Sempell Gate Valves, Forged High Pressure
Contents
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 IMPORTANT The segment ring has to be fixed by the safety ring Ensure that the segment ring is in the correct position 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 Fora correct disassembly it is necessary2. gt PENTAIR SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS High pressure forged gate valves buttwelded or flanged ends 1 VALVE STORAGE 1 1 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 www pentair com valves 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 1 2 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
3. 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 SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 2 5 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 e The technical data of the actuator e The correct adjustment torque e The operation instruction 4 Adjustment of the actuator for GATE valves WARNING e 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 e 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 e The adjustment of the limit switches in both end stop position has to be handled when the actuator is assembled to the valve
4. 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 2 2 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 SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 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 Han
5. 93 B7 17Cr 14122 Pure graphite F A105 A194 2H A193 B8 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel A105 F12 13CrMo44 F12 13CrMo44 FKM Steel F 15 400 C 575 C F22 10CrMo910 1 7380 F22 10CrMo910 F22 10CrMo910 A105 A105 F22 10CrMo910 F22 10CrMo910 Pure graphite A193 B7 A194 2H A194 2H A193 B7 17Er 14122 Pure graphite F6 A105 A194 2H A193 B8 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel A105 F22 10CrMo910 F22 10CrMo910 FKM Steel F Wedge seating surface 28 1 13 Cr Stellite 13 Cr F316 Stellite 16 500 C 650 C F91 P91 1 4903 F91 Pe A105 A105 F91 l Pure graphite A193 B7 A194 2H A194 2H A193 B7 17Cr 14122 Pure graphite F A105 A194 2H A193 B8 Pure graphite Bronze B 148 gr B or Ni resist D2 steel A105 EA F91 FKM Steel F Stem 20 13 Cr 13 Gr 17 Gr 13 Cr F316 or 17 4 PH below 450 C 17 38 C 450 C 15CuNiMoNb5 1 6368 15CuNiMoNb5 15CuNiMoNb5 A105 A105 15CuNIMoNb5 15CuNiMoNb5 Pure graphite A193 B7 A194 2H A194 2H A193 B7 17Cr 1 4122 Pure graphite F6 A105 A194 2H A193 B7 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel A105 1SCuNiIMoNbs 1SCuNiIMoNbs FKM Steel F PN 09 160 13250 25 500 45 720 Backseat 2 1 13 Cr 13 Ch 13 Cr F316 18 130 C 650 C F316 X6CrNiNb1810 1 4550 F316 X6CrNiINb1810 F316 X6CrNiINb1810 A105 A105 F316 X6
6. CrNiNb1810 F316 X6CrNiNb1810 Pure graphite A193 B7 A194 2H A194 2H A193 B7 17Cr 14122 Pure graphite F A105 A194 8 A193 B8 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel F316 F316 X6CrNiNb1810 F316 X6CrNiINb1810 FKM Steel F6 SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 3 2 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 FIGURE 5 wi 7 hai 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
7. LATION AND MAINTENANCE INSTRUCTIONS 5 LUBRICANTS AND SPECIAL TOOLS 5 1 Lubricants It is recommended to lubricate the yoke nut if any through the yoke nut lubricator every 2 months by using the following products e The bearings are lubricated with usual lubrications for bearings e Smear the stem threads with Molykote e All other bolts and nuts are assembled with usual lubricator or Molykote 5 2 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 Sk ALVANIA R2 SUPERGREASE A TEXACO MULTIFAK EP2 GREASE L2 TOTAL MOSS VISCOL SIGNAL ROLSFER 2 STATOIL UHIWAYLI LI G2 6 OPERATIONAL SAFETY INSTRUCTIONS 0 S 1 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 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
8. The connection pipe between the nozzle and the safety globe valve and that between the valve and the rupture disc are not at Sempell s care e The safety device has to be installed to the side of the valve with the outlet downwards e In case of gate valves for steam service it IS necessary to use a condensate filling pipe piece 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 e Nominal rupture pressure is calculated on a fixed temperature basis of 300 C e The rating of the rupture disc is 1 5 times bigger than the maximum operating pressure rounded to next higher rupture rating e Rupture ratings 150 200 250 300 350 425 500 bar FIGURE 6 ACC 7 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
9. according to the operation instructions e The adjustment of the wedge gate valve is the same as for a parallel gate valve For this reason note that e The calculated torque must be adjusted e The closing time must not be too short because the energy in the close blocked position depends on the actuator speed e The test performed without pressure under the piston must be avoided because the actuator runs with full speed into the seat without any reaction Gate valves must be closed only by way and not by torque TROUBLESHOOTING GUIDE Symptom Possible cause Stem packing leaking Gland flange nuts too loose Packing damaged Body bonnet leaking Valve leaking 1 2 1 2 Gasket damage 1 Valve not fully closed 2 Debris trapped in valve 3 Sealing surface damaged Jerky operation Packing is too tight Back seat leaking 1 Back seat damage Gasket bolting loose Figure 4 pos 10 3 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 e Ensure to perform periodic valve verification as described In paragraph 2 4 e In case of actuated valves always follow the Specific instruction given by the actuator s manufacturer e Never change the setting of torque and or limit switches which have been carefully set during the final test at Sempel
10. dling and lifting of the valves during installation MUST be performed following the same criteria and Instruction described in previous points 1 2 Handling requirements and 1 3 Storage and preservation before installation 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 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 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 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 the operating torque The bolt torque figures for the packing bolts can be calculated as indicated in Table 1 2 C
11. g Handwheel Distance wedge 11 20 C 425 C A105 C22 8 1 0460 C22 8 w 22 3 05 C228 G2 20 Pure graphite A193 B7 A194 2H A194 2H A193 B7 17Cr 14122 Pure graphite F A105 A194 2H A193 B7 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel A105 A105 C228 A105 C22 8 FKM Steel F INA NES ee e LAL Vif FE AM P 1 7 vz N UNS L gt T I 12 VAS Gis V N 12 46 C 425 C LF2 TT5 1 0411 LF2TT5 LEZ TIS A105 A105 LEZ TES EZ T15 Pure graphite A193 B7 A194 2H A194 2H A193 B7 17Cr 14122 Pure graphite F A105 A194 2H A193 B7 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel A105 BEATS LF2 TT5 FKM Steel F 4 S 22 21 25 19 15 20 28 13 200 C 540 C F1 15Mo3 1 5415 F1 15Mo3 F1 15Mo3 A105 A105 F1 15Mo3 F1 15Mo3 Pure graphite A193 B7 A194 2H A194 2H A193 B7 1Cr 14122 Pure graphite F A105 A194 2H A193 B7 Pure graphite Bronze B 148 gr B or Ni resist D2 Steel A105 F1 15Mo3 F1 15Mo3 FKM Steel F FIGURE GA251 6012 TO GA251 6015 Figure GA251 Class 200 1500 2500 4500 TRIM MATERIAL TO API 600 Item 1 5 8 12 Body seat surface 29 1 13 Cr Stellite Stellite F316 Stellite Over 450 C 14 250 C 550 C F12 13CrMo44 1 7335 F12 13CrMo44 F12 13CrMo44 A105 A105 F12 13CrMo44 F12 13CrMo44 Pure graphite A193 B7 A194 2H A194 2H A1
12. heck the operation of the valve by stroking it to full open and full close 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 3 Should the valve be equipped with electric actuator please refer to paragraph 2 5 for actuator adjustment instruction 2 4 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
13. l workshop IMPORTANT e Jo 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 e Yearly checking of bolt torque is recommended Solution Check the gland flange nuts torque Replace packing Tighten bolting Figure 4 pos 10 Replace the gasket Close the valve NCP Raa Cycle and flush with valve open to remove debris 3 Recondition the seat surface 1 Loosen gland nuts cycle the valve retighten 1 Recondition the back seat surface TABLE 1 BOLT TORQUE FOR PACKING BOLTS Stem diameter in mm 1 25 4 1 25 31 75 1 375 34 92 1 75 44 45 2 50 8 ADS 57 15 2 5 63 5 IS 69 85 3 76 2 S 82 55 3 79 95 25 Bolt diameter mm M16 M16 M20 M20 M24 M24 M27 M27 M27 M30 M33 Torque TABLE 2 BOLT TORQUE FOR BONNET BOLTS Diameter in 3g 1 2 Bolt diameter mm M10 M12 M16 M20 M24 M28 M32 Torque Nm 30 70 260 580 760 1350 SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 3 1 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
14. means of the appropriate fork hitches 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 2012 Pentair plc All Rights Reserved VCIOM 01039 EN 15 11 SEMPELL HIGH PRESSURE FORGED GATE VALVES 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 wedge must be in the closed position and the end faces must be protected with plastic or wooden discs fixed with straps If pos
15. sible 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 e Do not place consignment packages directly on the ground e Do not expose consignment packages to the weather or directly to the sun e 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 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 The
16. the right to change product designs and specifications without notice Pentair is an equal opportunity employer 2015 Pentair plc All rights reserved
17. this risk Sempell offers you four possible solutions e Solution 1 Acc 5 hole in the seat ring e Solution 2 Acc 6 hole in the wedge e Solution 3 Acc 7 three nozzle with caps In the plant the client can connect two of them depending on the flow direction e Solution 4 Acc 8 with over pressure protection for two directions ACC 8 eee ee a an A SS SN S SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS FIGURE 7 HS SSW NSE NIRS 7 y Pressure of trapped water bar p Percentage volume of water 100 200 300 400 500 600 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 4 VALVE REMOVAL To remove a valve from the line it is necessary to operate as follows 1 Obtain permission to work 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 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 SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTAL
18. 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 e Gasket 7 e Bearings 22 e Ground ring 13 e Stem 20 e Packing 14 e Gate two plates wedge 28 with the two distance parts 37 e Yokenut 21 FIGURE 2 2 2 E 2 Z 2 Z 3 TS RSS lu 4 Z 1 Wired pure graphite 2 3to 4 pure graphite rings with a density of 1 8 g cm 3 Wired pure graphite 4 Ground ring FIGURE 3 Segment ring Segment ring SEMPELL HIGH PRESSURE FORGED GATE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS FIGURE 4 Gate valves 29 29 1 V ANS NNNS 37 Oo NN p Nd a N f L H FH J E INN R N LLJ NA C JSN i tz N WK X W V R MATERIAL SPECIFICATIONS Item 0 co B oO oF WD amp NO 22 25 28 29 eZ 33 oy Body Bonnet Yoke Safety ring Segment ring Ring Gasket Bolts Nuts Nuts Bolts Ground ring Packing Gland Gland flange Gland nuts Bolts Cut ring Yoke nut Bearings Indicator Wedge Seat ring O rin
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