FASANI - Pentair Valves & Controls
Contents
1. ropes and load balancing tools in order to prevent them from falling or moving during the lifting and handling Pentair reserves the right to change the contents without notice FASLT 0024 EN 1306 Pressure Seal Globe Valves Style B 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 disc 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 Cauti2. f Y f d Y 1 g f a E H SSE ASS 3 1 Packing Maintenance r p 7 If leakage is observed through the packing tighten the gland nuts slowly and evenly until the leakage stops QKE n Caution 2 Co Do not over tighten packing gland nuts Over tightening will increase the torque required to e operate the valve When tightening the gland nut use half turn increments until leakage has stopped Please refer to Figure no 4 2 a o To replace the packing proceed as follows c L Warning NN Before starting any maintenance depressurize drain and vent the line check that the valves 1 R iat are not in temperature disconnect any electrical power supply SU i aware PEY SS RRS Failure to do so may cause serious personal injury and or equipment damage Li Ml 3 X S WSS v Aen 1 Open completely the valve up to the backseat position 2 Remove the nuts 16 of the gland bolts 15 3 Lift the gland flange 10 and the gland 9 ae Braided graphite l l 4 Remove the worm out packing using a hooking wire 2 Die formet graphite 5 or 6 ring 5 Fora better tightness proceed to an accurate cleaning of the stem and stuffing box and make 3 Metal rin ie J sure there are no scratches or signs of seizing Figure no 3 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
3. gt PENTAIR FASANI www pentair com valves Pressure Seal Globe Valves Style B Installation and Maintenance Instructions Cast Globe Valves Pressure Seal Style B 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 3 2 4 Operations Instructions 3 Table Bolt Torque Figures for Packing Bolts 4 Table II 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 sy Bonnet Gasket Replacement D 4 Valve Removal 6 5 Greases and Special Tools 6 51 Greases 6 Table lll Grease and Lubricant List 6 D 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 The valves must be packed with the disc in the closed position Ja Flanged sealing valves the flange sealing surfaces raised faces of the valves shall be protected with suitable protective grease The end faces must be protected with plastic or
4. 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 If a leakage is detected tighten the gland nuts slowly and evenly until the leakage stops aao ET 10 oN P 2 O FPF Warning Before starting any maintenance depressurize drain and vent the Figure no 4 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 3 2 Bonnet Gasket Replacement damage Pentair reserves the right to change the contents without notice Pressure Seal Globe Valves Style B Installation and Maintenance Instructions Fig no 5a Please refer to Figure no 5a 1 Unscrew the body yoke nuts pos 12 bonnet nuts pos 31 and the gland nuts 15 n pos 16 et p l L__ ZZZ aa O ce Lift up the yoke pos 24 operating by the handwheel or gearbox handwheel When the stem nut is free from the stem threads lift up the yoke 4 Lift up the bonnet pos 6 and pressure seal body gasket pos 5 Make sure not to damage the pac
5. the contents without notice Warning Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body See the actuator user manual for the actuator preparation Pressure Seal Globe Valves Style B Installation and Maintenance Instructions 2 2 Installation Instructions 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 Fasani 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 disc complete closure Unless otherwise recommended by Fasani the valve should be installed with the disc in the closed position to ensure that the seat ring in the disd 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 Installa
6. wooden discs fixed with straps 1b Buttweld end valves 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 straps 2 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 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 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
7. 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 1 1 8 443 600 1 1 4 627 850 2 5 Periodic Valve Verification during Service 1 3 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 o i 4 fol h aea k 31 To ensure tightness of Pressure Seal gasket the leakage does not stop follow the procedure for packing maintenance 3 1 pull up bolts must be tightened when valve is tae has been detected from the body bonnet tighten the nuts pos 31 as indicated in under fully hydrostatic test pressure able Il 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 ac
8. f the valve needs to be removed from the line for some 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 Table Ill Grease and Lubricant List 5 1 Greases Manufacturer Grease To lubricate the bearings on manual and gearbox operated valves we suggest to use the grease AGIP GRMUEP2 AGIP GRMUEP2 or an equivalent product as showed in table III API BERD For the lubrication of the stem thread use the grease SIGNAL CEP 30 produced by Viscol As an BP GREASE LTX2 alternative you can utilize Eoa BEACON 2 CEPLATTYN 300 produced by REINER FUCHS FINA FINAGREASE HP GRAFLOSCON produced by KLUBER FINAGREASE EPL2 You can also use a grease having more than 25 pure graphite content carbon 98 granulometry MOBIL MOBILUX EP2 5m without any abrasive agent Q8 REMBRANDT EP2 For the lubrication of the actuator refer to the relevant manual SHELL ALVANIA R2 SUPERGREASE A 5 2 Special Tools TEXACO MULTIFAK EP2 No special tool required for the Maintenance Operation described in this Manual GREASE L2 TOTAL MUTS ERZ MORS 2 VISCOL SIGNAL ROLSFER 2 Pentair reserves the right to change the contents without notice page 6
9. king We suggest to replace the packing when changing the body gasket 4 Carefully clean all the gasket housing and lubricate with suitable grease 5 Replace the body gasket Reassemble all parts following backwards the above mentioned steps SSS LL Z OOS XXX x lt gt lt a ee N YL IND AWM ZZZD to Wishes OD Please refer to Figure no 5b 1 Unscrew the body yoke nuts pos 12 or clamp bolt pos 39 and the gland nuts pos 16 Remove the clamp pos 38 where applicable i a aD 12 Lift up the yoke pos 24 operating by the i ee 6 handwheel or gearbox handwheel 4 When the stem nut is free from the stem iz ALLA KANON NNN oo POVAA ZAZA oO i threads lift up the yoke 5 Unscrew the nuts pos 31 6 Remove the retaining ring pos 36 or segment ring pos 42 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 Replace the body gasket 10 Reassemble all parts following backwards the above mentioned steps LL Z The nuts pos 31 need to be retightened after valve first pressurization as indicated in Table Il Section 4 Valve Removal I
10. on 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 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 Pentair reserves the right to change
11. s been shut down after testing for a long time the following 2 4 Operations Instructions recommendations should be adopted 1 Style B Series Globe Valves do not require special care to work properly a Use corrosion inhibitor with water to The following instructions will help provide a satisfactory and long life service pressurize the piping system 2 Make sure to perform periodic valve verification as described in paragraph 2 5 b After testing the piping system should 3 In case of actuated valves always follow the specific instructions given by the actuator s be depressurized and the test water manufacturer completely drained 4 Never change the setting of torque and or limit switches which have been carefully set during the final test at Fasani workshop Pentair reserves the right to change the contents without notice Pressure Seal Globe Valves Style B Installation and Maintenance Instructions Table II Table Bolt Torque Figures for Packing Bolts Bolt Torque to Ensure Tightness For System pressures lt 2533 psi For System pressures gt 2533 psi Torque ft Ibs 24 87 x OD2 _ ID2 x d Torque ft Ibs S P 101 8 x OD2 _ 1D2 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 OF 50 S P System Pressure psi 5 8
12. tion Buttweld Valves Position the valve and check the alignment with the pipe then proceed with welding in accordance with the applicable welding procedure Flanged Valves Place the valve between the two flanges of the pipe and put the seal gasket between the valve flange and the pipe flange make sure that it is correctly positioned Then assemble the valve to the pipe by the bolts which will be tightened crossing Progressively reach the requested torque value indicated by the Engineering Company that designed the plant Figure no 2 Installation positions recommended Important gt 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 Important 2 Check the operation of the valve by stroking it to full open and full close If piping system is pressurized with 3 If the valve has been stored for a long time check the bolt torque for bolting pos 31 in water for testing and in case the piping accordance with table Il system ha
13. tuated 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 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 sealing surface Jerky operation 1 Packing is too tight 1 Loosen gland nuts cycle valve retighten 2 Air supply inadequate for 2 Increase air Supply pressure pneumatic act Back seat leaking 1 Back seat damage 1 Replace the back seat Pentair reserves the right to change the contents without notice Pressure Seal Globe Valves Style B Installation and Maintenance Instructions Section 3 Maintenance The Style B 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 Fasani or Nominated Service Company i VW ZA 1224 UF Zaza AZZZ I f
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