Installation, Operation and Maintenance Manual of Pressure Seal Gate, Globe & Check Valves
Contents Page No. L&T Valves 3 Pressure Seal Gate, Globe & Check Valves 4, 5 Exploded View 6, 7, 8, 9 Delivery 10 Handling and Storage 11 Planning and Responsibilities 12 Valve Installation 13 Valve Operation 14 Do s and Don ts 15 Maintenance 16 Dismantling and Assembly Procedure 17,18,19, 20 Troubleshooting 21 Appendix 22 2
L&T Valves L&T Valves Limited is a wholly-owned subsidiary of L&T and one of the largest valve manufacturers in the world. The company has three modern manufacturing facilities, in Chennai (Manapakkam), Coimbatore and Kancheepuram, in Tamil Nadu, India. The company leverages its world-class capabilities in design, quality assurance and manufacturing to ensure that their products consistently meet customer expectations. Product Range: Gate, Globe & Check Valves Valves for Power Pipeline & Process Ball Valves Triple-offset Butterfly Valves Rubber lined Butterfly Valves Valves for Water Service Double Block & Bleed Plug Valves Control Valves Customised Solutions Designs for the valves are created by an experienced team of valve experts who have a deep understanding of user-industry processes. An extensive manufacturing and quality assurance infrastructure ensure that world-class designs are transformed into high performance products. Every phase of manufacture is governed by an institutionalised environment, health and safety policy. L&T Valves distribution network spans across the globe, partnering some of the largest valve distribution companies in the world. In India, L&T Valves has a presence in every industrial centre through a network of offices, stockists, automation centres and service franchisees 3
Installation, Operation and Maintenance Manual of Pressure Seal Gate, Globe & Check Valves is applicable to valves covered in GGC Catalogue (Publication Number: C2024-2/RP 0314). Pressure Seal Gate Valves Gate valves are multi-turn valves with rising stem i.e. they required a number of turns of rotation of handwheel for full closing or full opening of valve. All Gate valves should be used only in full open or full close position. If used in slight or half open position, the gate may vibrate/chatter and also cause wire drawing at the seating area. Therefore Gate valves should not be used for flow regulation. All valves close by rotating the hand wheel clockwise and open by rotating anti-clockwise. For handwheel operated valves the projection of stem above the handwheel indicates whether the valve is in open or close position. In gear operated valves as the stem top will not be visible, a separate indicator can be provided if required. The valve is closed by driving the wedge down into the corresponding taper in the body. The wedge and body seat rings are matched and lapped for perfect sealing. When the valve is fully open condition the stem back seats on the bonnet bushing. Range Size Pressure Rating 50 mm to 900 mm CLASS 600 50 mm to 750 mm CLASS 900 50 mm to 600 mm CLASS 1500 50 mm to 500 mm CLASS 2500 Pressure Seal Globe Valves PS Globe valves can be categorized into two by the type of pattern design. 1. Y type Globe valve 2. T type Globe valve Globe valves are multi turn valves with non-rotating stem and rotating hand wheel. Globe valves can be used for normal flow regulation. However if it is used in slightly opened position when the differential pressure is very high, the seating may erode. It is advisable not to use a globe valve for flow control below 20% of full opening. Valves close by rotating the hand wheel clockwise and open by rotating anti-clockwise. As the stem travel is very small in Globe valve compared to a same size gate valve, it is difficult to make out whether the valve is in open or close position from the stem position. 4
Generally, Globe valves are hand wheel operated. In case the Globe valve is required to be gear operated the valve will be modified to non-rotating stem. Range Size Pressure Rating 50 mm to 200 mm CLASS 600 50 mm to 450 mm CLASS 900 50 mm to 300 mm CLASS 1500 50 mm to 350 mm CLASS 2500 Pressure Seal Check Valves Check Valves automatically open by velocity pressure of the flow and close by the gravitational force when the flow reverse or stops. Pressure Seal Check valves are categorized into two by the type of Disc arrangement. 1. Swing type 2. Tilting Disc type Tilting disc check valve are non-slam type which are used in application involving multiphase & high turn down ratio. Range Size Pressure Rating 50 mm to 450 mm CLASS 600 50 mm to 700 mm CLASS 900 50 mm to 500 mm CLASS 1500 50 mm to 600 mm CLASS 2500 5
Exploded View Pressure Seal Gate Valve Fig 1 6
T-Type Y-Type Globe Valve Fig 2 7
Pressure Seal Swing Check Valve Fig 3 8
Pressure Seal Tilting Disc Check Valve Fig 4 9
Delivery Valves are shipped with the disc in a crack-open position & Orientation of the valve may be either horizontal or vertical depending on the shipped valve dimensions. Please check the packing slip attached to the container before opening the same. Valve identification details can be found on the name plate and on the body of the valve. A typical identification plate is shown in Fig 6 & 7. Name Plate - Gate & Globe Valves Fig 5 Name Plate Swing & Tilting Disc Check Valve Fig 6 Valves are supplied with end protectors for avoiding damage to internals. Hand wheels for gear operated valves are usually dismantled and packed separately. 10
Handling and Storage Handling Valve shall be properly supported and secured before moving, to prevent possible damage to valve, property or harm to personnel. Do not drag the valve on the ground while transporting. A minimum of one foot height from the ground is to be maintained while moving the valve. Valve shall not be slung around the valve port for transportation. Lifting lugs are provided for this purpose on the valves. The crane wire should not be slung around the actuator/gear unit to avoid any load acting on it. Also, ensure that the while handling the valve, no external load acts on the actuator/gear unit. Valves shall not be handled with the hand wheel keyed/ fixed to the gear unit. The hand wheel shall be dismantled before handling and transporting the valve. Storage Clean the yard and ensure that the end protectors are in place before the valve is stored, as dry contaminants like dust, sand, grit etc. can scratch metal seating surfaces and the soft parts, leading to leakages during operation. Valves shall be stored in covered area which is dust free, least humid and well ventilated. The valve shall always be maintained in an ambience with temperature higher than the dew point temperature at the storage location, so as to avoid collection of water droplets on the valve surface. Do not keep the valve directly on the floor. Valve shall be placed on wooden pallet such that it is at least at a height of 6 inches from the floor. Care should be exercised not to damage the extended portion of the adaptor, gear unit/ actuator while storage. Do not apply tar, grease or any other material inside the valve, as it could impair the performance of the valve. Improper storage and /or handling may cause disc/seal damage or deformation of shaft or seat, which will affect sealing and operational performance of the valve. 11
Planning & Responsibilities When installing or maintaining valves Conduct a risk assessment and eliminate or reduce hazards to an acceptable level. Work in accordance with safe systems of work site. Observe all site health and safety rules. Wear all necessary personal protective equipment. Never use a valve on a duty which exceeds its prescribed operating parameters. Refer to L&T Valves for further information The valve shall not be subjected to frequently occurring disturbances End user to ensure there are no external disturbances (e.g. Shocks, vibrations, electromagnetic fields etc.) Misuse of valves / valve components are strictly prohibited. Maximum surface temperature of the equipment will be same as the line media temperature. The end user must take account of the line media temperature. If the processes or environments that the valves are used in are likely to cause temperatures (high or low) that may cause injury to personnel if touched, then adequate insulation / protection must be fitted. Adequate safety measures shall be made for valves similar to pipe lines. Due to variety of duties in which these valves can be employed, it is the end user s responsibility to ensure the compatibility of media with the material of construction of the product for each specific application (i.e. corrosion and erosion which may affect integrity of the pressure containing envelope). Before valves are installed in areas which may be subject to seismic activity or extreme climatic conditions, consult L&T Valves with data. All exposed parts shall be cleaned to prevent dust deposit or insulation is needed similar to pipe line. Valves should be protected by other devices to prevent over-pressurisation. (i.e., caused by temperature, fire etc.). 12
Valve Installation General Carefully unpack the valve and check for tags or identification plates, etc. It is recommended to install Gate and Globe valves with Stem vertical up. It is recommended to install swing check valves at a distance equal to 5 times or more the pipe diameter from the upstream elbows for better performance. If the identification plate / arrow plate / tag is lost or destroyed during the shipment or while in storage or if it is not legible, contact your distributor or L&T Valves Look for any special warning tags or plate attached to or accompanying the valve and if any, take appropriate action. It is recommended to remove all foreign particles from the pipe line by flushing it with a suitable fluid. Corrosion inhibitors shall be added to the flushing medium to prevent any corrosion due to trapped fluids. Remove the end protectors and protective sheath within the flow bore valve, wherever provided. Gasket contact faces of the valve and pipe flanges shall be inspected thoroughly for scratches / defects. Scratches, if any, shall be corrected by grinding the surfaces or by rubbing with emery sheet. After cleaning, operate the valve for at least two complete cycles before installing. The pipes must be properly aligned and provisions made to minimize stresses from external load/thermal expansion. Always review pipe manufacturer s recommendation. In case of pipes with long overhangs, adequate support/jacks shall be provided at the flange ends of the pipe so as to avoid bending of pipes due to weight of the valve. The improper alignment of the pipe and the valve during installation can lead to unbalanced tightening of the flanges which may cause excessive stress on the bolts and lead to leakage Flanged Ends Refer Appendix A1 for applicable standards For handling refer relevant section on Handling and Storage Please refer to the arrow plate attached to the valve body for preferred direction of flow Ensure that the valve is in fully closed position during installation Clean valve flanges and companion flanges and remove protective grease from the valve flanges. Clean the valve interiors adjacent piping priors to mounting of the valve pipe joint. Align the bolt holes of the valve end flange and pipe flange. Insert the gasket (not supplied with valve) and tighten the bolts. Flange bolts shall be tightened evenly. Using suitable device, in cross rotation to prevent damage to the flange. Bolts should be lubricated for ease of installation For sequence of tightening bolts, refer Appendix A2 For larger flanged valves, which are provided with foot support supporting base/pedestal shall be placed beneath the valve after the alignment and bolting of the pipe. 13
If valve is not cleaned or if cleaning is done after valve installation cavities may form a natural trap in the piping system. Any impurity not dissolved or washed out by the flushing fluid/line fluid may settle in such cavities and adversely affect valve performance. Butt Weld Ends All the valves are provided with butt weld end preparation as per the standard ASME B16.25 or as per Customer requirements. Please refer to the GAD for the exact butt weld end dimensions. Care shall be taken to avoid weld spatter from falling onto the seating surfaces to prevent damage and maintain the sealing effect between the metallic contacts. It is recommended that the pipeline be flushed again, after welding, to avoid damage to disc(s) and seat(s). The valves shall be kept fully open during the flushing operation. After flushing is completed, operate the valve three times and ensure that it is smooth. It is recommended to carry out pressure testing of the joints Valve Operation General Operational life of the valve can be maximized if the valve is used within the rated range, in accordance with design parameters. For understanding the internal construction refer to the general assembly drawing of the valve. Operation Mechanism Gate and Globe valve opening/closing is achieved using Handwheel/Gear unit/electrical/hydraulic/pneumatic Actuator. Gear Unit Gear units are provided on valves for easier operation. Usually clockwise operation is for closing and anti-clockwise for opening of the valve. The position of the valve can be noted using the position indicator provided on top of the gear unit. The number of turns will depend on the gear unit used Forcing the hand wheel, Chain wheel or nut against the stops will not provide tighter shutoff of the valve and may damage the gear unit, only gear unit adjustment will affect the valve shut off. Electric Actuator It gives multi-turn output and is fitted either on the gear unit or directly mounted on valve. The actuator drives the gear unit shaft which in turn rotates the stem nut and because of this Gate / Globe valve stem travels linearly. Electrically actuated valves are provided with declutching mechanism for manual operation of the valve. For electric actuators, L&T Valves recommends to strictly adhere to the instructions as per actuator s manual. In Gate and Globe valves, electrically actuators shall be set as per the below Open : Position Close : Torque 14
Pneumatic / Hydraulic Actuator Pneumatic/hydraulic actuators are fitted directly on the valve, without separate gear unit. It is recommended to strictly adhere to the instructions as per actuator manufacturer s manual. In case, valves are supplied as bare stem, as per customer requirement, ensure that connecting devices for actuators does not exert any axial or radial loads on the valve stem, as it may lead to bending of the stem and excessive loading on the disc. This in turn can cause the torque to increase and may lead to problem in valve operation Do s and Don ts Do s Don ts Wear all necessary protective equipment before installing the valve Don t keep valve with open condition before installation. Ensure that the valves are used within the pressure temperature service conditions as per ASME B 16.34 Section 2. Also refer the Identification Plate for pressure and temperature limits. In case of additional assistance, consult with L&T Valves. Don t keep the valves with end cover removed Check tag no / name plate of valves before installation. Don t disturb actuator factory settings Check operation (Open/Close) of valves before installation Don t loose / over tight fasteners at gland & body-bonnet joint. Remove paper cover provided on stem before operating the valve. Don t give excess effort on valve during closing. Always operate the valve to open position to ensure that no trapped pressure exists within the cavity. Don t store the valve in open yard and sand environment. Visually check and clean seat area if required (seat ring/disc) before installation If valve tested at site, use only DM water. DO NOT remove operating mechanism from the valve when the disc is partially open. DO NOT install a valve in the pipe line without the operating mechanism Check gland bolts are not loose. Never remove or maintain a valve or joint unless the line fully depressurized and drained. DO NOT use adaptor, actuator body and Gear unit casting as lifting points DO NOT use force multiplying devices like levers or pulleys. In case a valve demands excessive operating torque, make sure there is no artificial obstruction in the pipe line or in the operating mechanism 15
Maintenance Introduction For enhanced life of the valve and better operability, it is recommended to do a periodic inspection and maintenance of the valves as per the procedure explained below: The frequency of observation depends on its application. L&T Valves recommends that valve shall be inspected every 50 cycles or three months (whichever earlier) for smooth operation and leak free performance. This is recommended even for stored valves also. It is advisable to maintain a record of the performance of the valve. Safety Procedure Always depressurize the pipeline when taking up any maintenance activity on the valve/ actuator. Always disconnect the electrical supply to the electrical actuator before carrying out any maintenance activity on the valve/actuator. Study carefully and understand the instructions outlined in the installation, operation & maintenance manual of the valve & actuator before taking up any maintenance. Routine Maintenance The following activities can be carried out during the routine maintenance of the valves. 1. Gland Leak Check the tightness of the gland eye bolts and tighten evenly if required. If the leak persists, the packing must be renewed. The pipeline must be shut off so that there is no pressure inside the valve before the gland eye bolts are loosened. Caution: Do not replace gland packing when the line is under pressure. Most of the packing rings are already cut so that they can be inserted around the stem. In case of solid moulded packing like graphite rings, use a sharp knife and cut the rings at 30 angle. Then slightly twist the ring and insert it around the stem. Do not open up the ring as it could break. 2. Pressure Seal Gasket leak The possibility of leak in this type of bonnet is very remote. If any leak is found, the gasket must be renewed (Refer Troubleshooting) 3. Gear Unit Gear operated valves are fitted with enclosed water tight bevel gear units. Generally the gear units are filled with grease (ZENITH EPSB-1 or equivalent). They do not require any additional maintenance. However in case extreme difficulty of operation, remove the top cover and refill the grease. 4. Lubrication Grease the stem threads and Yoke sleeve in Gate and Globe valves regularly 5. Hot Torque For the valves which are used at high temperature application, it is recommended to retighten the flange bolts to arrest the leak through joints. 16
Dismantling and Assembly Procedure Removal of Hand wheel unscrew and remove the Handwheel nut and Retainer nut. Remove the Hand wheel. Removal of Gear Unit Close the valve manually by turning the gear unit handwheel. In the case of an actuator operated gear unit, close the valve using the actuator. Prepare a hoist to support the gear unit weight, so that when disengagement begins, the valve stem does not get jammed or damaged. Remove the Cover Tube. Unscrew and remove the hexagonal screws and spring washers from the yoke underside. Slowly turn the handwheel in the valve closing direction. In the case of an actuator operated gear unit, slowly turn the actuator handwheel manually in the closing direction. Continue turning the handwheel. This will cause the valve stem to unthread itself from the gear unit and it will rise from the yoke plate. Remove the gear unit when it is completely disengaged from the stem. Electric Actuator Removal Turn off the electric power source and open the compartment cover of the electric actuator. Disconnect the outside wiring. Tag the wires during disassembly so as to ensure correct wiring during re-assembly. Change the actuator operation mode from motor to manual by declutching the actuator. Manually close the valve using the actuator handwheel. Prepare a hoist to support the actuator, so that when disengagement begins, the valve stem is not damaged by supporting the entire weight of the actuator. Remove the protector cap from the top of the actuator. For directly mounted actuators unscrew and remove the hexagonal screws and spring washers from the yoke plate underside. For actuators mounted to the adaptor flange of a gear unit, unscrew and remove the adaptor stud and nuts, and spring washers. Slowly turn the handwheel in the valve closing direction. Continue turning the handwheel. This will cause the valve stem to unthread itself from the actuator and the actuator will rise from the mounting flange. Remove the actuator when it is completely disengaged from the stem. 17
Actuator setting done in factory for open/close position of various types of Gate valves are given below. Valve Type Open Position Close Position Flexi Wedge Gate Limit Torque Dismantling Procedure All valves are designed to permit inspection without removing the body from the pipeline. The section of the pipe must be shut off and pressure is fully reduced before dismantling the valve for inspection. Gate and Globe valves can be inspected by removing the bonnet assembly. Check valves can be inspected by removing the cover assembly. In the case of Check valves there is no stem and hence only the cover is to be removed. The disc is hinged inside the body. For ease of illustration only the word bonnet is used in the dismantling and reassembly procedure. This may be changed to read as cover with respect to check valves. Pressure seal bonnet/cover valves Keep the disc in mid position. Loosen the yoke retaining nuts and pre-loading nuts of the bonnet. Rotate the hand wheel in clockwise direction so as to close the valve. The stem-disc will travel down and after touching the bottom, the yoke assembly will lift up along with actuator/gear unit. Removal of bonnet retainer. For threaded retainer unscrew the retainer in anti-clockwise direction using a special tool through the driving slots. In case of difficulty cautious hammering at the slots will be effective For Segmented retainer Remove any two bonnet pre-loading studs Push the bonnet down so that the segmental rings can slide over the top of the bonnet. Drive a pin thorough the hole provided on the body and remove the segmental ring out. By rotating the other segmental rings to the same position (opposite the hole), they can be removed. Lift the bonnet using gland studs. 18
There is no need to remove the gasket set from the bonnet and it can be used many times if there is no damage during dismantling. It is also not necessary to remove the gland packing and can be re-used as it is if there is no damage. Lift the entire stem-disc assembly out of the body. Check the disc seating and do not dismantle the assembly unless any damage is noticed. If damaged then remove the locking wire, lock nut and bolt of the disc carrier. Assembly Procedure General Stud and nut threads shall be lubricated. Clean thoroughly the disc and seat sealing faces. Conduct blue bearing test will confirm if there is a uniform contact between gate/disc and body seat rings. If the gasket is to be renewed, First lower the bonnet alone into the body Put the bottom ring over the bonnet Place the graphite ring over the bottom ring Put the top ring and spacer over it Push the gasket set into the cavity available between bonnet OD and body bore. If it is a threaded retainer apply anti-seize compound like molybdenum di-sulphate grease liberally on the threaded portion of the body and the retainer. Tighten the retainer in clockwise direction fully into the body till it touches the step in the body bore. Segmented retainer, Remove the pre-loading studs and insert the segmental rings one by one in the groove provided in the body. Align the segments in the body groove such that mid portion of one of the segments come against the hole in the body. Fix the pre-loading studs. Yoke assembly Place the yoke assembly over the stem and rotate the hand wheel so that yoke sleeve/actuator bush engages with the stem Yoke assembly will descend on to the body cover face Rotate the bonnet so that pre-loading studs and body studs are aligned to the drilled holes in the yoke. 19
Open the valve fully to get the disc back seated and bonnet is raised up In that condition tighten all the studs. While tightening the yoke bolting ensure that there is a minimum gap of 1.5 mm between the yoke raised face bottom and the retainer top. If this is not achieved then remove the yoke and tighten the threaded retainer further. There is no need to check this aspect in the case of segmented retainer. Tighten the bonnet nuts so as to pre-load the gasket but do not over tighten. Replace the gland packing, if necessary and tighten the eye bolts on to the gland. 20
Troubleshooting Problem Reason Action Leakage through the stem packing Problems while operating the valve Seat Leakage Leakage through valve body neck a) Gland nuts are loose b) Gland is binding against the stem or packing chamber wall c) Inadequate amount of packing rings d) Packing is hard and dry e) Packing was not properly cut and staggered f) Stem is damaged a) Stem binding during travel b) Packing is exerting excessive force on the stem c) Stem is damaged d) Internal components may be damaged a) Valve is not properly seated b) Internal components are damaged or have worn out. a) Pressure Seal Gasket is damaged or not properly compressed b) Anti-Extrusion Rings are damaged. a) Tighten gland nuts. b) Ensure gland is centered and evenly tightened c) Install additional packing rings. d) Replace with new packing. e) Replace with new packing. f) Repair or replace as required. a) Remove dirt and lubricate stem. b) Optimize the torque on gland nuts. c) Examine stem through full open and close action. Repair or replace as required. d) Disassemble the valve. Inspect and repair as needed. a) Check whether the valve is tightly closed. b) Disassemble the valve and inspect internal components. a) Check whether the gasket is properly placed between antiextrusion rings. b) Replace anti-extrusion rings. c) Use the values in Table 1 to tighten the studs. 21
Appendix A1 - References Face to Face Dimensions ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves End Connections ASME B16.25 Butt Welding Ends ASME B16.5 Pipe Flanges and Flange Fittings (NPS ½ through NPS 24) ASME B16.47 Large Diameter Steel Flanges (NPS 26 through NPS 60) Testing Standard API 598 EN12266 PART-1 Valve Inspection and Testing Industrial Valves Testing Of Valve A2 - Tightening Sequence & Torque The tightening sequence for all possible number of bolting is beyond the scope of this manual. However, the logic to be followed is explained below Tighten the first four nuts in the sequence shown Fig.10. This helps in correct location of the mating parts. Tighten the other bolts in the sequence shown Fig.11 the same way. The sequence goes clockwise around the bolt Ensure that the recommended torque (refer Table1) is maintained in all bolting. Fig. 10 Initial Tightening Fig. 11 Sequence of Tightening 22
Table 1 Tightening Torque TORQUE a, lbf ft THREAD SIZE, in B7/B7M/L7/L7M/B16 1/4 6 (B8/B8M)CL.2 5/16 10 3/8 20 7/16 30 ½ 55 9/16 65 5/8 100 90 ¾ 190 170 7/8 290 260 1 390 360 1.1/8 570 470 1.1/4 800 650 1.3/8 1100 750 1.1/2 1400 950 1.5/8 1800 1200 1.3/4 2300 1500 1.7/8 2800 1850 2 3400 2250 2.1/4 4900 3250 2.1/2 6600 4400 2.3/4 8800 5800 3 11500 7600 3.1/4 14000 9400 3.1/2 16400 11800 23
Document No : LTV-DEP-537-R0/0314 As we continuously endeavor to improve our products, the data given herein is subject to change. Please refer www.lntvalves.com for the latest IOM. 24