SA 216 WCB -29 ~ 425 ASTM SA 216 WCC -29 ~ 425 ASTM SA 351 CF3-29 ~ 425 ASTM SA 351 CF3M -29 ~ 450 Body/Plug/Cover ASTM SA 351 CF8-29 ~ 525 ASTM SA 351 CF8M -29 ~ 525 ASTM SA 351 CN7M -29 ~ 325 ASTM SA 352 LCB -46 ~ 325 ASTM SA 352 LCC -46 ~ 325 SEAL PFA -29 ~ 204 Gasket RTFE -29 ~

4 2. Exploded View of Lined Plug Valve Carbon Steel (PFA) 316 Stainless (PFA) Hastelloy - C (PFA) No Parts Specification No Specification No Specification 1 Body ASTM A216 WCB 2 Plug ASTM A216 WCB 3 Cover ASTM A216 WCB 4 Lining PFA 5 Cover Bolt ASTM A193 B7 6 Adjusting Bolt AISI Hub ASTM A351 CF8 8 Wrench AISI Delta Ring RTFE 10 Reverse Lip RTFE 11 Metal Diaphragm AISI Thrust Collar AISI Anti-static Device AISI Hub Bolt AISI Snap Ring Alloy Steel 16 BTM Adjusting Nut AISI BTM Adjusting Bolt AISI ASTM A351 CF8M 2 ASTM A351 CF8M 3 ASTM A351 CF8 4 PFA 5 ASTM A193 B8 6 AISI ASTM A351 CF8 8 AISI RTFE 10 RTFE 11 AISI AISI AISI AISI AISI AISI AISI ASTM A494 CW-12MW 2 ASTM A494 CW-12MW 3 ASTM A494 CW-12MW 4 PFA 5 ASTM A193 B8 6 AISI ASTM A351 CF8 8 AISI RTFE 10 RTFE 11 AISI AISI AISI AISI AISI AISI AISI 304 * In order to know the correct specification of delivered products, you have to refer the approved Proposal Drawing. -4-

5 3. Storage 3-1. When you transport the valve, do not throw, drop, throw down, or drag Before the valves are installed in the piping and operating, you must transport or storage with the valve open position to prevent damage to the sealing surface of the plug The valve shall not be stored in a cool and dry place to protect from the climatic condition such as dust, moisture, or rain. Avoid the flame, fire or hot/cold temperature, which could damage gasket or seal parts and happen to leakage. Dry the valve body before painting of the valve because humidity may cause the destruction of waterproof joint The flange cover should not be taken off from the valve until installation to prevent from the damages to the flange and contamination with foreign material into the valve. 4. Installation 4-1. A valve being carried, a rope, wire, and shackle should be strong enough to sustain the total weight The valve should be installed with the firm groundwork Flange ends type valves should be fitted parallel with counter flange and use standard gasket. The bolts to fit should be tightened by diagonal axis successively. Poorly aligned pipe connections cause leakage, fissuring rupture during use under pressure Please always follow up guidance specified at attached tag plate. Check material grade on name plate or body to verify compatibility of fluids with the valve In case welded ends types valves, the excessive heat may cause the damage on seal parts. There fore heat should not be transferred to the central seal parts of the body. -5-

6 5. Operation 5-1. No one may treat a valve except the practiced expert If the valve is equipped with a locking device, only the concerned operator or the supervisor should keep the key. In case the device wants repairs, it should be done right away After installation, the valve shall be fully opened and should remain in this full open position until lines are thoroughly cleaned and flushed During operation, care shall be taken not to adjust the adjusting bolts and cover bolts except for operators Never take away any attached tag or device from the valve nor any function could be removed at discretion Whatever slight defect if detected in the valve, the operation shall be stopped The application terms must be observed; for example, the pressure limitation and the application for material. Check the maximum working pressure on the Name plate. Check marking of maximum operating temperature on the name plate. Do not use v-notch stamps on the body which happen to weakness of the body strength and then cause leakage or serious injury during use under pressure In accord with the manual, the inspection of the function shall be carried out periodically any always right before the operation of the valve. Keep filtration of the fluid, internal wearing under the effect of an abrasive cause leakage, fissuring i rupture during use under pressure The maximum force required at the handwheel or wrench to apply the breakaway torque shall not exceed 360N. Any tool or other device to operate valves may cause serious problem like leak or malfunction. VALVE CLOSE VALVE OPEN -6-

7 6. Maintenance and Repair 3Z Lined plug valves are designed and manufactured for trouble-free for long time using. But, if problems are encountered in using, you can use it as the new valve by adjusting or maintaining as follows Troubleshooting Guide Possible Defect Remedy Guide Remark Leakage at flange 1. Tighten the gasket with flange bolt. 2. Replace the gasket. 1. ASME B16.5 (gasket size, flange bolt for class, size) 2. The Value of bolting torque (Section 6.6) 1. Tighten for 90 turning the adjusting bolt. 1. The Value of bolting torque Stem leakage If you over-adjust the adjusting bolt, The torque of valve is increased. (Section 6.6) 2. Replace top seal (Section 6.4) 2. Replace the top seal set. 1. Assembly Cover (Section 6.5) Cover leakage 1. Tighten the reverse lip with cover bolt. 2. Replace the reverse lip. 2. The Value of Bolting Torque (Section 6.6) Reverse lip (Part No.10) 3. Replace top seal (Section 6.4) 1. Tighten for 90 turning the adjusting In -line leakage Bolt. If you over-adjust the adjusting bolt, The torque of valve is increased. 1. The Value of bolting torque (Section 6.6) 2. Replace plug (Section 6.4) Plug (Part No.2) 2. Replace the plug. 1. Loosen the adjusting bolt until the Excessive torque torque is decreased. Leakage can occur at the valve if you loose too much the adjusting bolt. 1. The Value of bolting torque (Section 6.6) 6-2. Caution - If the leakage stop by excessive adjustment of adjusting bolt, perhaps the sealing part is damaged by abrasion. So you should replace the sealing part. - To check the leakage, confirm after performance the opening and closing the valve. - When the leakage occurs, the operator must not operate arbitrarily. Adjust with supervisor and the person in charge. -7-

8 6. Maintenance and Repair 6-3. Procedure * Perform the replacing components and maintenance of the valves by the following Guide. Content Top Seal Assembly Plug Assembly See section 6.4 replace top seal and plug Cover / Bolting Assembly Adjusting bolt Adjustment BTM Adjusting bolt See section 6.5 Assembly cover See section 6.6 Adjustment -8-

9 6. Maintenance and Repair 6-4. Replace Top Seal Set 3Z Lined plug valve has been properly adjusted at the factory, so no further adjustment is necessary. But if Line Leakage or Stem Leakage occur during use, replace TOP SEAL as following. 8. Assemble Snap ring by tools 7. Assemble Antistatic device after assembly cover and top seal. 6. Assemble Thrust collar on Metal diaphragm 5. Assemble Metal diaphragm on the Reverse lip 4. Assemble Reverse lip on Delta ring 3. Put Delta Ring over the Plug. CAUTION : When assemble the Reverse lip, prevent the scratch by Plug edge part. 2. Push plug to the body until reaching same level of body and plug by Press 1. Put Plug into the Body. (Check plug with open direction ) * Assemble the components same order as the pictures lastly. -9-

10 6. Maintenance and Repair 6-5. Cover Assembly & Adjustment 3Z Lined plug valve has been properly adjusted at the factory, so no further adjustment is necessary. But if Line Leakage or Stem Leakage occur during use, adjust the Cover Bolt and Adjusting Bolt as following. CAUTION Never do not attempt to repair the valves or components during under pressure. It can lead to serious injury or death Tighten the Cover Bolt crossed, and tighten until reach Bolt torque reference to The Value of Bolting Torque (Section 6.7). 5. Check the height of the fix bolt certainly by tightening Adjusting bolt until moving the plug. 1. Put on Cover to top of Plug. 2. When you assemble the Cover, you should match Cover material marking and Body material marking Adjustment 1. If the leakage occur Cover Seal, tighten Cover Bolt uniformly conform to the below table. : * Recommended Bolting Torque Bolt Size A193 B8 (N.M) A193 B7 (N.M) M M M M M M When you assemble the Cover Bolt, tighten diagonally and repeatedly, and tighten the proper torque with Torque Wrench. M , If the leakage occur stem or plug seal 1) Loosen the bottom adjusting bolt. 2) Tighten each three adjustment bolts (or screws) by 1/4 turn. 3) Operate valve and check for leakage. Repeat as necessary to stop the leakage. 4) Tighten the bottom-adjusting bolt until contact to the bottom of the plug is made. 3. When assemble the Adjusting Bolt, be careful not to exceed the limit of recommended Boling Torque. -10-

11 7. The Value of Valve 7-1. Valve Torque with PFA material Following Torque Table is Maximum Allowable Valve Torque. Fig Size Break Running Seating 121/ / / / / / / / / ,500 1,200 1, Valve Weight ,000 1,600 1, ,800 2,300 2, ,600 2,900 3,200 You must see the following table for the weight of the valve. CAUTION : The larger the size of the valves, the valves are heavier. So you must be careful when transporting the valve. * Valve Weight (units : kg) SIZE & Lifting Point You must see the following picture when transporting the valve. CAUTION : If you do not transfer in accordance with the instructions of the manual, it can occur damage to valve and l oss of lives. For other inquiries about data of valve, Please contact 3Z Head office :

12 8. Gear Operator 8-1. Lubrication The actuator is lubricated at the factory, and dose not require further lubrication Adjustments The open and closed position stops prevent the operator from rotating beyond the open and closed positions of the valve. Each stop is adjustable. If the is factory-mounted on the valve, the stops are preset, and do not require further adjustment. If the is not factory mounted on the valve, or if the has been removed, the stops will require adjustment as described below. Refer to Figure 1 for component identification. To adjust the closed position stop: 1. Loosen the handwheel nut on the closed position stop screw, and back out the stop screw. 2. Turns the handwheel so that the valve is in the closed position. 3. Turn the closed position stop screw clockwise until resistance is felt from the stop screw contacting the gear inside of the operator. 4. Hold the stop screw from turning, and tighten the nut. To adjust the open position stop: 1. Loosen the nut on the open position stop screw, and back out the stop screw. 2. Turn the handwheel so that the valve is in the open position. 3. Turn the open position stop screw clockwise until resistance is felt from the stop screw contacting the gear inside of the operator. 4. Hold the stop screw from turning, and tighten the nut. FIG 1 Operator Component -12-

13 8. Gear Operator 8-3. Removing Operator From Valve Refer to Fig 1 for component identification. 1.Remove the four mounting screws and washers. 2.Remove the operator from the valve Replacing Operator On Valve Refer to Fig 1 for component identification. 1.The bracket is mounted to the flange pads (or cover bolts), with the body and plug ports aligned. 2. Install the compensator over the valve stem. 3. Turn the operator input shaft until the position indicator is on open. 4. Insert the torque bar into the operator. 5. Lower the operator onto the bracket with the operator input shaft perpendicular to the flow path, engaging the torque bar with the compensator. 6. Insert and tighten the four operator bolt. 7. Adjust the actuator travel stops for 90 operation, being sure that the plug and body ports are aligned in the open position Changing Actuator Mounting Position On Valve Before changing the mounting position, check to assure that dimensional clearance is available for the proposed location. To change the position, follow the steps in the Removing Actuator from Valve section and in the Replacing Actuator on Valve section. -13-

14 3Z Headquarters 254 SIHWA VENTURE-RO, SIHEUNG-SI, GYEONGGI-DO, KOREA (TEL) (FAX) z@3zvalve.com 3Z provide perfect products. The copyright of this manual owned by 3Z Corp. You cannot act various action against copyright of this manual such as printing, reproduction, binding, etc Z Corporation,