Sempell High pressure forged gate valves, Sempell-EN Manuals & Guides

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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be fully read and understood
2. All actuated valves must be securely palleted or crated, with particular attention, in order to ensure that parts of actuator do not extend beyond the packing size.
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
Pallets: Lifting and handling of the packed
valves in pallets will be carried out by a fork lift truck, bymeans of the appropriate fork hitches.
Wedge and parallel slide configuration, buttwelded or flanged 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.
a. Buttwelding end valves: weld ends
surface shall be protected with suitable protective like Deoxaluminite. The ends shall be closed with plywood or plastic discs fixed at the edge by strips.
b. Flanged end 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.
Cases: The lifting of packed valves in cases will
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 have 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 large dimensions valves, the sling and the hooking of the load must be carried out by using the appropriate tools (brackets, hooks, fasteners, ropes) and load balancing tools in order to prevent them from falling or moving during the lifting and the handling.
© 2017 Emerson. All Rights Reserved.Emerson.com/FinalControl VCIOM-01039-EN 17/12
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 1
Valve slinging
Gate valves
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.
• 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.
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).
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.
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 de-grease both surfaces with a solvent. Clean the inside of the valve with a clean cloth.
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 and downstream side.
WARNING
See the actuator user manual for the actuator preparation.
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 the maintenance is much more difficult. For operating temperatures above 200°C (392°F) a thermal insulation of the valve body isrecommended.
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Handling and lifting of the valves during installation MUST be performed following the same criteria and instruction described in previous points 'Handling requirements' and 'Storage and preservation' before installation.
WARNING
Before lifting or handling the valve or the valve/ actuator assembly, make sure you have no limitation to do it. Check if there are some safety messages attached to the lifting points of the valve or to the actuator (red rigid label) and, if any, find the proper document in the user manual which describes how you can operate under safety conditions.
A - Buttweld valves
1. Open the valve.
2. Position the valve and check for alignment with the pipe, then proceed with welding, in accordance with the applicable welding procedure.
WARNING
Before welding, make sure the valve is completely open.
B - Flanged valves
1. Position the valve between the two flanges of the pipe and put the seal gasket between valve flange and pipe flange. Ensure that it is correctly positioned.
2. Assemble the valve to the pipe by means of bolts which shall be tightened by using the crossover method.
3. Progressively reach the requested torque.
WARNING
Verify that the direction of the flow of the line corresponds to the arrow indicated on the valve body. Valves without the arrow are bi-directional.
IMPORTANT
It is recommended to perform piping flushing before installation of valve. If this is not possible, the valves must be set with the wedge in full openposition before starting with flushing.
Valve verification before start up
1. Tighten the packing just enough to prevent stem leakage. Over-tightening will decrease packing life and increase the 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'.
3. Should the valve be equipped with electric actuator, please refer to the next paragraph (page 4) for actuator adjustment instruction.
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.
Periodic valve verification during service A - Normal checks
1. Verify every half month that there is no leakage from packing or in the body/bonnet area. If the leakage has been detected from the packing, tighten the gland nuts (Figure 4, pos. 17) slowly and evenly until the leakage stops, as indicated in Table 1.
If the leakage has been detected from the
body/bonnet, tighten the nuts (Figure 4, pos. 10) as indicated in Table 2.
If the leakage does not stop, it is necessary
to replace the body/bonnet gasket or to replace the packing.
2. Every 3-6 months, depending on operating frequency, verify the greasing of bearings and the stem thread.
3. For actuated valves, in addition to above, please refer also to the warnings in the actuator manual.
B - Preventive actions
1. Every 6 months verify the tightness of glandbolts.
2. Every 6 months on motorized valves and every 8 months on hand operated valves, grease the stem and the bearings.
3. Every 4 years disassemble the critical service valves and/or actuated valves, verify the seat surfaces and lap them again when necessary. Replace the bonnet gasket and the packing, clean the stem.
4. For the actuator, proceed as indicated in its maintenance manual.
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Adjustment of electric actuators
1. For each valve equipped with actuator, atorque calculation has been made.
The size of the actuator is selected on the
base of the calculation.
2. The calculated torque is adjusted in the open and close direction on the actuator. This torque is calculated to suit the valve.
3. Before assembling an actuator to a valve, itis necessary to check:
• The technical data of the actuator.
• The correct adjustment torque.
• The operation instruction.
4. Adjustment of the actuator for GATE valves.
WARNING
• In the open direction, only the stop has to be set
with the limit switch. In case the limit switch is not adjusted, the backseat will be destroyed by the high torque.
• In the close direction, the end-stop has also to
be set with the limit switch as the first stop. The torque switch in the close position has to be set as a second stop.
• The adjustment of the limit switches in both
end-stop position has to be handled when the actuator is assembled to the valve according to the operation instructions.
• The adjustment of the wedge gate valve is the
same as for a parallel gate valve.
OPERATION AND MAINTENANCE INSTRUCTIONS
Sempell high pressure forged valves do not require special care to work properly. The following instructions will help provide a satisfactory and long life service.
Cautions
• Ensure to perform periodic valve verification as described in the dedicated paragraph (page 3).
• In case of actuated valves, always follow the specific instruction given by the actuator’s manufacturer.
• Never change the setting of torque and/or limit switches which have been carefully set during the final test at Emerson workshop.
IMPORTANT
• To ensure tightness of pressure seal gasket, pull up bolts must be tightened when the valve is under fully hydrostatic pressure test or twenty-four hours in operation.
• Yearly checking of bolt torque is recommended.
TABLE 1 - BOLT TORQUE FOR PACKING BOLTS
Stem diameter in mm mm Nm
1 25.4 M16 14
1.25 31.75 M16 14
1.375 34.92 M20 18
1.75 44.45 M20 18 2 50.8 M24 20
2.25 57.15 M24 20
2.5 63.5 M27 23
2.75 69.85 M27 23 3 76.2 M27 23
3.25 82.55 M30 28
3.75 95.25 M33 35
Bolt
diameter Torque
TABLE 2 - BOLT TORQUE FOR BONNET BOLTS
Bolt Diameter in mm mm Nm
10 M10 30 ½ 12 M12 70 ⅝ 16 M16 140 ¾ 20 M20 260 1 24 M24 580 1⅛ 28 M28 760 1¼ 32 M32 1350
diameter Torque
For this reason note that:
• The calculated torque must be adjusted.
• The closing time must not be too short, because the energy in the close blocked position depends on the actuator speed.
• The test performed without pressure under the piston must be avoided, because the actuator runs with full speed into the seat without any reaction.
IMPORTANT
• To avoid damaging the valve components, please ensure the wedge gate valves are set to close firstly by the limit switch and then by the torque switch.
TROUBLESHOOTING GUIDE
Symptom Possible cause Solution
Stem packing leaking 1. Gland flange nuts too loose 1. Check the gland flange nuts torque
2. Packing damaged 2. Replace packing
Body-bonnet leaking 1. Gasket bolting loose (Figure 4, pos. 10) 1. Tighten bolting (Figure 4, pos. 10)
2. Gasket damage 2. Replace the gasket
Valve leaking 1. Valve not fully closed 1. Close the valve
2. Debris trapped in valve 2. Cycle and flush (with 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
Back seat leaking 1. Back seat damage 1. Recondition the back seat surface
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Operation and maintenance instructions
Please refer to Figure 4
Assembly
1. All the parts must be cleaned. It is necessary a visual examination to ensure that there are no foreign parts inside.
2. The internal seat ring surface (29.1) must be carefully lapped in order to avoid any defect.
3. The surfaces of the two plates of the wedge(28.1), must be lapped in order to avoid any defect.
4. The two plates of the wedge (28) must be assembled together with the two distance parts (37) and with the stem (20). Insert nowthis unit into the body.
5. Insert the bonnet (2) into the body. Take care that the operator wears gloves in order to ensure a careful assembly of the pure graphite gasket (7), covered with stainless steel inlets.
6. The ring (6) and the four pieces of the segment ring (5) must be assembled over the gasket (7). The segment ring has to be put into the body groove.
7. The bonnet must be brought into position with the necessary bolts and nuts. For the necessary torque, see Table 2.
8. Install the ground ring (13), the packing of pure graphite and two rings to the stuffing room (see Figure 2). The operator MUST wear gloves.
9. The packing shall be compressed by the gland (15) and the gland flange (16) with the cut ring (19) inside. Screw the nuts to the bolts with the torque indicated in Table 1.
10. Install the indicator (25) on the stem.
11. Assemble the yokenut (21), the two bearings (22) and the two O-rings (32) to the yoke with the lubrication nipple, then the gear/ actuator connection flange with the bolts.
12. Assemble the handwheel, the gear or the actuator to the valve.
Disassembly
1. For a correct disassembly it is necessary to follow in reverse the assembly instructions.
2. Follow this special remark to disassemble the seat ring: in the upper part of the body, in the area of the segment ring, there are some holes to drive out two parts of the segment ring by using a pin and a hammer.
Cautions
First, drive out the two parts of the segment ring as indicated in Figure 3, then the remaining two parts.
Recommended spare parts
Please refer to Figure 4
• Gasket (7)
• Bearings (22)
• Ground ring (13)
• Stem (20)
• Packing (14)
• Gate two plates wedge (28) with the two
distance parts (37)
• Yokenut (21)
FIGURE 2
1. Wired pure graphite.
2. 3 to 4 pure graphite rings with a density of 1.8 g/cm3.
3. Wired pure graphite.
4. Ground ring.
FIGURE 3
Segment
ring
IMPORTANT
The segment ring has to be fixed by the safety ring. Ensure that the segment ring is in the correct position.
Segment
ring
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 4
Gate valves
FIGURE GA251.6012 TO GA251.6015
Figure Class PN
GA251.6012 900 09 (160) GA251.6013 1500 15 (250) GA251.6014 2500 25 (500) GA251.6015 4500 45 (720)
TRIM MATERIAL TO API 600
Body seat
Item
1 13% Cr 13% Cr 13% Cr 13% Cr 5 Stellite Stellite 13% Cr 17% Cr* 13% Cr 8 Stellite 13% Cr 13% Cr 13% Cr 12 F316/Stellite F316/Stellite F316 or 17.4 PH
* Over 450°C
surface 29.1
Wedge seating
surface 28.1 Stem 20 Backseat 2.1
F316
below 450°C
MATERIAL SPECIFICATIONS
11 12 13 14 15 16 17 18
-20°C - 425°C -46°C - 425°C 200°C - 540°C 250°C - 550°C 400°C - 575°C 500°C - 650°C 38°C - 450°C 130°C - 650°C A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 P91 15NiCuMoNb5 F316 X6CrNiNb1810
Item
1 Body A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 15NiCuMoNb5 F316 X6CrNiNb1810 2 Bonnet A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 15NiCuMoNb5 F316 X6CrNiNb1810 3 Yoke A105 A105 A105 A105 A105 A105 A105 A105 4 Safety ring A105 A105 A105 A105 A105 A105 A105 A105 5 Segment ring A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 15NiCuMoNb5 F316 X6CrNiNb1810 6 Ring A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 15NiCuMoNb5 F316 X6CrNiNb1810 7 Gasket Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite 8 Bolts A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 9 Nuts A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H 10 Nuts A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H 11 Bolts A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 A193 B7 13 Ground ring 17Cr 1.4122 17Cr 1.4122 17Cr 1.4122 17Cr 1.4122 17Cr 1.4122 17Cr 1.4122 17Cr 1.4122 17Cr 1.4122 14 Packing Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite 15 Gland F6 F6 F6 F6 F6 F6 F6 F6 16 Gland flange A105 A105 A105 A105 A105 A105 A105 A105 17 Gland nuts A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194.8 18 Bolts A193 B7 A193 B7 A193 B7 A193 B8 A193 B8 A193 B8 A193 B7 A193 B8 19 Cut ring Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite 21 Yoke nut Bronze B
22 Bearings Steel Steel Steel Steel Steel Steel Steel Steel 25 Indicator A105 A105 A105 A105 A105 A105 A105 F316 28 Wedge A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 15NiCuMoNb5 F316 X6CrNiNb1810 29 Seat ring A105 C22.8 LF2 TT5 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 15NiCuMoNb5 F316 X6CrNiNb1810 32 O-ring FKM FKM FKM FKM FKM FKM FKM FKM 33 Handwheel Steel Steel Steel Steel Steel Steel Steel Steel 37 Distance wedge F6 F6 F6 F6 F6 F6 F6 F6
1.0460 1.0411 1.5415 1.7335 1.7380 1.4903 1.6368 1.4550
148 gr.B or
Ni-resist D2
Bronze B
148 gr.B or
Ni-resist D2
Bronze B
148 gr.B or
Ni-resist D2
Bronze B
148 gr.B or
Ni-resist D2
Bronze B
148 gr.B or
Ni-resist D2
Bronze B
148 gr.B or
Ni-resist D2
Bronze B
148 gr.B or
Ni-resist D2
Bronze B 148 gr.B
or Ni-resist D2
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Safety device (accessory 8)
Over pressure protection for two directions for Gate valves: assembly and maintenance instructions.
Safety device parts
The safety device is composed by the following parts:
1. Nozzle on the body (acc. 9).
The safety nozzle material is according to
the valve body material.
2. Safety globe valve with locking device in open position.
This safety globe valve will be delivered
unwelded, as a separate part. The material of the safety globe valve is also according to the gate valve body material with buttweld ends, suitable for a 15 mm (inside diameter) pipeline connection. The safety globe valve body lay out is in accordance with that of the gate valve.
3. Rupture disc unit with an approx. 60mm longitudinal pipe section.
General material F12 (13CrMo44).
This unit will also be delivered as a separate
part. The rupture disc is recommended as a spare part.
Installation of the safety device on site at customer care
To avoid any danger to people, it is mandatory to perform the safety device installation by following these instructions. The connection pipe between the nozzle and the safety globe valve, and that between the valve and the rupture disc are not at Emerson’s care.
• The safety device has to be installed to the side of the valve with the outlet downwards.
• In case of gate valves for steam service, it is necessary to use a condensate filling pipe piece.
FIGURE 5
7
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Replacement of the rupture disc
The replacement of the rupture disc after bursting does not require any shutdown of the plant operation.
1. The safety globe valve must be closed. Only the authorized staff must close this safety system.
2. After the safety globe valve has been closed, the screw of the rupture unit can be opened and the rupture disc can be replaced.
CAUTION
Verify the pressure data of the new rupture discbefore its replacement.
Lay out of the rupture disc
• Nominal rupture pressure is calculated on
a fixed temperature basis of 300°C.
• The rating of the rupture disc is 1.5 times
bigger than the maximum operating pressure, rounded to next higher rupture rating.
• Rupture ratings:
150/200/250/300/350/425/500bar.
Accessories
A gate valve in close position can retain a volume of water in the body cavity. An increase of the temperature will consequently increase the pressure in the body cavity with the risk of relevant damages of the body and bonnet. To eliminate this risk, Emerson offers you four possible solutions:
• Solution 1: Acc. 5 hole in the seat ring.
• Solution 2: Acc. 6 hole in the wedge.
• Solution 3: Acc. 7 three nozzle with caps. In the plant the client can connect
two of them depending on the flow direction.
• Solution 4: Acc. 8 with over pressure protection for two directions.
FIGURE 6
ACC. 5 ACC. 6
Open interlocked
ACC. 7 ACC. 8
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 7
Pressure of trapped water (bar)
IMPORTANT
Standard Sempell pressure seal valves will not be furnished with safety device, unless required by the user. It is the responsibility of the purchaser to require to supply a safety device, depending on the function of the gate valve.
VALVE REMOVAL
To remove a valve from the line, it is necessary to operate as follows:
1. Obtain permission to work.
2. During the valve cutting operation proceed with care in order to prevent any damage to the seats.
3. After the removal, clean carefully the valve and close the ends with plastic or wooden discs.
WARNING
Depressurize the line before starting any operation with the valve in open position, to avoid any remaining pressure in the body cavity. Then close manually the valve by way and not by torque.
Percentage volume of water (%)
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SEMPELL HIGH PRESSURE FORGED GATE VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
LUBRICANTS AND SPECIAL TOOLS
Lubricants
It is recommended to lubricate the yoke nut, if any, through the yoke nut lubricator every 2 months by using the following products:
• The bearings are lubricated with usual lubrications for bearings.
• Smear the stem threads with Molykote.
• All other bolts and nuts are assembled with usual lubricator or Molykote.
Special tools
No special tool is required for the maintenance operations described in this manual.
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 STATOIL UHIWAYLI LI G2
OPERATIONAL SAFETY INSTRUCTIONS (O.S.I.) IN ACCORDANCE WITH PED REQUIREMENTS
According to PED-ESR, par. 3.3 and related, the service pressure and temperature are indicated on the nameplate fixed on the valve. The Operation Safety Instructions (internal document TD-PED-0020) are indicated in the attached document (when applicable).
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.
Sempell 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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