Steamco Gate Globe Check Valve IOM

INSTALLATION, OPERATION & MAINTENANCE MANUAL

GATE, GLOBE & CHECK VALVES

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GATE, GLOBE & CHECK VALVES

INDEX Introduction

3-4

Safety Information

4-5

Valve Identification

6

1.0 Installation

7-9

1.1

Installation positions

7

1.2

Preparation for installation

7

1.3

End connections

7-9

2.0 Storage

9

3.0 Pre-operation

9

4.0 Operation

9-10

4.1

Difficulty opening & closing

10

4.2

Other services

10

5.0 Maintenance Procedures

11-14

5.1

Periodic inspection

5.2

Preventative maintenance

11-12

5.3

Adjusting gland packing

12

5.4

Use of backseat

5.5

Packing replacement

13

5.6

Gear operator maintenance

13

5.7

Leakage across seat

14

5.8

Disassembling valves

14

5.9

Leakage across gasket

14

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12-13

1

GATE, GLOBE & CHECK VALVES

5.10

Reassembly

14

6.0 Extraordinary Maintenance

15-18

6.1

Stem

15

6.2

Gland disassembly & replacement of stem packing

15-17

6.3

Bonnet disassembly & stem replacement

17-18

7.0 Other Maintenance & Repairs

19

Appendix A - Bolting torque sequence

20-21

Appendix B - Exploded B.O.M.

22-27

Warranty

28

© Copyright Australian Pipeline Valve 1990 - 2024 Edition Catalogues, photos, brochures and technical publications are the exclusive property of Australian Pipeline Valve.

Any unauthorised reproduction in total or in part, shall result in prosecution. Products and data sheets in this publication are subject to change at anytime without notice. Australian Pipeline Valve reserves the right to carry out amendments to products and materials.

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INTRODUCTION The majority of this information is common knowledge to experienced valve users. When properly installed in applications for which they were designed, Australian Pipeline Valve (APV) valves will give long reliable service. This instruction is only a guide for installation and operation of standard service valves. A professional APV approved valve engineering facility should be utilised for reconditioning or major repairs. This IOM is a generic general overview. For more detailed maintenance instructions refer to the APV Gate Valve IOM which covers parallel slide valves. Refer to the APV Check Valve IOM which covers piston check valves. Refer to the APV Globe Valves IOM which covers globe valves and screw down non-return (stop check) check valves. For speciality valves such as piston type globe valves and bellows sealed valves there are some differences but this IOM provides a generic overview for these valves. Refer to APV for specific instructions pertaining to these valves.

Note

We do recommend however that this entire document be read prior to proceeding with any installation or repair. Australian Pipeline Valve and it’s parent company take no responsibility for damage or injury to people, property or equipment. It is the sole responsibility of the user to ensure only specially trained valve repair experts perform repairs under the supervision of a qualified supervisor.

RESPONSIBILITY FOR VALVE APPLICATION The User is responsible for ordering the correct valves. The user is responsible for ensuring APV Valves are selected and installed in conformance with the current pressure rating and design temperature requirements. Prior to installation, the valves and nameplates should be checked for proper identification to ensure the valve is of the proper type, material and is of a suitable pressure class and temperature rating to satisfy the requirements of the service application.

Do not use valves in applications where either the pressure or temperature is higher than the allowable working values. Also valves should not be used in service media if not compatible with the valve material of construction, as this will cause chemical attacks, leakage, valve failure.

RECEIVING INSPECTION AND HANDLING Valves should be inspected upon receipt to ensure: - Conformance with all purchase order requirements.

- Correct type, pressure class, size, body and trim materials and end connections.

- Any damage caused during shipping and handling to end connections, hand wheel or stem.

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The User is advised that specifying an incorrect valve for the application may result in injuries or property damage. Selecting the correct valve type, rating, material and connections, in conformance with the required performance requirements is important for proper application and is the sole responsibility of the user.

SAFETY INFORMATION The following general safety information should be taken in account in addition to the specific warnings and cautions specified in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered in this IOM Never attempt to disassemble a valve while there is pressure in the line. Ensure both upstream and downstream pressures are removed. Disassemble with caution in the event all pressures are not relieved. Even when replacing stem packing, caution is necessary to avoid possible injury.

To prevent valve bending, damage, inefficient operation, or early maintenance problems, support piping on each side of the valve.

• A valve is a pressurised mechanism containing energised fluids under pressure and consequently should be handled with appropriate care.

• Valve surface temperature may be dangerously too hot or too cold for skin contact.

• Upon disassembly, attention should be paid to the possibility of releasing dangerous and or ignitable accumulated fluids.

• Ensure adequate ventilation is available for service.

Packing leakage could result in personal injury. Valve packing is tightened prior to shipping but may require readjustments to meet specific service conditions.

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Personal injury may result from sudden release of any process pressure. APV recommends the use of protective clothing, gloves and eyewear when performing any installation or maintenance.

Isolate the valve from the system and relieve pressure prior to performing maintenance.

Disconnect any operating line providing air pressure, control signals or electrical power to actuators.

Check the packing box for pressurised process fluids even after the valve has been removed from the pipeline, particularly when removing packing hardware or packing rings, or removing packing box pipe plug.

If a gasket seal is disturbed while removing or adjusting gasketed parts, APV recommends installing a new gasket while reassembling. A proper seal is required to ensure optimum operation.

This manual provides instructions for storing, general servicing, installation and removal of gate valves.

APV and it’s resellers refuse any liability for damage to people, property or plant as well as loss of production and loss of income under any circumstances but especially if caused by: Incorrect installation or utilisation of the valve or if the valve installed is not fit for intended purpose. It is the sole responsibility of the user to ensure the valve type and materials are correctly specified.

DURING OPERATION TAKE INTO ACCOUNT THE FOLLOWING WARNINGS: a- Graphite/Graphoil packing and body gasket is very brittle, any impacting, twisting or bending should be avoided. b- The valve’s internal parts such as disc, stem, seats, seals and gaskets shall be handled with care avoiding scratches or surface damage. c- All tools and equipment for handling the internal parts shall be soft coated or else take extreme care, especially on machined mating surfaces and with soft parts . d- Valves can be fitted with gaskets or seals in PTFE, Buna, Viton, etc., hence high temperatures will damage sealing components.

For all operations make reference to position number on part list of the applicable drawing listed.

At no time shall any weld repair be conducted on the valve while in service. Never strike the valve with a hammer or other impact device. Ensure that no excess weight is placed on the valve that was not part of the original manufacture design.

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VALVE IDENTIFICATION Each APV valve is identified with a nameplate. Below is an example.

6

5

3 4

SIZE 150NB CLASS 150 BODY WCB

DISC CR13 SEAT CR13+ST#6

APSLCLXU-Z 1096287-2

2

1

7

ITEM DESCRIPTION 1

APV-Steamco valve figure number

2

Shell material (e.g. body, bonnet)

3

Closure member material

4

Seat material

5

Rated pressure class as per ASME B16.34. Section 2

6

Nominal pipe size

7

Serial/batch number

When performing any work, ordering spare parts, or requesting technical support, please refer to this tag. The serial number, the part number and numbers cast on the side of the valve body are keys to proper valve identification.

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1.0 INSTALLATION Piping should be properly aligned and supported to reduce mechanical loading on the end connections.

1.1 INSTALLATION POSITIONS Parallel slide gate valves are usually bi-directional and therefore may be installed in either direction. In some cases, gate valves may be uni-directional, in which case the direction of flow will be indicated on the valve body. Globe valves and check valves are uni-directional (direction of flow indicated with arrow also refer to APV globe and check valve IOM). Parallel slide gate, globe & piston check valves are designed for horizontal pipelines with the bonnet faced upwards. In smaller sizes, specially guided right angle globe valves and specially guided piston check valves and spring loaded SDNR globe valves can be used for vertical service with upwards flow but must be specified with order and tested. Right angle design SDNR globe and piston check complete with spring are recommended for vertical service applications.

1.2 PREPARATION FOR INSTALLATION • Remove protective end caps or plugs and inspect valve ends for damage to threads, socket weld bores or flange faces.

• Ensure valve is in full closed position to protect seat area.

• Thoroughly clean adjacent piping system to remove any foreign material that could cause damage to seating surfaces during valve operation.

• Verify that the space available for installation is adequate to allow the valve to be installed and to be operated.

Note

Ensure sufficient clearance for the stem in the full open position may cause the valve to be inoperable. Inadequate clearance for valve may add mechanical loading to the valve ends. Sufficient clearance should be allowed for threaded valves to be ‘swung’ during installation.

1.3 END CONNECTIONS 1.3.1 Threaded Ends Check condition of threads on mating pipe.

Apply joint compound to the male end of joint only. This will prevent compound from entering the valve flow path.

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1.3.2 Flanged Ends Check to see that mating flanges are dimensionally compatible with the flanges on the valve body and ensure sealing surfaces are free of debris.

Install the correct studs and nuts for the application and place the gasket between the flange facings.

Stud nuts should be tightened in a an opposing criss-cross pattern in equal increments to ensure proper gasket compression.

1.3.3 Socket Weld Ends Remove all debris, grease, oil, paint, etc., from the pipe that is to be welded into the valve and from the valve end connections.

Insert the pipe into the valve end connection until it bottoms out in the socket weld bore. Withdraw the pipe 1/16” so that a gap remains between the pipe and the bottom of the socket weld bore to prevent cracks (ASME B16.11). Tack the pipe into the valve and complete the fillet weld.

Gate & Globe valves should be lightly closed during welding to prevent damage to the seating surfaces and stem caused by thermal expansion during the socket weld process.

1.3.4 Buttweld Ends Clean the weld ends as necessary and weld into the line using an approved weld procedure. Make sure the pipe and body material given on the nameplate or valve body is compatible with the welding procedure. (Refer our compatibility cross reference chart for equivalent pipe, valve & fittings grades).

1.3.5 Valve Installation by Welding Keep valve in full closed position to avoid seat distortion and debris entering seat area.

Unless the valve contains PTFE packing and/or gasket, leave valves assembled and in the lightly closed position during installation, welding and post-weld heat treatment. This will prevent the valve seat from floating or distorting during the process. After welding completion, open the valve and flush line to clear out any foreign matter. Valves of carbon steel should be allowed to cool slowly. The valve may be covered with a heat-insulating blanket to promote slow cooling and limit the heat-affected zone.

Appropriate industry standards should be followed for all PWHT. In the unlikely event that the valves under 80NB (3”) have a PTFE bonnet gasket and/or stem packing, ensure the temperature of the body near these areas does not go over 200°C during welding.

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The responsibility for welding of the valves into piping systems is that of those performing the welding.

Refer to ASME B31.1, B31.3, etc. Written welding procedures covering all attributes of the process and materials to be welded shall be in accordance with Section IX of the ASME Boiler and Pressure Vessel Code and any additional requirements from the applicable piping.

2.0 STORAGE 1. Steamco valves are thoroughly cleaned to remove fluids, rust and other foreign materials after testing and before shipping.

2. Valves should be stored in a suitable sheltered place to prevent contamination by weather, dirt or dampness. Valves will eventually rust unless treated with a light oil coating when stored for long periods of time.

3.0 PRE-OPERATION After installation, the line should be cleaned by flushing to remove any foreign material. When caustics are to be used to flush the line, additional flushing with clean water is required. The valve should be opened and closed after installation to ensure proper operating function.

With the line pressurised, check the valve end connections, body to bonnet/cover joints and stem packing area for leaks. The packing may have to be tightened to stop packing leakage. Ensure the following checks are done.

1. Make sure all piping and components are cleaned of dirt and foreign objects.

2. Install valves as indicated by the arrow marked on the valve body where applicable.

3. Install valves in a manner that will allow future service and ease of operation.

4. Use hangers to support the weight of the valve and piping properly.

4.0 OPERATION 1. Valves are manually actuated by means of the hand wheel – counter-clockwise to open and clockwise to close. (Not applicable to check valves).

2. Valves that do not require frequent opening and closing should have grease applied to the stem threads on a regular basis. (Not applicable to check valves).

3. If leakage starts in our valve, please follow this procedure: a) Do not apply extra force to close the valve. b) Open the valve fully, then close again. This will usually flush away foreign materials on the seating surface.

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c) If leakage still continues after flushing (Step b), disassemble the valve, clean the seating surface and assemble the valve.

4. Gate valves are not to be used part open or part closed. Throttling will damage the valve.

5. Globe valves are ideal for on/off service especially for frequent operation due to the short travel between open and closed. The globe design is heavy duty but the flow passage translates to flow resistance.

Globe valves should not be used continuously to openings less than 20% or else venturi effect will damage seat and disc. Never attempt throttling under 20% of travel stem. Any throttling will reduce the life of the seat and disc. Closer throttling, can result in higher pressure drops which may cause excessive velocities or cavitation and could cause vibration or high noise levels resulting in damage to the valve or adjacent components/structure.

Globe valves are multi-turn valves with a rotating stem and rising hand wheel (unless a guide bar/ stem guide is fitted, then they are non rotating rising stem (see APV Globe valve IOM). Standard plug disc globe valves can be used for some minor very short term flow regulation. Alternate disc types are available (see APV Globe valve IOM). Where a guided disc is specified and a torque arm (guide bar) is fitted, globe valves will have a longer life when used for minor throttling applications but should still be used under 20% open.

All globe valves close by rotating the hand wheel clockwise and open by rotating counter-clockwise.

Gate & globe valves should not be left in the fully back seated position under normal operating conditions. The packing may dry out under these conditions and leak as the valve is closed.

4.1 DIFFICULTY OPENING & CLOSING For manual operated valves, loosen the two gland tightening nuts and the spindle should become free (otherwise dismantle the valve bonnet to inspect).

After dismantling the valve bonnet, inspect the exposed part of the spindle for scouring marks. Smooth out these marks with fine emery paper. Lightly lubricate the spindle and the spindle should become free again.

4.2 OTHER SERVICES Use Graphite (Graphoil)/PTFE impregnated Graphoil/Pure PTFE packings as per permissible limits of line pressure, temperature as well as media of flow through the valves. Bellows sealed valves utilise special inconel bellows to seal area, refer to as-built drawing.

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5.0 MAINTENANCE PROCEDURES 5.1 PERIODIC INSPECTION APV recommends that periodic inspections be carried out on all valves. The frequency of these inspections depends on the severity of the service and the frequency of the valve operation. As a minimum, all valves should be inspected quarterly to ensure proper operation and discourage the damage compounding effects of leakage. The following list details the specific valve types and areas requiring inspection and maintenance.

Item to Inspect

Stop Check

Gate

Globe

Check

Check all lubrication points Check body/bonnet join for leaks Check for packing leaks Check stem threads for wear Ensure stem and seal areas are free from debris If conditions permit, operate valve Inspect all external connections Inspect condition of actuator and/or gear operators (if applicable) Inspect valve for obvious damage

Do not remove or loosen the packing gland or bonnet bolts while the valve is pressurised.

5.2 PREVENTATIVE MAINTENANCE 1. Inspect whether all valves can be opened or closed smoothly at least once a month. If the operation is sluggish, clean the spindle threads and lubricate the same. APV valves are supplied with the stem threads engaging the yoke nut pre-greased. These components should be kept constantly lubricated by applying the grease directly on the stem when the valve is in the open position or through the grease injector in the yoke nut when provided. Lubrication/greasing of the stem should be conducted every six months or more often as needed, based on the environment the valve is installed. Inspection should confirm that the valve is sealing properly. Stem packing should be inspected at least every six months to ensure zero leakage from the packing chamber. For water & oil service, regular maintenance should be scheduled every 3 months. For gas and more corrosive mediums, inspection and maintenance should be completed once a month.

2. Check the gland tightening nuts for any slackness, if required tighten these nuts and ensure that the valve operation is not hampered by over tightening the gland.

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GATE, GLOBE & CHECK VALVES

3. Bonnet bolt tension should be checked periodically when valves are used in high temperature applications where creep may occur. Refer Appendix A, Tables A & B and Figure 11 for torque figures and tightening sequence. Although leaks through bonnet ring or spiral gaskets are rare, erosion or corrosion could cause bonnet seal to fail. In these cases, a new gasket is required. Refer Section 5.3 for replacing bonnet gasket.

4. With problematic service applications it is recommended that the valve be periodically at least partially stroked to ensure valve functions and to ensure there is no product deposits entering into seat or stem area which may render operating more difficult. Duration depends on service, criticality, etc. However, it also must be factored in that if there are impurities or particulates in the line, likely to be built up in the seat area, each operation could reduce seat life proportionately.

Note, use suitable new gland packing rope/rings of correct size and type when replacing.

Do not attempt to repack the stem packing in line while the valve is under pressure. The line must be totally purged. Cast iron valves do not have ‘back seating’ feature. Prior to removing bonnet, exercise extreme caution no pressure is trapped in the valve cavity. Wear appropriate safety apparel and follow industry and plant safety procedures.

5.3 ADJUSTING GLAND PACKING (Not applicable for check valves).

1. When trying the valve for the first time in the piping, it is recommended to adjust the gland packing by tightening the gland bolt nut. Tighten the gland packing uniformly so as to stop leakage. Over tightening can result in the valve hand wheel being hard to turn.

2. If tightening of the gland does not stop the leakage around the stem, repacking should be considered at once.

3. When placing a new valve into service, Australian Pipeline Valve recommends a preliminary packing adjustment to verify proper packing load. Additionally, it is recommended that a Baseline Leakage Test be performed following installation, but prior to start-up.

4. During the packing life cycle, normal and routine maintenance of the packing arrangement must be administered. Normal cycle life will typically require 5 to 8 packing gland nut adjustments. Torque values vary depending upon valve size. Refer to the Packing Bolt Torque chart for the recommended torque values. Tighten the gland packing nuts clockwise. Do not over tighten or the valve will become too tight to turn.

5.4 USE OF BACKSEAT Some APV valves are designed with stem backseats. However, valve manufactures in general including APV do not allow packing in-line while the valve is under pressure due to the inability of determining the effectiveness of the backseat seal. In addition, backseating is not designed to be absolutely drip tight.

This is not the purpose of backseating. Due to the inherent risks, backseat should never be used to allow gland packing replacement or repair while the valve is pressurised.

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Over tightening will cause the packing to fail prematurely as well as increasing the force required to operate the valve.

Adding additional packing rings may damage the stem sealing system over a longer term. It is NOT ALLOWED TO REPACK VALVES UNDER PRESSURE. For low emission service, proprietary fugitive emission packing must be used.

For normal operation in the open position, the stem should be backed off so that the backseat (where applicable) is not in contact. This permits the stem packing to assume it’s intended sealing function and not conceal unsatisfactory stem packing. In the event of stem packing leakage, the back seat can be used to stop stem leakage until circumstances permit a system shutdown and time for packing replacement. Stem packing replacement with the valve under pressure and back seated represents a hazard and should not be undertaken. The hazard is magnified as fluid pressure or temperature increases or when the fluid is toxic.

5.5 PACKING RING REPLACEMENT Removal of old packing should be done in an experienced workshop. Using a special flexible removal tool. The removal tools have special hooks, which screw into the packing ring. Removal of the packing ring is a difficult and time-consuming operation. Care has to be taken not to scratch the stem of the walls of the packing chamber during the removal of the packing rings. Refer to Section 6.2 for full instruction.

5.6 GEAR OPERATOR MAINTENANCE The gear operator is lubricated with grease (2% MOS2) for life.

Only in case of failure of any components remove the upper gear casing from lower gear casing. After inspection replace the necessary components.

Do not dismantle the upper and lower gear casing as it will disturb the whole assembly and the deep groove ball bearings, the operator provided is properly lubricated for long life. In larger sizes a grease fitting may be fitted to the gearbox.

1. When repairing the drive sleeve and bearing (thrust ball bearing) there should not be any clearance, i.e. the drive should not move axially.

2. Proper installation will correct operation.

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5.7 LEAKAGE ACROSS SEAT It is always difficult to ascertain whether there is an internal seat leakage unless there is pressure or leak detection facility in place to monitor any rise or fall in pressure or leakage. Globe valves allow a higher rate of seat leakage than gate valves, consult appropriate test standard for leakage allowance.

To investigate suspected leakage, the valve should be removed from the line then dismantled. Prior to removal from line ensure all pressure and fluid is purged from line and valve cavity. Remove disc and inspect the seating surfaces, also inspect the body seat for any sign or wire drawing/light scratches.

Relap the seats or disc as required if minor damage or else send the valve to an experienced APV approved valve repair facility. Assemble the valve, should any leaks still persist then the concerned part may need complete replacement.

When ordering spare parts for replacements, kindly inform us the size, type, rating, part description, model number and serial number.

5.8 DISASSEMBLING VALVES 1. Check that the line is in a complete shut down phase.

2. Pre-order all necessary spare gland packings and jointing gaskets.

3. Open the valve slightly by turning the handwheel anti-clockwise and loosen the gland.

4. Put identification markings on valve body, bonnet, disc/gate, yoke, and actuator. This helps to avoid mismatching of parts at the time of re-assembly.

5. If the bolts and nuts are too tight, apply deep penetrating oil and then unscrew.

5.9 LEAKAGE ACROSS GASKET Should any bonnet gasket leaks occur, tighten the bolts/nuts & studs (refer Appendix A, Table A and Figure 2). If leakage still persists, the bonnet gasket should be changed.

5.10 REASSEMBLY 1. Re-assemble in reverse order of disassembly.

2. For larger valves, lift up the bonnet using lifting lugs where provided. For smaller valves, gently and evenly break the bonnet seat with a lever (if required) before lifting the bonnet off (where required use with a sling mechanical lifting device). Clean gasket surface areas, replace gasket and refit bonnet.

3. Refer Appendix A, Table A and Figure 2 in the Appendix for bonnet bolt re-tightening procedure.

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6 . 0 EXTRAORDINARY MAINTENANCE 6.1 STEM If the stem locks or “freezes”, causes can generally be attributed to dry worn packing or a dry yoke nut.

In either of these cases, the following service is required: a) Unscrew gland nuts, remove the gland flange and bushing to expose stem packing and lantern ring/ packing spacer (where applicable). Replace stem packing if it is damaged. If the lantern ring is seized, completely disassemble the stem and replace the lantern ring (where one is fitted). Smaller sizes and larger sizes with fugitive emission packing sets do not require spacers/lantern rings as standard. b) Check lubrication of yoke nut. If it is dry, remove the yoke nut and determine if there is evidence of seizure marks. If so replace it with a new yoke nut.

6.2 GLAND DISASSEMBLY & REPLACEMENT OF STEM PACKING In those cases where the valve cannot be removed from the piping system, it is important that prior to servicing, the valve be opened to its fullest extent and the valve be purged of any pressure and fluid (protective goggles should be worn). Partially unscrew nuts to reduce the compression load on the stuffing box. Next, if so equipped, remove the stem plug to check that there is no leakage. Remove the stem packing and, if so equipped, the lantern ring and bottom set of stem packing.

A compatible ribbon packing system or equivalent braided packing stock should be used but the emissions will be higher. Also, torque may increase. A stuffing box corrosion inhibitor is recommended.

The joints in the packing rings should be diagonally cut. When installing the rings, care should be taken to stagger the ring joints. Where it is necessary to repack the valve in-line, ensure the line pressure is totally isolated prior to attempting to repack valve in-line. Wear anti-splash eye protection goggles.

Especially in the case of dangerous, hazardous, volatile, caustic or flammable liquids or gases, do not ever attempt to repack the valve in-line even if pressure has been isolated.

Other specialty packing such as V-ring Teflon will require that the valve be disassembled if repacking is required.

6.2.1 Stem Packing Replacement First remove the valve from the line. To prevent injury ensure that all fluid and pressure is removed from the valve both upstream and downstream before removal and disassembly. When removing drain or stem plug wear protective eye masks to avoid injury.

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1. Check tightness of valve operation to serve as a reference when re-tightening. Remove gland nuts and the hook. Lift the gland up the stem clear away from the packing chamber.

2. Remove the defective packing rings with a sharp tool or packing hook. Do not scratch or score the machined surfaces of the stem or packing chamber.

3. Examine the machined surfaces of the stem and packing chamber. Remove any scratches, scoring or burrs with an emery cloth or by hand filing. Clean the stem with a solvent soaked rag.

Scratches to the stem and the packing chamber no deeper than 0.25mm (0.010”) can be removed by polishing the surface with a buffing wheel. The surface finish of the packing chamber should be Ra 3.2µm and the stem should be Ra 0.8µm.

4. Count original number of rings and measure x-section thickness. If original packing cannot be counted or measured, follow the steps below: a) Measure the stem diameter (OD), stuffing box diameter (ID) and stuffing box depth (d). b) Packing x-section (R)=(ID - OD)/2 c) # rings = (1.25 x d)/R 5. Install new packing. Use a genuine APV low emission, low friction packing set. If using standard coils of packing material: cut each ring at a 45 degree angle and stagger the joints at 120 degrees, every fourth joint will be in the same position as the first. Install rings individually using a split ring spacer, compressing each ring by hand tightening + 1/4 turns on each packing gland nut.

6. When packing chamber becomes filled with packing, reassemble gland and gland flange. Alternate tightening packing gland flange nuts 1/4 turn at a time until eyebolts begin to get tight. (If gland travels more than the height of one packing ring into the packing chamber, insert one more ring and repeat step 6. until chamber is filled).

7. Compare valve operation to original tightness. If valve operation is considerably tighter than original operating tightness, back off 1/4 turn on each gland nut & recheck tightness. Where proprietary packing sets are used such as (example only) Garlock EVSP 9000, Burgmann 6070 or Chesterton 1622 please consult packing manufacturer’s torques. The serialised as-built drawing will indicate the packing used, please refer to APV. Various packing types, materials, proprietary combinations and styles with and without spacers/lantern rings, etc, and torque limitations of some bolting materials, bonnet design variations, stuffing box and stem smoothness, means it is not possible to safely publish recommended torques for packing. In addition, higher pressure ratings will require higher torques especially if media types are hazardous or more leak searching prone such as gas and steam.

8. Several hours after a repacked valve has been returned to service, inspect the packing area to ensure full compression, tight bolting and no leakage. Should leakage occur, tighten gland nuts at 1/4 turn increments until leakage stops. Do not over tighten or valve will become difficult to turn.

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FIGURE 1 EYE-BOLT NUTS GLAND FLANGE EYE-BOLT GLAND PACKING

45º BRAIDED END RING DIE-FORMED RINGS

BRAIDED END RING

120° STAGGER OF JOINTS*

Stuffing Box*

45° END CUT*

Stem Packing*

* Example only, refer to as-built drawing. Genuine APV die formed/moulded packing sets are essential for fugitive emission service.

The stem packing style will vary according to valve size, type and class as well as the stem packing material specified. Examples include combination sets, wire reinforced braided packing, PTFE Chevron moulded sets, live loaded sets.

Note

6.3 BONNET DISASSEMBLY & STEM REPLACEMENT Before disassembly: 1. Check that the line is in a complete shut down phase then remove the valve from the line.

2. Pre-order all necessary spare gland packings and jointing gaskets.

3. Open the valve slightly by turning the handwheel anti-clockwise and loosen the gland.

4. Put identification markings on valve body, bonnet, disc/wedge, yoke and actuator. This helps to avoid mismatching of parts at the time of re-assembly.

5. If the bolts and nuts are too tight, apply deep penetrating oil then unscrew.

To replace the stem when the valve is completely disassembled for general maintenance follow this procedure: • Open valve half way then remove bonnet bolts and nuts.

• Lift up the bonnet to remove wedge. The wedge has to be reassembled in the same position as originally assembled: take care not to rotate it 180°. The valve could leak through the seats if wedge is rotated.

• With the bonnet removed, unscrew the gland bolts then lift up gland flange exposing the stem packing.

• Remove stem packing above the lantern ring (if so required) and then turn the hand wheel to force the stem down.

• Remove the stem through the stuffing box. Turn the bonnet up side down and remove lantern ring.

• If so equipped, remove stem packing below the lantern ring.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

17

GATE, GLOBE & CHECK VALVES

Always be sure that the valve is de-pressurised and isolated prior to performing any maintenance work. Do not attempt to repair valve in-line if volatile, dangerous, hazardous or flammable service.

Welded bonnet valves can be replaced but otherwise are not repairable.

Note

6.3.1 Bolted Bonnet Removal & Gasket Replacement Always replace the bonnet gasket whenever a valve is disassembled. Gasket sealing surface should be scraped clean (avoid radial marks).

1. Disassemble all cover bolts and nuts.

2. Lift up the bonnet using lifting lugs where provided, evenly break the bonnet seal with a lever if required before lifting the bonnet off (where required with a sling and mechanical lifting device).

3. Clean gasket surface areas, replace gasket and refit bonnet as detailed below.

6.3.2 Pressure Seal Bonnet Removal & Gasket Replacement Refer APV Gate & Globe valve IOMs.

18

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

GATE, GLOBE & CHECK VALVES

7.0 OTHER MAINT. & REPAIRS This IOM is a generic general overview. Due to the relatively low replacement cost of small diameter standard carbon steel valves under 100NB (4”), it is usually less expensive to replace the complete valve than to have maintenance personnel effect repairs. Generally, the only justifiable repairs are replacement of packing and gaskets as previously described. For more detailed maintenance instructions* refer to the APV Cast Gate Valve IOM, which also covers the key elements of parallel slide valves, even though the spring loaded disc design can vary* (see note below). Refer to the APV Cast Check Valve IOM section 3.0 and 4.0, which also covers piston check valves. Refer to the APV Globe Valves IOM section 3.0 to 6.0, which covers globe valves and screw down non-return (stop check) valves. For speciality valves such as piston type globe valves and bellows sealed gate and globe valves there are some differences but this IOM provides a generic overview for these valves. For Forged Globe & Gate valves also refer the APV Forged Gate & Globe valve IOM. Refer to APV for specific instructions pertaining to these valves if further information is required.

Only a specialist APV repairer should conduct reconditioning. Refer to the as-built drawing. * There are so many different configurations it is not possible to cover all configurations. Contact your nearest APV approved repairer facility for more information.

Note

During maintenance or servicing of the valve, all replacement parts must be the same as the original specification (parts dimensions and materials). End user may also purchase the spare parts such as packing, gaskets, bolt/nuts, etc. when ordering the valve. With the new packing, gasket or bolt/nuts installed, the valve must be applicable pressure testing prior to installation and service.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

19

GATE, GLOBE & CHECK VALVES

APPENDIX A INDICATIVE BONNET BOLTING (BOLTED BONNET) TORQUE NM TABLE A Stud Size

Bolting Material B7M/L7M

B7/B16/L7

B8/B8M CL.1 B8/B8M CL.2

3/8 - 16 UNC

15

(20)

20

(27)

15

(20)

20

(27)

7/16 - 14 UNC

25

(34)

30

(41)

22

(30)

25

(34)

1/2 - 13 UNC

40

(54)

50

(68)

35

(47)

45

(61)

9/16 - 12 UNC

55

(75)

70

(95)

55

(75)

65

(88)

5/8 - 11 UNC

75

(102)

100

(136)

70

(95)

85

(115)

3/4 - 10 UNC

135

(183)

170

(231)

125

(170)

150

(203)

7/8 - 9 UNC

200

(271)

270

(366)

170

(230)

200

(271)

1 - 8 UNC

350

(475)

400

(542)

219

(298)

350

(475)

1 1/8 - 8 UN

500

(678)

520

(705)

256

(398)

450

(610)

1 1/4 - 8 UN

675

(915)

850

(915)

321

(498)

650

(881)

1 3/8 - 8 UN

900

(1220)

1200

(1627)

384

(598)

900

(1220)

1 1/2 - 8 UN

1200

(1627)

1500

(2034)

1200

(1627)

1 5/8 - 8 UN

1600

(2170)

2000

(2712)

1501

(2035)

1 3/4 - 8 UN

2000

(2712)

2500

(3390)

1907

(2585)

1 7/8 - 8 UN

2500

(3390)

3100

(4204)

2357

(3195)

2 - 8 UN

3000

(4068)

3800

(5153)

2876

(3898)

2 1/8 - 8 UN

3600

(4882)

4500

(6102)

2 1/4 - 8 UN

4400

(5966)

5400

(7322)

2 1/2 - 8 UN

6000

(8136)

7500

(10170)

Note: (1) (2) (3) (4) (5)

Torques shown are for A193 B7/B7M/B16/B8/B8M and A320 L7/L7M/B8/B8M. Torque tolerance ±10%.

For temperatures above 750°F (400°C) use 75% of the torque values.

Above torque values are with the bolts lubricated.

Values above are based on 30,000 psi (206.85 Mpa) bolting stress and lubricated with heavy graphite and oil mixture or a copper based anti-seize grease.

(6) Do not exceed by more than 25% of values stated when emergency torquing is required.

(7) All bolts shall be torqued in the pattern as shown in Figure 2 on next page to ensure uniform gasket loading.

(8) Optimum torque can vary depending on type of body gasket but do not increase torque more than 10% above those shown.

(9) Consult us for other bolt material.

(10) Most B8M and B8 bolts are class 1 so do not assume class 2 unless you are sure.

(11) For ‘pressure seal’ bonnet torques consult APV.

Note

20

Bolt tensions shown must be decreased by 25% when other or no lubrication used.

Non lubricated bolts can have an efficiency of less than 50% the torque of values stated. Indicative torques are shown only, different body gasket systems, different sizes & classes, etc., will have different torque requirements. Furthermore, other stud grades can have much lower torques depending if class 1 or class 2 and or above variables.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

GATE, GLOBE & CHECK VALVES

APPENDIX A - CONT. BOLT TIGHTENING SEQUENCE FIGURE 2

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

21

www.australianpipelinevalve.com.au

100

4”

356

L

Dimensions in millimeters

DN

Inch

D1

2

3 L

4

20

D2 519

n-d1

30.2 8-ø22 350

c

H2

19

W

c

Globe Check (screw down non return)

1

255 200.0 157

D

DIMENSIONS (MM) & WEIGHT (KG)

22

21

10A

W

5

6

7

8

9

11 10

12

13

560 86

H1 Weight

1.6

-

C.S. C.S. 316SS BRONZE

WASHER NUT NAMEPLATE RIVET

19 21 22

0.55 Mpa 80 RFSF 3.2~6.3Ra

BACKSEAT

Australian Pipeline Valve

CHECKED

00 REV.

C.C.

S.Q.

B.T.

APV DWG FRM 98

DRAWN

APPROVED

OTHER

98

INVESTMENT CAST

NOTES

ORDER No/ DWG No

CAGE & STEM GUIDED

TRIM

Globe Check Valve Model 100AP151-D/XU-D, NPS 4” (DN100) Class 300, Cage & Stem Guided

FULL PORT API #8

PORT SIZE

OTHER REQ.

Water, Oil, Steam

MSS SP-25 PAINT PPWF07.002 OPTIONAL LP SEAT ALSO PERFORMED

MARKING & PAINT

MEDIUM

B16.34 BODY TEMPERATURE -29 TO 425 ºC -20 TO 797 ºF

ASME B16.5 API 598/ ISO 5208

TEST & INSPECTION

5.7 Mpa 825 Psi

END DIMENSION

Psi

1125 Psi 5.7 Mpa 825 Psi

END CONNECTION

Mpa

ASME B16.10

FACE TO FACE DIM.

SEAT AIR

ASME B16.34

PRESS-TEMP RATING

7.7

ASME B16.34 & BS1873 (API600 WALL) SHELL HYDRO SEAT HYDRO

DESIGN & MFG.

TEST PRESSURE

CL 300

RATING

(1) STEM SMOOTHNESS Ra ≤ 0.80 µm (2) STUFFING BOX SMOOTHNESS Ra ≤ 3.2 µm (SUPERIOR TO API 623)

ZINC PLATED

-

-

-

20

MALLEABLE IRON

-

HANDWHEEL

-

-

ZINC PLATED

18

C.S.

ALUMINIUM BRONZE

ASTM A216 WCB

-

STEM NUT

GLAND FLANGE

15

ASTM A276 410

C.S.

SCREW

GLAND

-

-

16

PIN

13 14

15

ASTM A194 2H

ASTM A193 B7

17

NUT

14

EYEBOLT

11 12

BRAIDED GRAPHITE

PACKING

10A

17 16

-

PACKING (2) 316 REINFORCED

-

ASTM A276 410 FLEXIBLE GRAPHITE

BACK SEAT

9

-

NUT

8 10

-

ASTM A193 B7

18

ENCAPSULATED

ASTM A216 WCB

BONNET BOLT

6

(1)

ASTM A182 F6A

7

-

ASTM A216 WCB+13CR

STEM

NOTES

316 JACKETED GRAPHITE

DISC GASKET SPIRAL WOUND

4 5

-

3

-

ASTM A105+STL #6

MATERIAL ASTM A216 WCB

PART NAME BODY SEAT

1 2

NO.

ASTM A194 2H

D1 D

d D2

22

H2 (Close) H1 (Open)

BILL OF MATERIALS

GATE, GLOBE & CHECK VALVES

APPENDIX B

EXPLODED B.O.M. GLOBE CHECK VALVE

Example only, refer to as-built drawing.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

10

150

6”

152

i

O

320

L

222

Dimensions in millimeters

DN

Inch

DIMENSIONS (MM) & WEIGHT (KG)

RAISED FACE

SERRATED 3.2~6.3um (125~250 ARRH)

Top View Disc Pin Guide

-

C

t

37

g

216

1

2

3

4

5

6

7

8

9

11 10

12

16

17

18

19

20

21

22

23

-

n-ø

24

630

H

25

W

680

H1

1A

450

W

L +- 1.6

13

14

15

The torque arm prevents stem movement which reduces wear on packing rings and enables better sealing as well as reducing torque. Non rotating stem, only the stem nut rotates. The arm also provides visual stem position indication and can be interfaced with position switches. Non rising handwheel.

Torque Arm

160

Weight

t

1.6

g C O

www.australianpipelinevalve.com.au

i n-d

H1(Open) H(Close)

-

SS304

ASTM A276 410SS

NUT BOLT PIN

13 14 15

COPPER ALLOY+ZP COPPER ALLOY AISI 1035 ASTM A192 2H AISI 1035

THRUST BEARING GREASE NIPPLE STEM NUT GLAND NUT HANDWHEEL HANDWHEEL LOCKING NUT GUIDE CAGE GUIDE PIN

18 19 20 21 22 23 24 25

-

(2) (4) BURMANN 6070 F.E.

(7) (8)

(7) (8)

PHOSPHATED

(7) (8)

-

-

-

-

(7) (8) TORQUE ARM

PHOSPHATED

-

-

-

-

0.55 Mpa 80 RFSF 3.2~6.3 Ra UNDRILLED

BACKSEAT

Australian Pipeline Valve

DRAWN

APV DWG FRM 1141

S.Q. C.C.

CHECKED

00 REV.

B.T. APPROVED

1141

INVESTMENT CAST, FUGITIVE EMISSION COMPLIANT

ORDER No/ DWG No

GUIDED DISC PLUG TYPE SCREW DOWN NON RETURN OTHER

TRIM NOTES

FULL PORT API #8 C/W SPRING

PORT SIZE

OTHER REQ.

Water, Oil, Steam

MSS SP-25 PAINT PPWF07.002 OPTIONAL LP SEAT ALSO PERFORMED

MARKING & PAINT

MEDIUM

B16.34 BODY TEMPERATURE -29 TO 425 ºC -20 TO 797 ºF

ASME B16.5 API 598/ ISO 5208

TEST & INSPECTION

5.7 Mpa 825 Psi

END DIMENSION

Psi

1125 Psi 5.7 Mpa 825 Psi

END CONNECTION

Mpa

ASME B16.10

FACE TO FACE DIM.

SEAT AIR

ASME B16.34

PRESS-TEMP RATING

7.7

ASME B16.34 & BS1873 (API623 WALL) SHELL HYDRO SEAT HYDRO

DESIGN & MFG.

TEST PRESSURE

CL 300

RATING

(1) STEM SMOOTHNESS Ra ≤ 0.80 µm AS PER API REQUIREMENTS (2) STUFFING BOX SMOOTHNESS Ra ≤ 3.2 µm (SUPERIOR TO API 623) (3) THICKNESS OF FACING MATERIAL ≥ 1.6MM AS PER API 623 (4) DIE FORMED SET INCONEL WIRE REINFORCED EXFOLIATED GRAPHITE PACKING, BURMANN 6070 (LOW FRICTION) FUGITIVE EMISSION CERTIFIED ISO 15848-1/API 622/API 624 & API 607 FIRESAFE CERTIFIED, CHEVRON TEXACO CERTIFIED. C/W CORROSION INHIBITOR. NON HARDENING & WILL NOT SHRINK OR ABSORB MOISTURE (5) SEAT & DISC SMOOTHNESS Ra 0.4 ~ 0.8 µm SUPERIOR TO API REQUIREMENTS (6) TAPERED PLUG DISC, CONICAL SEAT (7) 450MM HANDWHEEL & STEM BEARINGS & STEM GUIDE FOR EASE OF OPERATION. RISING STEM NON RISING HANDWHEEL (8) TORQUE ARM & GUIDED DISC FOR ASSURED SHUT OFF AND FOR INCREASED VALVE LIFE FOR THROTTLING APPLICATIONS (NEVER THROTTLE UNDER 20% STEM EXTRA TRAVEL). EXTRA TAPERED DISC FOR IMPROVED THROTTLING (9) RISING STEM, NON RISING HANDWHEEL

AISI 1035

MALLEABLE IRON

BEARING ALLOY

AISI 1020

ASTM A193 B7

SET SCREW STEM GUIDE TORQUE ARM

16 17

AISI 1035

ASTM A193 B7

ASTM A194 2H

ASTM A216 WCB

GRAPHITE+INCONEL WIRE

GLAND YOKE FLANGE

10 GLAND

NUT

9 PACKING (SET)

ASTM A193 B7 ASTM A194 2H

BOLT

8

11

-

ASTM A276 410SS

7

12

-

ASTM A216 WCB

BACK SEAT

6

-

ENCAPSULATED

SS316+GRAPHITE

GASKET SPIRAL WOUND BONNET

5

(1) (9)

(3) (5) (6)

ASTM A105+13CR

SPRING

3 4 ASTM A182 F6a

DISC (GUIDED) STEM

2

(3) (5) (6) OVERLAY

NOTES (5)

STELLITE #6

MATERIAL ASTM A216 WCB

PART NAME BODY SEAT (INTEGRAL)

1 1A

NO.

Right Angle Globe Valve SDNR Model 150AP151RXUDGRZ-UD-F, NPS 6” (DN150) Class 300, Undrilled Guided Disc, Rising Stem

L

BILL OF MATERIALS

GATE, GLOBE & CHECK VALVES

APPENDIX B - CONT.

EXPLODED B.O.M. RIGHT ANGLE GLOBE VALVE

Example only, refer to as-built drawing.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

23

L

250

10”

C

T

D

R

O

622 254 304.0 387.4 445

L

Dimensions in millimeters

DN

Inch

DIMENSIONS (MM) & WEIGHT (KG)

1

2

4

5

6

7

8

9

T

21

18

20

19

W

H

46 16-ø29 600 682

n-d

1.6

762

Weight

N-d

15

16

17

C

Point welding

BACK SEAT

(1)

Australian Pipeline Valve

CHECKED

00 REV.

B.T.

C.C.

S.Q.

APV DWG FRM 196

DRAWN

APPROVED

196 ORDER NO/ DWG NO

INVESTMENT CAST

Globe Valve, SDNR (Stop Check) BBOSY, NPS 10” (DN250) Class 300, Model No. 250AP143LXUD-F RF, GOP, FP, WCB, Trim API #8

OPTIONAL HP/LP SEAT TEST PERFORMED (NOT MANDATORY AS PER API 598)

Water, Oil, Gas

OTHER

MEDIUM

NOTES

FULL PORT API #8

TRIM

MSS SP-25 PAINT SPEC GGCFB-3

PORT SIZE

OTHER REQ.

MARKING & PAINT

-29 TO 538 ºC -20 TO 1000ºF

Psi

API 598/ISO 5208

5.7 Mpa 814

Psi

TEST & INSPECTION

Psi

BACKSEAT

1125 Psi 5.7 Mpa 814

B16.34 BODY TEMPERATURE

END CONNECTION

Mpa

SEAT AIR

7.7

0.55 Mpa 80

ANSI B16.10

FACE TO FACE DIM.

ASME B16.5

ASME B16.34

PRESS-TEMP RATING

SHELL HYDRO SEAT HYDRO

RFSF 3.2~6.3Ra

BS1873/ASME B16.34/API600

END DIMENSION

CL 300

DESIGN & MFG.

TEST PRESSURE

-

ASTM A276 410

-

-

-

-

-

-

-

-

-

-

-

-

(2) 316 REINFORCED

-

SPIRAL WOUND

-

RATING

NOTES INTEGRAL

-

ASTM A194 2H

ASTM A193 B7

ASTM A193 B7

ALLOY STEEL

BRONZE

SS316

ASSEMBLY

ASTM A193 B7

AISI 1025

ASTM A194 2H

ASTM A193 B7

ASTM A216 WCB

ASTM A276 410

FLEXIBLE GRAPHITE

ASTM A216 WCB

SS316+GRAPHITE

ASTM A276 410

ASTM A105+13Cr

(1) STEM SMOOTHNESS Ra ≤ 0.80 µm (2) STUFFING BOX SMOOTHNESS Ra ≤ 3.2 µm (SUPERIOR TO API 623)

21

BOLT

19

10 NUT

SCREW

18

MATERIAL ASTM A216 WCB+STL#6

APPENDIX B

D

20

BLOCK

17

11

12

BEVEL GEAR NAMEPLATE

14 15 RIVET

STUD

13

16

W

EYEBOLT NUT

11 PIN

10 12

GLAND BUSH GLAND FLANGE

8 9

PACKING

GASKET (ENCAPSULATED)

5 7

STEM

4 BONNET

DISC & DISC GUIDE

2

6

BODY

1

13

14

Top View Integral Disc Pin Guide

The torque arm prevents stem movement which reduces wear on packing rings and enables better sealing as well as reducing torque. The arm also provides visual stem position indication and can be interfaced with position switches.

Torque Arm

R

www.australianpipelinevalve.com.au

H

24 O

BILL OF MATERIALS NO. PART NAME

GATE, GLOBE & CHECK VALVES

- CONT.

EXPLODED B.O.M. SDNR GLOBE VALVE

Example only, refer to as-built drawing.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

9

80

3”

d

76

L

356

Dimensions in millimeters

DN

Inch

C

n-ø

g

L

210 168.5 8-22 127

O

10

32

t

NPS ≥3”NB

220

H

8

n-ø

48

Weight

t

d

g

6.4

O

C

Australian Pipeline Valve

CHECKED

00 REV.

C.C.

S.Q.

B.T.

APV DWG FRM 195

DRAWN

APPROVED

OTHER

195

INVESTMENT CAST

NOTES

Water, Oil, Steam

ORDER No/ DWG No

CAGE & DISC GUIDED

TRIM

Piston Check Valve Model AP-SLCLXU-Z, V-Plug NPS 3” (DN80) Class 600, Cage & Disc Guided

FULL PORT API #8

PORT SIZE

MEDIUM

MSS SP-25 PAINT PPWF07.002

MARKING & PAINT OTHER REQ.

API 598/ ISO 5208

TEST & INSPECTION

Psi

B16.34 BODY TEMPERATURE

Mpa

BACKSEAT

-29 TO 425 ºC -20 TO 797 ºF

Psi

ASME B16.5

Mpa

SEAT AIR

15.4 Mpa 2233Psi 11.3 Mpa 1639 Psi

END DIMENSION

RFSF 3.2~6.3Ra

ASME B16.10

FACE TO FACE DIM. END CONNECTION

ASME B16.34

PRESS-TEMP RATING

ASME B16.34 & BS1873 (API600 WALL) SHELL HYDRO SEAT HYDRO

DESIGN & MFG.

TEST PRESSURE

CL 600

RATING

Top View Disc Pin Guide

-

AISI 1035

GUIDE PIN

10

-

AISI 1035

GUIDE CAGE

9

-

STEEL+ZP

LIFTING EYE

ASTM A216 WCB

8

-

SS316+GRP

SPIRAL WOUND

ASTM A194 2H

GASKET

NUT

5

-

NOTES

ASTM A193 B7

INCONEL X750

COVER

BOLT

4

-

ASTM A105+13CR

6

SPRING

-

MATERIAL ASTM A216 WCB+STL6

7

DISC

2 3

PART NAME BODY

1

NO.

APPENDIX B

DIMENSIONS (MM) & WEIGHT (KG)

1

2

3

4

5

6

7

www.australianpipelinevalve.com.au

H

BILL OF MATERIALS

GATE, GLOBE & CHECK VALVES

- CONT.

EXPLODED B.O.M. PISTON CHECK VALVE

Example only, refer to as-built drawing.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

25

26

A

L

C

n-d1

W

6

H1

H2 Weight

Dimensions in millimeters

300 502 521 450.8 381.0 305 49.3 16-ø32 500 1392 1065 546

d

5

12”

D2

3

5

A

3

4

29 30

28

Closed

ASTM A105+STL.12 -

-

(1)

ASTM A182 F6A ASTM A193 B7 ASTM A194 2H 304SS+GRAPHITE

AISI 1035 ASTM A193 B7 ASTM A194 2H ALUMINIUM BRONZE AISI 1035

316SS 316SS SUB-ASSEMBLY ASTM A216 WCB ASTM A193 B7 ASTM A194 2H BRASS

STUDS NUTS GASKET SPIRAL WOUND BONNET BACKSEAT PACKING PACKING GLAND GLAND FLANGE PINS EYEBOLTS NUTS STEM NUT RETAINING NUT HANDWHEEL NUTS NAMEPLATE RIVETS BEARINGS YOKE STUDS NUTS GREASE NIPPLE

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Mpa

Australian Pipeline Valve

CHECKED

00 REV.

C.C.

S.Q.

B.T.

APV DWG FRM 100

DRAWN

APPROVED

PAINT SPEC PPWF07.002 (SILVER) OTHER

100

HP AIR TEST ON SEAT PERFORMED (OPTIONAL TEST UNDER API598) NOTES

ORDER No/ DWG No

FULL PORT TRIM #5

TRIM

Steam, Gas

PORT SIZE

MEDIUM

MSS SP-25

OPTIONAL: AS2129 TABLE F~H/AS4087/AS4331.1/ISO 7005-1 PN14~40

OTHER REQ.

-29 TO 425 ºC -20 TO 797 ºF

MARKING

API 598/ISO 5208

ASME B16.5

END DIMENSION TEST & INSPECTION

RF 3.2~6.3Ra

END CONNECTION

Psi

B16.34 BODY TEMPERATURE

ASME B16.5

FACE TO FACE DIM.

BACKSEAT 0.55 Mpa 80

ASME B16.10

PRESS-TEMP RATING

Psi

7.75 Mpa 1125 Psi 5.68 Mpa 825 Psi

API600

SEAT AIR

TEST PRESSURE SHELL HYDRO SEAT HYDRO

CL 300

DESIGN & MFG.

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

(2) REINFORCED

(2)

-

-

ENCAPSULATED

NOTES

RATING

(1) STEM SMOOTHNESS Ra ≤ 0.80 µm (2) STUFFING BOX SMOOTHNESS Ra ≤ 3.2 µm (SUPERIOR TO API 600)

AISI 1035

MALLEABLE IRON

ASTM A217 WCB

ASTM A276 410

316+BRAIDED GRAPHITE

FLEXIBLE GRAPHITE

ASTM A276 410

ASTM A216 WCB

-

C.S.

STEM

8 -

-

ASTM A743 C40

DISC YOKE GUIDES

6 7

-

ASTM A743 CA40

DISCS

4 5 INCONEL X-750

WEDGE BLOCKS SPRINGS

3

-

Parallel Slide Expanding Discs, Full Port, Gate Valve, Model AP-316UKS, NPS 10”~12” (DN250~DN300) Class 300

Dual disc design:- wedge energised, spring assisted

250 457 445 387.0 323.8 254 48.1 16-ø29 450 967 1221 337

D1

4

Open

10”

D

C

1.6

H1 (Open)

DN

L

8-ø22

25 26

H2 (Close)

Inch

DIMENSIONS (MM) & WEIGHT (KG)

1

31

31

27

-

ASTM A105+STL.6

MATERIAL ASTM A217 WCB

PART NAME BODY SEAT RING

1 2

NO.

BILL OF MATERIALS

APPENDIX B

5 4 3 2

8 7 6

10 9

11

12

15 14 13

17 16

2019 18

23 22 21

24

W

d D2 D1 D

www.australianpipelinevalve.com.au

NPS≥10

GATE, GLOBE & CHECK VALVES

- CONT.

EXPLODED B.O.M. PARALLEL SLIDE GATE VALVE

Example only, refer to as-built drawing.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

HANDWHEEL LOCKING NUT

23 24

PHOSPHATED

-

-

-

-

B16.34 BODY TEMPERATURE

ASME B16.5 RFSF 3.2~6.3 Ra ASME B16.5

FACE TO FACE DIM. END CONNECTION END DIMENSION

Mpa

290 Psi 5.7 Mpa 825 Psi

Water, Oil, Steam

76.2 210 165 127

283

Dimensions in millimeters

80

100 305 102 255 191 157 150 403.2 152 320 260 216

3”

4” 6”

98

50

2”

165 127

51

216

O

i

L

H1

8-18 395 475 250

74

28

Weight

32 8-18 480 584 250 87 37 12-22 640 796 350 162

29

22.7 4-18 350 401 200

H

Australian Pipeline Valve

Parallel Slide Gate Valve, Manually Operated Model AP-316SUS-300-H, NPS 2” ~ 6” (DN50 ~ DN150) Class 300, RF, FB, BBOSY, HWOP

CHECKED

00 REV.

C.C.

S.Q.

B.T.

APV DWG FRM 1152

DRAWN

APPROVED

1152 ORDER No/ DWG No

PAINT SPEC PP WF07.002 (SILVER)

MEDIUM

MSS SP-25

DRILLED AS 2129 TABLE H/AS 4087 PN35

OTHER REQ.

-29 TO 427 ºC -20 TO 800 ºF

Mpa

BACKSEAT

1125 Psi 5.7 Mpa 825 Psi SEAT AIR

7.7

MARKING

API598/ISO 5208

ASME B16.34

PRESS-TEMP RATING

TEST & INSPECTION

2.0

ASME B16.34 & API600

DESIGN & MFG.

SHELL HYDRO SEAT HYDRO

CL 300 DRILLED TABLE-H

RATING

TEST PRESSURE

(1) STEM SMOOTHNESS Ra ≤ 0.80 µm (2) STUFFING BOX SMOOTHNESS Ra ≤ 3.2 µm (SUPERIOR TO API 600) (3) THICKNESS OF FACING MATERIAL ≥ 1.6MM AS PER API 600 (4) DIE FORMED SET INCONEL WIRE REINFORCED EXFOLIATED GRAPHITE PACKING, BURGMANN 6070 (LOW FRICTION) FUGITIVE EMISSION CERTIFIED ISO 15848-1/API 622/API 624 & API 607-API 589 FIRESAFE CERTIFIED, CHEVRON TEXACO CERTIFIED. C/W CORROSION INHIBITOR. NON HARDENING & WILL NOT SHRINK OR ABSORB MOISTURE (5) STELLITE #12 ANTI-GALLING HARDNESS DIFFERENTIAL

AISI 1035

MALLEABLE IRON

AISI 1035

OPTIONAL HP & LP SEAT TEST PERFORMED (+ 20 BAR AIR ISO 5208-D)

W

GLAND NUT

OTHER

n-d

STEM NUT

21 22

-

-

-

NOTES

t

ASTM A439 D2

GREASE NIPPLE

20

AISI 1020

-

-

Inch DN

g

SS304

YOKE

19

(2) (4) BURGMANN 6070 F.E.

-

FULL

t

1.6

ASTM A216 WCB

PIN

18

ASTM A276 WCB ASTM A193 B7

ASTM A194 2H

YOKE FLANGE NUT BOLT

15 16 17

GRAPHITE+INCONEL WIRE ASTM A276 410SS

ASTM A274 410SS

BACK SEAT

BONNET PACKING SET GLAND

SS316+GRAPHITE ASTM A216 WCB

GASKET SPIRAL WOUND

9 10 11

ENCAPSULATED

ASTM A194 2H

12 14

(1)

ASTM A193 B7

NUT

8 -

-

ASTM A182 F6a

STEM BOLT

6

(3) (5)

ASTM A105

DISC SUPPORT GUIDE

4 5

NOTES

7

-

INCONEL X750 ASTM A105+ST#12

SPRINGS DISC

3

(3)

TRIM #5

L±1.5

14 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15

-

ASTM A105+ST#6

MATERIAL ASTM A216 WCB

PART NAME BODY SEAT

1 2

TRIM

C

H1 (open) H2 (close)

PORT SIZE

3

5

n-d

NO.

APPENDIX B

DIMENSIONS (MM) & WEIGHT (KG)

5

4

6

RAISED FACE

SERRATED 3.2~6.3um (125~250 ARRH)

W

i g

www.australianpipelinevalve.com.au

C O

BILL OF MATERIALS

GATE, GLOBE & CHECK VALVES

- CONT.

EXPLODED B.O.M. PARALLEL SLIDE GATE VALVE

Example only, refer to as-built drawing.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

27

GATE, GLOBE & CHECK VALVES

WARRANTY 1. LIMITED WARRANTY: Subject to the limitations expressed herein, Seller warrants that products manufactured by Seller shall be free from defects in design, material and workmanship under normal use for a period of one (1) year from installation but in no case shall the warranty period extend longer than eighteen months from the date of sale. This warranty is void for any damage caused by misuse, abuse, neglect, acts of God, or improper installation. For the purpose of this section, “Normal Use” means in strict accordance with the installation, operation and maintenance manual. The warranty for all other products is provided by the original equipment manufacturer.

2. REMEDIES: Seller shall repair or replace, at its option, any non-conforming or otherwise defective product, upon receipt of notice from Buyer during the Manufacturer’s warranty period at no additional charge. SELLER HEREBY DISCLAIMS ALL OTHER EXPRESSED OR IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS OR FITNESS FOR A PARTICULAR PURPOSE. 3. LIMITATION OF LIABILITY: UNDER NO CIRCUMSTANCES SHALL EITHER PARTY BE LIABLE TO THE OTHER FOR INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND. BUYER HEREBY ACKNOWLEDGES AND AGREES THAT UNDER NO CIRCUMSTANCES, AND IN NO EVENT, SHALL SELLER’S LIABILITY, IF ANY, EXCEED THE NET SALES PRICE OF THE DEFECTIVE PRODUCT(S) PURCHASED DURING THE PREVIOUS CONTRACT YEAR. 4. LABOR ALLOWANCE: Seller makes NO ADDITIONAL ALLOWANCE FOR THE LABOR OR EXPENSE OF REPAIRING OR REPLACING DEFECTIVE PRODUCTS OR WORKMANSHIP OR DAMAGE RESULTING FROM THE SAME. 5. RECOMMENDATIONS BY SELLER: Seller may assist Buyer in selection decisions by providing information regarding products that it manufacturers and those manufactured by others. However, Buyer acknowledges that Buyer ultimately chooses the product’s suitability for its particular use, as normally signified by the signature of Buyer’s technical representative. Any recommendations made

by Seller concerning the use, design, application or operation of the products shall not be construed as representations or warranties, expressed or implied. Failure by Seller to make recommendations or give advice to Buyer shall not impose any liability upon Seller.

6. EXCUSED PERFORMANCE: Seller will make a good faith effort to complete delivery of the products as indicated by Seller in writing, but Seller assumes no responsibility or liability and will accept no back-charge for loss or damage due to delay or inability to deliver, caused by acts of God, war, labor difficulties, accidents, inability to obtain materials, delays of carriers, contractors or suppliers or any other causes of any kind whatever beyond the control of Seller. Under no circumstances shall Seller be liable for any special, consequential, incidental, or indirect damages, losses, or expense (whether or not based on negligence) arising directly or indirectly from delays or failure to give notice of delay.

28

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

NOTES

Australian Pipeline Valve - Installation, Operation and Maintenance Manual

AUSTRALIAN PIPELINE VALVE® HEAD OFFICE 70-78 Stanbel Road Salisbury Plain South Australia 5109 Telephone +61 (0)8 8285 0033 email: admin@australianpipelinevalve.com.au

www.australianpipelinevalve.com.au LOCAL DISTRIBUTOR/AGENT

If you have any requirements in the field of valves, please contact us for a prompt response. Continuous development of Australian Pipeline Valve products may necessitate changes in the design or manufacture process. Australian Pipeline Valve reserves the right to effect any such changes without prior notice.

IOM Steamco Gate Globe Check

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