Escolar Documentos
Profissional Documentos
Cultura Documentos
MaintenanceManual for
AIL Cast Steel Gate,
Globe and Gheck Valves
1.0 STORAGE
On receipt check that the r.alr es
a n d a c c e s s o r i eas r e i n t a c t .E n s u r e
that the valve is in fullv closcd
position.
2.0 C O N S T R U C T ION
A I L G a t e . G l o b e a n d C h e c k r a l r e s a r e o f s t u r d v d e s i g na n d
give tight sealing against r.aried pressureand temperatureof
the line tluid.
Check Valves
AIL Checkvalr.esarecategorised
into trvoby thetype of Body-
Coverjoint. This manualco\:ersthe follorving types
Valves rvith l. BoltedCover Joint
2. PressureSeal Cover Joinl
3.0 INSTALLATION
3.1 Preparationfor Installation
Move the valves as close as possible to
the installation site before removins
packaging and end protectors. After
removing the end protector, check the
inside of the valr.e and remove anv rust
inhibitor or dirt. If the valves have been
in storage for a lon_speriod clean the
stem threads after removing the
protectivepaperand apply lresh grease.
Fig.2
3.2 Pre-commissioningTests
All valves are factory testedin accordance'*,ith the relevant
testingstandardas mentionedin the productcatalogue.
Wherevervalvesarerequiredto be re-testedbeforeinstallation
ensurethatproperTestrig is availableat the site.Valvesshould
be testedas per the relevanttestingstandard.
If \\,ateris used for-testingit is recommendedthat after testing
i s o v c r t h c r a l r e i n t e n r a l sb e d r i e d n ' i t h d n ' r r i t r o g e n o r a i r .
It rr.ould bc adr isable to add comosion inhibitor in the u'ater.
S u ' i n s c h e c k r a l r e s c a n b e i n s t a l l e de i t h e r i n h o r i z o n t a l o r
verlical pipelines.Hou'ever in vcrtical pipelinesthe flou, should
be only in upu'ard direction. Su'ing check valves should not
be installedat the outlet of a reciprocatingpump as the pulsating
flou' is likell' to damagc thc intcrnals.
A I L G a t e v a l v e s h a r e b i - d i r e c t i o n a ls e a l i n - qc a p a b i l i t i e sa n d
therefore can be installed in an1' direction. Hou,ever if the
v a l v e s a r e u ' i t h p r e s s u r e r e l i e v i n g f - e a t u r e( a h o l e i n t h e
upstream side of the gate) they. can be installed onlv in the
direction of arrou'.
Though AIL Globe valr.es har e bi-directional sealirrg
capabilities.tlie direction of flou'is influencedby the operating
c o n d i t i o n s .H o u ' e v e rl o r v a l v e s i n s t a l l e di n d r a i n l i n e s o f h i g h
tenrperaturc flLrids (cspcciallv steam) llorv over the disc is
strongly' recommendecl.
A I L C h e c k v a l v e s a r c u n i - d i r e c t i o n a la n d a r e i n s t a l l e ds u c h
that the arrou nrark is in line uith the t-lou.direction. If this
is not ensured check ralvc s'ill stop the flou, altogether.
3.4 L I F T I N GT O P OS IT ION
\alves shouldbe liftedLrsinssuitablemechanical equipment.
Chains-Slingsaudotherlitiin_eequipnrent shouldbe regularlv
inspected.Do not atten.rptto lift the r.alveby applyingload
on hand u,heel.Gearunit. Actuatoror Bv-passpiping.Chains
or Slinss shall be fired aroundthe valve bodv.
3.5 M a k i n g E n d co n n e cti o n s
AIL Gate. Globe and Check ralves are offered rvith Flanged
and Butt n'eld ends. The ends are machined in accordanceto
the standardspecified in the product caraloguesunless
otherrvisespecified by tlre custon-ler.
3. 5. 2 W e l d e d c o n n e cti o n s
All u,eldingshouldbe performedby thequalifiedrveldersusing
approvedprocedures.It is recomnrended that goodengineering
practicesareadoptedto ensurethat the heatfrom r.veldingdoes
not affect the internals.Though there are no soft seatsto be
affectedin AIL Gate,Globe and Check valves.care should
be taken to avoid rveld splatter so as to prevent damageto
metal to metal seating.
GateandGlobevalvesareto be in fully closedposition,uvhile
weldingon to thepipelineto prevent'*,eld
splatterfrom falling
directly on to the seatingsurfaceand sparkingbetu'eengate
and body.
Local post u'eld heattreatment(PWHT) of the heataffected
zonecanbe safebut u,edo not recommendthatthe entirevalve
be subjectedto PWHT. Excessivedirect heat may affect the
stem packingand other operatingequipnrents.
3.7 Start up
All vahes should be checkedfbr operationbeforestart-up.
For an actuatedvalve keepingthe gate/discin n-ridposition
by handrvheel,start the actuatorand check if the working
directionis correct.If not. check the wiring corrections.
The pipelineshouldbe cleanedby flushingthoroughlyrvith
\\'ateror air. The valvesshouldbe eitherfully closedor fully
openduringcleaningoperation.If they arepartiallyopenthe
gate/discseatingmay be damagedby the debris flushedout.
Somepipelinesarerequiredto be flushedout at very high speed
(suchassteamblou'in turbineinlet)andin suchcasesparticles
in the pipelinemi-shtdarnageeventhe body seating.Usemetal
protectorsaround the body seatingto prevent damage.
3.8 CommissioningTests
Valves are to be testedas per the relevant testing standard.
If thereis an operationalrequirementto testthevah'esat higher
pressures.temperaturesor durationsthesetest parameters
should be specified and checkedout with AIL prior to
subjectingthe valvesto such tests.
4.0 OPERATION
4.1 Gate Valves
Gate valvesare multi tutl valves
rvith rising stem i.e.. they require
number of turns of rotation of
handw'heelfor full closing or full
o p e n i n go f t h e v a l v e . A l l g a t e
valvesshouldbe usedonly in fully
openor fully closeposition.IF used
in slight or half openposition,the Top view of the Valve
Fig.3
gate may vibrateichatterand also
-Ihcrelbre
cause u,ire dran'ing at the seatins itrca. gatc r alve
should not be uscd lbr le-gulation.
A l l r a l r e s c l o s cb v r o t a t i n gt h e h a n d u ' h c c lc l o c k u ' i s ca n d o p e n
b y , r o t a t i n g a n t i - c l o c k ui s c .
A I L u e d - e es a t e r a l v c ' s f L r l l l ' c l o s e b v t o r q u e l i m i t a n d f u l l v
open (backseat) bl travel limit.
4 . 1 . 2 Pa r a l l e lS l i d e Ga te V a l ve s
Unlike \fu'edgesate valves. Parallcl slide gate valves do not
require rved_s:ing actiolt fbr seatin_rr. Tuo independent discs.
held toeetherbv a disc canier and a spring.moves dol'n parallel
and closethe valr e. As soon as the bodv port is sealed.a stopper
in the stent prevr-ntsfirrtht'r travcl. \\'hcn the ralre is opened.
the disc moves up and the stent backseats.Hou,ever in the
caseof actuatorvalvt-sthc stc-r"n is not allou.edto fullv backseat
to avoid danta_qe.
AIL Parallel slide sate \alves fullv close and open by travel
limit.
Fig.4 Fig.5
5.0 I N . L I NEMA IN T E N A N C E
G a t e a n d G l o b e v a l v e sr e q u i r eo n l y a m i n i m u m i n - l i n e
maintenancefor satisfactoryperformance.
5.1 Check the gland eye bolts for tightnessat regular intervals.
If loose tighten them evenll,'.
5.2 Greasethe stemthreadsin Gateand Globe Valvesas required.
7
5.3 Applf' a drop of oil into tlrc stenr packing arca to rcduce thc
friction betueen stell altd pacl<ing.
6_0 R O U T I N EMA IN T E N A N C E
6.1 Gland leak
C h e c k t h e t i g h t n e s so f t h e g l a n d e v e b o l t s a n d t i g h t e n n ' e n l 1 '
i f r e q u i r e d .I f t h e l e a k p e r s i s t s t. h e p a c k i n e r n u s tb e r e n e u c d .
For this the valve must be either in full1,'open position (back
seated) or the pipeline n.rustbe shut off so that there is no
p r e s s u r ei n s i d e t h e v a l r e b e f o r e t h e g l a n d c r e b o l t s a r e
loosened.
Most of tlre packing rinss are alreadv cut so that thev can be
inserted around the stem. In case of solid rnoulded packing
l i k e G r a p h i t er i n g s . u s e a s h a r p k n i l e a n d c u t t h e l i n s a t 3 0 "
angle.Then sliuhtll.trvist the ring and insert it around the stcr.t.r.
Do not ollen up the rin,s as it could break.
6.2 B o d y - Bo n n e tj o i n t l e a k
BO L T E DB OD Y .B ON N E TJOINT
Checkthe tightness of the boltingandti_uhten the boltsat the
vicinitv-of the leak. lf leak still persists.reneu the bonnet
gasket.The pipelrnenrustbe shut off bctbre disntantlinsthe
bonnet.
6. 4 Actuators
For operational
detailsand ntaintenance instructionconsult
the Actuatornranul-acturc-r's
instructionnranual.
Ensurethatproperelectricalconnections aregivenasindicated
in the u-irirrgdia_erant
for the speciticactuator.
7.0 PE R I O D ICMA IN T E N A N C E
7."1 D i s m a n tl i n g
All valr-esare desisnedto permit inspectionu.itltout rernoving
the body' lrom tlre pipcline. The scction of the pipe must be
shut off before disntantling the valve for inspection.
1.2 Gate and Globc r alvescan be inspectedby rentovingthe bonnet
assemblv.Check r.alvescan be inspectedby.'removingthe cor.er
assembly,'.
In the case of Check valr es there is no stent and hence only
the cor.er is to be rer-no\ed. The disc is hinsed inside thc body.
F o r e a s e o f i l l u s t r a t i o no n l v t h e u o r d b o n n e t i s u s e d i n t h e
disnrantlin-rr and reassen.rbly procedure.This nrav be chan-sed
to read as cover n ith respcct to check valves.
Fig.7 Fig.8
7.-'r.(r Lift the bonnet using gland studs.
Fig.9 F i g .1 0
7.5.7 Lift the entire stem-disc assenrblvout of the bodl'. Check the
disc seatin-eand do not dismantle the assenrbl;-unless any
damage is noticed. I1'damagedthen remove the locking rrire,
lock nut and bolt of the disc carrier.
7. 6 I n s p e c ti o n
7.6.1 Check thc seatingort the bodv seat ring and satei'discfor rvear
or danrage.
12
7.7 Reassemblyof Bolted bonnet/covervalves
7 . 1. l [-ou'er the bonnet asser.nblvincludin-athe gate'disc sntoothl!'
into the bod1.kecpins the gatei'discin open position. Rententber
to match the nrarkingsdone earlieron gate and bodt.seal riugs.
A blue bearing test u'ill confirnr if there is a unifornt contact
betu'een gater'discand body seat rings.
1.1.2 Replace the gland packing. if
necessaryand tighten the eye bolts
onto the eland.
1.1.3 Place the gasket on the bod1.
correctly'.
7.7.4 Fit the bonnet studsand tighten the
nuts evenlv u orkins at diagonally
oppositepairs. Do not over tighten
as rhe gasket ntav get danra-9ed.
I .1.5 Assemble the handhu.eel.oear
F i g .1 1
unit/actuator.
7. 7 . 6 Operate the ralve front fullv
closed to full;. open position rnanually and ensure free
operation.
13
c) place the graphitering or.er the bottom ring
d) put the top ring and spaceror er it
e) pushthegasketsetinto thecavityavailablebetu.een
bonnet
OD and body bore.
7.8.5 If it is a threadedretainerapply anti-seizecompoundlike
Molybdenum Di-sulphategreaseliberally on the threaded
portion of the body and the retainer.Tightenthe retainerin
clockrvisedirectionfully into the body till it touchesthe step
in the bod,vbore.
Fig.12
1.8.6 If it is segmentedretainer.
a) removethe pre-loadingstudsand insertthe segmentalrings
one by one in the qroove providedin the body.
b) alignthesegments in thebody groovesuchthatntid portion
of one of the segmentscomeagainstthe hole in the bod.v.
c) fix the pre-loadingstuds.
7.8.1 Yoke assembly
a) place the yoke assemblyover the stem and rotate the
handrvheelso that yoke sleeve/actuator
bush engagesrvith
the stem
b) yoke assemblyu,ill descendon to the body cover face
c) rotatethe bonnet so that pre-loadingstudsand body studs
are aligned to the drilled holes in the yoke.
14
d) open the valve full_,-to eet the disc back seatedand bonnet
is raised up
Fig.13
1.8.7.2 Tightenthe bonnetnuts so as to pre-loadthe gasketbut do
not over tighten.
7.8.8 Replacethe gland packing.if necessaryand tightenthe eve
bolts on to the gland.
7.8.9 Stopperassemblv
a) screu'in the stopperonto thestemand alignthe drill holes.
b) insertthe cl.lindricalpin and lock it *'ith the split pin.
c) in case of gear operatedvalr.e assemblethe position
indicatorback.
d) for actuatorvalves. removethe actuatorfrom the adaptor
and assemblethe stopper.Then mount the actuatorback
onto the adaptor.
7.8.10 Operatethe valve from fully closedto full-vopen position
manuallv and ensurefree operation.
15
7 . 8 . I1 When the r.alve is pressurizedfor tl-refirst time after reassemblv.
the pre-loading nuts rvill looscn because of con.rpre'ssion of
bonnetgasket.Retight thc-nuts u'hen the valve is under rr orking
pressure but do not over tighten.