Sapag Gate Valves, Cast High Pressure Style A (gate)
Contents
1. 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 2 Increase air Supply pressure for pneumatic act Back seat leaking 1 Back seat damage 1 Replace the back seat Pentair reserves the right to change the contents without notice ZZ LZA V ZA ZZZ LZ A A W j f h f f FEEF a Z ZZZ ZZA LEZA y ZZ ZZA EZZ ZZA VLLA zzz NWN AS Pe ZZA ZZZ Ni KIN EW 1 Braided graphite 2 Die formet graphite 5 or 6 ring 3 Metal ring Figure no 3 Pressure Seal Gate Valves Style A Installation and Maintenance Instructions Section 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 Sapag or Nominated Service Company 3 1 Packing Maintenance If leakage is observed through the packing tighten the gland nuts slowly and evenly until the leakage stops Do not over tighten packing gland nuts Over tightening will increase the torque required to operate the valve When tightening the gland nut use2. 1 To ensure tightness of Pressure Seal gasket If the leakage has been detected from the body bonnet tighten the nuts pos 31 as indicated in pull up bolts must be tightened when valve is Table II under fully hydrostatic test pressure 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 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 1 Tighten bolting pos 31 pos 31
3. accordance with the applicable welding procedure 10 10 Figure no 2 Installation positions recommended 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 I 2 Check the operation of the valve by stroking it to 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 Il 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 2 4 Operations Instructions 1 Style A Series Gate 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 d
4. 8 Pressure Seal Gate Valves Style A Installation and Maintenance Instructions Valve slinging Figure no 1 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 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 of the actuator 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 mu
5. Pressure Seal Gate Valves Style A Installation and Maintenance Instructions gt PENTAIR Cast Gate Valves Pressure Seal Style A SAPAG Wedge Gate and Parallel Slide Configuration 1 Valve Storage 1 1 1 Preparation and Preservation for Shipment 1 1 2 Handling Requirements 1 1 3 Storage and Preservation before Installation 2 2 Installation 2 Zl Preparation before Installation 2 2 2 Installation Instructions 3 23 Valve Verification before Start Up 5 2 4 Operations Instructions 3 Table Bolt Torque Figures for Packing Bolts 4 Table Il Bolt Torque to Ensure Tightness of Pressure Seal Gasket 4 2 5 Periodic Valve Verification during Service 4 Troubleshooting Guide 4 3 Maintenance 9 Sul Packing Maintenance 5 One Bonnet Gasket Replacement D 4 Valve Removal 6 5 Greases and Special Tools 6 51 Greases 6 Table lll Grease and Lubricant List 6 Da Special Tools 6 Section 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 2 The weld ends surface shall be protected with suitable protective like Deoxaluminite The end shall be closed with plywood or plastic disc fixed at the edge by st
6. escribed 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 Sapag workshop Pentair reserves the right to change the contents without notice Pressure Seal Gate Valves Style A Installation and Maintenance Instructions Table l Bolt Torque Figures for Packing Bolts Table II Bolt Torque to Ensure Tightness For System pressures lt 2533 psi For System pressures gt 2533 psi Torque ft lbs 24 87 x OD2 _ ID2 x d Torque ft lbs S P 101 8 x OD2 _ ID2 x d of Pressure Seal Gasket Torque Nm multiply Torque ft Ibs x 1 3558 Position 31 for Gate Valves Where OD Stuffing Box Bore In Stud Torque ft lbs Torque Nm ID Stem Diam In 3 8 18 24 5 d Gland Stud Diam in 1 2 a7 50 S P System Pressure psi 5 8 74 100 This Torque method may result in more or less than 30 compression 3 4 125 170 7 8 207 280 1 310 420 11 8 443 600 2 5 Periodic Valve Verification during Service pia oal SN 13 8 811 1100 A Normal Check 1 Verify monthly 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 Important Section 3 If the leakage does not stop follow the procedure for packing maintenance 3
7. half turn increments until leakage has stopped Please refer to Figure no 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 Open completely the valve up to the backseat position Remove the nuts 16 of the gland bolts 15 Lift the gland flange 10 and the gland 9 Remove the worm out packing using a hooking wire For a 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 no 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 Bolt Torque figures for Packing Bolts 9 Cycle the valve 10 Pressurize the line 11 Ifa leakage is detected tighten the gland nuts slowly and evenly until the leakage stops St ees D ro q ZAIN S77 Figure no 4 3 2 Bonnet Gasket Replacement Warning Before starting any maintenance depressurize drain and vent the line c
8. heck 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 Pentair reserves the right to change the contents without notice Pressure Seal Gate Valves Style A Installation and Maintenance Instructions Sa NIN iF PAN D H aq LLY SBC E BMY gt y ANZ LT NN jhe NVA UY Lifting lugs 4 For DN 3 tor DN 6 Please refer to Figure no 5 Unscrew the body bonnet nuts pos 12 and the gland nuts pos 16 Caution 1 2 Lift up the yoke pos 24 operating by the handwheel or gearbox handwheel ine Tuts posal Rees ie He retold 3 When the stem nut is free from the stem threads lift up the yoke ce we after valve first pressurization as indicated 4 Unscrew the nuts pos 31 in Table II 5 Remove the retaining ring pos 311 6 Remove the segment rings push them out from the body groove by using the body holes placed radially on the top of the body 7 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 8 Carefully clean all the gasket housing and lubricate with suitable grease 9 Replace the body gasket 10 Reassemble all parts following backwards the above mentioned steps Section 4 Valve Removal If the valve needs to be removed from the line for so
9. me extraordinary reason the user should ensure the following 1 The valve is depressurized drained and vent 2 The pipe shall be cut as far away from the valve as possible Section 5 Greases and Special Tools 5 1 Greases To lubricate the bearings on manual and gearbox operated valves we suggest to use the grease AGIP GRMUEP2 or an equivalent product as showed in the following table Table Ill Grease and Lubricant List Manufacturer Grease AGIP GRMUEP2 API PGX2 BP GREASE LTX2 ESSO BEACON 2 FINA FINAGREASE HP FINAGREASE EPL2 MOBIL MOBILUX EP2 08 REMBRANDT EP2 SHELL ALIVANIARZ SUPERGREASE A TEXACO MULTIFAK EP2 GREASE L2 POTAE MOLTS EPZ MWURTIS 2 VISCOL SIGNAL ROLSFER 2 STATOIL UHIWAYLI LI G2 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 bm 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 Operation described in this Manual Pentair reserves the right to change the contents without notice page 6
10. nts without notice Pressure Seal Gate Valves Style A Installation and Maintenance Instructions 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 this may require special construction depending on valve size service condition material and type of operator For a correct operation Sapag recommends that the valve shall be installed and oriented following the indications of fig 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 wedge complete closure Unless otherwise recommended by Sapag the valve should be installed with the wedge in the closed position to ensure that the seat ring in the wedge 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
11. rips 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 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 B Unpacked Valves 1 The lifting and the handling of these valves has to be carried out by using appropriate means and at respecting the carrying limits The handling must be carried out on pallets protecting the machined surfaces to avoid any damage 2 With valves of large dimensions the sling and the hooking of the load must be carried out using the appropriate tools brackets hook fasteners ropes and load balancing tools in order to prevent them from falling or moving during the lifting and handling www pentair com valves Pentair reserves the right to change the contents without notice SAPLT 0028 EN 130
12. st 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 Section 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 valve 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 Valves without the arrow are bi directional See the actuator user manual for the actuator preparation Pentair reserves the right to change the conte
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