Flowserve 50165 User Manual
USER INSTRUCTIONS
Nordstrom
Figure 50165 and 50169
Dynamic Balance® Iron Plug Valve
FCD NVENIM2006-00 09/05 (Replaces IOM-50169)
Installation
Operation
Maintenance
Experience In Motion
Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05
Contents
1 Valve Selection 4
Introduction
Pressure/Temperature Rating
Bending Strength
Pressure Surge
Throttling Service
Temperature Changes
Over-pressurization
Trapped Pressure
Material Compatibility
Operating Effort
2 Shipping and Storage
Introduction
Handling
Storage
3 Installation 1
Introduction 1
Inspection 1
Flanged Joint Assembly 1
Testing and Adjustment 1
4 Operation and Maintenance 1
Introduction 1
Operation, Manual Valves 1
Operation, Power Actuated Valves 1
Fluid Dynamics of Shutoff Valve Operation 1
Noise 1
Maintenance 1
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5 Dynamic Balance Iron Plug Valve Maintenance 18
Notice 1
Economics of Valve Repair 1
Customer Service 1
Field Service 1
Video Tapes 1
When You Call or Write... 2
Introduction 2
Basic Construction Principles 2
Sealant System 2
Design Features 2
Valve Front Identification 2
Gearing 2
Sealants 2
VXX Valve Purge 2
Sealant Injection Equipment 2
Valve Maintenance 2
Basic Sealant Injection 2
Valve Maintenance: Troubleshooting 2
Detail Sketch: Stem End Detail – Wrench Operated Valve 3
Detail Sketch: Stem End Detail – Gear Operated Valve 3
Detail Sketch: Cover End Detail – Ball Seat Arrangement 3
Technical Data: Procedure for Tightening Cap Screws 3
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Valve Selection
1
Introduction
It is beyond the scope of this manual to make recommendations for specific applications because
misapplication of a valve type could result in operating problems that adversely affect system safety and
efficiency. This manual is intended to call attention to important considerations in the selection of valves.
The manual addresses the important subjects of Shipping and Storage, Installation, and Operation and
Maintenance. Observance of the recommendations and cautions offered herein will provide increased
assurance of satisfactory valve performance.
The valve industry offers a wide variety of valve types and materials for use in industrial piping
applications. There are usually several possible choices for a given requirement; any one valve may offer
significant advantages and/or limitations compared to another valve. It is good practice to consult the
manufacturer regarding specific requirements. The purchasing function includes the responsibility for
securing the required valves at the lowest cost, but must also ensure that the valves purchased are in
fact satisfactory for the intended service. The lowest total user (life cycle) cost criteria should be used
only in choosing between alternatives that are known to satisfy the service requirement.
Pressure/Temperature Rating
The pressure/temperature rating of the valve must be properly selected for the service requirement.
If the service involves a temperature above 100ºF (38ºC), the valve pressure rating at the service
temperature must be verified as meeting the requirements of the application.
If system testing will subject the valve to a pressure in excess of its working pressure rating, then the
intended testing pressure and a statement explaining whether the test pressure is through the opened
valve or a differential across the closed valve, should be included in the purchase specification.
Some Source References for Pressure-Temperature Ratings: MSS SP-78; Cast Iron Plug Valves,
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Flanged and Threaded Ends
Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05
Bending Strength
Piping systems are subject to mechanical constraints at fixed support points such as rigid nozzles,
anchors, etc. Cold springing at assembly and system temperature changes, together with gravity,
possible inertia loads, landslides, non-uniform subsidence in buried lines, etc. all potentially affect the
bending moment at various points in the piping.
Valves are also subjected to the bending moment occurring in the adjacent pipe that is in addition to the
normal pressure loading. Bending loads can cause deformation in valve bodies that can be detrimental
to valve functional performance. It is therefore a recommended design practice to avoid locating valves
at points of large bending loads.
In many cases, normal valve design practice results in a body strength greater than the strength of the
adjoining pipe thereby providing inherent protection against valve damage. In other cases, piping conditions or systems designs may actually increase the possibility of harmful valve body deformation.
The following are examples of possible problems.
a) Basic “standard” valves that are made into “venturi” type valves by providing enlarged end connec
tions on the smaller standard basic valves.
b) Any “standard” valve installed in heavy-wall “overweight” piping where the extra thickness may e
the pipe to be stiffer and stronger than the valve.
Valve designs having a high body bending strength should be used if there is reason for concern
regarding possible high bending loads.
Pressure Surge
Closure of a valve in a flowing fluid line causes the velocity of the fluid to be reduced to zero. If the fluid
is a relatively incompressible liquid, the inertia of an upstream column produces a pressure surge at the
valve whose mag nitude is inversely proportional to the time required for closure. The surge pressure
is also proportional to the length of the upstream fluid column and the fluid velocity prior to closure
initiation. If the application involves a long upstream line, a long downstream line, high velocity, and/or
rapid closure, singly or in any combination, the possibility of an unacceptable pressure surge should be
investigated.
Also to be considered are condensation-induced pressure surges which occur when a fluid velocity
change is caused by rapid condensation or when a slug of water is accelerated by contact with steam.
An example would be when condensate collects on one side of a closed valve that has steam on the
other side. Opening the valve causes collapsing steam voids, sharp pressure surges and acceleration
of condensate slugs. Condensation-induced pressure waves can result in pressure pulses that are
significantly higher than those produced by a sudden valve closure. In such events, non-shock rated
gray iron valves installed in steel piping systems are particularly vulnerable to catastrophic failure. Traps
are required to prevent condensate accumulation and “blow off’ valves, located at the low point in the
system, are needed to ensure condensate drainage. Operation and maintenance personnel must be
aware of the function of these devices in relationship to the “shutoff’ valve operation and the necessity
for them to function properly.
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Throttling Service
Valves used to control the rate of fluid flow may be subject to severe fluid turbulence that can have the
effect of creating a high-energy conversion within the valve and piping system. This energy conversion
is usually indicated by high noise levels, either from cavitation of liquids or shock waves from gases.
(The noise in a water faucet is an example of a low-level cavitation noise.)
The possibility exists for mechanical damage to the valve and piping system when throttling of liquid
flow results in severe and continuous cavitation conditions. Likewise, with gas flow under severe throttling conditions, shock waves can possibly result in damage to the system.
Flowserve Nordstrom Valves should be consulted on proper valve selection for throttling applications.
Temperature Changes
Valve structural materials expand with rising temperatures and contract with falling temperatures.
Generally, increasing temperature causes a decrease of mechanical strength that is regained on return
to a lower temperature. A condition of non-uniform temperature in a structure may impose significant
thermal stresses or distortion with possible adverse effect on valve performance.
The possibility of thermal stress fatigue should be considered in applications involving frequent
temperature cycling. This possibility is increased by any one or a combination of the following:
increasing temperature range, increasing temperature level, increasing rate of temperature change,
increasing thermal conductivity of the fluid, increasing thickness of metal sections or increasing the
number of cycles. In some cases, thermal cycling may also increase the tendency for stem seal leakage.
Over-pressurization
Dynamic Balanced iron plug valves are not provided with a pressure relief device. It is the user’s
responsibility to provide a relief device as part of the system in which the valve will be used.
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Trapped Pressure
When a closed valve containing liquid is heated (e.g., from process condition, radiation or solar heating)
the cavity pressure will increase due to volumetric expansion or vaporization of the liquid. Conversely,
cooling an undrained cavity below the freezing point may also result in volumetric expansion of the
media. These expansions can result in extremely high pressures occurring in the valve.
The purchaser should consider the necessity of providing positive means for prevention of such overpressurization where these conditions can be anticipated.
Material Compatibility
It is important that valve structural materials and lubricants be chemically compatible with the other
piping system components, line fluids and the environment. Guidance should be obtained from
informed sources such as NAI or the system engineers whenever there appears to be reason for such
concern.
Operating Effort
Manually operated valves are usually designed to require a reasonable amount of physical effort applied
to a handwheels or handle to open or close at rated working pressure. However, typical use of a valve
may involve a lower working pressure thereby substantially reducing the differential pressure across
a valve closure element and a resulting reduced operating effort. Lower operating effort can also be
achieved by opening a bypass valve in some cases.
In all cases, the purchaser should determine that the manually operated valves selected will be capable
of being operated under the anticipated operating conditions by the personnel required to perform such
operation. Oversize handwheels and gear operators will require specific operator training to prevent
applying damaging overloads. NAI should be consulted for specific instruction on operating torques.
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Shipping and Storage
2
Introduction
Flowserve recognizes the importance of maintaining the as-built condition of valves, and has prepared
this section to call attention to important considerations in the handling of valves prior to installation.
Industrial valves as manufactured, tested, and ready for delivery to users, are typically well-designed
products that are property fabricated and inspected and capable of giving satisfactory service. Valves
enjoy a degree of inherent protection against degradation by impact, impingement or invasion of
harmful materials after installation. However, the intervening period between the production test and the
installation in line may involve substantial exposure to such degradation that can adversely affect the
subsequent service performance of the valves.
Observance of the recommendations and cautions offered herein should provide increased assurance of
satisfactory valve performance.
Handling
Appropriate care in handling valves should be complementary to the degree of protection provided in
preparation for transport. A basic consideration in handling valves should be to avoid damaging the
protection provided for shipment. An obvious general rule is that valves should never to thrown or
dropped. Valves whose size requires handling by crane or lift truck should be “slung” or “rigged” carefully to avoid damage to exposed valve parts. Handwheels and stems, in particular, should not be used
as lifting or rigging points for large valves.
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Storage
The problems to be considered in regard to storage are generally the same as those previously
discussed relative to preparation for transport. The time element is important as conditions that would
not be seriously harmful for a period of a few days could result in need for costly reconditioning if
extended over weeks or months.
Valve end protectors should not be removed unless necessary for inspection and installation.
Protection against weather should be provided. Ideally, valves should be kept indoors with actual valve
temperatures always higher than the dew point.
Valves should be supported off the ground and/or pavement and protected by a watertight cover if
outdoor storage is unavoidable.
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Installation
3
Introduction
A most critical point in time in the life of an industrial valve is the moment of installation. The possibilities for degradation of the valve are numerous. Conversely, the exercise of proper care in this process
will assure increased probability of trouble-free valve service.
The valve industry has prepared this Section in order to provide useful information, warnings and
reminders, in a format that will be helpful to all concerned. A judicious selection of these pages,
delivered to the installation site with the valve itself, will provide the opportunity for the person having
the greatest need to know to be informed or reminded of what is most important at the time such
information can be the most useful.
Inspection
The testing and inspection required by applicable standards and specifications make it generally reasonable to assume that a new valve, about to be installed in a piping system, has been properly designed
and manufactured. Nevertheless, it is important to recognize that in the transport, handling and storage
of a valve between the time of manufacture and the time of installation, there are numerous possibilities
for accident or error that could adversely affect valve performance.
It is therefore important to determine that the valve is in satisfactory condition before installation. The
following points are generally applicable and may be helpful in avoiding subsequent valve problems.
a) Carefully unpack the valve.
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b) Make a point of noting any special warning tags or plates attached to or accompanying the valve
and take any appropriate action.
c) Check the valve for any marking indicating flow direction. Make sure that the valve is installed in the
proper flow orientation when a flow direction is indicated on the valve.
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d) Inspect the valve interior to the extent practical through the end ports. Make sure it is reasonably
clean, free from foreign matter and harmful corrosion. Remove any special packing materials.
e) If practical, actuate the valve through an open-close-open or close-open-close cycle. Inspect
any significant functional features such as guides or seat faces that are made accessible by such
actuation.
CAUTION: Avoid contact with the valve closure element during cycling. It is usually desir-
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able to leave the valve closure member in the position in which it was shipped following
such inspection.
f) Check the piping to which the valve is to be fastened for proper alignment, cleanliness and freedom
from foreign materials immediately prior to valve installation.
Flanged Joint Assembly
Flanged joints depend on compressive deformation of the gasket material between the facing flange
surfaces for tight sealing. The bolting must provide the mechanical force necessary to maintain the
compressive stresses on the gasket, as well as resist the normal pressure forces tending to separate
the joint. It should be recognized that with “brute force” alignment of misaligned flanges, sufficient
bolting force may not be available to sustain the required gasket loading and to resist the load caused
by the pressure separating force, resulting in a joint leakage problem. The following practices should be
observed for satisfactory flange joint make-up.
a) Check the mating flange facings. Do not attempt to assemble the flanges if a condition is found
which might cause leakage (e.g., a deep radial groove cut by a retracting cutting tool or a dent
across the face caused by mishandling), until the condition is corrected
b) Check the gasket materials. See ASME B16.5 for additional requirements for flange joints using low
strength bolting, (e.g., gray iron flanges or Class 150 steel flanges). Metal gaskets (flat, grooved,
jacketed, corrugated, or spiral wound), should not be used with these flanges.
Types of Gaskets
There are two basic styles of gaskets used: full-face gaskets and flat ring gaskets. Full-face gaskets
cover the face of the flange and the bolting goes through them. Flat ring gaskets extend only to the
bolting.
What the Codes and Standards say about flanges and gaskets
ASME B16.1
tion about these flanges is shown in the Flowserve Nordstrom Iron Plug Valves brochure under
Drilling Templates, Flange Dimensions, and Bolting Data.
ASME B16.1, Section 5.2
installing items that have cast iron flanges. A footnote to this section reads as follows:
For Class 25 and Class 125 flanges note: The carbon steel bolts prescribed for the flanges in this
standard are based upon using a flat “ring” gasket that extends to the bolts.
Where cast iron-to-cast iron flanges or cast iron to steel flanges are used with full-face gaskets,
higher strength bolts may properly be used.
Where cast iron flanges are bolted to steel flanges and flat ring gaskets are used, carbon steel bolts
prescribed in this standard shall be employed.
covers Class 125, 250, and 800 Cast Iron Flanges and Flanged Fittings. Informa-
recommends the use of bolting conforming to ASTM A307 Grade B for
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MSS SP-92 in part, reads as follows:
Section 3.4c
ductile materials. The use of lower strength bolting is recommended to reduce the possibility of
overstressing the flanges by excessive flange bolt preload. Full-face gaskets on flat flanges provide
desirable protection against flange breakage by over-torquing of flange bolts. A flat-face flange
should not be installed against a raised face flange.
Good preassembly alignment is especially important in cast iron flange joints in order to assure that
adequate gasket compression can be achieved without excessive bolting loads.
Section 3.4d
provided for iron flanges (see Section 3.4c above) or Class 150 steel, metal gaskets (flat, grooved,
jacketed, corrugated, or spiral wound), should not be used. See ASME B16.5 for additional requirements.
In summary, all of this means that the following is to be considered:
1. Either full-face or flat ring gaskets may be used in conformance with recognized standards.
2. The use of flat ring gaskets requires the use of low-strength ASTM A307 Grade B bolting.
3. The use of full-face gaskets should minimize flange breakage.
4. Cast iron flange breakage is always a possibility if the mating flanges are not properly aligned.
c) Check the gaskets for freedom from injurious defects or damage.
d) Use care to provide good alignment of the flanges being assembled. Use suitable lubricants on the
bolt threads. Sequence the bolt tightening to make the initial contact of the flanges and gaskets as
flat and parallel as possible. Tighten the bolts gradually and uniformly to avoid the tendency to twist
one flange relative to the other. Use of a torque wrench is helpful to ensure correct and uniform final
tightening of the flange bolting. Parallel alignment of flanges is especially important when assembling a valve into an existing system. It should be recognized that if the flanges are not parallel,
then it would be necessary to bend something to make the flange joint tight. Simply forcing the
flanges together with the bolting may bend the pipe or it may bend the valve. This is particularly true
in large diameter piping. Such conditions should always be brought to the attention of someone
capable of evaluating the bending condition and the corrective measures that need to be taken. The
assembly of certain “short pattern” valves between mating flanges requires that the installation be
checked for any possibility of interference between the moving parts of the valve and the adjacent
pipe, fitting, or valve.
Cast iron flanges are less “forgiving” of improper installation than flanges of
Check gasket material. For flange joints using low-strength bolting, such as may be
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CAUTION: Torque wrenches should always be used to assure proper tightening of the flange
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bolting. If, in the tightening process, the torque on a given bolt has been increasing with each
part turn and then is observed to remain unchanged or increase a much lesser amount with an
additional part turn, that bolt is yielding. That bolt should be replaced and discarded since it is
no longer capable of maintaining the proper preload.
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