Flowserve F519 User Manual

Installation, Operating & Maintenance Instructions

Worcester 519 / 529 Series

15-40mm Full Bore

50mm Reduced Bore

1 STORAGE AND PRESERVATION

All valves are despatched in the open position and it is recommended that they are left in this position
during storage. All protective packaging should remain in position until the valve is to be installed.
Valves should be stored in a clean, dry environment.
Carbon steel valves are manganese phosphated and coated with a de-watering oil. This coating is
non-toxic and is quite safe on edible or potable products.

2 VALVE MARKINGS

Each valve has the following identification information plate attached to the side of the body:

2.1 Pressure Equipment Directive: If the identity plate carries the Pressure Equipment Directive number
'97/23/EC' and the Notified Body identity number '0086' beside the 'CE' mark, the product complies
with the Pressure Equipment Directive 97/23/EC and the Pressure Equipment Regulations 1999
(SI 1999/2001). Without these numbers, the product is classified as 'SEP' (Sound Engineering
Practice) and may only be used within the limitations defined in tables 6, 7, 8 & 9 of Schedule 3 of the
Pressure Equipment Regulations.

2.2 ATEX Directive: If the identity plate carries the ATEX Directive number '94/9/EC' followed by the
Explosion Protection Symbol and codes identifying the equipment group and category, the zone
suitability and protection type beside the CE mark, the product complies with the ATEX Directive and
The Equipment and Protective Systems for Use in Potentially Explosive Atmospheres
Regulations 1996.
Definition of identity plate marking above:
'II' = Equipment Group; '2' = Equipment Category; 'G' = Gas Zone suitability (Zones 1 & 2);
'D' = Dust Zone suitability (Zones 21 & 22); 'c' = type of protection i.e. constructional safety
(BS EN 13463-5).
'X' = Special temperature reference (Surface Temperature: As per BS EN 13463-1:2001
paragraph 14.2g, the temperature class or maximum surface temperature cannot be marked on the
product as it is dependant on the operating conditions. However, the maximum/minimum allowable
operating temperatures for the product are marked on the identification plate.

2.3 Should the valve soft trim materials be changed during the course of its operational life it is necessary
for this change to be reflected on the identification plate i.e. material change may impact pressure
and temperature limitations.
Refer to Flowserve Flow Control (UK) Ltd. Technical Sales for details.

2.4 Material traceability markings are hard marked on the valve body.

3 HEALTH AND SAFETY

When installing or maintaining valves:

a) Conduct a risk assessment and eliminate or reduce hazards to an acceptable level.

b) Work in accordance with Safe Systems of Work.

c) Observe all site Health and Safety Rules in particular Permit to Work and Hot Work procedures.

d) Wear all necessary Personal Protective Equipment.

e) Never remove or maintain a valve or joint unless the line has been fully de-pressurised, drained and

where necessary, purged of toxic / explosive / flammable media. Always operate the valve to the open
position to ensure that no trapped pressure exists within the cavity.

f) Never handle valves that have been used on harmful substances unless they have been completely

decontaminated and certified safe to handle.

g) Never use a valve on a duty which exceeds its prescribed operating parameters. Refer to Flowserve

Flow Control (UK) Ltd Technical Sales for performance curves or further information.

h) Never modify or alter valves unless the manufacturer has been consulted or recommends such

changes.

i) The valves wrenches are only designed for use in operating the valves and must not be used to carry

them by. Failure to observe this warning may result in operator injury.

j) Due to the large physical size and weight of some sizes of this product, always use correct lifting

methods and equipment when installing, removing and maintaining the product, and that it is correctly
supported in its final operating location.

k) Due to the variety of duties on which this product can be employed, it is the end users responsibility to

ensure the compatibility of the media with the materials of construction of the product for each specific
application (i.e.corrosion and erosion which may affect the integrity of the pressure-containing
envelope).

l) Before equipment is installed in areas which may be subject to seismic activity or extreme climatic

conditions consult Flowserve Flow Control (UK) Ltd. Technical Sales.

m) End Flanges: The end flange design of this product has been verified by either 2001(2003 addenda)

ASME Boiler and Pressure Vessel Code Section VIII Division 1 calculation method, by Finite Element
Analysis in accordance 2001(2003 addenda) ASME Boiler and Pressure Vessel Code Section VIII
Division 2 - Alternative Rules, or by experimental testing as defined in BS EN 12516-3
Valves Design Strength - Part 3 Experimental Method.

Gaskets: The gaskets used in all methods are Spiral Wound to BS4865 for PN rated flanges, and
ASME B16.20 for Class rated flanges. These have Gasket Factors and Design Stresses of 2.5 and
10000psi respectively for Carbon Steel gaskets, and 3.0 and 10000psi for Stainless Steel gaskets as
defined in the 2001(2003 addenda) ASME Boiler and Pressure Vessel Code Section VIII Division 1.

If gaskets are used with higher Gasket Factors and Design Stresses than those stated above, please
consult Flowserve Flow Control (UK) Ltd Technical Sales.

3 HEALTH AND SAFETY (cont.)

Bolting: End flanges have been verified by the methods stated above, using bolt design stress values
based on those for ASTM A193 B8 Cl.2 (i.e.25000/20000psi - dependant on the bolt size) for
Stainless Steel valves, and ASTM A320 L7 (25000psi) for Carbon Steel valves as defined in 2001
(2003 addenda) ASME Boiler and Pressure Vessel Code Section II - Materials - Part D - Properties.

n) Lethal Service. In accordance with the design verification code (2001 (2003 addenda) ASME Boiler

and Pressure Vessel Code Section VIII Division 1) a casting quality factor of 1.0 is allowable for
all products. Those intended for 'lethal service' must have had non-destructive examination carried out
in accordance with Appendix 7 of the code. Refer to Flowserve Flow Control (UK) Ltd Technical Sales.

o) If the processes or environments that the products are used in are likely to cause temperatures

(high or low) that may cause injury to personnel if touched, then adequate insulation/protection must
be fitted.

p) If the equipment is to be used on unstable gas duty, ensure that the operational parameters as

indicated on the product identification plate cannot be exceeded.

q) This equipment should be protected by other devices to prevent over-pressurisation.

(i.e. caused by external fire etc).

r) This equipment must be installed in a system that is designed to prevent excessive forces acting on

the flanges, connections, etc.

4 PREPARATION FOR INSTALLATION

When dispatched, valves contain a mineral oil which aids the bedding in of the valve. This may be
removed if found unsuitable. Special variants may contain other lubricants or be dry built.

Some valves contain a Silica gel bag inside the ball cavity to absorb humidity during storage.
These must be removed before installation, as must all other protective packaging.

It is important to ensure that the gland nut locking clip is retained at all times. If, during installation, it is
noted that the locking clip is not in place, the gland nut must be adjusted to the correct torque and a
new locking clip fitted.

Significant problems can arise with any valve installed in an unclean pipleline.
Ensure that the pipeline has been flushed free of dirt, weld spatter, etc. before installation.
The working area should be clean and clear of any debris which could contaminate the valve.