FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Basic configuration - Flanged or welded ends
2. All actuated valves must be carefully and
securely palleted or crated, in order to
ensure that the parts of actuator (especially
pneumatic piping or accessories) do not
extend beyond the skid/crate.
3. The type of packing must be defined in the
Customer’s Order and shall be appropriate
to ensure safe transportation to final
destination and eventual conservation
before installation.
Handling requirements
A - Packed valves
Crates: Lifting and handling of the packed
valves in crates will be carried out
by a fork lift truck, by means of the
appropriate fork hitches.
VALVE STORAGE
Preparation and preservation for shipment
All valves are properly packed in order
to protect the parts that are subject to
deterioration during transportation and storage
on site. In particular, the following precautions
should be taken:
1. The valves must be packed with the disc in
the closed position.
1a. Flanged sealing valves: The flange
sealing surfaces (raised faces) of the
valves shall be protected with suitable
protective grease. The end faces of the
valve must be protected with plastic or
wooden discs fixed with straps.
1b. Buttweld end valves: The weld ends
surface shall be protected with suitable
protective like Deoxaluminite. The end
shall be closed with plywood or plastic
disc fixed at the edge by straps.
Cases:
The lifting of packed valves in cases
should be carried out in the lifting
points and at the center of gravity
position which have been marked.
The transportation of all packed
material must be carried out safely and
following the local safety regulations.
B - Unpacked valves
1. The lifting and the handling of these valves
has to be carried out by using appropriate
means and by respecting the carrying limits.
The handling must be carried out on pallets,
protecting the machined surfaces to avoid
any damage.
2. With valves of large dimensions, the sling
and the hooking of the load must be carried
out by using the appropriate tools (brackets,
hook, fasteners, ropes) and load balancing
tools in order to prevent them from falling
or moving during the lifting and handling.
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FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 1
Valve slinging
Storage and preservation before installation
In case the valves have to be stored before
installation, the storage has to be carried out
in a controlled way, and has to be performed in
accordance with the following criteria:
1. The valves have to be stocked in a closed,
clean and dry storage room.
2. The disc must be in the closed position,
and the end faces must be protected with
plastic or wooden discs fixed with straps. If
possible, keep the original protection.
3. Periodical checks have to be carried out
in the storage area to verify that the above
mentioned conditions are maintained.
For actuated valves, in addition to the above,
please refer to the warnings in the manual of
the actuator.
INSTALLATION
Preparation before installation
1. Carefully remove the valve from the
shipping package (box or pallet) avoiding any
damage to the valve or, in case of automated
valves, to the electric or pneumatic/
hydraulic actuator or instrumentation.
2. The valves are shipped with the ends
protected with caps and a thin layer of
protective grease. Before installing the
valve, remove the caps and clean carefully,
then degrease both surfaces with a solvent.
Clean the inside of the valve by using an air
line. Ensure that there are no solid objects
such as pieces of wood, plastic or packing
materials within the valve or on the valve
seat.
3. Confirm that the materials of construction
listed on the valve nameplates (service and
temperature) are appropriate for the service
intended and are as specified.
4. Define the preferred mounting orientation
with respect to the system pressure.
If any (see arrow on the body), identify
the upstream side (high pressure) and
downstream side (low pressure).
WARNING
Verify that the direction of the flow in the line
corresponds to the arrow indicated on the valve
body.
See the actuator user manual for the actuator
preparation.
NOTE
Storage in an open area for a limited period can be
considered only in case the valves have appropriate
packing (packed in cases lined with tarred paper, and
contents well protected with barrier sacks).
Do not place consignment packages directly on the
ground.
Do not expose consignment packages to the weather
or directly to the sun.
Check the packaging every two months.
CAUTION
For valve handling and/or lifting, the lifting
equipment (fasteners, hooks, etc.) must be sized
and selected while taking into account the valve
weight indicated in the packing list and/or delivery
note. Lifting and handling must be made only by
qualified personnel.
Do not use the lifting points located on the
actuator, if any, to lift the valve. These lifting
points are for the actuator only.
Caution must be taken during the handling to
avoid that this equipment passes over the workers
or over any other place where a possible fall
could cause damage. In any case, the local safety
regulations must be respected.
2
FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 2
Installation positions recommended
40° max
40° max
Flow
Installation instructions
Globe valves are normally installed in
horizontal pipe with vertical stem.
These valves can also be installed in vertical or
horizontal pipe with stem other than vertical,
but this may require special construction
depending on valve size, service condition,
material and type of operator.
For a correct operation, Fasani recommends
that the valve shall be installed and oriented
following the indications of Figure 2. Different
positions from those indicated may cause a
non-correct valve operation, and/or a quick
deterioration of the valve.
Unless otherwise recommended by Fasani, the
valve should be installed with the disc in the
closed position, to ensure that the seat ring
in the disc is not damaged during installation.
Particular care should be taken with those
valves equipped with ‘fail-open’ actuators.
For operating temperatures above 200 °C
(392 °F) thermal insulation of the valve body is
recommended.
Handling and lifting of the valves during
installation MUST be performed following the
same criteria and instructions described in
previous points “Handling requirements” and
“Storage and preservation before installation”.
Buttweld valves
Position the valve and check the alignment
with the pipe, then proceed with welding,
in accordance with the applicable welding
procedure.
Flanged valves
Place the valve between the two flanges of the
pipe and put the seal gasket between the valve
flange and the pipe flange; make sure that it is
correctly positioned. Then assemble the valve
to the pipe by the bolts which will be tightened
crossing. Progressively reach the requested
torque value indicated by the Engineering
Company that designed the plant.
40° max
40° max
IMPORTANT
After the valves installation and before the
line testing, it is recommended to perform an
accurate cleaning of the lines to eliminate dirt and
any foreign objects that could seriously jeopardize
the tightness between seat/disc and the correct
operation of the valve.
After the valve installation on the line and
before the line pressurization, the following
activities must be performed:
- all the threads plugs tightening shall be
verified
- the packing bolts must be tightened
- the torque of the body-bonnet bolts shall be
verified
- the valve has to be fully stroke operated
- the paper protecting the stem must be
removed; stem and bearings must be
greased.
See Table 1 (Bolt torque figures for bodybonnet flanged connections) and table 2 (Bolt
torque figures for packing bolts).
If any, see the actuator instruction manual for
the related commissioning start-up procedure.
Valve verification before start up
1. Tighten the packing just enough to prevent
stem leakage. Over-tightening will decrease
packing life and increase operating torque.
The bolt torque figures for the packing bolts
can be calculated as indicated in Table 1.
2. Check the operation of the valve by stroking
it to “full open” and “full close”.
IMPORTANT
If piping system is pressurized with water for
testing, and in case the piping system has been
shut down after testing for a long time, the
following recommendations should be adopted.
a. Use corrosion inhibitor with water to
pressurize the piping system
b. After testing, the piping system should be
depressurized and the test water completely
drained.
3
FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Operations instructions
The following instructions will help provide a
satisfactory and long life service of the bolted
bonnet globe valves:
1. Make sure to perform periodic valve
verification as described in the next
paragraph.
2. In case of actuated valves always follow the
specific instructions given by the actuator’s
manufacturer.
3. Never change the setting of torque and/or
limit switches which have been carefully set
during the final test at workshop.
Periodic valve verification during service
A - Normal check
1. Verify monthly that there is no leakage
from packing or in the body/bonnet area.
If the leakage has been detected from
the packing, tighten nuts according to
the procedure described in following
Maintenance Section.
If the leakage does not stop, follow the
procedure for packing maintenance.
If the leakage has been detected from the
body/bonnet, tighten the nuts as indicated in
Table 1.
If the leakage does not stop, follow the
maintenance procedure for the replacement
of the body/bonnet gasket.
2. Every 2/3 months, depending on operating
frequency, verify the greasing of bearings
and stem thread.
3. For actuated valves, in addition to the above,
please refer also to the warnings in the
actuator manual.
B - Preventive actions
1. Every 3 months verify the tightness of gland
bolts.
2. Every 6 months on motorized valves and
every 8 months on hand operated valves,
grease stem and bearings.
3. Every 12 months check the travel of the
gland follower, setting a new packing when
the end of the travel is approaching.
4. Every 4 years disassemble the critical
service valves and/or actuated valves,
verifying the sealing surfaces and lap them
again when necessary. Substitute the
bonnet gasket and the packing, grease the
stem.
5. For the actuator, proceed as indicated in its
maintenance manual.
TABLE 1 - BOLT TORQUE FIGURES FOR BODY-BONNET FLANGED CONNECTIONS
(Corresponding to approx. 40% Of yield strength on dry steel surface)
Materials: A193 B7 / A193 B16 / A320 L7 Material: A193 B8
Nominal bolt
Diameter (In.)
½ 9 66 90 3 19 26
⅝ 18 129 175 5 37 50
¾ 31 224 305 9 64 87
⅞ 50 358 487 14 102 139
1 74 533 725 21 152 207
1⅛ 107 772 1050 31 221 300
1¼ 149 1075 1462 43 307 418
1⅜ 201 1447 1968 57 413 562
1½ 263 1896 2579 75 542 737
1⅝ 339 2445 3325 97 699 950
1¾ 426 3072 4178 122 878 1194
1⅞ 527 3798 5165 150 1085 1476
2 642 4630 6297 183 1323 1799
2¼ 921 6640 9030 263 1897 2580
2½ 1271 9162 12460 363 2618 3560
2¾ 1537 11085 15076 439 3167 4307
3 2003 14447 19648 572 4128 5614
3¼ 2556 18428 25062 730 5265 7161
3½ 3201 23079 31387 914 6594 8968
Kgm Ft⋅lb Nm Kgm Ft⋅lb Nm
Torque Torque
TABLE 2 - Torque (Nm) for packing bolts
Diameter
(In.)
¼ 39 12
⅜ 74 24
½ 127 40
⅝ 305 96
¾ 588 186
⅞ 793 251
1 1006 318
1⅛ 1973 623
1¼ 2662 841
1⅜ 3418 1080
1½ 4395 1389
1⅝ 5436 1718
1¾ 6751 2133
1⅞ 8125 2568
2 10443 3300
2¼ 12978 4102
2⅜ 16317 5157
2½ 19457 6149
2⅝ 23515 7431
B7/L7/B16 B8/B8M
Material
4
FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
TROUBLESHOOTING GUIDE
Symptom Possible cause Solution
Stem packing
leaking
Body-Bonnet
leaking
Valve leaking 1. Valve not fully closed 1. Close valve
Jerky operation 1. Packing is too tight 1. Loosen gland nuts, cycle valve, retighten
Back seat leaking 1. Back seat damage 1. Replace the back seat
MAINTENANCE
1. Gland flange nuts too loose 1. Tighten gland flange nuts.
2. Packing damaged 2. Replace packing (See paragraph Packing
maintenance)
1. Body-bonnet flange bolting loose 1. Tighten bottom flange bolting
2. Gasket damage 2. Replace the gasket
2. Debris trapped in valve 2. Cycle and flush (with valve open) to remove debris
3. Sealing surface damaged 3. Recondition the sealing surface
2. Air supply inadequate
(for pneumatic act.)
2. Increase air supply pressure
1. Open completely the valve up to the
backseat position.
The Fasani bolted bonnet globe valves
have been designed to require minimum
maintenance.
This manual describes on site repairs as:
- Packing maintenance
- Body/bonnet flange gasket maintenance
2. Remove the nuts (16) of the gland bolts (15)
3. Lift the gland flange (10) and the gland (9)
4. Remove the worn-out packing using a
hooking wire
5. For a better tightness, proceed to an
accurate cleaning of the stem and stuffing
box and make sure there are no scratches
All the other repairs should be performed by
Emerson
or signs of seizing
6. The repacking shall be carried out by
placing one ring at a time around the stem,
Packing maintenance
If leakage is observed through the packing,
tighten the gland nuts slowly and evenly until
the leakage stops.
inside the stuffing box and by making sure
that they are correctly oriented. Press it into
the bottom (refer to Figure 3).
7. When the stuffing box is filled, replace
the gland (9) and gland flange (10) in their
CAUTION
Do not over-tighten packing gland nuts. Overtightening will increase the torque required to
operate the valve.
When tightening the gland nut, use half-turn
increments until leakage has stopped.
original position.
8. T
ighten gland nuts in accordance with Table 2
(Bolt torque figures for packing bolts).
9. Cycle the valve.
10. Pressurize the line.
11. If a leakage is detected, tighten the gland
nuts slowly and evenly until the leakage
Please refer to Figure 4.
stops.
To replace the packing proceed as follows:
Body-bonnet flange gasket maintenance
WARNING
Before starting any maintenance, depressurize,
drain and vent the line; check that the valves are
not in temperature; disconnect any electrical
power supply.
Failure to do so may cause serious personal injury
and/or equipment damage.
WARNING
Before starting any maintenance, depressurize,
drain and vent the line; check that the valves are
not in temperature; disconnect any electrical
power supply.
Failure to do so may cause serious personal injury
and/or equipment damage.
FIGURE 3
1 = Braided graphite rings
2 = Die formed graphite (4 rings)
FIGURE 4
15 16
10
9
5
FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 5
1. Before replacing the gasket, carefully clean
the flange surfaces.
2. Place the gasket in its seat and begin to
carefully position the bonnet flange. Position
it perfectly parallel to the gasket face; do
not use the bolts to obtain this alignment.
3. In case the coupling is vertical (valve with
horizontal stem), position the bonnet flange
by means of a hoist; lock it with four bolts
placed at 90° on from the other and tighten
them until the flanges are perfectly coupled
in their seat. Insert all the other bolts.
4. During tightening, make sure that the faces
of the flanges remain perfectly parallel.
5. Tighten the bolts in the sequence indicated
in Figure 5, using for the first turn a torque
of approx. ¼ of the maximum torque listed
on table 1. For a better performance of the
joint, tighten again all the bolts after the
equipment has been pressurized.
VALVE REMOVAL
If the valve needs to be removed from the line
for some extraordinary reason, the user should
ensure the following:
1.
The valve is depressurized, drained and vent.
2. The pipe shall be cut as far away from the
valve as possible (only for welded valves).
GREASES AND SPECIAL TOOLS
Greases
To lubricate the bearings on manual and
gearbox operated valves, we suggest to use
the grease AGIP GRMUEP2 or an equivalent
product, as showed in the following table:
TABLE 3 - GREASE AND LUBRICANT LIST
Manufacturer Grease
AGIP GRMUEP2
API PGX2
BP GREASE LTX2
ESSO BEACON 2
FINA FINAGREASE HP FINAGREASE EPL2
MOBIL MOBILUX EP2
Q8 REMBRANDT EP2
SHELL ALVANIA R2 SUPERGREASE A
TEXACO MULTIFAK EP2 GREASE L2
TOTAL MULTIS EP2 MULTIS 2
VISCOL SIGNAL ROLSFER 2
For the lubrication of the stem thread, use the
grease SIGNAL CEP 30 produced by Viscol.
As an alternative you can utilize:
- CEPLATTYN 300 produced by REINER-FUCHS
- GRAFLOSCON produced by KLUBER
You can also use a grease having more than
25% pure graphite content (carbon 98%)
granulometry 5 microns, without any abrasive
agent.
For the lubrication of the actuator, refer to the
relevant manual.
Special tools
No special tool required for the maintenance
operation described in this manual.
6
FASANI BOLTED BONNET GLOBE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
7
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.
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