Piston Valve - Forbes Marshall
Contents
1. 200 5 bonnet piston spindle sub assembly on clean table To replace gland sealing stack 10 remove nyloc nut 19 and handwheel 18 Hold bonnet 2 by hand and remove spindle piston sub assembly by rotating spindle 6 in clockwise direction with the help of screw driver 7 Remove gland nut 13 and extract gland sealing stack 10 with extractor tool Insert new gland sealing stack 10 with the inserter tool Use mallet to apply light strokes on inserter tool ensuring they fit perfectly Refer Fig 12 for extractor tool and insertor tool for piston valve of size DN65 200 Screw gland nut 13 in the bonnet 2 Place bonnet 2 on spindle piston sub assembly and rotate spindle 6 in anticlockwise direction until it stops 8 Align bonnet piston spindle sub assembly in the body top sealing stack 4 and push it gently Place the handwheel 18 on the square of spindle 6 place name plate 21 and nyloc nut 19 Place Belleville washer 17 in the cup form and hand tighten all the nuts Now rotate handwheel 18 in clockwise direction until it touches the bonnet 2 Close position of the valve 9 Tightenallthe nuts 16 equally Open isolation valve if any leakage is observed through the gland tighten gland nut 13 In case leakage is observed at the outlet or between body face 1 and bonnet 2 tighten nut equally half or one turn as explained earlier For piston valve of size DN65 200 PULL aer2. LUBRICATION POIN UBRICATION POINT jun Hy SS INLET OUTLET 2 i INLET a 4 Lubrication details DN65 200 Lubrication details DN15 50 Figure 13 Lubrication for piston valve 18 m Troubleshooting AV Forbes 5 Marshall Trusted Partners Innovative Solutions If the expected performance is unachievable after installation of the piston valve check the following points for appropriate corrective measures Failure Mode Possible Cause Remedy Inadequate flow rate at outlet The piston valve is not completely open Ensure the piston valve is completely open Fluid leakage from end connection Fluid leakage from bonnet and body End connection is not tight Sealing stack worn out Tighten the end connection with proper torque for flange end and tighten the screwed end piston valve For piston valve of sizes DN15 50 if any leakage is observed through bonnet hole first close the valve till handwheel touches bonnet and then tighten all the nuts equally by half or one turn until leakage stops Refer table 1 for recommended tightening torque If leakage does not stop dismantle the valve check if sealing stack is worn out If worn out replace with new set of sealing stack Note Never tighten nuts when valve is in open condition For pisto
3. 0 Gland Sealing Slack S S Reinforced graphite Ph Bronze 2 Back Seat Stainless stee ASTM A 276 Type410 3 Hex Gland Nut Stainless stee ASTM A 276 Type410 4 Bonnet sealing stack Graphite 5 Carbon steel ASTM A 193 Gr B7 6 Nut Carbon steel ASTM A 194 Gr 2H 7 Belleville washer Spring steel 50CrVA 8 Handwheel S G Iron 9 Nyloc nut Carbon steel 20 Name plate Stainless steel ASTM A 240 Type304 21 Thrust plate Stainless steel ASTM A 276 Type420 22 Washer Stainless steel ASTM A 240 Type304 23 Grub screw Hardened steel 1 5 12 9 24 Gap Ring Stainless steel ASTM A 276 Type 410 Dimensions approx in mm Size DN 65 to 200 AV Forbes Marshall Trusted Partners Innovative Solutions Sizes Pressure NO OF Approx DN Class 3 D SB H Howes ETE 65 CLASS 300 292 191 49 22 8 335 400 31 65 CLASS 150 216 178 40 9 4 335 400 27 65 PN 16 25 290 185 45 8 8 335 400 27 65 PN40 290 185 45 8 8 335 400 31 80 CLASS 300 318 210 68 22 8 320 384 37 80 CLASS 150 241 191 52 9 4 320 384 31 80 PN 16 25 310 200 60 8 8 320 384 31 80 PN 40 310 200 68 8 8 320 479 37 00 CLASS 300 356 254 200 22 8 395 479 58 00 CLASS 150 292 229 91 9 8 395 479 47 00 PN 16 25 350 220 80 20 8 395 479 47 00 PN 40 350 235 90 24 8 395 479 58 25 CLASS 300 400 280 235 22 8 446 540 87 25 CLASS 150 356 254 216 22 8 446 540 70 25 PN 16 25 400 250
4. 8 Belleville Washer Spring Steel 50CrVA 9 Sealing stack S S Reinforced Graphite 10 Spacer Stainless Steel ASTM A 276 TYPE 410 11 Handwheel Sheet Metal SG Iron 12 Name Plate Stainless Steel ASTM A 240 TYPE 304 13 Grease Cap Stainless Steel SS 304 14 Gap ring Stainless Steel ASTM A 276 TYPE 410 Additional material DN 40 Note For DN 15 25 Handwheel Sheet Metal For DN32 40 Hand wheel S G Iron Sr No Description Material 15 Split Nut Brass DIN En12164 16 Thrust Plate Stainless Steel ASTM A 275 TYPE 420 Dimensions approx in mm Flange Class Tol 1mm Size DN A B Size DN A B 15 110 118 146 Class 150 Class 300 Class 600 20 110 118 146 15 252 265 265 118 146 25 126 133 165 20 252 265 265 118 146 32 165 175 215 25 260 278 278 133 165 40 165 175 215 32 305 317 320 175 215 40 305 317 320 175 215 Material DN 50 AV Forbes ps Marshall Trusted Partners Innovative Solutions Figure 4 DN50 Piston Valve Note Always open and close piston valve fully do not use valve or F key Sr No Part Material Standard 1 Body Cast stee ASTM A 216 Gr WCB 2 Bonnet Cast stee ASTM A 216 Gr WCB 3 Piston Stainless steel ASTM A 276 Type304 4 Spindle Stainless steel ASTM A
5. Gland Nut 95 110 Nm Table 2 Recommended tightening torques for gland nuts Size Kv Values DN15 20 2 5 DN25 5 8 DN32 40 13 DN 50 41 DN65 51 DN80 77 DN100 131 DN125 194 DN150 221 DN200 438 Table 3 Kv Values 7 4 Maintenance of size DN15 50 piston valve Refer Figure 2 3 and 4 AN Note The graphite sealing stacks contain thin stainless steel support rings which may cause physical injury if not handled and disposed carefully Maintenance of piston valve is very easy and can be done when valve is not in operation If any leakage is observed through the bonnet hole close the valve till handwheel 11 touches bonnet 2 then tighten all nuts 7 equally by half or one turn until leakage stops Refer Table 1 for recommended tightening torques Note Never tighten nuts 7 when valve is in open condition If leakage still does not stop then follow the procedure mentioned below 14 AV Forbes Marshall Trusted Partners Innovative Solutions 1 Keep piston valve fully open remove nuts 7 amp Belleville washer 8 turn handwheel 11 in clockwise direction till it stops at the top Pull handwheel 11 carefully along with bonnet 2 to remove piston 3 from body 1 Avoid any damage to piston 3 Clean piston 3 with lint free cloth DE ME IN Remove top sealing stack 9 with the help of extractor tool remove spacer 10 which is free in the body 1 and remove bottom sealing stack 9 with th
6. hydraulic test pressure 156 bar g IBR requirement For DN 15 20 25 Screwed ends aximum operating pressure 78 bar g aximum operating temperature 425 deg c aximum hydraulic test pressure 156 bar g IBR requirement Ad P Forbes Marshall Trusted Partners Innovative Solutions For DN 32 40 Screwed ends Maximum operating pressure 41 5 bar g Maxim um operating temperature 425 deg c Maxim um hydraulic test pressure 83 bar g IBR requirement Body design conditions DN 15 20 25 32 40 Class 600 Flanged ends Maximum allowable pressure 41 5 bar g Maximum operating pressure 425 deg c Maximum operating temperature 83 bar g IBR requirement Maxim um hydraulic test pressure 156 bar g Body design conditions DN 50 200 PN 16 Flanged End Maximum allowable pressure 16 bar g at 38 deg C Maximum operating pressure 16 bar g at 204 deg C Maximum operating temperature Cold hydraulic test pressure 425 deg C at 9 1 bar g 24 bar g Body design conditions DN 50 150 PN 25 Flanged End Maximum allowable pressure Maximum operating pressure 25 bar g at 38 deg C 25 bargat 226 deg C Maximum operating temperature 425 deg C at 14 bar g Cold hydraulic test pressure 38 bar g Body design conditions DN 50 200 PN 40 Flanged End Maximum allowable pressure 40 bar g at 38 deg C Maximum opera
7. oS T anbe t t dem W ts i D Forbes Marshall Forbes Marshal Trusted Partners Innovative Soluti Bombay Poona Road Kasarwadi Pune 411 034 INDIA Tel 91 02135 393400 Tel 91 0 20 27145595 39858555 CIN U27109PN1959PTCO1 1334 www forbesmarshall com Email segGforbesmarshall com
8. 210 18 8 446 540 70 25 PN 40 400 270 220 26 8 446 540 87 50 CLASS 300 445 318 270 22 12 486 598 117 50 CLASS 150 406 279 241 22 8 486 598 90 50 PN 16 25 480 285 240 22 8 486 598 90 50 40 490 300 250 26 8 486 598 117 200 CLASS 300 559 381 330 25 12 591 728 210 200 CLASS 150 495 343 298 22 8 591 728 164 200 PN 16 600 340 295 22 12 591 728 164 200 PN 40 600 375 320 30 12 591 728 210 AV Forbes 5 Marshall Trusted Partners Innovative Solutions 3 4 Operating Range DN50 200 3 The product must not be used o 300 in this region 2 amp 200 5 Steam A B Flanged ANSI 150 Flanged ANSI 300 0 PMO Maximum operating Pressure Pressure bar g Class 800 Pressure psi g 0 400 800 1200 1600 1972 5 MU 700 4 8 800 3 The product must not be used 3 St 500 9 S 200 S en 400 d in this region 100 200 A D Screwed and socket weld 100 0 20 40 60 80 100 120 136 Pressure barg DIN PSVAL 425 400 The product must not be used in this region A B Flanged PN 16 A C Flanged PN 25 0 5 10 15 2 2 30 35 40 45 A D Flanged PN 40 Pressure barg w Q m Temperature C N e 10 AV Forbes Marshall Trusted Partners Innovative Solutions NYLOC NUT NAM
9. 276 Type410 5 Nyloc nut Carbon steel 6 Stud Carbon steel ASTM A 193 Gr B7 7 Nut Carbon steel ASTM A 194 Gr 2H 8 Belleville washer Spring steel 50crv4 9 Sealing Stack S S Reinforced Graphite 10 Spacer Stainless steel ASTM A 743 Gr CA15 11 Handwheel 5 0 Iron 12 Split nut Brass DIN EN12164 13 Thrust plate Stainless steel ASTM A 276 420 14 Name plate Stainless steel ASTM A 240 Type304 15 Gap Ring Stainless Steel ASTM A276 TYPE 410 Dimensions approx in mm Size DN 50 ANSI Noof Weight 150 203 152 121 19 4 19 210 262 14 5 kg 200 267 165 127 19 8 22 210 262 17 5 kg PN 16 25 230 165 125 18 4 18 210 262 14 5 kg PN 40 230 165 125 18 4 20 210 262 17 5 kg Ad A Forbes Marshall Trusted Partners Innovative Solutions Figure 5 DN 65 200 Piston Valve Note Always open and close piston valve fully do not use valve or F key Material DN 65 200 Sr No Part Material Standard 1 Body Cast steel ASTM A 216 Gr WCB 2 Cast steel ASTM A 216 Gr WCB 3 Piston Stainless stee ASTM A 351 CF8 4 Body Sealing Stack S S Reinforced graphite 5 Spacer Stainless stee ASTM A 743 CA 15 6 Spindle Stainless stee ASTM A 276 Type 410 7 Stem Stainless stee ASTM A 276 Type 304 8 Split nut Brass DIN En12164 9 LH Nut Stainless stee ASTM A 276 Type 304
10. A2017752 30 Piston spare kit for DN150 piston valve 3 6 7 8 9 12 20 22 F3A2017753 31 Piston spare kit for DN200 piston valve 3 6 7 8 9 12 20 22 F3A2017754 How to Order Example DN 15 Piston Valve with socket weld ends How to Order Spares Order spares as per the code no specified in the user manual n Warranty Period As per ordering information and agreements in the contract 21 OW LAVIVASd IND S 970 554 200 SIU JO UaJUOD au Jo Aue jo uone idde 10 asn au jo p eurpur 10 e se pauunoui esiwiaujo 10 Jeuosiad 5551 10 59550 senijiqei Aue Ajjeryinads suoissiuo 10 5 10 Ajjiqisuodsai ou auunsse sajueduio pue 5 seyeossy seueipisqns S 10 14 4 1 pe qns si 3usunoop sjy ur GALISIHOUd SI NOISSINY3d N3LLIHM LAOH LIMIYNSO1ISIC YO NOILNIYLSIG NOLLINGOYdIY ANY SLHOIY 4 TWALDITISLNI JHL Y3GNN NOILDJLOYd ONIAVH ANY 38 AVN ISV JHL Sv 1455 04 JLVAIYd SIN31SAS INV31S TIVHSuvIN S38304 144 QILINI JLVAINd TIVHSWVIA S39Y04 JO ALYIdOYd 1 38V NI3H3H SIN31NOO TIY Formerly Spirax Marshall Pvt Ltd Forbes Marshall Steam Opp 106th Milestone Systems Pvt Ltd lt o 2 S amp 2 2 2 GU S 5 sors a S 9 uy 5
11. AW Installation and Maintenance Manual f Boden Trusted Partners Innovative Solutions Piston Valve PSVAL ProductHUB Installation and Maintenance Guide ANDROID APP ON gt Google play Energy Conservation Environment Process Efficiency www forbesmarshall com Forbes Marshall Forbes Marshall Arca Codel International Krohne Marshall Forbes Solar Forbes Vyncke Forbes Marshall Steam Systems AV Forbes i Marshall Trusted Partners Innovative Solutions Table of Contents i Qiu MET x EN 1 2 Important Safety NOBBS uci metiri a ei teta aqu pen etes 1 3 Brief Product 1 isa ick ipa ret pt bent rn Rhein tasa 3 4 D 11 5 Installation Guidelines 11 6 Start up and COMMISSIONING 2 7 Maintenance Guidelines 12 8 TOMES TOOLING NIS ROT ETT 19 g Available Spares 21 TO Warranty Patton te on eti dineros 21 PLEASE NOTE Throughout this manual this cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked This symbol denotes CAUTION WARNING or DANGER AV Forbes Marshall Trusted Partners Innovative Solutions Preface This manual is intended for anyone using commissioning servicing or disposing the below mentione
12. E PLATE HANDWHEEL HEX 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 BELEVILLE WASHER BOTTOM SEALING STACK GAP RING BODY Figure 6 Exploded View of DN65 200 Piston Valve AV Forbes 5 Marshall Trusted Partners Innovative Solutions m Operation Refer figure 5 The piston valve is operated manually by a handwheel 18 it should be either fully open or fully closed To open the piston valve turn the handwheel 18 in the anticlockwise direction until it stops completely To close the piston valve turn the handwheel 18 until it stop rotating further Note The piston valve spindle should be periodically checked to ensure adequate lubrication is present for efficient valve operation For Lubrication Molykote M30 lubricating oil is recommended When fitted on high temperature applications or where severe weather conditions prevail the lubrication should be checked more frequently Note Never tighten bonnet nuts when piston valve is in open condition Do not use piston valve for throttling which result in excessive wear of internals Operation of the handwheel 18 should always be by the hand itis not recommended to use a valve key or F key If the handwheel is over tightened damage of the piston valve internals may occur E Installation Guidelines Refer figure 7 and 8 Note Before impleme
13. d products safely and efficiently Piston Valve PSVAL Size DN15 2 DN20 84 DN25 1 DN32 1 74 DNAO 1 7 DN50 2 DN65 2 2 DN80 3 DN100 4 DN125 5 DN150 6 DN200 8 PLEASE NOTE Throughout this manual the following cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked Important Safety Notes AI Read this section carefully before installing operating maintaining the product The precautions listed in this manual are provided for personnel and equipment safety Furthermore Forbes Marshall accepts no responsibility for accidents or damage occurring as a result of failure to observe these precautions Note that the product is designed to perform for non contaminated fluids only A contamination in the form of chemical foreign particle etc can lead to problem with product performance and life of the product If these products in compliance with the operating instructions are properly installed commissioned maintained and installed by qualified personnel refer Section 2 7 the safety operations of these products can be guaranteed General instructions for proper use of tools and safety of equipments pipeline and plant construction must also be complied with 2 1 Intended use Check if the product is suitable for intended use application by referring to the installation and maintenance instructions name plates and technical in
14. delines Note Before undertaking any maintenance of the product it must be isolated from both supply line and return line and ensure pressure is normalized to atmosphere The product should then be allowed to cool When re assembling ensure that all joint faces are clean Once completed open the product slowly and check for leaks 7 1 Routine and preventive maintenance AV Forbes 5 Marshall Trusted Partners Innovative Solutions Please refer to the maintenance schedule mentioned in the table below to undertake routine maintenance of the piston valve PARAMETERS TO BE CHECKED FREQUENCY FOR CHECKING VARIOUS PARAMETERS SR NO PISTON VALVE Half Daily yearly Weekly Monthly Quarterly Annually 1 Manually Operate the valve 2 Lubrication of piston valves Y 3 Visual inspection and cleaning of stem piston threads Y 4 Refilling of Loctite Anti Seize in grease cap 15 20 25 for DN Loctite Anti seize threaded compound 767 high performance conforms to ML A 907 E 7 2 Tool Kit To carry out maintenance of the piston valve refer the tools mentioned in the table below Sizes Component Tool used amp size M 10 Stud Stud runner M10 x 1 5 Nut Box spanner of 17 mm A F DN15 20 25 Nyloc nut Box spanner of 13 mm A F Sealing stack Insertor tool Available as spares Sealing stack Extractor tool Availabl
15. e ER PULL PUSH C A BY HAND lt EXTRACTOR EXTRACTOR 1 Extract body top sealing stack first 2 Remove spacer which is free 3 Extract body bottom sealing stack from the body MALLET Ini INSERTOR Fig 14 amp inse Or RAST MP stack of WANED Nes 200 4 MALLET INLET 17 AV Forbes Marshall Trusted Partners Innovative Solutions a 4 MALLET _ INSERTOR 4 INSERTOR TOOL EXTRACTOR AME ur Yan SEALING RING STACK 3 Extract gland sealing stack 2 Insert gland sealing stack 3 Place gland sealing stack in this way in insertor tool Fig 12 View showing extractor tool amp insertor tool for gland sealing stack of piston valve of size DN65 200 7 6 Lubrication Procedure for Piston Valves of all sizes Refer figure 13 Clean the valve unit before lubrication For lubrication use Molykote M30 lubricating oil For piston valve of sizes DN15 50 lubricate spindle through the hole provided in the bonnet and spindle threads on quarterly basis and for piston valve of sizes DN 65 200 lubricate between the spindle and threaded bush at the upper part of bonnet amp stem and spindle at the lower part of bonnet on quarterly basis asmentioned in section 9 Note Molykote M30 lubricating oil is not available please use equivalent lubricating oil with specification as shown in table 4
16. e as spares M12 Stud Stud runner M12 x 1 75 Nut Box spanner of 17mm A F DN32 40 50 Sealing stack Insertor tool Available as spares Sealing stack Extractor tool Available as spares M16 Stud Stud runner M 16 x 2A Nut Box spanner of 24 mm A F DN65 80 100 125 Sealing stack Insertor tool Available as spares Sealing stack Extractor tool Available as spares M20 Stud Stud runner M20 x 2 Nut box spanner of 30mm A F DN 150 Sealing stack Insertor tool Available as spares Sealing stack Extractor tool Available as spares M24 Stud Stud runner M24 x 3 Nut Box spanner of 36mm A F DN200 Sealing stack Insertor tool Available as spares Sealing stack Extractor tool Available as spares DN40 50 65 80 Split nut tightening Open spanner of 20mm A F DN 100 125 150 200 Split nut tightening Open spanner 24 mm A F 13 AV Forbes Marshall Trusted Partners Innovative Solutions 7 3 Recommended tightening torques for bonnet nuts gland nuts and Kv values Size Part No Component Torque Range DN15 20 Nu 3 5Nm DN25 Nu 5 7 Nm DN32 40 Nu 18 20 Nm DN50 Nu 20 25 Nm DN65 80 16 Nu 50 60Nm DN100 125 16 Nu 70 80Nm DN150 200 16 Nu 80 90Nm Table 1 Recommended tightening torques for bonnet nuts Size Part No Component Torque Range DN65 80 13 Gland Nut 35 45Nm DN100 125 13 Gland Nut 75 85 Nm DN150 13 Gland Nut 80 90 Nm DN200 13
17. e help of extractor tool Replace with new set of bottom sealing stack 9 place spacer 10 and replace top sealing stack 9 with the insertor tool Use mallet to apply light strokes on insertor tool ensuring they fit perfectly Refer figure 9 for extractor tool and insertor tool of piston valve for size DN15 40 figure 10 for extractor tool and insertor tool of piston valve for size DN50 6 Align piston 3 with the top sealing stack 9 and push gently and close the piston valve by rotating handwheel 11 in the clockwise direction until it touches the bonnet 2 7 Ensurethat the Belleville washer 8 are placed properly in cup form and tighten all nuts 7 with equal torque when the piston 3 is at the end of bottom sealing stack 9 Refer Table 1 for recommended tightening torque For piston valve of size DN15 40 PUSH GENTLY PUSH GENTLY BY HAND BY HAND EXTRACTOR TOOL EXTRACTOR TOOL E M 1 Extract top sealing stack first 2 Remove spacer which is free from the body and then extract bottom sealing stack MALLET MALLET INSERTOR TOOL 4 INSERTOR TOOL SEALING RING STACK 072 2 3 Insert bottom sealing stack first 4 Place sealing stack in 5 Place spacer which is free from the body this way on Insertor tool and then insert
18. formation sheets i The product is suitable for use as defined in the technical information sheet In case the need arises to use the product on any other fluid please contact Forbes Marshall for assistance i Check for the suitability in conformance to the limiting conditions specified in technical information sheet of the product iii The correct installation and direction of fluid flow has to be determined iv Forbes Marshall products are not intended to resist external stresses hence necessary precautions to be taken to minimize the same 2 2 Accessibility and Lighting Safe accessibility and working conditions are to be ensured prior to working on the product 2 3 2 4 2 5 2 6 2 7 2 8 2 9 AV Forbes Marshall Trusted Partners Innovative Solutions Hazardous environment and media The product has to be protected from hazardous environment and check to ensure that no hazardous liquids or gases pass through the product Depressurizing of systems and normalizing of temperature Ensure isolation and safety venting of any pressure to the atmospheric pressure Even if the pressure gauge indicates zero do not make an assumption that the system has been depressurized To avoid danger of burns allow temperature to normalize after isolation Tools and consumables Ensure you have appropriate tools and or consumables available before starting the work Use of original Forbes Marshall replacement par
19. n valve of sizes DN65 200 if any leakage is observed through the gland tighten gland nut half or one turn until leakage stops To stop the leakage between body and bonnet first close the valve till handwheel touches bonnet and then tighten all the nuts equally by half or one turn until leakage stops Refer table 1 for recommended tightening torque If leakage does not stop dismantle the valve check if gland sealing stack bonnet sealing stack amp body sealing stack is worn out If worn out replace with new one Note Never tighten nuts when valve is in open condition Piston is damaged or corroded Check if piston is damaged due to scouring corrosion of the piston valve If damaged replace with new piston kit Excessive force is required to turn the handwheel Seizing of the piston valve Lubricate the piston valve using Molykote M30 lubricating oil on quarterly basis for sizes DN15 50 lubricate spindle through the hole provided in the bonnet and spindle threads and for sizes DN65 200 lubricate between the spindle and threaded bush at the upper part of bonnet and stem and also spindle at the lower part of the bonnet Note Never attempt to modify the product When replacing old parts with new parts use the spare parts listed in section 9 Molykote M30 lubricating oil is not available please use equivalent lubricating oil with specification as shown in table 4 19 AV Forbes ps Marshall Tr
20. nting any installations observe the Important Safety notes in N section 2 Referring to the installation and maintenance instructions name plate and technical information sheet check the productis suitable for intended installation 1 The piston valve should be installed in the direction of fluid flow given by the arrow on the body The preferred orientation is with the spindle vertical with handwheel on the top The piston valve can be installed from the vertical to the horizontal plane Note Do not install the piston valve with handwheel on lower side as maintenance or lubrication of the piston valve will be difficult 1 AY Forbs Marshal The preferred orientation for installation valve can be installed in vertical pipework Figure 7 Correct orientation for installation Marshall av Forbes Figure 8 Incorrect orientation for installation 11 12 AV Forbes ps Marshall Trusted Partners Innovative Solutions 2 Adequate space should be available while installation of the piston valve so that they can be conveniently operated and maintained 3 Before installing a piston valve check to ensure that the size pressure rating materials of construction end connections etc are suitable for the service conditions of the particular application Remove the cover plugs from the ports Note Lubricate
21. of sealing stack for DN100 piston valve 4 10 14 F3A2017741 8 Set of sealing stack for DN125 piston valve 4 10 14 F3A2019421 9 Set of sealing stack for DN150 piston valve 4 10 14 F3A2017742 10 Set of sealing stack for DN200 piston valve 4 10 14 F3A2017743 11 Inserter kit for DN15 20 piston valve Refer figure 9 F3A2017990 12 Insertor kit for DN25 piston valve Refer figure 9 F3A2017991 13 Insertor kit for DN32 40 piston valve Refer figure 9 F3A2017992 14 Insertor kit for DN50 piston valve Refer figure 10 F3A2017993 15 Insertor kit for DN80 piston valve Refer figure 11 F3A2017994 16 Insertor kit for DN100 piston valve Refer figure 11 F3A2017995 17 Insertor kit for DN150 piston valve Refer figure 11 F3A2017996 18 Insertor kit for DN125 piston valve Refer figure 11 F3A2019418 19 Insertor kit for DN65 piston valve Refer figure 11 F3A2019433 20 Insertor kit for DN200 piston valve Refer figure 11 F3A2019435 21 Extractor Tool for sizes DN15 DN200 piston valve Refer figure 9 10 11 F3A2019471 22 Piston spare kit for DN15 20 piston valve 3 4 F3A2017744 23 Piston kit for DN25 piston valve 3 4 F3A2017746 24 Piston kit for DN40 piston valve 3 4 18 19 F3A2017747 25 Piston kit for DN50 piston valve 3 4 12 13 F3A2017748 26 Piston kit for DN65 piston valve 3 6 7 8 9 12 20 22 F3A2017749 27 Piston kit for DN80 piston valve 3 6 7 8 9 12 20 22 F3A2017750 28 Piston kit for DN100 piston valve 3 6 7 8 9 12 20 22 F3A2017751 29 Piston kit for DN125 piston valve 3 6 7 8 9 12 20 22 F3
22. or mechanical damage which may present a health safety or environmental risk This information must be provided in writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous AV Forbes 5 Marshall Trusted Partners Innovative Solutions EI Brief Product Information 3 1 Description Forbes Marshall Piston Valves PSVAL provide perfect tightness and durable stability on different media such as steam superheated steam heat transfer fluid water and compressed air rr ass LT UE Lt DN 15 20 DN 25 DN 32 40 f TS cx 50 Figure 1 Piston Valve DN 65 to 200 3 2 Sizes and Pipe Connection 1 DN15 20 25 32 40 Screwed BSPT socket weld ends flanged to class 150 300 600 available on special request 2 0350 65 80 100 125 150 200 Flanged class 150 300 3 0350 65 80 100 125 150 200 Flanged to PN16 PN25 PN40 For higher sizes DN 250 and 300 contact Forbes Marshall 3 3 Limiting Conditions For DN 15 20 25 32 40 Socket weld ends aximum operating pressure 78 bar g aximum operating temperature 425 deg c aximum
23. the product before installation as indicated if stored for more than 6 months 4 Caremustbe taken to ensure before installing the piston valve that the line is clear from all foreign particles such as welding fluxes metal burr and dirt and maintain cleanliness during installation since the introduction of foreign particles can result in damage to the piston and sealing stack 5 When a socket weld piston valve is being installed the welding should be carried outto an approved procedure to a recognised standard During welding the piston valve should be in the open position to allow maximum heat dissipation 6 Ensure that the discharged flow is directed to a safe place Start up and Commissioning 6 1 Flushing of lines As part of pre installation all fluid handling equipment particularly piping should be thoroughly cleaned of scale and the internal debris which accumulates during construction This is accomplished by blowing or flushing with air steam water and other suitable medium Note For a detailed procedure on flushing of lines please visit Forbes Marshall website 6 2 Commissioning After installation or maintenance ensure that the system is fully functioning by confirming fluid is passing through it 1 After flushing of lines is complete open the piston valve fully by rotating handwheel in anticlockwise direction 2 Operation of the handwheel should always be by hand 3 Checkforleaks and attend if any Maintenance Gui
24. ting pressure 39 bar g at 250 deg C Maximum operating temperature 425 deg C at 22 8 bar g Cold h ydraulic test pressure 60 bar g Body design conditions DN 15 200 Class 150 Flanged ends Maximum allowable pressure 19 6 bar g at 38 deg C Maximum operating pressure 14 bar g at 197 deg C Maximum operating temperature 425 deg C at 5 5 bar g Cold h ydraulic test pressure 28 bar g IBR requirement Body design conditions DN15 200 Class 300 Flanged End Maxim um allowable pressure 51 bar g at 38 deg C Maxim um operating pressure 41 5 bar g at 253 deg C Maxim um operating temperature 425 deg C at 28 8 bar g Cold h ydraulic test pressure 83 bar g IBR requirement Figure 2 DN15 20 25 Piston Valve AV Forbes i Marshall Trusted Partners Innovative Solutions INLET Figure 3 DN32 40 Piston Valve Note Always open and close piston valve fully do not use valve or F key Material DN 15 40 No Description Material Standard 1 Body Forged Carbon Steel ASTM A105N 2 Bonnet Forged Carbon Steel ASTM A105N 3 Piston Stainless Steel ASTM A 276 TYPE 304 4 Spindle Stainless Steel ASTM A 276 TYPE 410 5 Nyloc Nut Carbon Steel 6 Stud Carbon Steel ASTM A193 Gr B7 7 Nut Carbon Steel ASTM A 194 Gr 2H
25. top sealing stack Figure 9 View showing extractor tool and insertor tool for sealing stack of piston valve of size DN15 40 15 AV Forbes ps Marshall Trusted Partners Innovative Solutions For piston valve of size DN50 PUSH GENTLY gt BY HAND PUSH GENTLY BY EXTRACTOR TOOL EXTRACTOR TOOL T LEE 1 Extract top sealing stack first 2 Remove spacer which is free from the body and then extract bottom sealing stack MALLET MALLET INSERTOR TOOL INSERTOR TOOL LE 4 INSERTOR TOOL 4 SEALING RING STACK 3 Insert bottom sealing stack first 4 Place sealing stack in 5 Place spacer which is free from the body this way in insertor tool and then insert top sealing stack Figure 10 View showing extractor tool and insertor tool for sealing stack of piston size of DN50 7 5 Maintenance of piston valve of size DN65 DN200 Refer Figure 5 ANI Note The graphite sealing stacks contain thin stainless steel support rings which may cause physical injury if not handled and disposed carefully Maintenance of piston valve is very easy and can be done when piston valve not in operation If any leakage is observed through the gland tighten gland nut 13 to s
26. top the leakage through gland If any leakage is observed through outlet or between the body 1 and the bonnet 2 first close the valve till handwheel 18 touches the bonnet 2 then tighten all nuts 16 equally by half or one turn until leakages stops Refer Table 1 for recommended tightening torques Note Never tighten nuts 7 when valve is in open condition If leakage yet does not stop then follow the procedure mentioned below 1 Keep piston valve fully open remove nuts 16 amp Belleville washer 17 turns handwheel 18 in anti clockwise direction until it touches the bonnet 2 Pull handwheel carefully along with bonnet 2 to remove piston 3 from body 1 2 Incase the bonnet assembly does not come out of the body 1 use tapped hole for removing bonnet assembly Avoid any damage to piston 3 3 Clean piston 3 with lint free cloth 16 AV Forbes Marshall Trusted Partners Innovative Solutions 4 Remove body top sealing stack 4 with the help of extractor tool remove spacer 5 which is free in the body 1 and remove body bottom sealing stack 4 with the help of extractor tool Replace body bottom sealing stack 4 place spacer 5 and replace body top sealing stack 4 with the insertor tool Use mallet to apply light strokes on insertor tool ensuring they fit perfectly Insert bonnet sealing stack 14 carefully Refer figure 11 for extractor tool and insertor tool for piston valve of size DN65
27. ts is recommended Protective clothing Consider for the requirement of any protective clothing for you or others in the vicinity for protection against hazards of temperature high or low chemicals radiation dangers to eyes and face noise and falling objects Permits to work All work to be carried out under supervision of a competent person Training should be imparted to operating personnel on correct usage of product as per Installation and Maintenance instruction Permit to work to be complied with wherever applicable in case of absence of this system a responsible person should have complete information and knowledge on what work is going on and where required arrange to have an assistant with his primary goal and responsibility being safety Warning Notices should be posted wherever necessary Handling There is a risk of injury if heavy products are handled manually Analyze the risk and use appropriate handling method by taking into consideration the task individual the working environment and the load Freezing Provision should be made to protect systems which are not self draining against frost damage in environment where they may be exposed to temperatures below freezing point to be made 2 10 Returning products Customers and Stockist are reminded that when returning products to Forbes Marshall they must provide information on any hazards and the precautions to be taken due to contamination residues
28. usted Partners Innovative Solutions Specification of Molykote M30 Colour Black Synthetic oil Composition Molybdenum disulphide Dispersant x Density at 20 C 68 F Density Standard DIN 51 757 1 0 g ml Base oil viscosity at 40 C 104 F 3 Viscosity Standard DIN 51 562 ee Oil lubrication up to 200 C 397 F Temperature Service temperature range Dry lubrication up to 450 C 842 F Load carrying capacity wear protection Storage life Weld Load Standard DIN 51 562 pt 2 SUUM a Wear scar under 800 N Standard DIN 51 350 1 02 mm tester pt 3 VKA Almen Wieland machine OK load 20000 N 1 years 20 Table 4 Specification of Molykote M30 AV Forbes 5 Marshall Trusted Partners Innovative Solutions 9 Available Spares Refer figure 2 3 4and 5 Always order spares part by using the description and Spare Code No given below amp stating size Sr No Spares Part No Spare Codes 1 Set of sealing stack for DN15 20 piston valve 9 F3A2017591 2 Set of sealing stack for DN25 piston valve 9 F3A2017592 3 Set of sealing stack for DN40 piston valve 9 F3A2017678 4 Set of sealing stack for DN50 piston valve 9 F3A2017679 5 Set of sealing stack for DN65 piston valve 4 10 14 F3A2019470 6 Set of sealing stack for DN80 piston valve 4 10 14 F3A2017740 T Set
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