USER INSTRUCTIONS
G4, G4ZHF and G4R
Sleeveline® Plug Valves
Non-Lubricated Plug Valves for Chemical Service
Installation
Operation
Maintenance
Experience In Motion
Quality
System
Certificate
FCD DVENIM0240-06
(Bulletin V-240)
G4, G4ZHF AND G4R USER INSTRUCTIONS ENGLISH 5-14
FOREWORD
Flowserve Corporation, Flow Control Division, has established
this Installation, Operating and Maintenance Manual to facilitate field installation, operation and repair of G4, G4ZHF and
G4R valves.
It is recommended that questions or concerns involving
the processes described in this manual be directed to the
local Sales Representative of Flowserve Corporation. Only
Flowserve replacement repair parts and assembly tooling
made or designed by Flowserve Corporation should be used.
Part numbers referenced in the following sections are available from Flowserve Corporation, Flow Control Division.
TABLE OF CONTENTS
SECTION TITLE PAGE
FOREWORD
I INSTALLATION INSTRUCTIONS – FLANGED AND WELDED G4, G4ZHF, G4R 2
II OPERATING/MAINTENANCE – G4, G4ZHF, G4R 3
III VALVE DISASSEMBLY – G4, G4ZHF, G4R 4
IV PRESSURE CONTAINING FASTENERS 5–6
V A. VALVE ASSEMBLY – 1/2" & 3/4" G4, G4R 7–8
B. VALVE ASSEMBLY – 1"– 8" G4, G4R 9–11
VI ASSEMBLY SPECIFICATIONS – FIRESAFE VALVES G4Z, G4ZHF, G4ZR 12–14
VII RECOMMENDED SPARE PARTS 15
SECTION I
INSTALLATION INSTRUCTIONS – FLANGED AND WELDED G4, G4ZHF, G4R PLUG VALVES
FLANGED:
Installation of Flowserve flanged valves is best accomplished by
locating valves in pipeline flanges, assuring all corrosion and
foreign materials are removed from pipe flange, and then center
gaskets with the valve flanges. Fastener or taper pins should be
used to align holes and locate gaskets. Fasteners should be
tightened to the corresponding valve and fastener size.
WELDING:
Flowserve Corporation, Flow Control Division recommends
using only qualified welding procedures and personnel for weld
installation of G4R valves.
The following precautions should be observed:
1. The valve should be inspected prior to welding to assure that
no foreign materials obstruct the flow passageway and that the
weld preparation is free of corrosion and physical damage.
2.
The valve should be in the open position while being welded.
Open position is when the flats on the plug stem are parallel with
the pipeline.
3.
The G4R valve contains various sleeve and diaphragm materials
that have a different maximium temperature limitation. Refer to
Table 1.1 for temperature limitations.
4.
The valve body sleeve and diaphragm must not exceed these
tem peratures during welding. This includes preheats, inter passes,
or post weld heat treatments, as applicable. Refer to Figure 11-1
for locations of the sleeve and diaphragm in the center valve
2
section.
5. Welding of the G4R valve without disassembly may be
accomplished with no damage to the sleeve and diaphragm.
Precautions MUST be taken to cool the valve bowl and
monitor temperature. The temperature of the center or bowl
area of the valve must not exceed the listed temperature for the
material. Valves, sizes two inch and smaller, must be wrapped
with water-soaked, fire-resistant material to cool the valve bowl
and inlet where the weld is to be made. Use temperature melt
crayons equal to the sleeve and diaphragm rating to mark
the body welding end and monitor the body temperature.
Thermocouples may be attached to the welding end of the
body, or surface pyrometers may be used to monitor the body
bowl temperature.
CAUTION: DO NOT ALLOW WATER FROM THE SOAKED
WRAPPING MATERIAL TO ENTER THE WELDMENT.
TABLE 1.1
TEMPERATURE LIMITATIONS
MAXIMUM
MATERIAL DESCRIPTION SERVICE
TEMPERATURE
Ultra High Molecular Weight
Polyethylene (UMPE) 200°F (93°C)
Tetrafluoroethylene Polymer (PTFE) 400°F (204°C)
Durlon 2 450°F (232°C)
Duriron Durco 82 (DU-82) 275°F (135°C)
G4, G4ZHF AND G4R USER INSTRUCTIONS ENGLISH 5-14
SECTION II
OPERATING/MAINTENANCE INSTRUCTIONS FOR G4, G4ZHF, G4R
Maintenance requirements for G4, G4ZHF and G4R valves
may vary due to operating conditions of the process. Factors
such as operating temperature, pressure, solids content, and
frequency of cycling can influence valve performance and
maintenance requirements.
Seal wear is compensated by adjusting appropriate parts. For
G4, G4ZHF and G4R valves, there are three possible leak paths:
1. Top Cap (bonnet)
2. Stem
3. Line (through)
Corresponding adjustments for each leak path are as follows:
NOTE: Refer to Figure II-1 or Figure VI-1A for parts identification.
1. Top Cap (bonnet)
Leakage due to thermal or pressure cycling is eliminated
by snugging the top cap fasteners (Part 3A) in a “crisscross" pattern. This adjustment is most effective when the
valve is not pressurized. It is important that the top cap
fasteners not be tightened excessively and that torque
values applied be within industry standard for fasteners.
2. Stem
Leakage due to wear of the diaphragm, and/or wear to
the sleeve (primary seal) is eliminated by tightening the
adjuster fasteners (Part 12A) in 1/4 turn increments. It is
recommended that the adjuster fasteners be tightened
evenly.
FIGURE II-1
TYPICAL ASSEMBLY OF G4 AND G4R VALVE
WRENCH (13)
STOP COLLAR RETAINER (19A)
STOP COLLAR (19)
ADJUSTER FASTENERS (12A)
ADJUSTER (12)
TOP CAP FASTENERS (3A)
TOP CAP (3)
GROUNDING SPRING (17)
THRUST COLLAR (11)
DIAPHRAGM (6)
PLUG (2)
The valve should be operated between adjustments to
assure that the plug properly seats itself into the sleeve.
If leakage persists after repeated adjustments, the sleeve
and diaphragm will require replacement, as covered in
Section V A and V B or Section VI.
3. Line (through)
Through leakage due to wear of the primary seal can be
eliminated by tightening the adjuster fasteners (Part 12A)
in 1/4 turn increments. It is recommended that the
fasteners be tightened evenly.
The valve should be operated during adjustments to pre-
vent excessive operating torque. Should leakage persist
after repeated adjustments, the sleeve will require replacement, as covered in Section V A and V B or Section VI.
WARNING
!
To avoid personal injury and prevent damage to
equipment, do not operate or repair this valve without
observing the following procedures outlined in this
manual.
SLEEVE (5)
BODY (1)
3
SECTION III
VALVE DISASSEMBLY – G4, G4ZHF, G4R
G4, G4ZHF AND G4R USER INSTRUCTIONS ENGLISH 5-14
Recommended Precautionary Measures
1. Valves must be relieved of process fluid and pressure
prior to disassembly.
2. Personnel performing disassembly must be suitably
protected and alert for emission of hazardous process
fluid.
3. If there is a pipe plug located at the bottom bowl of
the valve, DO NOT remove the pipe plug until the valve
plug has been removed.
Disassembly Steps
NOTE: Refer to Figure II-1 or VI-1A for parts identification. If
an actuator or gearbox operates the valve, alignment marks
should be noted to assure correct orientation when reassembled.
This may best be accomplished by making matching marks
on the plug stem and operator housing with no burrs on the
plug stem.
1. Gradually loosen adjuster fasteners (Part 12A) – DO NOT
REMOVE.
2. Turn plug (Part 2) in order to raise the plug to vent any
material trapped in the valve (see note below).
NOTE: If there is no upward movement of the plug
(Part 2), it will be necessary to devise a method of lifting
the plug upward. This may require removal of the valve
operator (Step 3). This operation should be under taken
noting the above precautionary measures. Methods of
plug removal must include protective measures on plug
stem and plug end.
3. WARNING: Do not loosen or remove top cap fasteners
(Part 3A) when removing an operator or accessory.
Remove the operator by un fastening it from the
bracket.
4. Once the plug (Part 2) has lifted, the adjuster fasteners
(Part 12A) can be completely removed.
5. Gradually loosen but DO NOT REMOVE all of the top cap
fasteners (Part 3A). Turn the plug until it is loose from
the sleeve (Part 5) and all pressure has been vented.
(Again, it may be necessary to use a mechan ical means
to move the plug upwards.)
6. Remove the top cap fasteners (Part 3A) and top cap
(Part 3) from the plug stem (Part 2).
7. Remove the plug (Part 2) from the body (Part 1).
8. Remove the grounding spring (Part 17) and thrust collar
(Part 11) from plug stem (Part 2).
9. Remove the diaphragm (Part 6) from plug stem (Part 2).
10. Inspect the valve sleeve (Part 5) for wear or damage,
especially scratches near the top, bottom and port areas.
If wear or damage is excessive, the sleeve should be
replaced.
11. Remove sleeve (Part 5) as follows:
NOTE: Care should be taken not to damage the inter nal
body bore.
a. Using a screwdriver and mallet, cut the old sleeve
through one of the port openings, top and bottom.
b. Grasp the sleeve with a pair of pliers while twisting,
and lift the sleeve from the body.
12. Thoroughly clean all valve parts with an acceptable
cleaner.
13. Inspect parts for damage. Look for marred, scratched or
rough sealing surfaces on the valve plug (Part 2).
NOTE: Reinstallation of damaged or unclean parts will
ruin any replacement seals installed into the valve.
4
SECTION IV
PRESSURE CONTAINING FASTENERS
G4, G4ZHF AND G4R USER INSTRUCTIONS ENGLISH 5-14
Material Selection
Selecting the proper fastener material is the ultimate responsibility of the customer because the supplier does not typically
know in what service the valves will be used or what elements
may be present in the environment. Flowserve normally supplies B7 (carbon steel) for ductile cast iron and carbon steel
valves. For stainless steel and high alloy valves, B8 (stainless
steel) fasteners are supplied as standard. All fasteners
used must have a minimum yield strength of 40 000 PSI,
a minimum elongation of 12% and be compatible with the
process fluid. Determining com patibility to the process fluid
goes beyond a material being resistant to general corrosion
because the more important consideration is a material’s
resistance to stress corrosion cracking. Depending on the
service, it may make sense to use B7 fasteners on high alloy
valves. One such service would be marine environments
because of stainless steel’s susceptibility to stress corrosion
cracking in chloride environments. Another key aspect of
fasteners is frequent visual inspection. Because of the common practice of using steel fasteners rather than stainless
steel to avoid chloride stress corrosion cracking, visual
inspection is recommend ed to monitor the general corrosion
of these fasteners. If jacketing or insulation is used on a valve,
CAP SCREWS - STUDS
HHCS - Finished Heavy Hex Head Cap Screw
HCS - Finished Hex Head Cap Screw
STUD - Stud
Dimensions per ASME B18.2.1
it must be periodically removed for visual inspection of the
fasteners. If you wish assistance in determining the proper
fasteners to use, please refer to the attached chart.
Design & Type
The Flowserve valve design standards adopt ASME B18.2.1
(1996) as the standard for fastener type and design. This
national standard requires that finished hex “head” cap
screws be used when the head of the fastener is turned. A
finished hex “head” cap screw and a heavy hex cap screw
have a bearing surface under the head to minimize fric tional
resistance during tightening. They also comply to qualified
body diameters and fully formed head dimen sions. Cookeville
Valve Operation policy is to use finished hex “head” and heavy
hex “head” cap screws for all pres sure retaining fasteners.
This includes top caps, packing adjusters, plug adjusters,
bottom caps, body halves or other pressure retaining components. Compliance is made with ANSI B18.2.2 (1987), Square
and Hex Nuts, when studs and heavy hex nuts are required.
Additional information on these items may be obtained
from the Flowserve Corporation, Cookeville Valve Operation,
Cookeville, Tennessee.
TABLE 1
Alloy identification stamp required on each piece.
Certification required.
Alloy Specification (40 KSI Minimum Yield Strength, 12% Minimum El.)
B840 - Stainless Steel per ASTM A193, Grade B8M2 or B8M3
B7 - Chromium - Molybdenum Alloy Steel per ASTM A193, Grade B7
B7M - Chromium - Molybdenum Alloy Steel per ASTM A193, Grade B7M, 100% hardness tested
B7MT - Chromium Molybdenum Alloy Steel per ASTM A193, Grade B7M, 100% hardness tested, Teflon coated, Dupont SP11C, Type B - Color blue
or green
B8MC2 - Per ASTM A193, Grade B8M (AISI Type 316), Class 2
C20 - Carpenter C20, CB-3 (UNS N08020), ASTM B473, 40 KSI Min. Yield Strength, 12% Min. El.
HC - Hastelloy C276 (UNS N10276), ASTM B574
I625 - Inconel 625 (UNS N006625), ASTM B446
I825 - Incoloy 825 (UNS N08825), ASTM B425, 40 KSI Min. Yield Strength, 12% Min. El.
IN - Inconel 600 (UNS N0660), ASTM B166, 40 KSI Min. Yield Strength, 12% Min. El.
M - Monel (UNS N04400), ASTM B164, Class A or B, 40 KSI Min. Yield Strength, 12% Min. El.
HB - Hastelloy B (UNS 10665), ASTM B335
I718 - Incoloy 718, AMS 5596B, ASTM B637
MKH - Monel K-500, Cold drawn and aged hardened, QQN-286 and ASTM F468
L7 - Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7
L7M - Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7M, 100% hardness tested
L7T - Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7, Teflon coated, Dupont SP11C, Type B - Color green
L7MT - Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7M, 100% hardness tested, Teflon coated, Dupont SP11C, Type B - Color green
N - Nickel per ASTM B160 (UNS N0220), 40 KSI Min. Yield Strength, 12% Min. El.
B7YC - Chromium-Molybdenum Steel per A193, Grade B7, Yellow Zinc Dichromate Plated
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