Before installation these instructions must be fully read and understood INTRODUCTION Actuator or Counterweight assisted, flanged or welded ends. This manual provides guidelines to be observed for the following operations: storage installation into the pipeline maintenance preservation The manual is intended for the following personnel/staff: plant warehouse staff installers maintenance engineers In addition to the instructions in this manual, specific plant safety regulations must always be followed. Before starting any maintenance activity, it is strongly recommended to read carefully and completely this manual. It is also recommended to verify the availability of the suggested spare parts, so you can always assemble the valve and minimize intervention time. For installation and maintenance operations no specific equipment or tools are required, other than those usually available in the plant. Do not use the valve as an interception valve for cleaning the line. Maximum admitted velocity for fluids: 6m/s for liquids 80m/s for gas or steam/vapour VERIFICATION UPON RECEIPT AND STORAGE Before start-up: On arrival of materials, it is recommended to: - Check the integrity of the case/packing. - Open the case and verify that there is no damage due to transportation. - Do not open the barrier bag - if any. - Verify that the content matches the packing list. - Store the valves in their original packing (unless damaged). When doing so, please observe the following: - Store the valves in a closed, clean and dry storage room. - Do not place the packages directly on the ground. - Check the packages every two months. - Substitute the silica gel every six months (not applicable in the case of barrier bag). For actuated valves, in addition to the above, please refer to the actuator manual. Emerson is always at the customer s disposal for further technical information. Emerson.com/FinalControl 2017 Emerson. All Rights Reserved. VCIOM-01600-EN 17/11
HANDLING During handling operations, valves must be lifted and handled as indicated in Fig. 1 by using lifting equipment respecting the carrying limits (valve weight indicated in the drawings). Optional eyebolts on the valve body can be used to lift the valve. Do not use any lifting equipment that is either damaged or/and of an inadequate/unknown size. Do not use the eyebolt in the bonnet to lift the valve. INSTALLATION For correct operation of the valve, this must be installed in horizontal position only as indicated in Fig. 2. Different positions from those indicated may cause non-correct valve operation and/or quick deterioration of the valve. The following operations must be performed only immediately before the installation: 1. Remove the protection caps of the end faces. 2. Remove pin protection. 3. Check the pipeline sections upstream and downstream. Make sure that there are no solid particles or any other kind of dirt or debris inside. If necessary, clean carefully by using an air line. 4. Verify the flow direction in the line. Verify that the direction of the line corresponds to the flow direction indicated by the arrow on the valve body. Make sure that the materials of construction listed on the valve nameplates (service and temperature), are appropriate for the service and fluid of the plant. Flanged valves Place the valve between the two pipe flanges, and the gasket between the valve s flange and the pipe s flange. Make sure that it is positioned in the center. Assemble the valve to the pipe by tightening the bolts according to the torques given by the Engineering Company that designed the plant. Drain connection Draining connection in the valve body (Fig.4) to be connected to plant draining system before putting valve in operation. In case of lack of draining, condensate retained in the valve bottom could flash generating pressure peaks which may damage the valve and/or other equipments in the plant. Protect eyes with appropriate welding masks or goggles during all welding operations. General notes Should one end not be connected to the line for longer than half a day, the open end must be properly closed and sealed in order to prevent entry of dirt or debris. After the installation of the valve and before the line testing, it is strongly recommend cleaning the line in order to remove dirt and/or foreign bodies that may damage the tightness between the seat and the disc, and the correct operation of the valve. We strongly recommend checking the torque of the body-bonnet bolts, especially if the valve is to operate at high temperatures. Tightening must be done alternatively on the bolts that are diametrically opposed, see Fig. 3. The torque values are those reported in Table 3. FIGURE 1 - VALVE LIFTING AND HANDLING FIGURE 2 - POSITION FOR VALVE INSTALLATION 2 max 2 max Flow 2 max FIGURE 3 - TIGHTEN BOLTS - FLANGE TIGHTENING SEQUENCE 2 max FIGURE 4 - CONNECTION FOR DRAINING Butt-welding valves Position the valve and verify its alignment with the pipe. Proceed with the welding in accordance with the procedure indicated by the Engineering Company that designed the plant. Usually, the first weld layer will be made with TIG, while following weld layers will be made with the appropriate electrode for the valve body material. Drain in G position 2
START UP REQUIREMENTS Before the start up of the plant, we recommend to: Check that the lines have been accurately cleaned. If the valve has been stocked for a long time and should operate at high temperatures, verify the tightness of the body/bonnet bolts. Tightening must be done alternatively on the bolts that are diametrically opposed. See Fig. 3. The torque values are those reported in Table 3. Check the tightness of the gland bolts. Check that the pin s protection has been removed. Check electrical, pneumatic and hydraulic connection - if any. Check that the drain in the valve body is properly connected to the plant draining system. Check that the actuator is properly installed according to section 8. Check that the torque/travel switches are properly set according to actuator maintenance manual. Preventive Check the space between the gland and the bonnets every 12 months. In case of a reduction of the space, restore the space by installing a new ring packing. Remove the bonnet of the valve every 4 years. Check the inside and verify that the valve is not damaged, especially the disc pin and the bushes. Re-lap the seats if necessary and replace the body/bonnet gasket and the packing. After 4 years operation, replace bushes 108 and 126. Disassemble the valve every 8 years. Recondition the seats, replace the bushes, the anti-clutch spacer, the gasket, the packing and the keys. It is recommended having a pin available during the operation. For the actuator, proceed as indicated in its maintenance manual. An incorrect connection of the actuator is dangerous and may cause irreversible damages to the valve. During the start-up of the plant, verify the packing seal. In case of leakage, tighten the bolts alternatively. During the start-up, for the valves equipped with lever and external counterweight, make sure the counterweights are in the right position for the intended service. Under regular service conditions, operate the lever in the sense of close position. When discharged the lever should return by itself to its former position. Without fluid in the valve, the disc shall position itself in the close position. The actuator should be energized before the start up of the plant, in order to avoid damages to the valve, and to minimize drops of charge, maximizing the performance of the plant. SCHEDULED MAINTENANCE Routine inspections Monthly check that there is no leakage from the body/bonnet area. In case of leakage from the body/bonnet area, tighten the appropriate the bolts according to the sequence in Fig. 3. In addition to the above, please refer to the actuator manual. 3
TROUBLESHOOTING GUIDE Problems reported are not exhaustive, they represent the most frequent ones. Leakage from the packing In case of leakages from the packing that cannot be stopped by tightening the gland bolts, proceed as follows. Packing may have hardened. In this case, it must be replaced. The distance between the gland and the bonnet is reduced. Thus, the packing cannot be compressed. Packing must be replaced. Scratches or other marks are found on the pin or the pin itself is bent. In these cases, the pin must be replaced. The gland may be jammed on the pin because of a non-uniform tightness of the gland bolts. Loosen the gland bolts. Move the gland and set it again; then tighten the bolts progressively and uniformly. Leakage from the body/bonnet joint A leakage from the body/bonnet joint may be the consequence of a long storage time of the valve. The gasket may have lost elasticity and/ or the bolts may have loosened. In the first case, the leakage will progressively decrease, the gasket regaining part of its elasticity with the contact of the process fluid. A verification of the bolts tightness will contribute to stop the leakage. In the second case, bolts should be tightened according to Fig. 3. Usually these two actions are combined. Leakage under operation of the plant requires the tightening of the bolts and the replacement of the gasket as soon as possible. Leakage between seat and disc In case of leakage between seat and disc, check that: No foreign material is locked between seat and disc, scratching the sealing surfaces. No foreign material is laid down between the seats, preventing the disc from closing. During a previous closure the fluid has laminated the seal surfaces, eroding these. For all the above cases it is absolutely necessary to disassemble the valve as soon as possible and perform an inspection of the internal parts in order to reduce further damage. Jamming of valve along the stroke If a higher torque is required at some points when opening/closing the valve, proceed as follows: Disassemble the valve, as body guides and disc may start to seize. Problems regarding motor operation Please, refer to the actuator instruction manual. DISASSEMBLING INSTRUCTIONS Here below are the procedures to follow to disassemble valves. Before starting any operation, it is important to: identify the problem clean the area around the valve that is to be disassembled prepare a box and/or a pallet where to collect all pieces prepare a polyethylene sheet to protect all components and to prevent particles from entering the body of the valve. During disassembling operations, identify all pieces to keep track of the position/orientation of the parts regarding the valve body. Actuator disassembling 1. Hold the actuator using the eyebolts with a strip suitable to its weight. 2. Remove the bolts (79) that join the actuator and the valve s flange together 3. Remove the actuator from the pin of the valve. If necessary use a lever between the valve and the flange of the actuator. Before starting disassembling any part of the valve it is very important to verify - for your safety - that: the line is not pressurized the valve is not in temperature all electrical, pneumatic and/or hydraulic devices have been switched off and disconnected. Counterweight disassembling 1. Hook the counterweight s opening protection structure (276) with a steel thread. 2. Remove the bolts that close the protection of the counterweight and the opening itself. 3. Hold the counterweight s lever (107) with a strip. Then remove the blocking nut (115) and the washer (211). 4. Hold the strip tight and remove the counterweight. If necessary use a lever. 4
Disassembling of the disc 1. In order to remove the disc, the actuator and the counterweight have to be previously removed. 2. Remove the bolts between the body and the bonnet (11). Place them in a clean space. 3. Lift the bonnet (6) by means of a strip and a hoist and hold it to the eyebolt. 4. Hold the hinge pin and the disc together (45-3). Place the strip between the hinge pin and the disc and hold it by means of a hoist. 5. Remove the gland bolts (16), the gland flange (10), and the gland (9) from the side of the actuator and from the side of the counterweight (if existing). 6. Remove the packing by means of an iron hook-shaped thread. 7. Remove the pin (49) always from the side from which the actuator was installed. During this operation, the spacer (65) will be removed and saved for reassembling. 8. Remove the hinge pin/disc from the valve. Removal of valves welded to the line Shall the valve need to be removed from the line, cut the pipe far from the welding point so that the valve s gauge can be restored. The packing assembling must be done without pressure in the valve and in the line. ASSEMBLING INSTRUCTIONS Before starting reassembling is recommended to verify the following points: Remove any dirt or particles with a wire brush or abrasive cloth; remove any oil or grease with a suitable solvent, to avoid damage caused by foreign particles - in particular on the sealing area. Never re-use the old gaskets, even though they seem to be in good condition. During reassembling operations, match the punched pieces so that they are correctly assembled. Packing assembling 1. Remove gland nuts (16) and bolts (15). 2. Lift the gland flange (10) and the gland (9). 3. Remove the used packing by means of a steel hook-shaped thread. 4. For a better sealing, carefully clean the packing room and the shaft. Make sure that they are not damaged (scratches) and there are not seizing signs. 5. The packing assembly must be done by placing, in the packing room, one ring at a time. Be careful to allocate them correctly and press them to the bottom of the packing room. 6. Once the packing room is full, replace the gland (9) and the gland flange (10) to their original positions. 7. Tighten the gland bolts gradually and uniformly, the torque valves can be calculated according to table 4. For some alternative days, especially during start up, re-tighten the bolts in order to repristine the loosening of the gland. Body/bonnet gasket replacement 1. Before replacing the body/bonnet gasket, clean the body/bonnet flange s surfaces carefully. 2. Fit the gasket in the seat, then align in a parallel position the bonnet flange with the flange in which the gasket is placed. Do not use the bolts to align. 3. While tightening, make sure that the flange s pairing is completely parallel. 4. Tighten the bolts according to fig.3. In the first tightening be careful to apply 1/4 of the final torque reported in Table 3. For a better performance of the joint, tight again all bolts once the installation is started up. Actuator assembling Valve without counterweight 1. Check that the key on the valve pin is oriented vertically upwards (Fig. 5.A). 2. Insert the coupling on the valve pin checking that the housing for actuator square shaped pin is positioned horizontally (Fig. 5.B). 3. Fix the actuator to the valve flange through the bolts checking that the square shaped pin is properly inserted into the coupling. FIGURE 5.A Key on the valve pin to be oriented vertically upwards FIGURE 5.B Housing for actuator pin in the coupling to be positioned horizontally 5
Valve with counterweight 1. Check that the key on the valve pin is oriented 45 downwards facing the valve outlet (Fig. 6.A). 2. Insert the coupling on the valve pin checking so that the housing for actuator square shaped pin is positioned horizontally (Fig. 6.B). 3. Fix the actuator to the valve flange through the bolts checking that the square shaped pin is properly inserted into the coupling. PRESERVATION IN THE PLANT FIGURE 6.A Valve inlet For a correct preservation of the valve in the plant, once the lines have been cleaned up, follow the instructions below. Key to be oriented 45 downwards facing the valve outlet 1. Fill in the valve with inert gas (azote), 2 bar. 2. Verify that the pin is covered with a layer of grease. FIGURE 6.B For the actuator, please refer to the instructions below and the actuator s manual: 1. Replace the plastic cap with an adapted cap, able to guarantee the sealing from water. 2. When necessary, connect by means of suitable plug-cable (minimum IP55), the resistance anti-condensation as indicated in the electrical scheme in the electrical junction box. 3. Check the general conditions of the valve and the actuator once a year. SPARE PARTS LIST Emerson guarantees the supply of all spare parts for a period of at least ten years from the manufacturing date (month/year) indicated on the tag plate. Housing for actuator pin in the coupling to be positioned horizontally The suggested spare parts and the correlative quantity is reported in the table below and refer to the typical designs attachment. Spare part Description Percentage [1] Minimum quantity 2 Seat 5% 1 set 3 Disc 5% 1 49 Pin 5% 1 5 / 52 Gasket 20% 2 8 Packing 20% 2 sets 108 / 126 Bush 5% 1 set 60 / 330 / 241 Key 10% 1 1. The percentage must be calculated on the base of equal valves and round off to the unit 6
ATTACHMENTS The reference designs are those supplied with the valve. The designs below are just a typical sample and cannot be considered for further purposes. FIGURE 7 - Swing Check valve bolted bonnet ASME Class 600 - Welding ends - Assisted pneumatically on the right side SECTION A - A (not in scale) 11/12 'Y' 6 23 55 50/51 108 5 328 52 45 A A 65 49 47 64 60 126 279 78 309 8 3 2 1 79 9 10 15/16/17 330 45 331 60 77 Detail Y TABLE 1 - PARTS LIST No. Description 1 Body 2 Seat 3 Disc 5 Gasket 6 Bonnet 8 Packing 9 Gland 10 Gland flange 11 Body bolts 12 Body nuts 15 Gland bolt 16 Gland nut No. Description No. Description 17 Washer 77 Actuator 23 Name plate 78 Disc washer 45 Hinge 79 Stud/Screw 47 Disc bolts and nuts 108 Anti-friction bush 49 Pin 126 Anti-friction bush 50 Stud 279 Bottom ring 51 Nut 309 Spacer 52 Pin gasket 328 Bush 55 Pin cover 330 Key 60 Key 331 Coupling actuator-pin 64 Split pin 65 Spacer 7
FIGURE 8 - Swing check valve bolted bonnet ASME Class 150 - Welding ends - Pneumatically assisted on the left side and with counterweight 11/12 'Y' 276 107 241 SECTION A - A (not in scale) 6 23 115 5 A B 211 45 50/51 47 64 133 132 55 8 279 309 108 65 78 3 60 126 49 279 2 309 8 1 79 9 15/16/17 45 Detail Y 10 330 60 331 Close position Open position 77 TABLE 2 - PARTS LIST No. Description 1 Body 2 Seat 3 Disc 5 Gasket 6 Bonnet 8 Packing 9 Gland 10 Gland flange 11 Body bolts 12 Body nuts 15 Gland bolt 16 Gland nut 17 Washer 23 Name plate No. Description No. Description 45 Hinge 115 Nut 47 Disc bolts and nuts 126 Bush 49 Pin 132 Screw 50 Stud 133 Top screw 51 Nut 211 Washer 55 Pin cover 241 Key 60 Key 276 Counterweight protection 64 Split pin 279 Bottom ring 65 Spacer 309 Spacer 77 Actuator 330 Key 78 Disc washer 331 Coupling actuator-pin 79 Stud/Screw 107 Lever 108 Bush 8
ACTUATOR OR COUNTERWEIGHT ASSISTED, FLANGED OR WELDED ENDS TABLE 3 - BODY/BONNET BOLTS TORQUE Bolts: A 193 B7 / A 193 B16 Torque values Torque values Bolts: A 193 B8 Torque values Ø Bolts Kgm (Nm) Ø Bolts Kgm (Nm) Ø Bolts Kgm (Nm) Ø Bolts Kgm (Nm) ½ 9 (90) 1¾ 426 (4178) ½ 3 (26) 1¾ 122 (1194) ⅝ 18 (175) 1⅞ 527 (5165) ⅝ 5 (50) 1⅞ 150 (1476) ¾ 31 (305) 2 642 (6297) ¾ 9 (87) 2 183 (1799) ⅞ 50 (487) 2¼ 921 (9030) ⅞ 14 (139) 2¼ 263 (2580) 1 74 (725) 2½ 1271 (12460) 1 21 (207) 2½ 363 (3560) 1⅛ 107 (1050) 2¾ 1537 (15076) 1⅛ 31 (300) 2¾ 439 (4307) 1¼ 149 (1462) 3 2003 (19648) 1¼ 43 (418) 3 572 (5614) 1⅜ 201 (1968) 3¼ 2556 (25062) 1⅜ 57 (562) 3¼ 730 (7161) 1½ 263 (2579) 3½ 3201 (31387) 1½ 75 (737) 3½ 914 (8968) 1⅝ 339 (3325) 1⅝ 97 (950) Torque values TABLE 4 - CONSTANT FOR CALCULATION OF PACKING TORQUES Shaft Gland bolts diameter dia. ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ 1 1⅛ 1¼ 1⅜ 1½ 1⅝ 1¾ 1⅞ 2 2¼ 2½ 2¾ 19.1 0.57 1.03 1.47 1.91 2.36 2.79 3.25 3.70 4.12 4.55 4.98 5.40 4.68 5.03 5.38 7.12 8.00 8.86 9.72 22.2 0.64 1.15 1.65 2.14 2.65 3.13 3.64 4.15 4.62 5.11 5.59 6.06 5.25 5.65 6.04 7.99 8.98 9.94 10.91 25.4 0.71 1.28 1.84 2.38 2.95 3.49 4.05 4.61 5.14 5.68 6.21 6.74 5.84 6.28 6.72 8.89 9.98 11.06 12.13 28.6 1.03 1.85 2.65 3.43 4.25 5.02 5.84 6.65 7.41 8.19 8.96 9.71 8.42 9.05 9.68 12.81 14.39 15.93 17.48 31.8 1.11 1.99 2.86 3.71 4.59 5.42 6.30 7.18 8.00 8.84 9.67 10.48 9.09 9.77 10.45 13.82 15.53 17.20 18.87 34.9 1.21 2.17 3.10 4.02 4.98 5.89 6.85 7.80 8.68 9.60 10.50 11.39 9.87 10.61 11.35 15.01 16.87 18.68 20.50 38.1 1.60 2.87 4.12 5.34 6.61 7.82 9.09 10.35 11.53 12.74 13.94 15.12 13.11 14.09 15.07 19.93 22.39 24.80 27.21 41.3 1.72 3.09 4.42 5.74 7.10 8.40 9.76 11.12 12.38 13.68 14.97 16.23 14.07 15.13 16.18 21.40 24.04 26.63 29.22 44.5 1.82 3.26 4.67 6.06 7.50 8.87 10.31 11.74 13.08 14.45 15.81 17.15 14.87 15.98 17.09 22.61 25.40 28.13 30.86 47.6 1.93 3.47 4.97 6.45 7.98 9.44 10.97 12.49 13.91 15.37 16.82 18.25 15.82 17.00 18.18 24.06 27.02 29.93 32.84 50.8 2.43 4.37 6.26 8.12 10.05 11.88 13.81 15.73 17.52 19.36 21.18 22.97 19.91 21.40 22.89 30.28 34.02 37.68 41.34 54.0 2.56 4.59 6.58 8.54 10.57 12.49 14.52 16.54 18.42 20.36 22.27 24.16 20.94 22.51 24.08 31.85 35.78 39.63 43.47 57.2 3.14 5.64 8.09 10.49 12.98 15.35 17.84 20.32 22.63 25.01 27.36 29.68 25.73 27.65 29.58 39.13 43.95 48.68 53.41 60.3 3.28 5.89 8.45 10.95 13.55 16.03 18.64 21.22 23.64 26.12 28.57 30.99 26.87 28.88 30.89 40.86 45.90 50.84 55.78 63.5 3.43 6.15 8.82 11.43 14.15 16.73 19.45 22.15 24.67 27.26 29.83 32.35 28.05 30.15 32.24 42.65 47.91 53.07 58.22 69.8 3.71 6.66 9.55 12.38 15.32 18.12 21.06 23.98 26.71 29.52 32.29 35.03 30.37 32.64 34.91 46.18 51.88 57.46 63.04 73.0 3.85 6.92 9.92 12.86 15.91 18.82 21.88 24.91 27.75 30.66 33.54 36.38 31.54 33.91 36.26 47.97 53.89 59.68 65.48 NOTES 1. Select the constant in relation to stem diameter and packing bolts size. 2. To obtain the packing bolts torque in Nm please multiply the selected constant for pressure in MPa. Valve under pressure of 2MPa with stem diameter equal to 44.5 mm and packing bolts size equal to ⅝ inches: a. Constant is equal to 7.5 b. Packing bolts torque is equal to 7.5*2= 15 Nm 9
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user. Fasani is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson.com/FinalControl