Emerson HANCOCK Installation, Operation And Maintenance Instructions

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HANCOCK CAST STEEL - GATE, GLOBE AND CHECK VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

1.2 Inspection

Before carrying out a valve installation, it is important to determine whether the valve is in asatisfactory condition. The following generally applicable procedure may be helpful in avoiding subsequent valve problems and should be observed. a) Carefully unpack the valve and check tags,

identification plates, direction of rotation of handwheels etc, against bill of material, specifications, schematics etc.

b) Make a point of noting any special warning Instructions for DN 50 - 600 (NPS 2 - 24) ASMEclass 150, 300 and 600 bolted bonnet caststeel valves.

SAFETY NOTICE

It is essential that a safe system of work should be adopted before any maintenance work is done on a valve. The following safety considerations should be taken in to account when preparing maintenance instructions. Before removing valves from a pipework system or dismantling a valve to carry out maintenance, it will be necessary to open, or partially open, the valves and to flush the system to remove all traces of dangerous fluidsand pressures. It is important to recognize the danger associated with the removal of the stem packing gland with pressure in the pipework system and the use of the backseat should not be regarded as a device permitting repacking of the stem packing gland whilst the valve is under pressure as this is recognized as dangerous practise.

tags or plates attached to or accompanying the valve, and take any appropriate action.

c) Check the valve for any marking indicating

flow direction. If the flow direction is indicated, appropriate care should be exercised to install the valve for proper flowdirection.

d) As far as is practicable, inspect the valve

interior through the end ports to determine whether it is reasonably clean, free from foreign matter and harmful corrosion. Remove any special packing materials, such as blocks used to prevent disk movement during transport and handling, and anti-corrosion packs. Wipe clean from preservation coatings, particularly seatings.

e) If practicable, cycle the valve through open

and close. Check guides or seat faces, etc.

f) Immediately prior to valve installation,

check the pipework to which the valve is tobe fastened for cleanliness and freedom from foreign materials.

1 GENERAL INSTALLATION INSTRUCTIONS

1.1 General

The installation procedure is a critical stage in the life of a valve and care should be taken to avoid damaging the valve.

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HANCOCK CAST STEEL - GATE, GLOBE AND CHECK VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

1.3 Flanged joint assembly

Pipe flanged joints depend on compressive deformation of gasket material between the facing flange surfaces for tight sealing. In order to obtain satisfactory flange joints, thefollowing points should be observed. a) Check the mating flange facings (both valve

and pipework flanges) for correct gasket contact face, surface finish and condition.

b) Check the bolting for proper size, length

and material. A carbon steel bolt on a high temperature flange joint can result in early joint failure.

c) Check the gasket material. For flange joints

using low strength bolting, such as may be provided for iron flanges, metal gaskets (flat, grooved, jacketed, corrugated or spiral wound) should not be used.

d) Check the gaskets for freedom from defects

or damage.

e) Take care to provide good alignment of

the flanges being assembled. Use suitable lubricants on bolt threads. In assembly, sequence bolt tightening to make the initial contact of flanges and gaskets as flat and parallel as possible. Tighten gradually and uniformly to avoid the tendency to twist one flange relative to other.

f) Parallel alignment of flanges is especially

important in the case of the assembly of a valve in to an existing system. It should be recognized in such instances that, if the flanges are not parallel, it will be necessary to introduce bending to make the flange joint tight. Simply, forcing the flanges together with the bolting may bend the pipe, or it may bend the valve.

g) All bolts shall be tightened in a star

pattern as shown below to ensure uniform gasketloading.

1.4 Butt weld joint assembly

All welding should comply with the appropriate pipe system or application code. Welded joints, properly made, provide a structural andmetallurgical continuity between the pipeand the valve body. Butt welds require full penetration and thickness at least equal to that of the pipes. If a pipe of high strength alloy is welded to a valve with body material of lower mechanical strength, the weld should taper to a compensating greater thickness at the valve end, or the valve should have a matching high strength welded-on extension.

Particular care is necessary when welding

valves into the line. Considerable distortion,

resulting in line strains, may occur if valves

are not welded into the line with care, where

required, the weld properly stress relieved,

but it is necessary to ensure that such stress

relieving does not result in valve components,

particularly the seatings being subjected to

unacceptable temperatures.

It is recommended that the valves are not

installed in the pipework at points of high

bending moments, as this can adversely

affectthe seating performances.

1.5 Testing and adjustment

Following installation, all valves should

be operated to check that they still

functioncorrectly.

On new pipework systems, system pressure

testing and commissioning follow after

installation when various checks are made.

Valves are usually supplied in the lubricated

condition, but it is recommended that checks

are made to ensure that this is still intact,

particularly after the application of heat

(e.g.welding operation).

A first observation can be made by actuating

the valve through an open-close or

close-opencycle.

It is common practice, after installation of

pipework systems, to clean the system by

blowing with a gas or steam or flushing with

a liquid to remove debris and / or internal

protective films and coatings. It should be

recognized that valve cavities may form a

natural trap in a pipework system and material

not dissolved in or carried out by the flushing

fluid may settle in such cavities and adversely

affect valve operation. Also, abrasive material

carried by a high velocity fluid stream may

cause serious damage to seating surfaces.

Do not subject the valve to pressures/

temperature testing in excess of its

statedlimits.

BOLT TORQUING SEQUENCE 1-2-3-4-5-6-7-8

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HANCOCK CAST STEEL - GATE, GLOBE AND CHECK VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

2 GATE VALVES

2.1 Installation and operation

2.1.1 Prior to installation

Valves not required for immediate use should be stored under clean conditions to reduce the risk of foreign matter entering the valve during unpacking. If the valves are unpacked for checking purposes, they should be immediately re-packed until required for use. Protection caps fitted to inlet and outlet connections must be removed, but not until immediately prior to installation. Seating faces should be wiped clean with a drycloth before commencing installation.

2.1.2 Installation

Valves are suitable for flow in either direction, but they should be fitted in either horizontal pipelines with the stem upright or vertical lines. Other positions can be detrimental to theproper seating of the wedge. The valves should be installed in positions where the minimum stress is imposed on them from expansion and contraction of the pipe, and pipework should be adequately supported close to the valve to minimize mechanical pipe strain. For bolting valves into the pipeline, see General Installation Instructions Section 1. All valves will have been pressure tested at ambient temperature before delivery, so it is recommended that gland packing nuts should be tightened after a short time on higher temperature service.

2.1.3 Operation

Rotation of the handwheel in the clockwise direction (see markings) will cause the valve to close, and vice versa. Shut off should be achieved by application of the handwheel torque only. Excessive application of force can result in failure of the thrust assembly or damage to the valve seating.

2.2 Maintenance

Gland leakage

CAUTION

On no account should stem gland repacking be

attempted under pressure if the contained fluid is

dangerous because of temperature, high pressure

or chemical composition.

Evenly tighten the gland adjusting nuts to

compress the packing rings.

If this does not correct the leakage or if

the adjustment is fully used up, it will be

necessaryto repack the gland using a new

set of the correct grade packing, or to add

packingring(s).

Re-packing glands

To gain access to the packing box, the gland

adjusting nuts should be removed and the

gland and packing flange removed or retracted

along the stem as far as possible. When the

stuffing box has been completely emptied of the

original packing, it must be thoroughly cleaned

before the new packing is introduced. It is

recommended that the packing manufacturers

general instructions are followed when

repacking glands.

General

It is recommended that the reconditioned valve

should be subjected to hydrostatic testing in

line, before being reinstated on line working

conditions.

2.3 Spares

The normal requirement for spare parts for

normal wear in service are gland packing

andgaskets.

PARTS LIST

No. Description

1 Body 2 Seat ring 3 Wedge gate 4 Stem 5 Bonnet bolt 6 Bonnet nut 7 Gasket 8 Bonnet 9 Backseat 10 Packing 11 Gland eyebolt 12 Gland 13 Gland flange 14 Eyebolt nut 15 Eyebolt pin 16 Nipple 17 Stem nut 18 Yoke sleeve nut 19 Hand wheel 20 Hand wheel nut

13 12

Braided end ring

Die-formed rings

(3 min.)

Braided end ring

120° Stagger of joints

45° End cut

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HANCOCK CAST STEEL - GATE, GLOBE AND CHECK VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

3 GLOBE VALVES

3.1 Installation and operation

3.1.1 Prior to installation

Valves not required for immediate use should be stored under clean conditions to reduce the risk of foreign matter entering the valve during unpacking. If the valves are unpacked for checking purposes, they should be immediately re-packed until required for use. Protection caps fitted to inlet and outlet connections must be removed together with any internal anti-corrosion sachets, but not until immediately prior to installation.

3.1.2 Installation

Valves are suitable for flow in one direction only (as indicated on the body) and must be installed accordingly. They should be installed with the stem in either the upright or horizontal position. Other positions may be detrimental to the proper seating of the disk. The valves should be installed in positions where minimum stress is imposed on them from expansion and contraction of the pipe, and pipework should be adequately supported close to the valve to minimize mechanical pipe strain. All valves will have been pressure tested at ambient temperature before delivery so it is recommended that gland packing nuts should be tightened after a short time on higher temperature service.

3.1.3 Operation

Rotation of the handwheel in the clockwise direction (see marking) will cause the valve toclose, and vice versa. Excessive force application other than by the handwheel can result in failure of the thrust assembly or damage to the valve seating.

3.2 Maintenance

Routine maintenance

While the valve is working satisfactorily, the only requirement for routine service is lubrication of the thrust assembly.

Valves are supplied with this assembly fully

lubricated and should operate smoothly.

To avoid problems from developing, the

assembly should be regularly lubricated on

thestem.

Recommended grade of grease is:

MobuluxEP2 (or equivalent).

Gland Leakage

CAUTION

On no account should stem gland repacking be

attempted under pressure if the contained fluid is

dangerous because of temperature, high pressure

or chemical composition.

Evenly tighten the gland adjusting nuts to

compress the packing rings.

If this does not correct the leakage or if the

adjustment is fully used up, it will be necessary

to repack the gland using a new set of the

correct grade packing, or to add packingring(s).

Re-packing glands

To gain access to the packing box, the gland

adjusting nuts should be removed and the

gland and packing flange removed or retracted

along the stem as far as possible. When the

stuffing box has been completely emptied of the

original packing, it must be thoroughly cleaned

before the new packing is introduced. It is

recommended that the packing manufacturers

general instructions are followed when

repacking glands.

General

It is recommended that the reconditioned valve

should be subjected to hydrostatic testing

in-line, before being reinstated on line working

conditions.

3.3 Spares

The normal requirement for spare parts for

normal wear in service are gland packing

andgaskets.

PARTS LIST

No. Description

1 Body 2 Seat ring 3 Disc 4 Stem 5 Disc nut 6 Bonnet nut 7 Bonnet stud 8 Gasket 9 Backseat 10 Bonnet 11 Packing 12 Eyebolt pin 13 Gland eyebolt 14 Gland 15 Gland flange 16 Eyebolt nut 17 Stem nut 18 Hand wheel 19 Hand wheel nut

Braided end ring

Die-formed rings

(3 min.)

Braided end ring

120° Stagger of joints

45° End cut

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HANCOCK CAST STEEL - GATE, GLOBE AND CHECK VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

4 SWING CHECK VALVES

4.1 Installation of valve

4.1.1 Prior to installation

Valves not required for immediate use should be stored under clean conditions to reduce the risk of foreign matter entering the valve during unpacking. If the valves are unpacked for checking purposes, they should be immediately re-packed until required for use. Protection caps fitted to inlet and outlet connections must be removed but not until immediately prior to installation. Check that the disk is swinging freely on its hinge arrangement with no hang-ups. Seating faces should be wiped clean with a dry clean cloth before commencing installation.

4.1.2 Installation

Valves are suitable for flow in one direction only and this is shown by a direction arrow marked on the valve body. It is essential that they are installed in the correct flow (arrow) situation.

They may be fitted in horizontal or vertical

(flow-upwards) pipelines, or any in-between

lines with flow-upward. They must always be

orientated so that the hinge swings downwards

and with the hinge pin horizontal.

The valves should be installed in positions

where the minimum stress is imposed on them

from expansion and contraction of the pipe,

and pipe work should be adequately supported

each side of the valve to minimize mechanical

pipestrain.

4.2 Maintenance

Routine Maintenance

While the valve is working satisfactory, there

isno requirement for servicing.

PARTS LIST

No. Description

1 Body 2 Seat ring 3 Disc 4 Lever arm 5 Nut 6 Hinge pin 7 Yoke 8 Bonnet nut 9 Bonnet stud 10 Bolt 11 Gasket 12 Cover 13 Eye bolt

9 8

5 TROUBLE-SHOOTING

The following table will cover the various problems which are common to most valves. Theinformation provided will aid in isolating and correcting these problems.

Problem Possible cause Solution

Leakage through thestempacking

Problems in operating valve

Bonnet leakage 1. Bonnet nuts are loose. 1. Tighten to values as listed.

Seat leakage 1. Valve not properly seated.

1. Gland nuts are loose. 1. Tighten gland bolts.

2. Gland is binding against the stem or packing chamber wall. 2. Check to ensure gland is centered and evenly tightened.

3. Inadequate amount of packing rings. 3. Install additional packing rings.

4. Packing is hard and dry. 4. Replace with new packing.

5. Packing was not properly cut and staggered. 5. Replace with new packing.

6. Stem is damaged. 6. Repair or replace as required.

1. Stem binding during travel. 1. Remove dirt and lubricate stem with grease.

2. Stem packing is exerting excessive force on the stem. 2. Check torque on gland nuts.

3. Stem is damaged. 3. Examine stem through full open and close action. Repairorreplaceasrequired.

4. Internal components may be damaged. 4. Disassemble the valve. Inspect and repair as needed.

2. Gasket is damaged. 2. Disassemble and install a new gasket.

3. Flange faces are damaged. 3. Repair and install a new gasket.

1. Check to see if valve is tightly closed.

2. Internal components are damaged or worn.

2. Inspect internal components and repair as required.

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HANCOCK CAST STEEL - GATE, GLOBE AND CHECK VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

6 TORQUE VALUES FOR BONNET BOLTING

Torque

Bolt nominal diameter (in)

½ 61 45

⁄

16 88 65

⅝ 118 87 ¾ 206 152 ⅞ 328 242 1 488 360 1⅛ 725 533 1¼ 1017 750 1⅜ 1383 1020 1½ 1627 1200 1⅝ 2237 1650 1¾ 3051 2250 1⅞ 4068 3000 2 4475 3300

NOTES

1. Values are for B7 bolting only. For other materials please consult Hancock.

2. Values listed are based on 45000 psi bolting stress, lubricated with heavy graphite/oil mixture. Non lubricated bolts have an efficiency of 50% ofthe values stated above.

3. All bolts should be torqued in the bolting sequence shown above to ensure uniform bonnet gasketloading.

(Nm) (ft·lb)

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