Operation and Maintenance Manual
Contents
1. a Forbes P Marshall Trusted Partners Innovative Solutions LJ K 7 z dii 7 Piston Valves Operation and Maintenance Manual Energy Conservation Environment Process Efficiency www forbesmarshall com Forbes Marshall Forbes Marshall Arca Forbes Marshall Codel Krohne Marshall Spirax Marshall Forbes Vyncke aV Forbes Marshall Trusted Partners Innovative Solutions Table of Contents What s Inside 1 1 Description 1 2 Size amp pipe connection 1 3 Limiting conditions 1 4 Installing the valve 1 5 Operation 1 6 Safety information 1 7 Maintenance 1 8 How to use extracting tool 1 9 How to use inserting tool 2 0 How to order spares PISTON VALVES aV Forbes PF Marshall Trusted Partners Innovative Solutions 1 1 Description Piston valves provide perfect tightness and durable stability on different mediums such as steam superheated steam heat transfer fluid alkalies etc 1 2 Size and Pipe Connections Screwed BSPT NPT ends Socket weld ends 50NB 65NB 80NB 100NB 125NB 150NB 200NB 2 21502 4 5 49 49 Flange type ANSI 150 Flange type ANSI 300 Limiting Conditions as per IBR norms For 15 20 25 amp 40NB 12 34 1 115 socket weld ends Maximum operating pressure 78 bar g 1131 29 psig Maximum operating temperature 425 C 797 F Maximum hydraulic test pressure 156 bar g 2262 58 psig2. 2 REMOVE SPACER WHICH IS FREE IN THE BODY EXTRACT BOTTOM SEALING RING STACK PLACE SPACER WHICH IS FREE IN THE BODY INSERT TOP SEALING RING STACK aV Forbes PISTON VALVES Marshall Trusted Partners Innovative Solutions For 50NB 2 PUSH GENTLY BY HAND EXTRACTING TOOL 1 EXTRACT TOP SEALING RING STACK FIRST REMOVE SPACER WHICH IS FREE IN THE BODY PLACE SPACER WHICH IS FREE IN THE BODY EXTRACT BOTTOM SEALING RING STACK INSERT TOP SEALING RING STACK aV Forbes Marshall Trusted Partners Innovative Solutions For 65 200NB 212 8 PULL PUSH BY HAND EXTRACTING TOOL a EXTRACT TOP SEALING STACK FIRST C A f A h Z REMOVE SPACER WHICH IS FREE FROM THE BODY PISTON VALVES PUSH BY HAND 1 INSERT BOTTOM SEALING STACK aV Forbes P Marshall Trusted Partners Innovative Solutions INLET 2 INSERT SPACER WHICH IS FREE IN THE BODY KEEPING BLIND WALL OF SPACER AT THE INLET SIDE OF THE VALVE INSERT TOP SEALING STACK PISTON VALVES 4 TOOL lt SEALING RING STACK PLACE SEALING STACK IN THIS WAY ON INSERTER TOOL 3 INSERT GLAND SEALING STACK aV Forbes Marshall Trusted Partners Innovative Solutions COMPONENT LIST AND LUBRICATION DETAILS 5 D 42 Il 12 Nfa LUBRICATION POINT REFER 1 7 MAINTENANCE 4 98 AX
3. For 15 20 amp 25NB 12 34 1 screwed ends Maximum operating pressure 78 bar g 1131 29 psig Maximum operating temperature 425 797 F Maximum hydraulic test pressure 156 bar g 2262 58 psig For 32 40 NB 174 17 screwed ends Maximum operating pressure 41 5 bar g 601 90 psig Maximum operating temperature 425 C 797 F Maximum hydraulic test pressure 83 bar g 1203 81 psig 1 3 Limiting Conditions For 5ONB 65NB 80NB 100NB 125NB 150NB 200NB BY 2 Body design conditions ANSI 300 Flanged ends Maximum allowable pressure 51 bar g 739 69 psig 38 C 100 4 F Maximum operating Pressure 41 5 bar g 601 90 psig 253 C 487 4 F Temperature C F PISTON VALVES Maximum operating temperature 425 C 797 F 28 8 bar g 417 70 psig Maximum hydraulic test Pressure 83 bar g 1203 81 psig Body design conditions ANSI 150 Flanged ends Maximum allowable pressure 19 6 bar g 284 27 psig 38 C 100 4 F Maximum operating Pressure 14 bar g 203 05 psig Q 197 C 386 6 F Maximum operating temperature 425 797 F Q 5 5 bar g 79 77 psig Maximum hydraulic test Pressure 28 bar g 406 1 psig Operating Range 50 200 NB 2 to 8 F C Operating Range 50 200 NB 2 to 8 797 425 572 300 392 200 Nie N w dili 0 10 14 20 30 40 41 5 51 barg 145 0 203 05 290 07 435 11 580 15 601 90 739 69 psig Pressure bar g psig The
4. and off in a gradual way to avoid system shocks 1 6 7 Pressure systems Ensure that any pressure is isolated and safely vented to atmospheric pressure Consider double isolation double block and bleed and the locking or labeling PISTON VALVES of closed valves Do not assume that the system has depressurized even when the pressure gauge indicates zero 1 6 8 Temperature Allow time for temperature to normalize after isolation to avoid danger of burns Consider whether protective clothing including safety glasses is required 1 6 9 Tools and consumables Before starting work ensure that you have suitable tools and or consumables available Use only genuine Forbes Marshall replacement parts 1 6 10 Protective clothing Consider whether you and or others in the vicinity require any protective clothing to protect against the hazards of for example chemicals high low temperature radiation noise falling objects and dangers to eyes and face 1 6 11 Permits to work All work must be carried out or be supervised by a suitably competent person Installation and operating personnel should be trained in the correct use of the product according to the User Manual Where a formal permit to work system is in force it must be complied with Where there is no such system it is recommended that a responsible person should know what work is going on and where necessary arrange to have an assistant whose primary responsibility is s
5. 272 8 Maintenance of Piston valve is very easy and can be done when valve is in position and not in service If any leakage is observed through the gland tighten gland nut to stop the leakage through gland and to stop the leakage at outlet or between the body and the bonnet face tighten all nuts equally as explained earlier If Leakage yet does not stop then follow the procedure mentioned below Keep Valve fully open remove nuts amp Belleville Washer turn handwheel in clockwise direction till it touches the bonnet Pull hand wheel carefully along with Bonnet to remove piston from Body In case the bonnet assembly does not come out of the body use tapped hole for removing bonnet assembly as shown in Fig 1 Avoid any damage to piston Clean Piston with Soft Cloth Remove top sealing stack with the help of extracting tool Remove Spacer which is free in the body Remove Bottom sealing stack with the help of extracting tool Replace Bottom sealing stack place spacer and replace top sealing stack with the inserting tool aV Forbes Marshall Trusted Partners Innovative Solutions Insert Bonnet sealing ring Graphite carefully Place Bonnet piston spindle sub assembly on clean table To replace gland sealing rings remove nyloc nut and handwheel Hold bonnet by hand and remove spindle piston sub assembly by rotating spindle in clock wise direction with the help of screw driver Remove gland nut and extract gland sealing stack with extr
6. 77 9851022039 9851036530 Tel 977 1 4247676 4238131 Email ekta ecomail com np a Forbes Marshall Trusted Partners Innovative Solutions ASIA PACIFIC THAILAND Forbes Marshall Pvt Ltd Room No 403 4th Floor House No 567 Seri 6 Road Soi 51 Rama 9 Road Suan Luan Bangkok 10250 Thailand Tel 66 2 7203483 4 66 81 9020690 Fax 66 2 7203483 9435500 Email thailandforbesmarshall com vphillip ksc th com INDONESIA Forbes Marshall Pvt Ltd NC 8 11 Ji Lilin Raya Kelapa Gading Jakarta Uttara Indonesia Tel 62 8 15199 17178 Email hbhatforbesmarshall com MALAYSIA Forbes Marshall Pvt Limited Tel 62 8 15199 17178 Fax 62 21 4530773 Email hbhat forbesmarshall com VIETNAM Email vphillip ksc th com Tel 66 81 90 20690 i SOUTH KOREA Shin Woo FA Co Ltd 510 Leaders Tower 60 15 Gasan Dong M Geumchun Gu Seoul Korea 153 801 Mob 8211 732 7695 Tel 822 2026 6364 Direct Fax 822 2026 6363 Email shinwoofa empal com forbeskorea empal com SINGAPORE Forbes Marshall Pvt Limited Tel 62 8 15199 17178 Email hbhat amp forbesmarshall com AFRICA 2i KENYA Forbes Marshall Pvt Ltd PO Box 58338 00200 Nairobi Kenya Tel 254 734 763 913 254 725 490 866 Email africa forbesmarshall com ETHIOPIA Rapture Import amp Export PLC Kolfe Keranio Sub City Kebele13 14 House Nr 624 Box 28447 1000 Addis Ababa Ethiopia Te
7. B 242 80NB 3 50 60 Nm 442 53 531 04 Lbsf inch 70 80 Nm 619 55 708 05 Lbsf inch 80 90 Nm 708 05 796 56 Lbsf inch LUBRICATION POINT ra REFER 1 7 MAINAINANCE PISTON VALVES NYLOC NUT NAME PLATE HANDWHEEL GLAND NUT GLAND SEALING STACK BONNET SPINDLE SPLIT NUT THRUST PLATE STEM BACK SEAT PISTON SS WASHER LH NUT BONNET SEALING RING TOP SEALING STACK SPACER STUD NUT BELEVILLE WASHER BOTTOM SEALING STACK 65 200NB 272 8 EXPLODED VIEW How to order spares Always order spares by using the description amp P C No given below amp stating size 15 50NB 2 2 Spare kit contains Sealing ring stack 65 200NB 272 8 spare kit contains Body sealing ring stack Bonnet sealing ring Gland sealing ring stack Part codes for spares i basin neo 15 20 NB 2 2 34 Spare Kit 3 4 5 7 150 NB 6 Spare Kit 200 NB 8 Spare Kit F3A2017743 Use only genuine Forbes Marshall components Please call our local representative or Head office as per the contact details given a Forbes PISTON VALVES PF Marshall Trusted Partners Innovative Solutions NOTES a Forbes PISTON VALVES PF Marshall Trusted Partners Innovative Solutions NOTES Your local Forbes Marshall representative would be happy to provide you with further information and support OFFICES AND REPRESENTATIVES AMERICA USA Forbes Marshall Inc USA 480 California A
8. BW SS nd O WS 4 INLET NIN NJ 15 25 NB 7 1 Piston Valve Always open amp close Valve fully Do not use Valve Key Description of Component 6 8 B Washer 9 SealingRings Recommended tightening torques for bonnet nuts TORQUE 1 II ne Ua 3 5 Nm 26 55 44 25 Lbsf inch 5 7 Nm 44 25 61 95 Lbsf inch 1 PISTON VALVES bo M w al MA YN VAN CATV LUBRICATION POINT 62 A REFER 1 7 MAINTENANCE VAL 9 dh A h o OY T WR HG L 44 4 7 MS SZ TI INLET 2 01222 O 7 PA 7 A j 7 2 2 40 50 NB 11 2 2 Piston Valve Always open amp close Valve fully Do not use Valve Key Description of Component 32 50NB 114 2 No Part __ 6 Sud 8 B Washer 9 SealingRings aV Forbes Marshall Trusted Partners Innovative Solutions EVM NASS 77 WIN CS S UN 22728 TAL Ey 27 ZIP YE k A Wer 2 RS ONES SS E WM e INLET KE SS OPEN POSITION Always open valve fully 65 200 NB 27 8 Piston Valve Always open amp close Valve fully Do not use Valve Key Recommended tightening torques for bonnet nuts SIZE TORQUE 65N
9. ack on the inserting tool as shown in Page No 8 11 amp place the inserting tool inside the body perpendicular to the face Ensure that sealing ring PISTON VALVES Stack is properly guided in the body bore Now use a Mallet to push the inserting tool inside the body to place the bottom sealing stack After placing bottom sealing stack remove inserting tool from the body place spacer inside the body which is free in the body Now repeat the same process to insert top sealing ring stack with the help of inserting tool Gap between Body amp bonnet face TABLE 1 SIZE inches GAP mm 15 20 25NB V2 2A 1 6mm 0 23 32 40 50NB 4 1 V2 2 9 5mm 0 37 65NB 215 17mm 0 66 80NB B 18mm 0 70 100 125NB 4 5 20mm 0 78 150NB 6 26mm 1 02 8 30mm 1 18 Two tapped holes provided for removing the bonnet assly from body by tightening the bolts BONNET GAP Ref Above Table Fig 1 SIZE inches TAPPING 65 80 100 125NB 2 2 3 4 5 M12 0 472 150 200NB 6 8 M16 0 629 aV Forbes PISTON VALVES Marshall Trusted Partners Innovative Solutions For 15 40NB 1 es PUSH GENTLY BY HAND INSERTING TOOL EXTRACTING TOOL 3 INSERT BOTTOM SEALING RING STACK FIRST MALLET 1 EXTRACT TOP SEALING RING STACK FIRST PUSH GENTLY BY HAND EXTRACTING TOOL SEALING RING STACK PLACE SEALING STACK IN THIS WAY ON INSERTING TOOL il a AV AW pili 5 D
10. acting tool Insert new gland sealing stack with the inserting tool Screw gland nut in the bonnet Place bonnet on spindle piston sub assembly and rotate spindle in anticlockwise direction till it stops Align Bonnet piston sub assembly in the Top sealing stack and push it gently Place the handwheel on the square of spindle Place name plate and nyloc nut Place Beleville washer in the cup form as shown in the diagram and hand tighten all the nuts Now rotate handwheel in clockwise direction till it touches the bonnet Close position of the valve Tighten all the nuts with equal pressure Open isolation valve if any leakage is observed through the gland tighten gland nut In case leakage is observed at the outlet or between body face and bonnet tighten opposite nut equally half or one turn as explained earlier Please refer Page No 8 11 for Extracting tool amp inserting tool sealing ring stack amp page 12 component details For Lubrication use Molykote M30 lubricating oil Lubricate frequently through spindle threads split nut and stem Operate once or twice after lubrication 1 8 How to use Extracting tool Insert extracting tool in the body dig extracting tool in the sealing rings amp lever up to remove Top Sealing Stack as shown in Page No 8 11 Remove spacer which is free from the body Repeat the same process to remove bottom sealing Stack as explained above 1 9 How to use Inserting tool Insert Sealing Ring St
11. afety Display warning notices If necessary 1 6 12 Handling Manual handling of large and or heavy products may present a risk of injury Lifting pushing pulling carrying or supporting a load by bodily force can cause injury particularly to the back You are advised to assess the risks taking into account the task the individual the load and the working environment and use the appropriate handling method depending on aV Forbes Marshall Trusted Partners Innovative Solutions the circumstances of the work being done 1 6 13 Residual hazards In normal use the external surface of the product may be very hot If used at the maximum permitted operating conditions the surface temperature may reach temperatures in excess of 425 C 797 F Many products are not self draining Take due care when dismantling or removing the product from an installation 1 6 14 Freezing Provision must be made to protect products which are not self draining against frost damage In environments where they may be exposed to temperatures below freezing point 1 6 15 Safety information The graphite stem sealing rings contain thin stainless steel support rings which may cause physical injury if not handled and disposed of carefully 1 6 16 Disposal Unless otherwise stated in the User Manual this product is recyclable and no ecological hazard is anticipated with its disposal providing due care is taken 1 6 17 Returning products Customers a
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13. luid flow iv Forbes Marshall products are not intended to aV Forbes Marshall Trusted Partners Innovative Solutions withstand external stresses that may be induced by any system to which they are fitted It is the responsibility of the installer to consider these stresses and take adequate precautions to minimize them 1 6 2 Access Ensure safe access and if necessary a safe working platform suitably guarded before attempting to work on the product Arrange suitable lifting gear if required 1 6 3 Lighting Ensure adequate lighting particularly where detailed or intricate work is required 1 6 4 Hazardous liquids or gases Consider what is in the pipeline or what may have been in the pipeline at some previous time Consider flammable materials substances hazardous to health extremes of temperature in the pipeline 1 6 5 Hazardous environment around the product Consider explosion risk areas lack of oxygen e g tanks pits dangerous gases extremes of temperature hot surfaces fire hazard e g during welding excessive noise moving machinery 1 6 6 The system Consider the effect on the complete system of the work proposed Will any proposed action e g closing isolation valves electrical isolation put any other part of the system or any personnel at risk Dangers might include isolation of vents or protective devices or the rendering ineffective of controls or alarms Ensure isolation valves are turned on
14. nd stockiest are reminded that while returning products to Forbes Marshall they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage 1 7 Maintenance For 15 50NB 2 2 Maintenance of Piston valve is very easy and can be done when valve is in position and not in service If any leakage is observed through the Bonnet hole tighten all nuts equally refer 1 5 If leakage still does not stop then follow the procedure mentioned below Keep Valve fully open remove nuts 7 amp PISTON VALVES Belliville Washer 8 turn handwheel in clockwise direction till it touches the bonnet Pull hand wheel carefully along with Bonnet to remove piston from Body Avoid any damage to piston Clean Piston with Soft Cloth Remove top Sealing Rings 9 with the help of extracting tool Remove Spacer 10 which is free in the body Remove Bottom sealing rings 9 with the help of Extracting tool Replace new set of Bottom sealing rings Spacer and Top sealing rings stack with the inserting tool Align piston with the Top sealing ring and push gently Ensure that the belleville washers are placed properly in cup form and tighten all nuts with equal pressure when the Piston is at the end of bottom sealing rings Please refer Page No 8 11 for Extracting tool amp inserting tool sealing ring stack amp page 12 for component details Maintain body and bonnet gap as per table 1 For 65 200NB
15. product must not be used in this region A B Flanged Class 150 A F Flanged Class 300 PMO Maximum operating pressure 15 20 25 NB 5 34 1 30 40 NB 114 11 2 aV Forbes Marshall Trusted Partners Innovative Solutions 50 NB 2 65 200 NB 2 2 8 35 On unpacking check all the materials for any damages and suitability and ensure material to be as per packing list 1 4 Installing the Valve Please ensure before installing the valve that the line is clear from all foreign particles such as welding fluxes metals burrs and dirt The valve should be fitted either in Vertical or Horizontal line with inlet as per the arrow direction on the valve body 1 5 Operation To open the valve turn the hand wheel till it stops at the top and to close the valve turn hand wheel till it touches the bonnet If any leakage is observed through the gland tighten gland nut till leakage stops if any leakage is observed between the body bonnet face amp outlet tighten opposite Nuts equally half or one turn until leakage stops Never tighten nuts when valve is in open condition Do not use Valve for throttling It should be either fully open or fully close 1 6 Safety Information Hazard analysis Warning The graphite sealing rings contain thin stainless steel support rings which may cause physical injury if not handled and disposed of carefully PISTON VALVES Welding a Keep your head out of the fumes b U
16. se enough ventilation exhaust at the arc or both to keep fumes and gases away from your breathing zone and the general area C Wear correct eye ear and body protection d Do not touch live electrical parts Safe operation of this product can only be guaranteed if it is properly installed commissioned used and maintained by qualified personnel in compliance with the User Manual General installation and safety instructions for pipeline and plant construction as well as the proper use of tools and safety equipment must also be complied with 1 6 1 Intended use Referring to the User Manual Nameplate amp Technical Instruction Sheet check that the product is suitable for the intended use application i The products have been specifically designed for use on steam air or water condensate Use on other fluids may be possible but if this contemplated Forbes Marshall should be contacted to confirm the suitability of the product for the application being considered li Check material suitability pressure and temperature and their maximum and minimum values If the maximum operating limits of the product are lower than those of the system in which it is being fitted or if malfunction of the product could result in a dangerous over pressure or over temperature occurrence ensure a safety device is included in the system to prevent such over limit situations lii Determine the correct installation situation and direction of f
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