Sempell Globe Valves, Forged High Pressure
Contents
1. 28 with the plug nut 30 and screw to 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 SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 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 necessary to follow in reverse t2. 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 torque switch shall be set e The adjustment of the limit switches has to be handled when the actuator is assembled to the valve according to the operation instructions 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 TABLE 2 BOLT TORQUE FOR BONNET BOLTS Diameter Bolt diameter Torque in mm mm Nm Y 10 M10 30 Y 12 M12 70 g 16 M16 140 Y 20 M20 260 1 24 M24 580 11 28 M28 760 114 32 M32 1350 SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS TROUBLESHOOTING GUIDE Symptom Possible cause Stem packing leaking Packing damaged Body bonnet leaking Valve leaking 1 2 1 2 Gasket damage 1 Valve not fully closed 2 Debris trapped in valve o3 Sealing surface damaged Jerky operation Packing is too tight Back seat leaking 1 Back seat damage 3 OPERATION AND MAINTENANCE INSTRUCTIONS High pressure forged Sempell valves do not require special care to work prope
3. NHN AY 8 Stellite 13 Cr 13 Cr NENI ZO Accessory 18 NI Vem 10 yee CA ll wis af 12 F316 Stellite F316 Stellite F316 or 17 4 ZEN NY a HEN NB h PS aes aL AN NS PH below 5 AN Vi i RNY IS pas PX DA Y ALY Na ie 6 OF vn Lbs ATH A P Over 450 C 7 Z AN N dE ZA Y Y AT 1 NSN NS 2 ALA TSZLASSS FAA LAS 30 UP ES gt EZ Vie 28 ZEON a 28 1 LS7TFY XS Screw down check A 1 1 1 MATERIAL SPECIFICATIONS 21 22 23 24 25 26 28 20 C 425 C 46 C 425 C 200 C 540 C 250 C 550 C 400 C 575 C 500 C 650 C 130 C 650 C A105 C22 8 LF2 TT5 F1 15M03 F12 13CrMo44 F22 10CrMo910 F91 P91 F316 X6CrNiNb1810 Item 1 0460 1 0411 1 5415 1 7335 1 7380 1 4903 1 4550 1 Body A105 C22 8 LF2 TTS F1 15Mo3 F12 13CrMo44 F22 10CrMo910 Pv F316 X6CrNiNb1810 1 1 Body A105 C2773 LF2 TIS F1 15Mo3 F12 13CrMo44 F22 10CrMo910 Foi F316 X6CrNiNb1810 2 Bonnet A105 C22 8 LF2 TTS F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 F316 X6CrNiNb1810 3 Yoke A105 A105 A105 A105 A105 A105 A105 4 Safety ring A105 A105 A105 A105 A105 A105 A105 5 Segment ring A105 C228 L2 T18 F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 F316 X6CrNiNb1810 6 Ring A105 C22 8 LF2 ITS F1 15Mo3 F12 13CrMo44 F22 10CrMo910 F91 F316 X6CrNiNb1810 7 Gasket 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 7 Nuts A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H 10 Plate A194 2
4. gt PENTAIR SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS High pressure forged steel globe valves pressure seal I Y and angle pattern 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 plug in the closed position la 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 1b 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 p
5. H A194 2H A194 2H A194 2H A194 2H A194 2H A194 2H 11 Screw 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 14 Packing Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite 15 Gland F F F F F6 F6 F6 16 Gland flange A105 A105 A105 A105 A105 A105 A105 17 Gland nuts 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 B8 19 Cut ring Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite Pure graphite 21 Yoke nut Bronze B 148 gr B Bronze B 148 gr B Bronze B 148 gr B Bronze B 148 gr B Bronze B 148 gr B Bronze B 148 gr B Bronze B 148 gr B or Ni resist D2 or Ni resist D2 or Ni resist D2 or Ni resist D2 or Ni resist D2 or Ni resist D2 or Ni resist D2 22 Bearings Steel Steel Steel Steel Steel Steel Steel 25 Indicator A105 A105 A105 A105 A105 A105 F316 28 Plug F F F F F F F 30 Plug nut F F F F F F F 32 O ring FKM FKM FKM FKM FKM FKM FKM 33 Handwheel Steel Steel Steel Steel Steel Steel Steel SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 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 i
6. allets will be carried out by a fork lift truck by 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 02213 EN 15 11 SEMPELL HIGH PRESSURE FORGED GLOBE 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 plug must be in the closed position and the end faces must be protected
7. emarks 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
8. essages 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 Handling 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 lt is recommended to perform piping flushing before installation of valve If this is not possible the valves must be set with the plug in full open position before starting with flushing 2 3 Valve verification before start up 1 Tighten the packin
9. g 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 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 SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 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 depend
10. he 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 Yoke nut 21 e Ground ring 13 e Bearings 22 e Packing 14 e Stem 20 e Globe plug 28 with the plug nut 30 FIGURE 2 Si _ Si _ m E 1 Wired pure graphite 2 3to 4 pure graphite rings with a density of 1 8 g cm 3 Wired pure graphite Ground ring FIGURE 3 Segment ring Segment ring SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS FIGURE VA250 6022 TO VA250 6025 FIGURE 4 Globe valves Figure Class PN VA250 6022 900 09 160 A NS VA250 6023 1500 15 250 Hh a 33 AS VA250 6024 2500 25 500 21 DE Heat 32 19 il VA250 6025 4500 45 720 ee gin son 22 IX S 18 KY P IS ES NI id 3 N a 17 N a 20 Site 1 NOU TRIM MATERIAL TO API 600 QA N 25 N 13 N Body seat Plug seating 19 N A T 9 N A Gtr Item surface 1 3 surface 28 1 Stem 20 16 y Ez Xl r4 8 y IA yi 1 13 Cr 13 Cr 13 Cr 15 SAS NJ 1 3 N N N 5 Stellite Stellite 13 Cr i ll Ned In mec 12 HEN NA Dc
11. ing 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 TABLE 1 BOLT TORQUE FOR PACKING BOLTS Stem diameter Bolt diameter Torque in mm mm Nm 1 234 M16 14 ee SS M16 14 1 375 34 92 M20 18 1 75 44 45 M20 18 2 50 8 M24 20 2A SAIS M24 20 2 5 63 5 M27 23 LS 69 85 M27 29 3 76 2 M27 23 3 75 82 55 M30 28 3 75 95 25 M33 35 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 GLOBE
12. n open position Then close the valve 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 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 Sme ALVANIA R2 SUPERGREASE A TEXACO MULTIFAK EP2 GREASE L2 TOTAL MULTIS EP2 MULTIS 2 VISCOL SIGNAL ROLSFER 2 STATOIL UHIWAYLI LI G2 6 OPERATIONAL SAFETY INSTRUCTIONS 0 S 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 trad
13. rly The following instruction 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 our 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 Gland flange nuts too loose Gasket bolting loose Figure 4 pos 10 Solution Check the gland flange nuts torque Replace packing Tighten bolting Figure 4 pos 10 Replace the gasket Close the valve Rae o 7 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 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 surface 1 3 must be carefully lapped in order to avoid any defect 3 The surfaces of the plug seat 28 1 must be lapped in order to avoid any defect 4 Assemble the plug
14. tomated 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 SEMPELL HIGH PRESSURE FORGED GLOBE VALVES INSTALLATION AND MAINTENANCE INSTRUCTIONS 2 2 Installation instructions Globe 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 Globe valves are usually installed on horizontal pipe with the same flow direction of the arrow stamped on the body For operating temperatures above 200 C 392 F a thermal insulation of the valve body is recommended 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 m
15. 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 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 Globe valves Y type globe valves 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 au
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