Fasani Gate Valves, Fasani-EN Manuals & Guides

FASANI GATE VALVES

BOLTED BONNET

Installation and maintenance instructions for bolted bonnet gate valves Basic configuration - Flanged or welded ends

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 wedge in the closed position.

. 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.

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.

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.

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.

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.

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FASANI GATE VALVES

BOLTED BONNET

VALVE SLINGING

FIGURE 1

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 wedge 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.

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. Valves without the arrow are bi-directional. See the actuator user manual for the actuator preparation.

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.

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.

FASANI GATE VALVES

BOLTED BONNET

0° -90° 0° - 90°

FIGURE 2 Installation positions recommended

Installation instructions

Gate 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 Fig. 2. For gate valves of DN larger than 18 inches (unless specified in the order) the angle of inclination from vertical shall not exceed 30°. Different positions from those indicated may cause a non-correct valve operation, and/or a quick deterioration of the valve. Unless otherwise recommended by Emerson the valve should be installed with the wedge in the closed position, to ensure that the seat ring in the wedge 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 “1.2 Handling requirements” and “1.3 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.

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 and 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 I (Bolt torque figures for body-Bonnet flanged connections) and table II (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 I.

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.

FASANI GATE VALVES

BOLTED BONNET

Operations instructions

The following instructions will help provide a satisfactory and long life service of the bolted bonnet gate valves:

1. Make sure to perform periodic valve verification as described in paragraph 2.5.

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 Fasani 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 Section 3.

If the leakage does not stop, follow the

procedure for packing maintenance (3.1).

If the leakage has been detected from the

body/bonnet, tighten the nuts as indicated in Table I.

If the leakage does not stop, follow the

maintenance procedure for the replacement of the body/bonnet gasket (3.2).

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 I: BOLT TORQUE FIGURES FOR BODY-BONNET FLANGE CONNECTIONS

Materials: A193 B7 / A193 B16 / A320 L7 Material: A193 B8 Nominal bolt Torque Torque Torque Torque Torque Torque Diameter (In.) Kgm Ftlb Nm Kgm Ftlb Nm

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 1 - ⅛ 107 772 1050 31 221 300 1 - ¼ 149 1075 1462 43 307 418 1 - ⅜ 201 1447 1968 57 413 562 1 - ½ 263 1896 2579 75 542 737 1 - ⅝ 339 2445 3325 97 699 950 1 - ¾ 426 3072 4178 122 878 1194 1 - ⅞ 527 3798 5165 150 1085 1476 2 642 4630 6297 183 1323 1799 2 - ¼ 921 6640 9030 263 1897 2580 2 - ½ 1271 9162 12460 363 2618 3560 2 - ¾ 1537 11085 15076 439 3167 4307 3 2003 14447 19648 572 4128 5614 3 - ¼ 2556 18428 25062 730 5265 7161 3 - ½ 3201 23079 31387 914 6594 8968

(Corresponding to approx. 40% of yield strength on dry steel surface)

TABLE II: BOLT TORQUE FIGURES FOR PACKING BOLTS

For system pressures < 2533psi For system pressures ≥ 2533psi

Torque (ft·lbs) = (24.87) x (OD2 _ ID2) x (d) Torque (Nm) = multiply Torque (ft lbs) x 1.3558 Where: OD = Stuffing box bore (in)

This “Torque method” may result in more or less than 30% compression.

Torque (ft lbs) = (S.P./101.8) x (OD2 _ ID2) x (d)

ID = Stem dia (in) d = Gland stud dia (in) S.P. = System pressure (psi)

FASANI GATE VALVES

BOLTED BONNET

TROUBLESHOOTING GUIDE

Symptom Possible cause Solution

Stem packing leaking 1. Gland flange nuts too loose 1. Tighten gland flange nuts.

2. Packing damaged 2. Replace packing

Body-Bonnet leaking 1. Body - bonnet flange bolting loose 1. Tighten bottom flange bolting

2. Gasket damage 2. Replace the gasket

Valve leaking 1. Valve not fully closed 1. Close valve

2. Debris trapped in valve 2. Cycle and flush (valve open) to remove debris

3. Sealing surface damaged 3. Recondition the seat surface

Jerky operation 1. Packing is too tight 1. Loosen gland nuts, cycle the valve, retighten

2. Air supply inadequate (forpneumatic act.)

Back seat leaking 1. Back seat damage 1. Replace the back seat

MAINTENANCE

The Emerson bolted bonnet gate valves have been designed to require minimum maintenance. This manual describes on site repairs as:

- Packing maintenance

- Body/bonnet flange gasket maintenance

All the other repairs should be performed by Emerson or nominated service company.

Packing maintenance

If leakage is observed through the packing, tighten the gland nuts slowly and evenly until the leakage stops.

2. Increase air supply pressure

6. The repacking shall be carried out by placing one ring at a time around the stem, 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 original position.

Tighten gland nuts in accordance with Table II (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 stops.

1 = Braided graphite rings 2 = Die formed graphite (4 rings)

FIGURE 3

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.

Please refer to Figure 4. To replace the packing proceed as follows:

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.

1. Open completely the valve up to the backseat position.

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 or signs of seizing.

Body-bonnet flange gasket maintenance

WARNING

FIGURE 4

FASANI GATE VALVES

BOLTED BONNET

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 fig. 5, using for the first turn a torque of approx. ¼ of the maximum torque listed on table I. 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:

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:

Special tools

No special tool required for the maintenance operation described in this manual.

FIGURE 5

TABLE III: 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 STATOIL UHIWAYLI LI G2

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.

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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Fasani Gate Valves, Fasani-EN Manuals & Guides

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User Manual