Dewrance Globe Valves, Cast High Pressure Style A
Contents
1. of the actuator WARNING 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 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 2 INSTALLATION 2 1 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 Clean the inside of the valve using an air line Ensure that there are no solid objects such as pieces of wood plastic or packing materials within the va2. cut as far away from the valve as possible 5 GREASES AND SPECIAL TOOLS 4 Unscrew and remove gland bolts 5 1 Greases pos 15 16 and gland flange pos 10 To lubricate the bearings on manual and Remove the screw pos 31 and remove gearbox operated valves we suggest to use bonnet retaining flange pos 35 the grease AGIP GRMUEP7Z or an equivalent 6 Push the bonnet down inside the body until product as showed in Table 3 the segment rings pos 42 are free 7 Remove the segment rings push them out from the body groove by using the body holes placed radially on the top of the body 8 Lift up the bonnet pos 6 and pressure seal body gasket pos 5 Make sure not to damage the packing We suggest to replace the packing when changing the body gasket 9 Carefully clean all the gasket housing and lubricate with suitable grease 10 Replace the body gasket 11 Reassemble all parts following backwards the above mentioned steps 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 m without any abrasive agent For the lubrication of the actuator refer to the relevant manual 5 2 Special tools No special tool required for the maintenance 4 VALVE REMOVAL operation described in th
3. gt PENTAIR SEMPELL DEWRANCE PRESSURE SEAL GLOBE VALVES STYLE A INSTALLATION AND MAINTENANCE INSTRUCTIONS Cast globe valves pressure seal Style A 1 VALVE STORAGE B Unpacked valves TL Te lifting and the handling of these valves 1 1 Preparation and preservation for has to be carried out by using appropriate shipment means and at respecting the carrying limits All valves are properly packed in order The handling must be carried out on pallets to protect the parts that are subject to protecting the machined surfaces to avoid deterioration during transportation and storage any damage on site In particular the following precautions 2 With valves of large dimensions the sling should be taken and the hooking of the load must be carried 1 The valves must be packed with the disc in out using the appropriate tools brackets the closed position hook fasteners ropes and load balancing 2 The weld ends surface shall be protected tools in order to prevent them from falling with suitable protective like Deoxaluminite or moving during the lifting and handling The end shall be closed with plywood or plastic disc fixed at the edge by strips 3 All actuated valves must be carefully 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 4 The type of packing must be defined in the Customer s Order and shall be appropriate to ensure safe
4. transportation to final destination and eventual conservation before installation 1 2 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 www pentair com valves 2012 Pentair plc All Rights Reserved VCOSI 01414 EN 15 05 SEMPELL DEWRANCE PRESSURE SEAL GLOBE VALVES STYLE A INSTALLATION AND MAINTENANCE INSTRUCTIONS FIGURE 1 Valve slinging 1 3 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 disc 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
5. F 50 Yg 74 100 3 125 170 7 3 207 280 1 310 420 11 443 600 1 627 850 13 811 1100 IMPORTANT To ensure tightness of pressure seal gasket pull up bolts must be tightened when valve is under fully hydrostatic test pressure 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 see Paragraph 3 1 Body bonnet leaking 1 Gasket bolting loose pos 31 1 Tighten bolting pos 31 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 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 2 Air supply inadequate for pneumatic act 2 Increase air supply pressure Back seat leaking 1 Back seat damage 1 Replace the back seat SEMPELL DEWRANCE PRESSURE SEAL GLOBE VALVES STYLE A INSTALLATION AND MAINTENANCE INSTRUCTIONS 3 MAINTENANCE The Style A Series Valves have been designed to require minimum maintenance This manual describes on site repairs as Packing replacement Body bonnet gasket replacement All the other repairs should be performed by Dewrance or Nominated Service Company 3 1 Packing maintenance If leakage is observed through the packing tighten the gland nuts slowly and evenly un
6. e the line 11 If a leakage is detected tighten the gland nuts slowly and evenly until the leakage Stops 3 2 Bonnet gasket replacement 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 255 140 59 242 15 16 FIGURE 3 Ew ZZA ELA ZZA PA Z LA ZZA V Z Z ZZ Z IZ ZZ LZZ ZZA V ZLA IZZZ LZZ PEF pA f 4 y 4 4 FZZ RZA IZZA j 4 en YZZY UZZNVKZZA ZAZI a E LZ ZZ V ZZA E ZZA FEP ZZ ZZA a ae EZZ ZZA ELEA PERA LELE FEF ZZZA ZZZ ZZZ ZA aa a ZZ ZA EFTA Z7 ZZ ZZZ ZZA ELA My Woes WE VV A AZZA I At A VY v A DG y What fai ji f f ASS RSI SRA SSR QAASA 1 Braided graphite 2 Die formet graphite 5 or 6 ring 3 Metalring SEMPELL DEWRANCE PRESSURE SEAL GLOBE VALVES STYLE A INSTALLATION AND MAINTENANCE INSTRUCTIONS FIGURE 5 DETAILA 255 71 8 140 31 59 242 42 15 16 43 98 a 279 R i X N 10 35 3 23 Z 6 Please refer to Figure 5 1 Remove any operator 2 Unscrew the screw pos 71 and remove adaptor flange pos 255 3 Unscrew and remove column pos 140 2 The pipe shall be
7. he seat ring in the disd 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 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 disc and the correct operation of the valve 2 3 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 1 2 Check the operation of the valve by stroking itto full open and full close 3 If the valve has been stored for a long time check the bolt torque for bolting pos 31 in accordance with Table 2 IMPORTANT If piping system is pressurized with water for test
8. ing 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 2 4 Operations instructions 1 Style A Series globe valves do not require special care to work properly The following instructions will help provide a satisfactory and long life service 2 Make sure to perform periodic valve verification as described in Paragraph 2 5 3 In case of actuated valves always follow the specific instructions given by the actuator s manufacturer 4 Never change the setting of torque and or limit switches which have been carefully set during the final test at Dewrance workshop SEMPELL DEWRANCE PRESSURE SEAL GLOBE VALVES STYLE A INSTALLATION AND MAINTENANCE INSTRUCTIONS TABLE 1 BOLT TORQUE FIGURES FOR PACKING BOLTS For system pressures lt 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 lin ID Stem diam in d Gland stud diam lin S P System pressure psi For system pressures 2 2533 psi Torque ft lbs S P 101 8 x 0D2 _ ID2 x d This Torque method may result in more or less than 30 compression 2 5 Periodic valve verification during service A Normal check 1 Verify m
9. is manual CAUTION The nuts pos 31 need to be retightened after valve first pressurization as indicated in Table 2 If the valve needs to be removed from the line for some extraordinary reason the user should ensure the following 1 The valve is depressurized drained and vent TABLE 3 GREASE AND LUBRICANT LIST Manufacturer Grease AGIP GRMUEP2 NEI PGX2 BP GREASE LTX2 ESSO BEACON 2 FINA FINAGREASE HP FINAGREASE EPL2 MOBIL MOBILUX EP2 Q8 REMBRANDT EP2 SHEME AIVANIAR2 SUPERGREASE A TEXACO MULTIFAK EP2 GREASE L2 TOTAL MUIETISERZ MUETIS 2 VISCOL SIGNAL ROLSFER 2 gt PENTAIR PENTAIR VALVES amp CONTROLS www pentair com valves All Pentair trademarks and logos are owned by Pentair plc All other brand or product names are trademarks or registered marks of their respective owners Because we are continuously improving our products and services Pentair reserves the right to change product designs and specifications without notice Pentair is an equal opportunity employer 2015 Pentair plc All rights reserved
10. lve 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 See the actuator user manual for the actuator preparation SEMPELL DEWRANCE PRESSURE SEAL GLOBE VALVES STYLE A INSTALLATION AND MAINTENANCE INSTRUCTIONS FIGURE 2 Installation positions recommended J wee oO 3 gt Flow 2 2 Installation instructions IMPORTANT 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 Dewrance recommends that the valve shall be installed and oriented following the indications of Figure 2 This can help minimize any problem associated with solid particles present in the fluid that otherwise could deposit in the lower part of the body and be obstacle to the disc complete closure Unless otherwise recommended by Dewrance the valve should be installed with the disc in the closed position to ensure that t
11. onthly 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 pos 31 as indicated in Table 2 If the leakage does not stop follow the maintenance procedure for the replacement of the body bonnet gasket 3 2 3 3 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 2 BOLT TORQUE TO ENSURE TIGHTNESS OF PRESSURE SEAL GASKET Position 31 for gate valves Stud Torque ft lbs Torque Nm g 18 24 5 1 2 o
12. til the leakage stops CAUTION Do not over tighten packing gland nuts Over tightening 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 FIGURE 4 71 58 EOLO NIZI L L 35 23 A s J DOIVZZZZZZ7 gt 4 Remove the worm out packing using a hooking wire 5 Fora better tightness proceed to an accurate cleaning of the stem and stuffing box and make sure there are no scratches or signs of seizing 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 8 Tighten gland nuts in accordance with Table 1 bolt torque figures for packing bolts 9 Cycle the valve 10 Pressuriz
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