Fasani Gate Valves, Bolted Bonnet LP/MP
Contents
1. Torque Torque Torque 1 Make sure to perform periodic valve Diameter In Kgm Ftlb Nm Kgm Ftlb Nm verification as described in paragraph 2 5 9 66 90 3 19 26 2 In case of actuated valves always follow the s 18 129 lis 5 37 50 specific instructions given by the actuator s Ya 31 224 305 9 64 87 manufacturer 3 50 358 487 14 102 ey 3 Never change the setting of torque and or 1 74 933 129 21 152 207 limit switches which have been carefully set 1 107 772 1050 Si 221 300 during the final test at Fasani workshop 1 149 1075 1462 43 307 418 98 201 1447 1968 oy 413 562 2 5 Periodic valve verification during service ten 263 1896 2579 75 542 Tod A Normal check Oo 2445 6025 97 699 950 1 Verify monthly that there is no leakage l 426 3072 4178 122 878 1194 from packing or in the body bonnet area EE 027 3798 5165 150 1085 1476 If the leakage has been detected from 2 642 4630 6297 183 1323 1799 the packing tighten nuts according to the 22 921 6640 9030 263 1897 2580 procedure described in Section 3 22M 1271 9162 12460 363 2618 3560 If the leakage does not stop follow the ao 1537 11085 15076 439 A7 4307 procedure for packing maintenance 3 1 3 2003 14447 19648 572 4128 5614 If the leakage has been detected from the 3 2596 18428 25062 730 5265 7161 body bonnet tighten the nuts as indicated in 3 1 3201 23079 31387 914 6594 8968 Table I If the leakage does not stop follow the Corresponding to approx 40 of yield strength on dry st2. 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 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 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 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 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 degrease both surfaces with a solvent Clean the inside of the valve by 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 Confirm that the materials of construction listed on the valve nameplates service and temperature are appropriate for the service intended and are as Specified Define the preferred mounting
3. gt PENTAIR FASANI GATE VALVES BOLTED BONNET Installation and maintenance instructions for bolted bonnet gate valves Bas c configuration Flanged or welded ends CONTENTS 1 Valve storage 1 1 Preparation and preservation for shipment 1 2 Handling requirements 1 3 Storage and preservation before installation 2 Installation 2 1 Preparation before installation 2 2 Installation instructions 2 3 Valve verification before start up 2 4 Operations instructions Table Bolt torque figures for body bonnet flanged connections Table Il Bolt torque figures for packing bolts 2 5 Periodic valve verification during service Troubleshooting guide 3 Maintenance 3 1 Packing maintenance 3 2 Body bonnet flange gasket maintenance 4 Valve removal 5 Greases and special tools 5 1 Greases Table Ill Grease and lubricant list 9 2 Special tools 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 1a Flanged sealing 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 1b Buttweld end val
4. worn out packing using a hooking wire 5 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 Body bonnet flange bolting loose Solution Tighten gland flange nuts Replace packing Tighten bottom flange bolting Replace the gasket Close valve 1 2 1 2 1 2 Cycle and flush valve open to remove debris 3 Recondition the seat surface 1 Loosen gland nuts cycle the valve retighten 2 Increase air Supply pressure 1 Replace the back seat 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 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 3 2 Body bonnet flange gasket maintenance 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 1 Braided graphite rings 2 Die fo
5. ERE ALVANIA R2 SUPERGREASE A TEXACO MULTIFAK EP2 GREASE L2 SECTION 5 GREASES AND SPECIAL TOOLS TOTAL MULTIS EP2 MULTIS 2 TT MISCOL SIGNAL ROLSFER 2 5 1 Greases STATOIL UHIWAYLI LI G2 To lubricate the bearings on manual and gearbox operated valves we suggest to use For the lubrication of the stem thread use the grease SIGNAL CEP 30 produced by Viscol the grease AGIP GRMUEP7Z or an equivalent As an alternative you can utilize product as showed in the following table CEPLATTYN 300 produced by REINER FUCHS GRAFLOSCON produced by KLUBER 5 2 Special tools You can also use a grease having more than 25 pure graphite content carbon 98 No special tool required for the maintenance granulometry 5 microns without any abrasive agent operation described in this manual For the lubrication of the actuator refer to the relevant manual 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 the right to change product designs and specifications without notice Pentair is an equal opportunity employer 2015 Pentair plc All rights reserved
6. alve has to be fully stroke operated the paper protecting the stem must be removed stem and bearings must be greased See table Bolt torque figures for body Bonnet flanged connections and table II Bolt torque figures for packing bolts If any see the actuator Instruction manual for the related commissioning start up procedure 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 l 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 FASANI GATE VALVES BOLTED BONNET 2 4 Operations instructions The following instructions will help provide a TABLE l BOLT TORQUE FIGURES FOR BODY BONNET FLANGE CONNECTIONS satisfactory and long life service of the bolted Materials A193 B7 A193 B16 A320 L7 Material A193 B8 bonnet gate valves Nominal bolt Torque Torque Torque
7. eel surface maintenance procedure for the replacement of the body bonnet gasket 3 2 TABLE II BOLT TORQUE FIGURES FOR PACKING BOLTS 2 Every 2 3 months depending on operating For system pressures lt 2533 psi For system pressures 2 2533 psi frequency verify the greasing of bearings Torque ft lbs 24 87 x 0D2 _ ID2 x d Torque ft lbs S P 101 8 x OD2 _ ID2 x d and stem thread Torque Nm multiply Torque ft lbs x 1 3558 3 For actuated valves in addition to the above Where OD Stuffing box bore in please refer also to the warnings in the ID Stem dia in actuator manual d Gland stud dia in S P System pressure psi B Preventive actions This Torque method may result in more or less than 30 compression 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 FASANI GATE VALVES BOLTED BONNET TROUBLESHOOTING GUIDE Symptom Possible cause Stem packing leaking 1 Gland flange nuts too l
8. eners ropes and load balancing tools in order to prevent them from falling or moving during the lifting and handling 2012 Pentair plc All Rights Reserved VCIOM 01612 EN 15 11 FASANI GATE VALVES BOLTED BONNET VALVE SLINGING FIGURE 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 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
9. oose Packing damaged Body Bonnet leaking Gasket damage Valve leaking Valve not fully closed Sealing surface damaged Jerky operation Packing is too tight 1 2 1 2 1 2 Debris trapped in valve 3 1 2 Air supply inadequate for pneumatic act Back seat leaking 1 Back seat damage SECTION 3 MAINTENANCE The Pentair bolted bonnet gate valves have been designed to require minimum maintenance This manual describes on site repairs as Packing maintenance Body bonnet flange gasket maintenance All the other repairs should be performed by Pentair 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 CAUTION Do not over tighten packing gland nuts Over tightening will increase the torque required to operate the valve When tightening the gland nut use half turn increments until leakage has stopped Please refer to Figure 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 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 4 Remove the
10. 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 FASANI GATE VALVES BOLTED BONNET FIGURE 2 Installation positions recommended 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 Fasani recommends that the valve shall be installed and oriented following the indications of Fig 2 For gate valves of DN larger than 18 inches unless specified in the order the angle of inclination from vertical shall not exceed 30 Different positions from those indicated may cause a non correct valve operation and or a quick deterioration of the valve Unless otherwise recommended by Pentair 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 actua
11. rmed graphite 4 rings FIGURE 3 FIGURE 4 FASANI GATE VALVES BOLTED BONNET 1 Before replacing the gasket carefully clean FIGURE 5 the flange surfaces 2 Place the gasket in its seat and begin to carefully position the bonnet flange Position it perfectly parallel to the gasket face do not use the bolts to obtain this alignment 3 In case the coupling is vertical valve with horizontal stem position the bonnet flange by means of a hoist lock it with four bolts placed at 90 on from the other and tighten them until the flanges are perfectly coupled in their seat Insert all the other bolts 4 During tightening make sure that the faces of the flanges remain perfectly parallel o Tighten the bolts in the sequence indicated in fig 5 using for the first turn a torque of approx 1 4 of the maximum torque listed on table For a better performance of the joint tighten again all the bolts after the equipment has been pressurized TABLE IIl GREASE AND LUBRICANT LIST Manufacturer Grease SECTION 4 VALVE REMOVAL AGIP GRMUEP2 Oo ap PGX2 If the valve needs to be removed from the line BP GREASE LTX2 for some extraordinary reason the user should ESSO BEACON 2 ensure the following FINA FINAGREASE HP FINAGREASE EPL2 1 The valve is depressurized drained and vent MOBIL MOBILUX EP2 2 The pipe shall be cut as far away from the Q8 REMBRANDT EP2 valve as possible only for welded valves SW
12. tors 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 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 IMPORTANT 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 and disc and the correct operation of the valve After the valve installation on the line and before the line pressurization the following activities must be performed all the threads plugs tightening shall be verified the packing bolts must be tightened the torque of the body bonnet bolts shall be verified the v
13. ves 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 www pentair com valves 2 All actuated valves must be carefully and 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 by 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 by using the appropriate tools brackets hook fast
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