IOM-P14-R0 Quarter Turn BV

8/11/2019 IOM-P14-R0 Quarter Turn BV

1/9

Page 1 of 9 Weir Valves & Controls UK LtdBritannia House, Huddersfield Rd,, Elland. HX5 9JR

Tel: +44 (0) 1422 282000 Fax: +44 (0) 1422 282100

IOM-P14-R0

Before Starting Work Refer toSafety With Valves &Maintenance with Valves &Seats

SAFETY

These instructions contain essential health andsafety requirements concerning the safe use of theequipment.

1. For the intended purpose that was specified toWeir Valves & Controls UK Ltd, e.g. location,pressure, temperature, fluid, etc.

2. When installed, operated, maintained, etc. inaccordance with these instructions.

Failure to comply with these points in their entiretyinvolves serious risk.

The manufacturer of this valve is:

WEIR VALVES & CONTROLS Ltd,Britannia House,Huddersfield Rd, Elland,West Yorkshire,HX5 9JR. England.

A nameplate is attached to the valve body (1) givingdetails in accordance with the valve standard towhich this valve has been manufactured. Itincludes details of the manufacturing contract anditem number and the valve figure number. Thenameplate details should be quoted in their entiretyin any correspondence with Weir valves & Controls,for the enquiry of spare parts or other technicalinformation.

Where actuators are employed, a nameplate is alsoattached to the actuator, and similarly all nameplatedetails should be quoted in any correspondenceconcerning the actuator. In addition to theseinstructions, the Operating and MaintenanceInstructions for the actuator must be read and fullyunderstood, and must be consulted in any matterrelating to the actuator.

The following warning/instructions are attached tothe valve assembly and must be observed andfollowed at all times.

SAFETY WARNINGS:

Hot surfaces.Pneumatically isolate actuator before adjustment ormaintenance to valve.Valve must be depressurised before adjustment ormaintenance.

Please refer to Weir Valves & Controls UK LtdPublications 'SAFETY WITH VALVES' and'SAFETY WITH ELECTRIC ACTUATORS' forgeneral principles on installation, operation andmaintenance. However, in all cases theseOperating and Maintenance Instructions supersede

any alternative information that may be given in, forexample non-specific catalogues or the abovementioned general safety publications.

At all times the valve must be maintained to a safecondition and any damaged or worn parts must bereplaced with the correct parts supplied by WeirValves & Controls UK Ltd. Users are stronglyrecommended to avail themselves of the trainingcourses that can be provided by Weir Valves &Controls UK Ltd.

Contents

Page

Safety1

Description & Use 2

Manual Operation 2Actuators 2Standard Handwheel 2

Installation andCommissioning 2

Installation 2Commissioning 3

Routine Maintenance 3Dismantling 4Valves without actuator 4Valves with actuator 4Examination and Course of Action 5

Assembly 5Valves without actuator 5Valves with actuator 5

AppendicesFig. 1 6Fig. 2 7


2/9


3/9

Page 3 of 9 Weir Valves & Controls UK LtdBritannia House, Huddersfield Rd,, Elland. HX5 9JRTel: +44 (0) 1422 282000 Fax: +44 (0) 1422 282100

IOM-P14-R0


valve connections, the correct remote operation of thevalve, etc.), and then equipping the valve for the start ofits operational life (e.g. charging up the system to the

valve). During commissioning, it is sometimes necessaryto bypass interlocks or safeguards on equipment in orderto simulate meaningful commissioning trials. Underthese circumstances, the utmost care must be exercised.As Weir Power & Industrial Ltd. has not been informed ofany procedure which will either interfere with this valve inorder to test other plant, or to interfere with otherequipment to test this valve, it is the responsibility of theuser to ensure the total safety of persons and equipment.

The following items may require to be attended to duringcommissioning, and it must be recognised that theirmention here is on the strict understanding thatmeasures will be taken to prevent any risk.

CHEMICAL CLEANING OF PIPELINES

If chemical cleaning has to be undertaken, ensure thechemicals are compatible with the materials in the valve.It is important to ensure that any chemicals used in thisoperation do not soak into the gland packing where theycould promote corrosion of the valve stem and/ordeterioration of the packing. For this reason, it isrecommended that the valve is first pressurised withwater to "saturate" the gland packing, operating the valveat the same time to promote this, and leaving the valve inthe half-open position. Proceed with the chemicalcleaning and passivation. Then with water in the valve,operate it several times to flush away any chemicals that

may have penetrated the gland packing.

HYDRAULIC TESTING

Test only up to the maximum hydraulic test pressurefor the valve rating. At shell test pressure theactuator is not designed to close the valve and alsothe gland packing is permitted to leak at thispressure. Check for other leaks, e.g. at valve to pipeflanges.

Use corrosion inhibited water for testing.

NOTE: Shell test pressure is 1.5 times the "coldrating pressure" stated on the valve nameplate.

ELECTRICAL TESTING/FUNCTIONAL TESTING

Carry out full electrical testing and functional testingincluding earth continuity checks and ensureeverything is working correctly. Isolate electricallybefore removing actuator covers.

PREPARATION FOR OPERATION

Ensure that the actuator covers are secure with nopossible ingress of water, moisture etc.

Set the valve in the position required for starting upthe plant after bleeding through or draining as

required any fluid appropriate to thecommencement of operation.

Note that when the valve enters full and properoperation this may be the first time that the valveand actuator are subjected to the most arduouscombination of conditions e.g. flow, temperature(including ambient temperature), pressure,operating loads, full load current on the actuator etc.It is therefore important that the valve is seen tooperate correctly not only during "commissioning",but also when the valve has entered "operation".The same is true if the valve should be subjected toany changed conditions of operation.

COMMISSIONING AND OPERATIONALPRECAUTIONS

In certain circumstances, it is possible that the valveis operated more frequently during commissioningthan that which occurs during normal operation.Routine maintenance, overhaul, lubrication etc. maytherefore still be necessary and it should not beassumed that these can be neglected duringcommissioning and early operation.

Internal damage to the valve can also occur duringthis period as weld spatter, pipe scale, debris etc. isstill finding its way through the system pipework.

Care should be taken to ensure that no damage isdone to the valve during such times.

ROUTINE MAINTENANCE

The valve requires little routine maintenance.However, the valve should be inspected regularly,preferably whilst it is operating, to check for glandleakage, loose fasteners, signs of ball & seat wearor leakage etc., so that timely rectification work canbe arranged. This inspection can also determine ifadditional lubrication is required where the valvestem screws into the actuator drive sleeve/handledrive sleeve.

The frequency of this inspection depends on theamount of use received by the valve, and thus it isrecommended that a suitable inspection interval betaken as say six months, and that this interval isadjusted as necessary in the light of siteexperience.

Take care when approaching a valve, particularly ifit is seen to be leaking at the gland.


4/9


IOM-P14-R0


If the gland has been leaking then depressurise thesystem, isolate the actuator, and tighten the glandnuts. Glands benefit from early attention to stop

leakage, or else a path through the gland packing willbe cut which cannot be remedied by simply re-tightening the gland nuts.

The gland nuts must not be over-tightened!

Reconnect the pneumatic supply, and re pressurisethe system to test for gland leakage. If re-tighteningthe gland has not made it leak-tight then overhaul thevalve in accordance with pages 6 and 7 dismantlingand assembly is required.

IMPORTANT: After any maintenance ensure theactuator covers are properly in place before the valveis returned to service.

Refer to the actuator manufacturers recommendationfor routine maintenance of the actuator.

DISMANTLING

Due to the design of the valve, only the packing,gland and top works are replaceable when the valveis installed in a pipeline.

Before any dismantling work, ensure that theequipment is safe to work on, that the system hasbeen depressurised and drained and that the

actuator has been pneumatically isolated. Ensure allsite safety regulations, permit systems etc., arecomplied with, and take care if handrails or flooringhas to be removed to gain access to the valve.

Ensure adequate lighting and lifting facilities areavailable. Refer to the arrangement drawings for thevalve. (Fig. 1 & 2)

DISMANTLE VALVE

VALVES WITHOUT ACTUATOR (FIG 1)

1. Use the handle to open the valve.

2. Remove lock nut (527) and spring washer whichsecure the handle (853) to the stem (9).

3. Remove the nut (99) from the spring (70) and slidespring off the stem (9).

4. Remove gland nuts (141), taking care to loosenthem equally before removing.

5. Remove gland cover (994), gland plate (718) andcleaning ring (2058).

6. Remove gland follower (12)

7. Remove the packing blocks (61) and packingrings (921), taking care not to scratch the stem.

8. Transport all removed parts to workshop.

VALVES WITH ACTUATOR (FIG 2)

Before commencing work, make sure that theairlines to the actuator are isolated before removing

them.1. Make sure valve is open.

2. Take car to support the actuator (660) andremove cap screws (520C) and spring washers(920B) from actuator support (605).

3. Remove actuator (660) and place in a safeposition.

4. Remove cap screws (520B) and spring washers(920A) from the support brackets (858) taking careto support the actuator support (605) whenremoving the final cap screws.

5. Remove cap screws (520A) and spring washers(920) from the support brackets (858) taking care tosupport them when removing the final cap screws.

6. For valves with grub screws securing the drivesleeve (993) remove these before sliding the drivesleeve off the stem (9).

7. Remove key (589) from the stem (9) andexamine condition.

8. Continue as per point 3 Valves without

actuator.

EXAMINATION AND COURSE OF ACTION

Carefully clean and examine all parts for damage,wear, corrosion etc. and replace or renovate allparts as necessary.


5/9


IOM-P14-R0


ASSEMBLY

Make sure all parts being re-assembled are cleanand free from defects.

New parts required after strip down are as follows:

Packing rings (921)Packing blocks (621)Cleaning ring (2058)

When tightening cap screws and stud nuts, refer Fig.3. for applicable torques. For gland nuts, follow Fig.4. for applicable torques.

Note: This part of the re-assembly procedure is byfar the most important as damage to the gasket orsurfaces at this point can undo all previous work.

VALVES WITHOUT ACTUATOR (FIG 1)

1. Slide bottom packing block (61) over stem (9) andinto stuffing box and tamp it in with a tubular ram.

This ram should preferably be of brass or any othersoft alloy so as to prevent damage to stuffing box orstem (9).

2. Slide new packing rings (921) into stuffing box,firmly tamping down each one in turn.

3. Enter top packing block (61) into stuffing box andfirmly tamp down.

4. Fit gland follower (12) over stem (9) and enter intotop of stuffing box, ensuring it is square to the top ofthe body (1) and that valve stem (9) is central instuffing box.

5. Fit gland plate (718), correct way up, over glandstuds (15) and onto gland follower(12), ensuring it is central on follower and parallel tothe top of the body (2).

6. Fit cleaning ring (2058) and gland plate (994) andtighten the gland nuts (522) progressively and evenlyuntil they are all tightened. Ensure gland plate is stillparallel and square.

7. Fit spring (169) and lock nut(s) (99) to stem (9)

8. Slide handle (853) over stem, making sure thecorrect handle marking for the position of the valve

is aligned with the lever stop (873).

9. Fit spring washer (823) and nut (527) to the topof the stem (9).

VALVES WITH ACTUATOR (FIG 2)

Continue from point 7 (Valves without actuator)

1. For stems with a key way, re fit key (589) to stem(9) before sliding drive sleeve (993) over thestem(9).

For stems with a grub screw, slide drive sleeve overthe stem and attach grub screws.

2. Attach both support brackets (858) to the valvebody (1) using spring washers (920) and capscrews (520A).

3. Attach actuator support (605) to support brackets(858) using spring washers (920A) and cap screws(520B).

4. Line up actuator square drive with drive sleeve(993) and slot actuator onto drive sleeve until flushwith actuator support (605).

5. Attach actuator (660) to actuator support (605)using spring washers (920B) and cap screws(520C).

Complete the refitting of the valve. Instigate safeconditions to hydraulically test the valve and adjustthe gland packing to be leak-tight at pressures up to1.1 times the designed operating pressure. Replacethe covers before operating the actuator. Whenfinished make a complete check of the operation ofthe valve and actuator (refer to Section 3 onInstallation and Commissioning). Take care whilstactuator covers are open.

Reinstate the job-site to safe working conditionse.g. remove lifting tackle, replace flooring, handrails,etc. cancel permits.

For actuator assembly checking and re-setting referto the actuator information.

IF IN DOUBT ASK!


6/9


IOM-P14-R0


Consult Weir Valve & Controls Ltd if anything isnot clear. Safe working practices must prevail atall times.

Fig.1


7/9


IOM-P14-R0


Fig. 2


8/9


IOM-P14-R0


Fig. 3

Torques for nuts, studs, bolts and socket head cap screws.

Unified

Size (Inch) Torque (lb-ft) Torque (Nm)

1/4 6 9

1/3 13 18

3/8 23 31

4/9 37 50

1/2 50 68

5/8 80 109

3/4 135 184

7/8 215 292

1 320 435

Metric

Size (mm) Torque (lb-ft) Torque (Nm)

5 3 4

6 5 7

8 13 14

10 25 34

12 50 68

14 60 82

16 95 129

20 140 190

22 190 258


9/9


IOM-P14-R0


Fig. 4

Torques for valve gland nuts

Nut size UNC

Valve pressure rating

Class 600 & lower Class 900 & 1500 Class 2000

Seat test pressure

120 bar & lower between 121 bar & 350 bar 351 bar and higher

Torque lb ft (Nm)

1/4 2 (3) 3 (4) 3 (4)

5/16 3 (4) 4 (5.5) 5 (7)

3/8 4 (5.5) 6 (8) 8 (11)

7/16 7 (9.5) 10 (13.5) 14 (19)

1/2 10 (13.5) 15 (20) 20 (27)

9/16 12 (16) 18 (24) 24 (33)5/8 15 (20) 22 (30) 30 (41)

3/4 20 (27) 30 (41) 40 (54)

7/8 35 (48) 50 (68) 70 (95)

1 50 (68) 75 (102) 100 (136)

Documents

IOM-P14-R0 Quarter Turn BV